Toyota 2006 Tundra Service - Repair - Maintenance Download Page 4238

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Code

Part Name

Part Number

Code

Part Name

Part Number

2005 TOYOTA TUNDRA (EW611U)

581

K 1

Knock Sensor (Bank 1)

90980-11875

K 2

Knock Sensor (Bank 2)

90980-11875

L 1

License Plate Light LH

90980-11162

L 2

License Plate Light RH

90980-11162

L 3

Lumbar Support Control SW (Driver’s Seat)

90980-10789

L 4

Leak Detection Pump Assembly

90980-12380

M 1

Mass Air Flow Meter (1GR-FE)

90980-11317

M 1

Mass Air Flow Meter (2UZ-FE)

90980-12292

M 4

Mirror Heater SW

90980-10797

M 5

Main SW

90980-10957

M 6

Moon Roof Control ECU and Motor

90980-10997

N 1

Noise Filter

90980-10843

O 1

O/D Direct Clutch Speed Sensor

90980-11156

O 2

Oil Pressure SW

90980-11363

O 4

O/D Main SW

90980-11470

O 5

Option Connector

90980-11603

O 7

Option Connector (Glass Breakage Sensor)

90980-10871

O 8

Overhead Module

90980-10805

O10

Occupant Classification ECU

90980-12356

O11

Occupant Classification ECU

90980-12357

O12

Occupant Classification Sensor Front LH

90980-12353

O13

Occupant Classification Sensor Front RH

90980-12354

O14

Occupant Classification Sensor RearLH

90980-12354

O15

Occupant Classification Sensor RearRH

90980-12353

O16

Occupant Detection Sensor

90980-10825

P 1

Park/Neutral Position SW

90980-12362

P 2

Power Steering Oil Pressure SW

90980-11428

P 5

Parking Brake SW (A/T)

90980-10871

P 5

Parking Brake SW (M/T)

90980-10825

Power Outlet (Access Cab, Standard Cab)

90980-10760

P 6

Power Outlet (Double Cab Captain seat)

P 6

Power Outlet (Double Cab Except Captain
seat)

90980-10905

P 7

Power Outlet

90980-10905

P 8

Personal Light

90980-10908

P 9

Power Window Control SW Front RH

90980-10789

P10

Power Window Master SW

90980-10997

P11

Power Window Motor Front LH (Access
Cab, Standard Cab)

90980-10860

P11

Power Window Motor Front LH (Double
Cab)

90980-11011

P12

Power Window Motor Front RH

90980-10860

Pretensioner LH (Access Cab)

90980-12452

P13

Pretensioner LH (Double Cab)

90980-12253

Pretensioner LH (Standard Cab)

90980-11862

Pretensioner RH (Access Cab)

90980-12452

P14

Pretensioner RH (Double Cab)

90980-12253

Pretensioner RH (Standard Cab)

90980-11862

P15

Power Seat Motor (Driver’s Seat Front
Vertical Control)

90980-10825

P16

Power Seat Control SW (Driver’s Seat)

90980-10997

P17

Power Seat Motor (Driver’s Seat Rear
Vertical Control)

P18

Power Seat Motor (Driver’s Seat Reclining
Control)

90980-10825

P19

Power Seat Motor (Driver’s Seat Slide
Control)

90980-10825

P20

Power Seat Motor (Driver’s Seat Lumbar
Support Control)

P21

Power Window Control SW (Back Window)

90980-10996

P22

Power Window Motor (Back Window)
(Access Cab, Standard Cab)

90980-10860

P22

Power Window Motor (Back Window)
(Double Cab)

90980-11012

P23

Power Outlet (115V)

90980-10601

P24

Power Outlet (Rear)

90980-10760

P25

Power Window Control SW Rear LH

P26

Power Window Control SW Rear RH

90980-10797

P27

Power Window Motor Rear LH

90980-10797

P28

Power Window Motor Rear RH

R 1

Radio and Player

90980-10996

R 2

Radio and Player

90980-10997

R 3

Rheostat

90980-10216

R 4

Rear Combination Light LH

90980-10988

R 5

Rear Combination Light RH

90980-10988

R 6

Rear Door Speaker LH

90980-10935

R 7

Rear Door Speaker RH

90980-10935

Remote Control Mirror LH (Access Cab,
Standard Cab w/ Mirror Heater)

90980-11452

R 8

Remote Control Mirror LH (Access Cab,
Standard Cab w/o Mirror Heater)

90980-10907

Remote Control Mirror LH (Double Cab)

90980-11487

Remote Control Mirror LH (Access Cab,
Standard Cab w/ Mirror Heater)

90980-11452

R 9

Remote Control Mirror RH (Access Cab,
Standard Cab w/o Mirror Heater)

90980-10907

Remote Control Mirror RH (Double Cab)

90980-11487

R10

Remote Control Mirror SW

90980-11657

R12

Radio and Player

90980-12038

R13

Radio and Player

90980-12259

R14

Radio and Player

90980-12038

R15

Radio and Player

90980-12259

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Summary of Contents for 2006 Tundra

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Page 4: ... a PRECAUTION that pertains to all repair operations contained in that sec tion is given Read these precautions before starting any repair task 3 TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause The fundamentals of how to proceed with troubleshooting are described on page IN 19 Be sure to read this before performing troubleshoo...

Page 5: ... glance when necessary and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept to a minimum However when they are required you are given the page to refer to 7 SPECIFICATIONS Specifications are presented in bold type throughout the text where needed You never have to leave the procedure to look ...

Page 6: ...D ENGINE SERIAL NUMBER 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label A Vehicle Identification Number Plate B Certification Label 2 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown in the illustration A Engine Serial Number ...

Page 7: ... pry the cable off 4 Clean the battery terminals and cable ends with a clean shop rag Do not scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals after loosening the nut and tighten the nut after installa tion Do not use a hammer to tap the cable ends onto the terminals 6 Be sure the cover for the positive terminal is properly in place d Check hose a...

Page 8: ...use a sealer on gaskets to prevent leaks h Carefully observe all specifications for bolt tightening torques Always use a torque wrench i Use of special service tools SST and special service ma terials SSM may be required depending on the nature of the repair Be sure to use SST and SSM where speci fied and follow the proper work procedure A list of SST and SSM can be found in the Preparation sectio...

Page 9: ...the following precautions to avoid damage to the following parts 1 Do not open the cover or case of the ECU unless absolutely necessary Static electricity transmitted through human touch may destroy the IC 2 To disconnect vacuum hoses pull off the end of the hose not the middle 3 To pull apart electrical connectors pull on the con nector itself not the wires 4 Be careful not to drop electrical com...

Page 10: ...eting a job double check that the vacu um hoses are properly connected A label under the hood shows the proper layout n Unless otherwise stated all resistance should be mea sured at an ambient temperature of 20 C 68 F Mea surement should be made after the engine has cooled down If measured at high temperatures immediately af ter the vehicle has been running resistance may be out side specification...

Page 11: ...IN0DY 05 B07972 JACK POSITION Front Center of crossmember Rear Center of rear axle housing SUPPORT POSITION Safety stand Front IN 8 INTRODUCTION REPAIR INSTRUCTIONS VEHICLE LIFT AND SUPPORT LOCATIONS ...

Page 12: ... Malfunction symptoms of the supplemental re straint system are difficult to confirm so the diag nostic trouble codes become the most important source of information when troubleshooting When troubleshooting the SRS always check the diag nostic trouble codes before disconnecting the bat tery see page DI 1810 2 Work must be started after 90 seconds from the time the ignition switch is turned to the...

Page 13: ...d front passenger airbag assembly or seat belt pre tensioner has been dropped or if there are cracks dents or other defects in the case bracket or con nector replace them with new ones 8 Do not directly expose the airbag sensor assembly steering wheel pad front passenger airbag assem bly or seat belt pretensioner to hot air or flames 9 Use a voltmeter ohmmeter with high impedance 10 kΩ V minimum f...

Page 14: ...easure the resistance of the airbag squib This may cause the airbag to deploy which could cause serious injury 3 Grease or detergents of any kind should not be ap plied to the steering wheel pad 4 Store the steering wheel pad where the ambient temperature remains below 93 C 200 F with low humidity and away from electrical noise 5 Before using an electric welder first disconnect the airbag connecto...

Page 15: ...is may cause the airbag to deploy which could cause serious injury 3 Grease or detergents of any kind should not be ap plied to the steering wheel pad 4 Store the steering wheel pad where the ambient temperature remains below 93 C 200 F with low humidity and away from electrical noise 5 Before using an electric welder first disconnect the airbag connector the connector is yellow and has 4 pins und...

Page 16: ...e the seat belt pretensioner where the ambient temperature remains below 80 C 176 F with low humidity and away from electrical noise 5 Before using an electric welder first disconnect the connector the connector is yellow and has 2 pins 6 As a safety measure always activate the seat belt pretensioner before disposal see page BO 245 Activate the pretensioner in a safe place away from electrical noi...

Page 17: ... very dangerous 3 Grease should not be attached to the side airbag assembly and the surface should not be cleaned with any kind of detergents 4 Store the airbag assembly where the ambient tem perature remains below 93 C 200 F without high humidity and away from electrical noise 5 When using electric welding first disconnect the air bag connector yellow color and 2 pins under the seat before starti...

Page 18: ...eploy which is very dangerous 3 Grease should not be attached to the curtain shield airbag assembly and the surface should not be cleaned with any kind of detergents 4 Store the airbag assembly where the ambient tem perature remains below 93 C 200 F without high humidity and away from electrical noise 5 When using electric welding first disconnect the air bag connector yellow color and 2 pins into...

Page 19: ...injury servicing the SRS must be started 90 seconds after The ignition switch is turned to the LOCK position The negative terminal cable is discon nected from the battery Even if only loosening the set bolts of the airbag sensor assembly you must follow the above guide lines j WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly All the conn...

Page 20: ...ones observe the following precautions 1 Install the antenna as far away as possible from the ECU and sensors of the vehicle s electronic system 2 Install the antenna feeder at least 20 cm 7 87 in away from the ECU and sensors of the ve hicle s electronic systems For details about ECU and sensor locations refer to the applicable component s section 3 Avoid winding the antenna feeder together with ...

Page 21: ...Anti Lock Brake System DI 1383 7 ABS with EBD BA TRAC VSC System DI 1456 8 Can Communication System DI 1693 9 Supplemental Restraint System DI 1810 10 TOYOTA Vehicle Intrusion Protection System DI 2297 11 Cruise Control System DI 2341 12 Sliding Roof System DI 2376 13 Body Control System DI 2391 14 Driver Door Control System DI 2453 15 Passenger Door Control System DI 2475 16 Multiplex Communicati...

Page 22: ...the system or the part that should be checked using the diagnostic trouble code chart or the problem symptoms table 4 5 6 Check and repair the affected system or part in accordance with the instructions in Step 6 7 After completing repairs confirm that the problem has been eliminated To be absolutely sure the problem no longer ex ists perform the confirmation test under the same conditions and env...

Page 23: ...her Temperature Vehicle Operation Fine Cloudy Starting Idling Driving Constant speed Acceleration Other Inspector s Name CUSTOMER PROBLEM ANALYSIS CHECK Production Date Rainy Snowy Other Approx Deceleration IN 20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 1 CUSTOMER PROBLEM ANALYSIS The 5 items in the table below are important points in the problem analysis In troubleshooting the prob...

Page 24: ...eck functions the problem areas can be narrowed down and troubleshooting is more effective Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA System Diagnostic Trouble Code Check Input Signal Check Sensor Check Diagnostic Test Mode Active Test 1 Engine 1GR FE with Check Mode 2 Engine 2UZ FE with Check Mode 3 Automatic Transmission A750E for 1GR FE with Check Mode 4...

Page 25: ...ace other than the diagnostic circuit No problem symptoms exist Normal code is displayed The problem occurred in a place other than the diagnostic circuit in the past IN 22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS In the DTC Check it is very important to determine whether the problem indicated by the DTC is 1 still occur ring or 2 occurred in the past but has since returned to norma...

Page 26: ...stem Normal Troubleshooting of each problem symptom If a diagnostic trouble code was displayed in the initial diagnostic trouble code check it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past Therefore check the wire harness and con nectors see page IN 30 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN 23 Taking into account the poi...

Page 27: ...t No matter how much skill or experience a technician has troubleshooting without confirming the problem symptoms will lead to something important in the repair operation being overlooked and lead to mistakes or delays in repairs For example With a problem that only occurs when the engine is cold or occurs as a result of vibration caused by road during driving the problem can never be determined a...

Page 28: ...ll electrical loads including the heater blower head lights rear window defogger etc and check to see if the mal function occurs ON HINT If a vehicle is subject to water leakage the leaked water may damage the ECU When testing a vehicle with a water leakage problem special caution must be taken Malfunction Do not heat to more than 60 C 140 F Exceeding this temperature may damage components Do not ...

Page 29: ...it Malfunction Open or short in throttle position sensor circuit Throttle position sensor ECM DTC CHART SAE Controlled HINT Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors If a malfunction code is displayed during the DTC check mode check the circuit for that code listed in the table below For details of each code refer to t...

Page 30: ...lete combustion Does not start 1 Starter and starter relay 1 ECM power source circuit 2 Fuel pump control circuit 3 Engine control module ECM 1 Starter signal circuit 2 Fuel pump control circuit 1 Fuel pump control circuit DI 147 DI 151 IN 29 PROBLEM SYMPTOMS TABLE 1 Compression 2 Fuel pump control circuit 1 A C signal circuit 2 Fuel pump control circuit 1 A C signal circuit Compressor circuit 2 E...

Page 31: ...es a voltage when it becomes deformed which occurs when the cylinder block vibrates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed 1 200 rpm or more Open or short in knock sensor1 circuit Knock sensor 1 looseness ECM If the ECM detects the above diagnosis condit...

Page 32: ...heck from the connector back side with harness Ignition Switch LOCK OFF Ignition Switch START LOCK Ignition Switch ON Ignition Switch ACC START ON ACC Indicates the place to check the voltage or resistance Indicates the connector position to checked from the front or back side Connector being checked is disconnected Check from the connector front side without harness In this case care must be take...

Page 33: ...ocedure are common and applicable to all DTCs Fol low the procedure outlined below whenever these instructions appear OPEN CIRCUIT An open circuit could result from a disconnected wire harness a faulty contact in the connector a connector terminal pulled out etc HINT A wire is rarely broken in its middle Most problems occur at the wire ends Carefully check the connectors of sen sors and actuators ...

Page 34: ...onnectors Resistance Below 1 Ω HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally 4 RESISTANCE CHECK SHORT CIRCUIT CHECK a Disconnect the connectors on both ends b Measure the resistance between the applicable terminals of the connectors and body ground Be sure to carry out this check on the connectors on both ends Resistance 10 kΩ or higher HINT Measure...

Page 35: ...nti nuity check step a below or a voltage check step b below a Check the continuity 1 Disconnect connectors A and C and measure the resistance between them In the case of Fig 2 Between terminal 1 of connector A and terminal 1 of connector C 10 kΩ or higher open Between terminal 2 of connector A and terminal 2 of connector C Below 1 Ω An open circuit exists in the wire harness between terminal 1 of...

Page 36: ...ults 5V Between Terminal 1 of connector A and Body Ground 5V Between Terminal 1 of connector B and Body Ground 0V Between Terminal 1 of connector C and Body Ground In the above example an open circuit is in the wire harness be tween terminal 1 of B and terminal 1 of C 7 CHECK SHORT CIRCUIT If the wire harness is shorted Fig 5 locate the section by con ducting a resistance check with ground below C...

Page 37: ...erminal 1 of connector B2 and body ground Below 1 Ω short A short circuit is between terminal 1 of connector B2 and terminal 1 of connector C 8 CHECK AND REPLACE ECU First check the ECU ground circuit If it is faulty repair it If it is normal the ECU could be faulty Replace the ECU with a func tioning one and check if the symptoms occur If the trouble symptoms stop replace the ECU 1 Measure the re...

Page 38: ...M Automatic Transmission Transaxle ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B L Bi Level B S Bore Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve CB Circuit Breaker CCo Catalytic Converter For ...

Page 39: ...rol Unit ED Electro Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E G Engine EGR Exhaust Gas Recirculation EGR VM EGR Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ESA Electronic Spark Advance ETCS i Electronic Throttle Control System intelligent EVAP Evaporative Emission Control E...

Page 40: ... Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand LHD Left Hand Drive L H W Length Height Width LLC Long Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX Maximum MIC Microphone MIL Malfunction Ind...

Page 41: ...t RFS Rigid Front Suspension RH Right Hand RHD Right Hand Drive RLY Relay ROM Read Only Memory RR Rear RRS Rigid Front Suspension RWD Rear Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD...

Page 42: ...ndersize VCV Vacuum Control Valve VENT Ventilator VIM Vehicle Interface Module VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT i Variable Valve Timing intelligent W With WGN Wagon W H Wire Harness W O Without 1ST First 2ND Second 2WD Two Wheel Drive Vehicle 4 x 2 3RD Third 4TH Fourth 4WD Four Wheel ...

Page 43: ...3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode ECL Engine Coolant Level ECM Engine Control Module Engine ECU Electronic Control Unit ECT Engine Coolant Temperature Coolant Temperature Water Temperature THW EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory EEPROM Erasable Program...

Page 44: ...ic On Board Diagnostic System OBD OC Oxidation Catalytic Converter Oxidation Catalyst Convert OC CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction AS PCM Powertrain Control Module PNP Park Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer Diesel Particulate Filter DPF Diesel Particulate Trap DPT RAM Random Access Me...

Page 45: ...Way Catalytic Converter Three Way Catalytic TWC Manifold Converter CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU OC Warm Up Oxidation Catalytic Converter WU TWC Warm Up Three Way Catalytic Converter 3GR Third Gear 4GR Fourth Ge...

Page 46: ...als between periodic maintenance unless noted Failing to check each vehicle part could lead to poor engine performance and increase exhaust emis sions 2 TIRES a Check the tire pressure with a gauge Make adjustment if necessary b Check the surfaces of tires for cuts damage or excessive wear 3 WHEEL NUTS Check for nuts that are loose or missing Tighten them if necessary 4 TIRE ROTATION See page SA 3...

Page 47: ...LAMPS AND BUZZERS Check that all the warning lamps and buzzers are working 4 HORN Check that the horn is working 5 WINDSHIELD Check for scratches pits or abrasions 6 WINDSHIELD WIPER AND WASHER a Check if the wind washers are aimed properly Also check if the washer fluid hits the center of the oper ating range of each wiper on the windshield b Check that the wipers do not streak 7 WINDSHIELD DEFRO...

Page 48: ...freeplay c Check the brake booster function 16 BRAKES In a safe place check that the vehicle remains straight when applying the brakes 17 PARKING BRAKE See page BR 18 a Check that the parking brake pedal has the proper range of motion b On a low incline check that the parking brake alone can stabilize the vehicle 18 AUTOMATIC TRANSMISSION PARK MECHANISM a Check the lock release mechanism of the se...

Page 49: ...HOSES a Check that the front of the radiator is clean and free of leaves dirt and bugs b Check the hoses for cracks kinks rotting and loose connections 5 BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all the battery cells is between the upper and lower lines on the case 6 BRAKE AND CLUTCH FLUID LEVELS Check that the brake and clutch fluid levels are near the upper level line on the...

Page 50: ...AND MOUNTINGS Visually inspect the pipes hangers and connections for severe corrosion leaks or damage 7 INSPECT AIR FILTER a Visually check that the air filter is not excessively dirty or oily HINT Oiliness may indicate a stuck PCV valve If necessary replace the air filter b Clean the air filter with compressed air First blow from the inside of the filter thoroughly then re peat from the outside 8...

Page 51: ...MA 6 MAINTENANCE ENGINE 11 REPLACE SPARK PLUGS 1GR FE See page IG 1 2UZ FE See page IG 1 12 INSPECT CHARCOAL CANISTER 1GR FE See page EC 6 2UZ FE See page EC 9 ...

Page 52: ...osion Leaks Bends Twists b Check all the clamps for tightness and connections for leakage c Check that the hoses and lines are not near sharp edges moving parts and the exhaust system d Check that the lines installed pass through the center of the grommets 2 INSPECT FRONT BRAKE PADS AND DISCS See page BR 44 HINT If a squealing or scraping noise occurs from the brake during driving check the pad we...

Page 53: ... TRANSFER AND DIFFERENTIAL Remove the filler plug and feel inside the hole with your finger Check that the oil comes to within 5 mm 0 20 in of the bottom edge of the hole If the level is low add oil until it reaches the bottom of the fire hole Transmission oil See page MT 7 Transfer oil See page TR 5 Front differential oil 4WD See page SA 36 Rear differential oil See page SA 101 6 REPLACE MANUAL T...

Page 54: ...eller shaft referring to the lubrication chart Before pumping in grease wipe off any mud and dust on the grease fitting Grease grade Propeller shaft Except Double cardan joint Lithium base chassis grease NLGI No 2 Double cardan joint Molybdenum disulphide lithium base chassis grease NLGI No 2 b Tighten the bolts for propeller shaft 2WD See page PR 8 4WD See page PR 15 10 ROTATE TIRES See page SA 3...

Page 55: ... BODY a Where necessary tighten all parts of the chassis Front axle and suspension Drive train Rear axle and suspension Brake system Engine mounting etc b Where necessary tighten all parts of the body Seat belt system Seats Doors and hood Body mountings Fuel tank Exhaust pipe system etc ...

Page 56: ...PP0G5 02 PREPARATION MAINTENANCE PP 1 MAINTENANCE EQUIPMENT Mirror Brake hose Torque wrench ...

Page 57: ... 09201 10000 Valve Guide Bushing Remover Replacer Set CYLINDER HEAD 09201 41020 Valve Stem Oil Seal Replacer CYLINDER HEAD 09202 70020 Valve Spring Compressor CYLINDER HEAD 09202 00010 Attachment CYLINDER HEAD 09213 54015 Crankshaft Pulley Holding Tool TIMING CHAIN 91651 60855 Bolt TIMING CHAIN 09222 30010 Connecting Rod Bushing Remover Replacer CYLINDER BLOCK 09223 78010 Crankshaft Oil Seal Repla...

Page 58: ... 09950 50013 Puller C Set TIMING CHAIN 09951 05010 Hanger 150 TIMING CHAIN 09952 05010 Slide Arm TIMING CHAIN 09953 05020 Center Bolt 150 TIMING CHAIN 09954 05031 Claw No 3 TIMING CHAIN 09950 60010 Replacer Set CYLINDER BLOCK CYLINDER HEAD 09951 00250 Replacer 25 CYLINDER HEAD 09951 00350 Replacer 35 CYLINDER BLOCK 09950 70010 Handle Set CYLINDER BLOCK CYLINDER HEAD 09951 07100 Handle 100 CYLINDER...

Page 59: ...PP 4 PREPARATION ENGINE MECHANICAL 1GR FE 09951 07150 Handle 150 CYLINDER BLOCK CYLINDER HEAD ...

Page 60: ...L 1GR FE PP 5 RECOMMENDED TOOLS 09040 00011 Hexagon Wrench Set 09043 20080 Socket Hexagon Wrench 8 09043 20100 Socket Hexagon Wrench 10 09043 30140 Straight Hexagon Wrench 14 09042 00010 Torx Socket T30 09043 50100 Bi hexagon Wrench 10 mm ...

Page 61: ...r Cylinder gauge Dial indicator with magnetic base Engine sling device Feeler gauge Heater Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Reamer Spring tester Steel square Tachometer Timing light Torque wrench Valve seat cutter V block Vernier calipers Wooden block Press ...

Page 62: ...E MECHANICAL 1GR FE PP 7 SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent ...

Page 63: ...Valve Spring Compressor 09202 00010 Attachment 09213 70011 Crankshaft Pully Holding Tool 90105 08076 Bolt 90119 08216 Bolt 09222 30010 Connecting Rod Bushing Remover Replacer 09223 46011 Crankshaft Front Oil Seal Replacer Crankshaft pulley Crankshaft timing pulley 09223 56010 Crankshaft Rear Oil Seal Replacer 09330 00021 Companion Flange Holding Tool Crankshaft pulley 09843 18030 Tacho pulse Picku...

Page 64: ...Arm Crankshaft pulley Crankshaft timing pulley 09953 05010 Center Bolt 100 Crankshaft pulley Crankshaft timing pulley 09953 05020 Center Bolt 150 Crankshaft pulley Crankshaft timing pulley 09954 05011 Claw No 1 Crankshaft timing pulley 09954 05021 Claw No 2 Crankshaft pulley 09950 60010 Replacer Set 09951 00240 Replacer 24 09951 00440 Replacer 44 09952 06010 Adapter 09950 70010 Handle Set ...

Page 65: ...00 Handle 100 Spark plug tube Valve guide bushing 09960 10010 Variable Pin Wrench Set 09962 01000 Variable Pin Wrench Arm Assy Camshaft sub gear 09963 00400 Pin 4 Camshaft sub gear 09963 00500 Pin 5 Camshaft sub gear 09963 01000 Pin 10 Camshaft sub gear ...

Page 66: ...ICAL 2UZ FE PP 11 RECOMMENDED TOOLS 09040 00011 Hexagon Wrench Set 09090 04020 Engine Sling Device For suspension engine 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc 09904 00010 Expander Set ...

Page 67: ...ant Engine tune up tester Groove cleaning tool Heater Magnetic finger Micrometer Pin hole grinder OBD II scan tool Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Soft brush Ridge reamer Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter V block Vernier calipers Wire brush Valve ...

Page 68: ...inder head cover Rear oil sear retainer 08826 00080 Seal Packing Black or equivalent FIPG Camshaft housing plug 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG Coolant drain union 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent Drive plate bolt Torque converter clutch bolt 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent No 1 idler pulley bolt ...

Page 69: ...PP43H 01 PP 14 PREPARATION EMISSION CONTROL 1GR FE EMISSION CONTROL 1GR FE EQUIPMENT Vacuum gauge Pressure gauge ...

Page 70: ...PP42V 02 PREPARATION EMISSION CONTROL 2UZ FE PP 15 EMISSION CONTROL 2UZ FE RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester ...

Page 71: ...PP1AK 06 PP 16 PREPARATION EMISSION CONTROL 2UZ FE EQUIPMENT MITYVAC Hand held vacuum pump Pressure gauge Torque wrench Vacuum gauge Hose Clipper ...

Page 72: ...91 NO 7 Union INJECTOR 09268 41140 Adapter INJECTOR 09268 41400 Clamp INJECTOR 90467 13001 Clip FUEL PUMP 95336 08070 Hose INJECTOR FUEL PUMP 09268 45014 EFI Fuel Pressure Gauge FUEL PUMP 09268 41200 Gauge FUEL PUMP 09268 41220 Hose FUEL PUMP 09268 41250 T Joint FUEL PUMP 90467 13001 Clip FUEL PUMP 09808 14020 Retainer Tool Fuel Pump FUEL PUMP ...

Page 73: ...PP 18 PREPARATION SFI 1GR FE 09808 01410 Holder FUEL PUMP 09808 01420 Claw FUEL PUMP 09808 01430 Bolt FUEL PUMP 09842 30070 Wiring F EFI Inspection SFI SYSTEM 09842 30080 EFI Inspection Wire H INJECTOR ...

Page 74: ...PP43J 01 PREPARATION SFI 1GR FE PP 19 RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set ...

Page 75: ...PP43K 01 PP 20 PREPARATION SFI 1GR FE EQUIPMENT Graduated cylinder Transmission jack ...

Page 76: ...ool Set 09268 41091 NO 7 Union 09268 41110 Adaptor 09268 41300 Clamp 09268 52011 Injection Measuring Attachment 09268 45014 EFI Fuel Pressure Gauge 09268 41190 Adapter 90405 06167 I Union 09612 24014 Steering Gear Housing Overhaul Tool Set 09617 24011 Steering Rack Wrench Fuel pressure pulsation damper 09808 14020 Retainer Tool Fuel Pump ...

Page 77: ...PP 22 PREPARATION SFI 2UZ FE 09808 01410 Holder 09808 01420 Claw 09808 01430 Bolt 09842 30070 Wiring F EFI Inspection ...

Page 78: ...PP0U4 05 PREPARATION SFI 2UZ FE PP 23 RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc ...

Page 79: ...PP0NI 02 PP 24 PREPARATION SFI 2UZ FE EQUIPMENT Graduated cylinder Injector OBD II scan tool Sound scope Injector Torque wrench Vacuum gauge ...

Page 80: ...PP435 01 PREPARATION COOLING 1GR FE PP 25 COOLING 1GR FE EQUIPMENT Heater Radiator cap tester Slide calipers Thermometer Torque wrench ...

Page 81: ...Capacity Classification Engine coolant 11 6 liters 12 3 US qts 10 2 lmp qts Toyota Super Long Life Coolant or similar high quality ethylene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid organic acid technology ...

Page 82: ...PP1AQ 05 PREPARATION COOLING 2UZ FE PP 27 COOLING 2UZ FE EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench ...

Page 83: ...Capacity Classification Engine coolant 11 6 liters 12 3 US qts 10 2 lmp qts TOYOTA Super Long Life Coolant or similar high quality ethylene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid organic acid technology ...

Page 84: ...PP1AS 04 PREPARATION COOLING 2UZ FE PP 29 SSM Special Service Materials 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG Water inlet housing ...

Page 85: ...PP43L 01 PP 30 PREPARATION LUBRICATION 1GR FE LUBRICATION 1GR FE SST Special Service Tools 09226 10010 Crankshaft Front Rear Bearing Replacer OIL PUMP 09228 07501 Oil Filter Wrench OIL AND FILTER ...

Page 86: ...PP43M 01 PREPARATION LUBRICATION 1GR FE PP 31 RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit ...

Page 87: ...PP43N 01 PP 32 PREPARATION LUBRICATION 1GR FE EQUIPMENT Oil pressure gauge Drain hose ...

Page 88: ...ilter change w o Oil filter change Dry fill 4 5 liters 4 8 US qts 4 0 Imp Qts 4 2 liters 4 4 US qts 3 7 Imp Qts 5 6 liters 5 9 US qts 4 9 Imp Qts API grade SL Energy Conserving or ILSAC mul tigrade engine oil SAE 5W 30 is the best choise for good fuel economy and good starting in cold weather ...

Page 89: ...PP43P 01 PP 34 PREPARATION LUBRICATION 1GR FE SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent ...

Page 90: ...ATION 2UZ FE PP 35 LUBRICATION 2UZ FE SST Special Service Tools 09032 00100 Oil Pan Seal Cutter 09228 07501 Oil Filter Wrench 09316 60011 Transmission Transfer Bearing Replacer 09316 00011 Replacer Pipe Crankshaft front oil seal ...

Page 91: ...PP1AU 04 PP 36 PREPARATION LUBRICATION 2UZ FE RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit 09905 00013 Snap Ring Pliers ...

Page 92: ...PP1AV 02 PREPARATION LUBRICATION 2UZ FE PP 37 EQUIPMENT Oil pressure gauge Precision straight edge Torque wrench ...

Page 93: ...pacity Classification Engine oil Dry fill Drain and refill w Oil filter change w o Oil filter change 7 1 liters 7 5 US qts 6 2 Imp qts 6 2 liters 6 6 US qts 5 5 Imp qts 5 7 liters 6 0 US qts 5 0 Imp qts API grade SL Energy Conserving or ILSAC mul tigrade engine oil ...

Page 94: ...BRICATION 2UZ FE PP 39 SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG Oil pump No 1 oil pan No 2 oil pan 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch ...

Page 95: ...PP43Q 01 PP 40 PREPARATION IGNITION 1GR FE IGNITION 1GR FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09200 00010 Engine Adjust Kit ...

Page 96: ...PP43R 01 PREPARATION IGNITION 1GR FE PP 41 EQUIPMENT Spark plug cleaner Torque wrench ...

Page 97: ...PP3WQ 01 PP 42 PREPARATION IGNITION 2UZ FE IGNITION 2UZ FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit ...

Page 98: ...PP1AM 01 PREPARATION IGNITION 2UZ FE PP 43 EQUIPMENT Megger Insulation resistance meter Spark plug Spark plug cleaner Torque wrench ...

Page 99: ...PP438 01 PP 44 PREPARATION STARTING 1GR FE STARTING 1GR FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester 09904 00010 Expander Set 09904 00050 No 4 Claw ...

Page 100: ...FE PP 45 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Armature bearing Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commutator Vernier calipers Commutator Brush ...

Page 101: ...TING 2UZ FE STARTING 2UZ FE SST Special Service Tools 09286 46011 Injection Pump Spline Shaft Puller Armature bearing 09810 38140 Starter Magnet Switch Nut Wrench 14 09820 00031 Alternator Rear Bearing Replacer Armature front bearing ...

Page 102: ...PP3WS 01 PREPARATION STARTING 2UZ FE PP 47 RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester ...

Page 103: ...G 2UZ FE EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Armature bearing Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commutator Vernier calipers Commutator Brush ...

Page 104: ...Cone Replacer 09820 00021 Alternator Rear Bearing Puller 09820 00031 Alternator Rear Bearing Replacer 09820 63011 Alternator Pulley Set Nut Wrench Set 09950 40011 Puller B Set 09951 04020 Hanger 200 09952 04010 Slide Arm 09953 04020 Center Bolt 150 09954 04010 Arm 25 09955 04071 Claw No 7 09957 04010 Attachment 09958 04011 Holder ...

Page 105: ...PP 50 PREPARATION CHARGING 1GR FE 09950 60010 Replacer Set 09951 00250 Replacer 25 09951 00470 Replacer 47 09950 70010 Handle Set 09951 07100 Handle 100 ...

Page 106: ...PP43D 01 PREPARATION CHARGING 1GR FE PP 51 RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester 09083 00150 Test Lead Set ...

Page 107: ...PP43E 01 PP 52 PREPARATION CHARGING 1GR FE EQUIPMENT Ammeter A Dial indicator with magnetic base Ohmmeter ...

Page 108: ...over 09286 46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820 00021 Alternator Rear Bearing Puller 09820 00031 Alternator Rear Bearing Replacer 09820 63011 Alternator Pulley Set Nut Wrench Set 09950 60010 Replacer Set Rotor front bearing 09951 00260 Replacer 26 09951 00460 Replacer 46 70 A type 09951 00520 Replacer 52 80 A type 09952 06010 Adapter ...

Page 109: ...PP3WU 01 PP 54 PREPARATION CHARGING 2UZ FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester ...

Page 110: ...PP1B4 05 PREPARATION CHARGING 2UZ FE PP 55 EQUIPMENT Battery specific gravity gauge Battery Torque wrench Vernier calipers Rotor Slip ring ...

Page 111: ...TION CLUTCH CLUTCH SST Special Service Tools 09023 00101 Union Nut Wrench 10mm CLUTCH RELEASE CYLINDER CLUTCH MASTER CYLINDER 09301 00110 Clutch Guide Tool CLUTCH UNIT 09333 00013 Clutch Diaphragm Spring Aligner CLUTCH UNIT ...

Page 112: ...PP0EO 04 PREPARATION CLUTCH PP 57 RECOMMENDED TOOLS 09031 00030 Pin Punch 09904 00010 Expander Set ...

Page 113: ...PP0EP 02 PP 58 PREPARATION CLUTCH EQUIPMENT Vernier calipers Dial indicator ...

Page 114: ...al Puller MANUAL TRANSMISSION ASSEMBLY 09309 37010 Transmission Bearing Replacer COUNTER GEAR INPUT SHAFT 09388 40010 Input Oil Seal Replacer MANUAL TRANSMISSION ASSEMBLY 09520 00031 Rear Axle Shaft Puller MANUAL TRANSMISSION ASSEMBLY 09556 16030 Differential Drive Pinion Holding Tool 28 MANUAL TRANSMISSION ASSEMBLY 09608 03070 Replacer mk2 COUNTER GEAR 09608 06041 Front Hub Inner Bearing Cone Rep...

Page 115: ...R GEAR OUTPUT SHAFT MANUAL TRANSMISSION ASSEMBLY 09951 00540 Replacer 54 COUNTER GEAR 09951 00650 Replacer 65 OUTPUT SHAFT MANUAL TRANSMISSION ASSEMBLY 09950 60020 Replacer Set No 2 MANUAL TRANSMISSION ASSEMBLY 09951 00640 Replacer 64 MANUAL TRANSMISSION ASSEMBLY 09950 70010 Handle Set MANUAL TRANSMISSION ASSEMBLY 09951 07100 Handle 100 MANUAL TRANSMISSION ASSEMBLY 09951 07360 Handle 360 MANUAL TR...

Page 116: ...PP43Z 01 PREPARATION MANUAL TRANSMISSION RA60 PP 61 RECOMMENDED TOOLS 09905 00012 Snap Ring No 1 Expander 09904 00010 Expander Set 09031 00040 Pin Punch ...

Page 117: ...43V 01 PP 62 PREPARATION MANUAL TRANSMISSION RA60 EQUIPMENT Plastic hammer Chisel Feeler gauge Dial indicator with magnetic base Belt Wooden block Hexagon wrench Vernier caliper Micrometer Cylinder gauge ...

Page 118: ...PP43W 01 PREPARATION MANUAL TRANSMISSION RA60 PP 63 LUBRICANT Transmission oil 1 8 liters 1 9 US qts 1 5 Imp qts API GL 4 or GL 5 SAE 75W 90 ...

Page 119: ...PP43X 01 PP 64 PREPARATION MANUAL TRANSMISSION RA60 SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG ...

Page 120: ...ansmission Tool Set 09351 32020 Stator Stopper Torpue converter clutch and drive plate 09992 00095 Automatic Transmission Oil Pressure Gauge Set 09992 00231 Adaptor C 09992 00271 Gauge Assy 09308 10010 Oil Seal Puller Extension housing oil seal 09325 40010 Transmission Oil Plug Extension housing oil seal 09023 12701 Union Nut Wrench 17mm Oil cooler pipe ...

Page 121: ...PP42P 01 PP 66 PREPARATION AUTOMATIC TRANSMISSION A750E A750F RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester ...

Page 122: ...2Q 01 PREPARATION AUTOMATIC TRANSMISSION A750E A750F PP 67 EQUIPMENT OBD II scan tool Torque wrench Calipers Torque converter clutch Straight edge Torque converter clutch Dial indicator Drive plate runout ...

Page 123: ...ION AUTOMATIC TRANSMISSION A750E A750F LUBRICANT Item Capacity Classification Automatic transmission fluid Dry fill Drain and refill 10 4 liters 11 0 US qts 9 2 lmp qts 3 0 liters 3 2 US qts 2 6 lmp qts Toyota Genuine ATF WS ...

Page 124: ...AR OUTPUT SHAFT 09330 00021 Companion Flange Holding Tool TRANSFER ASSEMBLY 09515 30010 Rear Wheel Bearing Replacer PLANETARY GEAR 09554 22010 Differential Oil Seal Replacer OIL SEAL 09554 30011 Differential Oil Seal Replacer PLANETARY GEAR 09555 55010 Differential Drive Pinion Bearing Replacer PLANETARY GEAR REAR OUTPUT SHAFT DRIVEN SPROCKET 09612 65014 Steering Worm Bearing Puller PLANETARY GEAR...

Page 125: ...r Bolt 200 TRANSFER ASSEMBLY 09954 04010 Arm 25 TRANSFER ASSEMBLY 09955 04051 Claw No 5 TRANSFER ASSEMBLY 09957 04010 Attachment TRANSFER ASSEMBLY 09958 04011 Holder TRANSFER ASSEMBLY 09950 60010 Replacer Set OIL SEAL PLANETARY GEAR 09951 00220 Replacer 22 OIL SEAL 09951 00350 Replacer 35 OIL SEAL 09951 00570 Replacer 57 PLANETARY GEAR 09951 00590 Replacer 59 OIL SEAL ...

Page 126: ... PREPARATION TRANSFER PP 71 09952 06010 Adapter OIL SEAL 09950 70010 Handle Set OIL SEAL PLANETARY GEAR 09951 07100 Handle 100 OIL SEAL PLANETARY GEAR ...

Page 127: ...PP440 01 PP 72 PREPARATION TRANSFER RECOMMENDED TOOLS 09040 00011 Hexagon Wrench Set 09042 00010 Torx Socket T30 09082 00040 TOYOTA Electrical Tester 09905 00012 Snap Ring No 1 Expander ...

Page 128: ...PP441 01 PREPARATION TRANSFER PP 73 EQUIPMENT Dial indicator Micrometer Torque wrench Feeler gauge Magnetic finger Steel square ...

Page 129: ...PP442 01 PP 74 PREPARATION TRANSFER LUBRICANT Transfer oil 1 0 liters 1 1 US qts 0 9 Imp Qts API GL 4 or GL 5 SAE 75W 90 ...

Page 130: ...PP443 01 PREPARATION TRANSFER PP 75 SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent ...

Page 131: ...ol PROPELLER SHAFT ASSEMBLY 09332 25010 Universal Joint Bearing Remover Replacer SPIDER BEARING 09950 30012 Puller A Set PROPELLER SHAFT ASSEMBLY 09951 03010 Upper Plate PROPELLER SHAFT ASSEMBLY 09953 03010 Center Bolt PROPELLER SHAFT ASSEMBLY 09954 03010 Arm PROPELLER SHAFT ASSEMBLY 09955 03030 Lower Plate 130 PROPELLER SHAFT ASSEMBLY 09956 03020 Adapter 18 PROPELLER SHAFT ASSEMBLY ...

Page 132: ...PP0EZ 03 PREPARATION PROPELLER SHAFT PP 77 EQUIPMENT Dial indicator Torque wrench ...

Page 133: ...eal Replacer Rear axle 09226 10010 Crankshaft Front Rear Bearing Replacer Front differential 09240 00020 Wire Gauge Set Front drive shaft 09308 00010 Oil Seal Puller Front differential Rear axle 09308 10010 Oil Seal Puller Front differential Rear differential 09309 37010 Transmission Bearing Replacer Front differential Front suspension 09316 12010 Transfer Bearing Replacer Rear differential 09316 ...

Page 134: ...placer Front differential Front suspension 09504 22012 Differential Side Bearing Replacer Rear differential 09506 30012 Differential Drive Pinion Rear Bearing Cone Replacer Front differential 09506 35010 Differential Drive Pinion Rear Bearing Replacer Rear differential 09515 30010 Rear Wheel Bearing Replacer Rear axle 09520 01010 Drive Shaft Remover Attachment Front drive shaft 09520 24010 Differe...

Page 135: ...ront Bearing Remover Front differential Rear differential 09564 32011 Differential Preload Adaptor Front differential 09570 22011 Differential Mounting Cushion Remover Replacer Front differential 09608 32010 Steering Knuckle Oil Seal Replacer Front differential 09610 20012 Pitman Arm Puller Front suspension 09612 65014 Steering Worm Bearing Puller Front differential 09612 01020 Claw B 09612 01050 ...

Page 136: ...nch Front suspension 09632 36010 Steering Vane Pump Bearing Replacer Front suspension Rear suspension 09636 20010 Upper Ball Joint Dust Cover Replacer Front differential 09649 17010 Steering Knuckle Tool Front axle Rear differential 09650 17011 Hub Bolt Remover Front axle Rear axle 09710 28012 Front Suspension Bushing Tool Set Rear suspension 09710 07062 Bushing Replacer 09710 30021 Suspension Bus...

Page 137: ...Compressor 09922 10010 Variable Open Wrench Front suspension 09950 00020 Bearing Remover Front drive shaft Front differential Front suspension Rear differential 09950 30012 Puller A Set 09951 03010 Upper Plate Front differential Rear differential 09953 03010 Center Bolt Front differential Rear differential 09954 03010 Arm Front differential Rear differential 09955 03030 Lower Plate 130 Front diffe...

Page 138: ... suspension Rear differential 09953 04020 Center Bolt 150 Front axle Front differential Front suspension Rear differential 09954 04010 Arm 25 Front axle Front differential Front suspension Rear differential 09955 04011 Claw No 1 Front differential 09955 04031 Claw No 3 Front axle Front suspension 09955 04061 Claw No 6 Front differential Rear differential 09957 04010 Attachment Front axle Front dif...

Page 139: ...Rear differential 09951 00540 Replacer 54 Front differential 09951 00560 Replacer 56 Rear axle 09951 00610 Replacer 61 Rear axle 09951 00640 Replacer 64 Rear differential 09951 00650 Replacer 65 Front axle Front differential 09950 60020 Replacer Set No 2 09951 00680 Replacer 68 Front suspension 09951 00710 Replacer 71 Rear axle Rear differential 09951 00790 Replacer 79 Front differential ...

Page 140: ...09951 00810 Replacer 81 Front axle 09951 00890 Replacer 89 Rear axle 09951 00910 Replacer 91 Front axle Rear differential 09950 70010 Handle Set Front axle Front differential Rear axle Rear differential Rear suspension 09951 07150 Handle 150 ...

Page 141: ...ECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgf cm 09031 00030 Pin Punch 09044 00010 Torx Socket E14 09082 00040 TOYOTA Electrical Tester 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ring Pliers Torx is a registered trademark of Textron Inc ...

Page 142: ...PP09A 03 PREPARATION SUSPENSION AND AXLE PP 87 EQUIPMENT Dial indicator with magnetic base Torque wrench Micrometer Voltmeter Ohmmeter Saw ...

Page 143: ...rd Cab and Access Cab Double Cab 3 80 liters 4 02 US qts 3 34 lmp qts 4 00 liters 4 23 US qts 3 52 lmp qts 3 50 liters 3 70 US qts 3 08 lmp qts 4 00 liters 4 23 US qts 3 52 lmp qts Hypoid gear oil API GL 5 Above 18 C 0 F SAE 90 Below 18 C 0 F SAE 80W or 80W 90 Rear differential LSD type Differential oil 2WD Standard Cab and Access Cab Double Cab 4WD Standard Cab and Access Cab Double Cab 3 15 lite...

Page 144: ...SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG Front differential 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent Front differential 08833 00100 THREE BOND 1360K or equivalent Rear differential ...

Page 145: ...09703 30010 Brake Shoe Return Spring Tool 09709 29018 LSPV Gauge Set 09718 00010 Shoe Hold Down Spring Driver 09737 00011 Brake Booster Push Rod Gauge 09737 00020 Brake Booster Push Rod Wrench 09751 36011 Brake Line Union Nut 10 x 12 mm Wrench 09843 18020 Diagnosis Check Wire 09950 50013 Puller C Set ...

Page 146: ...PP0FB 04 PREPARATION BRAKE PP 91 RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09905 00013 Snap Ring Pliers ...

Page 147: ...PP0FC 02 PP 92 PREPARATION BRAKE EQUIPMENT Torque wrench Micrometor Brake disc Dial indicator Brake disc Vernier calipers Brake drum ...

Page 148: ...PP0FD 02 PREPARATION BRAKE PP 93 LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT 3 ...

Page 149: ...ar 09612 00012 Rack Pinion Steering Rack Housing Stand PS gear 09612 07010 Main Shaft Retaining Ring Remover Replacer Steering column 09612 22011 Tilt Handle Bearing Replacer PS gear 09612 24014 Steering Gear Housing Overhaul Tool Set 09613 22011 Steering Rack Shaft Bushing Puller PS gear 09616 00011 Steering Worm Bearing Adjusting Socket PS gear 09630 00014 Power Steering Gear Housing Overhaul To...

Page 150: ...g Tool PS gear 09640 10010 Power Steering Pressure Gauge Set 09641 01010 Gauge Assy Power steering fluid 09641 01030 Attachment B Power steering fluid 09641 01060 Attachment E Power steering fluid 09816 30010 Oil Pressure Switch Socket PS gear 09910 00015 Puller Set 09911 00011 Puller Clamp Steering column 09912 00010 Puller Slide Hammer Steering column 09922 10010 Variable Open Wrench PS gear ...

Page 151: ...05020 Center Bolt 150 Steering column 09954 05021 Claw No 2 Steering column 09950 60010 Replacer Set 09951 00180 Replacer 18 PS gear 09951 00250 Replacer 25 PS gear 09951 00260 Replacer 26 PS gear 09951 00280 Replacer 28 PS vane pump 1GR FE 09951 00300 Replacer 30 PS gear 09951 00310 Replacer 31 PS gear 09951 00320 Replacer 32 PS gear ...

Page 152: ...ouble Cab 09951 00430 Replacer 43 Steering column Standard Cab Access Cab 09951 00460 Replacer 46 Steering column PS gear 09951 00490 Replacer 49 PS gear 09952 06010 Adapter PS gear 09950 70010 Handle Set 09951 07100 Handle 100 PS vane pump 1GR FE 2UZ FE 09951 07150 Handle 150 Steering column PS gear 09951 07200 Handle 200 PS gear 09951 07360 Handle 360 Steering column PS gear ...

Page 153: ...25I 02 PP 98 PREPARATION STEERING RECOMMENDED TOOLS 09025 00010 Small Torque Wrench 30 kgf cm PS vane pump PS gear 09042 00010 Torx Socket T30 Steering column Torx is a registered trademark of Textron Inc ...

Page 154: ...TEERING PP 99 EQUIPMENT Caliper gauge PS vane pump 1GR FE 2UZ FE Vernier calipers PS vane pump 1GR FE 2UZ FE Dial indicator PS gear Feeler gauge PS vane pump 1GR FE 2UZ FE Micrometer PS vane pump 1GR FE 2UZ FE Torque wrench ...

Page 155: ...PP0FX 03 PP 100 PREPARATION STEERING LUBRICANT Item Capacity Classification Power steering fluid Total 1 0 liters 1 1 US qts 0 9 Imp qts ATF DEXRON II or III ...

Page 156: ...PP1B9 08 PREPARATION STEERING PP 101 SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PS gear ...

Page 157: ...l Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00750 Airbag Deployment Wire Sub harness No 3 09082 00760 Airbag Deployment Wire Sub harness No 4 09082 00780 Airbag Deployment Wire Sub Harness No 6 09082 00802 Airbag Deployment Wire Sub Harness No 8 09082 10801 Wire A 09082 30801 Wire C ...

Page 158: ...PP0FS 03 PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM PP 103 RECOMMENDED TOOLS 09042 00010 Torx Socket T30 09082 00040 TOYOTA Electrical Tester Torx is a registered trademark of Textron lnc ...

Page 159: ...e wrench Bolt Length 35 mm 1 387 in Pitch 1 0 mm 0 039 in Diam 6 0 mm 0 236 in Airbag disposal Tire Width 185 mm 7 28 in Inner diam 360mm 14 17 in Airbag disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Plastic bag Airbag disposal ...

Page 160: ...PP06F 12 PREPARATION BODY ELECTRICAL PP 105 BODY ELECTRICAL SST Special Service Tools 09843 18020 Diagnosis Check Wire ...

Page 161: ...TION BODY ELECTRICAL RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09041 00030 Torx Driver T30 For removing and installing steering wheel pad 09042 00010 Torx Socket T30 For removing and installing steering wheel pad ...

Page 162: ...PP06H 05 PREPARATION BODY ELECTRICAL PP 107 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb 3 4 W Torque wrench ...

Page 163: ...PP25L 02 PP 108 PREPARATION BODY BODY SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00740 Airbag Deployment Wire Sub harness No 2 09812 00020 Door Hinge Set Bolt Wrench ...

Page 164: ...PP25M 03 PREPARATION BODY PP 109 RECOMMENDED TOOLS 09041 00030 Torx Driver T30 09042 00010 Torx Socket T30 09042 00020 Torx Socket T40 Torx is a registered trademark of Textron Inc ...

Page 165: ...lding Piano wire Windshield Sealer gun Brush Putty spatula Wooden block or similar object For tying both piano wire ends Plastic sheet To avoid surface damage Rope no projections difficult to break Seat belt pretensioner disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Seat belt pretensioner disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Seat belt pretin...

Page 166: ...PP0MW 03 PREPARATION BODY PP 111 LUBRICANT Item Capacity Classification MP grease ...

Page 167: ...PP 112 PREPARATION BODY SSM Special Service Materials 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent 08833 00030 Three cement black or equivalent 08850 00801 Windshield Glass Adhesive Set or equivalent ...

Page 168: ...lve 07117 58070 T Joint 07117 58080 Quick Disconnect Adapter 07117 58090 Quick Disconnect Adapter 07117 88060 Refrigerant Charging Hose 07117 88070 Refrigerant Charging Hose 07117 88080 Refrigerant Charging Hose 07112 66040 Magnetic Clutch Remover 07112 76060 Magnetic Clutch Stopper 07116 38360 Gas Leak Detector Assembly 09870 00025 A C Quick Joint Puller No 2 Liquid tube ...

Page 169: ...PP 114 PREPARATION AIR CONDITIONING 09960 10010 Variable Pin Wrench Set 09962 01000 Variable Pin Wrench Arm Assy 09963 00500 Pin 5 95994 10020 Snap Ring Pliers DENSO Part No ...

Page 170: ...PP0E3 04 PREPARATION AIR CONDITIONING PP 115 RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09216 00021 Belt Tension Gauge 09216 00030 Belt Tension Gauge Cable ...

Page 171: ...P 116 PREPARATION AIR CONDITIONING EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch Hexagon wrench Expansion valve ...

Page 172: ...DITIONING PP 117 LUBRICANT Item Capacity Classification Compressor oil ND OIL 8 or equivalent When replacing receiver 20 cc 0 71 fl oz When replacing condenser 40 cc 1 4 fl oz When replacing evaporator 40 to 50 cc 1 4 to 1 7 fl oz ...

Page 173: ... Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class 4T 5T 6T 7T 8T 9T 10T 11T No Mark w Washer No Mark No Mark w Washer SERVICE SPECIFICATIONS STANDARD BOLT SS 1 STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH ...

Page 174: ...0 65 in lbf 13 26 48 76 6T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 8 19 39 71 110 170 80 195 400 730 1 100 1 750 69 in lbf 14 29 53 80 127 9 21 44 80 125 90 210 440 810 1 250 78 in lbf 15 32 59 90 7T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 10 5 25 52 95 145 230 110 260 530 970 1 500 2 300 8 19 38 70 108 166 12 28 58 105 165 120 290 590 1 050 1 700 9 21 43 76 123 8T 8 10 12 1 25 1 25 1 25 29 61 1...

Page 175: ...k w Washer No Mark No Mark w Washer No Mark No Mark Nut with 1 or more marks on one side surface of the nut SERVICE SPECIFICATIONS STANDARD BOLT SS 3 HOW TO DETERMINE NUT STRENGTH HINT Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas sification number when tightening parts with a bolt and nut Example Bolt 4T Nut 4N or more ...

Page 176: ...in 5 460 mm 0 2150 in 5 480 mm 0 2157 in 5 500 mm 0 2165 in 5 520 mm 0 2173 in 5 540 mm 0 2181 in 5 560 mm 0 2189 in 5 580 mm 0 2197 in 5 600 mm 0 2205 in 5 620 mm 0 2213 in 5 640 mm 0 2220 in 5 660 mm 0 2228 in 5 680 mm 0 2236 in 5 700 mm 0 2244 in 5 720 mm 0 2252 in 5 740 mm 0 2260 in Ignition timing w Terminals TC and CG connected of DLC3 w o Terminals TC and CG connected of DLC3 8 to 12 BTDC a...

Page 177: ... 0024 in 0 030 to 0 065 mm 0 0012 to 0 0026 in 0 08 mm 0 0031 in 0 10 mm 0 0039 in 106 95 mm 4 2106 in 105 80 mm 4 1654 in 106 40 mm 4 1890 in 105 30 mm 4 1457 in Valve spring Deviation Maximum Free length Installed tension at 33 3 mm 1 311 in 2 0 mm 0 079 in 47 80 mm 1 8819 in 186 2 to 205 8 N 19 0 to 21 0 kgf 41 9 to 46 3 lbf Valve guide bush ing Inside diameter 5 51 to 5 53 mm 0 2169 to 0 2177 ...

Page 178: ...011 mm 0 8665 to 0 8666 in 22 012 to 22 014 mm 0 8666 to 0 8667 in 0 005 to 0 011 mm 0 0002 to 0 0004 in 0 050 mm 0 0020 in Crankshaft Thrust clearance Standard Maximum Crankshaft bearing cap set bolt tension portion diameter Standard Circuit runout Maximum Main journal diameter Main journal taper and out of round Maximum Crank pin diameter Crank pin taper and out of round Maximum Oil clearance St...

Page 179: ... Side rail Maximum No 1 No 2 Oil Side rail 93 910 to 93 920 mm 3 6972 to 3 6976 in 0 080 to 0 102 mm 0 0031 to 0 0040 in 0 13 mm 0 0051 in 22 001 to 22 004 mm 0 8662 to 0 8663 in 22 005 to 22 007 mm 0 8663 to 0 8664 in 22 008 to 22 010 mm 0 8665 to 0 8665 in 21 997 to 22 000 mm 0 8660 to 0 8661 in 22 001 to 22 003 mm 0 8661 to 0 8663 in 22 004 to 22 006 mm 0 8663 to 0 8664 in 0 001 to 0 007 mm 0 0...

Page 180: ...inder block 54 551 40 Idler pulley No 2 x Cylinder block 39 398 29 Water inlet x Cylinder head 9 0 92 80 in lbf V ribbed belt tensioner x Cylinder block 36 367 27 Oil pan x Cylinder block Bolt A B Nut See page EM 89 Bolt C 21 10 214 102 15 7 Oil pan x transmission 37 377 27 Oil strainer x Oil pan 9 0 92 80 in lbf Oil pan No 2 x Oil pan Bolt See page EM 89 Nut 9 0 10 92 102 80 in lbf 7 Drain plug x...

Page 181: ...Cylinder head 9 0 92 80 in lbf Stud bolt x Cylinder head A and C See page EM 82 B 4 0 19 5 41 199 35 in lbf 14 Union x Cylinder head 15 153 11 Straight screw plug x Cylinder head 80 816 59 Drive plate x Crankshaft 49 500 36 Engine mounting bracket x Frame bracket 38 388 28 Water outlet pipe No 1 x Cylinder block 10 102 7 Knock sensor x Cylinder block 20 204 15 Water drain lock x Cylinder block 25 ...

Page 182: ... 040 mm 0 0803 in 2 060 mm 0 0811 in 2 080 mm 0 0819 in 2 100 mm 0 0827 in 2 120 mm 0 0835 in 2 140 mm 0 0843 in 2 160 mm 0 0850 in 2 180 mm 0 0858 in 2 200 mm 0 0866 in 2 220 mm 0 0874 in 2 240 mm 0 0882 in 2 260 mm 0 0890 in 2 280 mm 0 0898 in 2 300 mm 0 0906 in 2 320 mm 0 0913 in 2 340 mm 0 0921 in 2 360 mm 0 0929 in 2 380 mm 0 0937 in 2 400 mm 0 0945 in 2 420 mm 0 0953 in 2 440 mm 0 0961 in 2 ...

Page 183: ... to 0 0026 in 0 08 mm 0 0031 in 0 10 mm 0 0039 in 1 0 mm 0 039 in 0 5 mm 0 020 in Valve spring Deviation Maximum Free length Installed tension at 35 0 mm 1 378 in 2 0 mm 0 079 in 54 1 mm 2 130 in 210 to 226 N 21 4 to 23 0 kgf 47 2 to 50 7 lbf Valve lifter Lifter diameter Lifter bore diameter Oil clearance STD Maximum 30 968 to 30 976 mm 1 2192 to 2 2195 in 31 000 to 31 016 mm 1 2205 to 1 2211 in 0...

Page 184: ...rk 3 Mark 4 Mark 5 Mark 6 Mark 7 Rod bend Maximum per 100 mm 3 94 in Rod twist Maximum per 100 mm 3 94 in Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt tension portion diameter STD Minimum 0 160 to 0 290 mm 0 0063 to 0 0138 in 0 35 mm 0 0138 in 22 880 to 22 920 mm 0 9008 to 0 9024 in 0 021 to 0 047 mm 0 0008 to 0 0019 in 0 059 mm 0 0023 in 1 487 ...

Page 185: ... taper and out of round Maximum 2 487 to 2 490 mm 0 0979 to 0 0980 in 2 490 to 2 493 mm 0 0980 to 0 0981 in 2 493 to 2 496 mm 0 0981 to 0 0983 in 2 496 to 2 499 mm 0 0983 to 0 0984 in 2 499 to 2 502 mm 0 0984 to 0 0985 in 2 481 to 2 484 mm 0 0977 to 0 0978 in 2 484 to 2 487 mm 0 0978 to 0 0979 in 2 487 to 2 490 mm 0 0979 to 0 0980 in 2 490 to 2 493 mm 0 0980 to 0 0981 in 2 493 to 2 496 mm 0 0981 t...

Page 186: ...90 Camshaft bearing cap x Cylinder head Bolt A Others 7 5 16 80 160 66 in lbf 12 Cylinder head cover x Cylinder head 6 0 60 53 in lbf Engine hanger x Cylinder head 37 380 27 Front water bypass joint Rear water bypass joint x Cylinder head 18 185 13 Intake manifold x Cylinder head 18 185 13 Timing belt rear plate x Cylinder head 7 5 80 66 in lbf Drive plate x Crankshaft 1st 2nd 49 Turn 90 500 Turn ...

Page 187: ...ECIFICATIONS ENGINE MECHANICAL 2UZ FE SS 15 Front exhaust pipe x Exhaust manifold 62 630 46 Center exhaust pipe x Front exhaust pipe 48 489 35 Heated oxygen sensor Bank 1 2 sensor 2 x Front exhaust pipe 44 450 32 ...

Page 188: ...arcoal canister x Charcoal canister cover 14 7 150 11 Heated oxygen sensor x Front exhaust pipe 44 450 33 A F sensor x Front exhaust pipe 44 450 33 Exhaust manifold x Cylinder head 21 214 15 Manifold stay x Exhaust manifold 40 408 30 Front exhaust pipe x Exhaust manifold 62 630 46 Exhaust center pipe x LH front exhaust pipe 48 489 35 Exhaust center pipe x RH front exhaust pipe 43 440 32 ...

Page 189: ...SS1M8 02 SERVICE SPECIFICATIONS EMISSION CONTROL 2UZ FE SS 17 EMISSION CONTROL 2UZ FE SERVICE DATA VSV for air injec tion system Resistance at 20 C 68 F 33 to 39 Ω ...

Page 190: ...ed N m kgf cm ft lbf Front exhaust pipe x Exhaust manifold 62 632 46 Front exhaust pipe x Center pipe 48 489 35 Heated oxygen sensor x Front exhaust pipe 44 450 32 Air pump assembly x Cylinder head 16 163 12 Air switching valve No 2 x Cylinder head 10 102 7 Air tube No 3 x Cylinder head 10 102 7 ...

Page 191: ...21 to 2 69 kΩ 0 49 to 0 67 kΩ VSV for ACIS Resistance at 20 C 68 F 33 to 39 Ω Fuel pump resistor Resistance at 20 C 68 F 0 70 to 0 76 Ω VSV for EVAP Resistance at 20 C 68 F 26 to 30 Ω ECT sensor Resistance at 20 C 68 F at 80 C 176 F 2 32 to 2 59 kΩ 0 310 to 0 326 kΩ Fuel cut rpm Fuel cut off rpm Fuel return rpm 2 500 rpm 1 200 rpm Throttle body Standard percentage of the valve opening angle Resist...

Page 192: ...1 214 16 Intake air surge tank x throttle body bracket 21 214 16 Intake air surge tank x Intake manifold 28 286 21 Fuel pressure regulator x Fuel delivery pipe 9 0 92 80 in lbf Fuel pipe bracket x Body 20 204 15 Charcoal canister x Body 14 7 150 11 Throttle body x Intake manifold 11 112 9 Camshaft timing oil control valve x Cylinder head 9 0 92 80 in lbf ECT sensor x Front water bypass joint 20 20...

Page 193: ...ngle 5 5 Throttle control motor Motor resistance at 20 C 68 F 0 3 to 100 Ω VSV for EVAP Resistance at 20 C 68 F 30 to 34 Ω VSV for ACIS Resistance at 20 C 68 F 33 to 39 Ω VT sensor Resistance Cold Hot 835 to 1 400 Ω 1 060 to 1 645 Ω Knock sensor Resistance at 20 C 68 F 120 to 280 Ω ECT sensor Resistance at 20 C 4 F 0 C 32 F 20 C 68 F 40 C 104 F 60 C 140 F 80 C 176 F 10 to 20 kΩ 4 to 7 kΩ 2 to 3 kΩ...

Page 194: ... pipe 7 5 80 66 in lbf Delivery pipe x Intake manifold 21 214 15 Fuel tank band x Body 62 632 45 Fuel pressure regulator x Delivery pipe 7 5 76 66 in lbf Throttle body x Intake manifold 18 185 13 ECT sensor x Front water bypass joint 19 6 200 14 Knock sensor x Cylinder head 20 204 15 Air fuel ratio sensor x Exhaust manifold 44 450 32 Heated oxygen sensor x Front exhaust pipe 44 450 32 Fuel pump re...

Page 195: ...RVICE DATA Water inlet w thermostat Valve opening temperature Valve lift at 95 C 203 F 80 to 84 C 176 to 183 F 8 mm 0 31 in or more Radiator cap Relief valve opening pressure Standard Minimum 93 to 123 kPa 0 95 to 1 25 kgf cm2 13 5 to 17 8 psi 78 kPa 0 8 kgf cm2 11 4 psi ...

Page 196: ...0 47 in head 9 0 23 92 235 80 in lbf 17 Idler pulley sub assy No 2 x Timing chain or belt cover sub assy 39 398 29 Water inlet x Timing chain or belt cover sub assy 9 0 92 80 in lbf Fan shroud x Radiator 5 0 51 44 in lbf Fan w fluid coupling x Water pump 21 214 15 V bank cover x Intake air surge tank 7 5 76 66 in lbf Engine under cover sub assy No 1 x Frame assy 29 296 21 Water inlet w thermostat ...

Page 197: ...Z FE SERVICE DATA Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 to 84 C 176 to 183 F 10 mm 0 39 in or more Radiator cap Relief valve opening pressure Standard Minimum 74 to 103 kPa 0 75 to 1 05 kgf cm2 10 7 to 14 9 psi 59 kPa 0 6 kgf cm2 8 6 psi ...

Page 198: ...linder block 12 7 130 9 Fan x Fluid coupling 5 5 55 47 in lbf Water pump x Cylinder block Bolt Stud bolt and nut 21 18 215 185 15 13 Water inlet housing x Water pump 18 185 13 Water inlet x Water inlet housing 19 195 14 Radiator x Radiator support 12 7 130 9 No 1 fan shroud x Radiator 5 50 44 in lbf Radiator mounting bolt 12 120 9 ...

Page 199: ... kgf cm2 4 3 psi or more 294 to 588 kPa 3 0 to 6 0 kgf cm2 43 to 85 psi Oil pump Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0 06 to 0 16 mm 0 0024 to 0 0063 in 0 16 mm 0 0063 in 0 03 to 0 09 mm 0 0012 to 0 0035 in 0 09 mm 0 0035 in 0 250 to 0 325 mm 0 0098 to 0 0128 in 0 325 mm 0 0128 in ...

Page 200: ... lbf Oil pressure switch 15 152 11 Drain plug x Oil pan No 2 40 408 30 Oil pipe x Timing chain cover 9 0 92 80 in lbf Oil pump cover x Timing chain cover 9 0 92 80 in lbf Relief valve plug x Oil pump cover 49 500 36 Union bolt x Oil filter bracket 68 693 50 Oil filter bracket x Timing chain cover 19 194 14 ...

Page 201: ...gf cm2 4 3 psi or more 294 to 588 kPa 3 0 to 6 0 kgf cm2 43 to 85 psi Oil pump Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0 060 to 0 180 mm 0 0024 to 0 0071 in 0 18 mm 0 0071 in 0 030 to 0 090 mm 0 0012 to 0 0035 in 0 09 mm 0 0035 in 0 250 to 0 325 mm 0 0098 to 0 0128 in 0 325 mm 0 0128 in ...

Page 202: ...f valve x Oil pump body 49 500 36 Oil strainer x Cylinder block Oil pump 7 5 80 66 in lbf No 1 oil pan x Oil pump Oil seal retainer Cylinder block 10 mm head 12 mm head 7 5 28 80 290 66 in lbf 21 Oil pan baffle plate x No 1 oil pan 7 5 80 66 in lbf No 2 oil pan x No 1 oil pan 7 5 80 66 in lbf Oil filter bracket x Oil pump 18 185 13 Oil dipstick guide x Cylinder head 15 153 11 Oil cooler x Oil filt...

Page 203: ...TION 1GR FE SERVICE DATA Spark plug Recommended spark plug NGK made DENSO made Electrode gap Standard Maximum LFR6C 11 K20HR U11 1 0 to 1 1 mm 0 039 to 0 043 in 1 46 mm 0 057 in Crankshaft posi tion sensor Resistance Cold Hot 1 630 to 2 740 Ω 2 065 to 3 225 Ω ...

Page 204: ...cleaner assy 8 0 82 71 in lbf Throttle body bracket x Intake air surge tank 21 214 16 Intake air surge tank x Intake manifold 28 286 21 Surge tank stay x Intake air surge tank 21 214 16 Oil baffle plate x Surge tank stay No 1 9 0 92 80 Crankshaft position sensor x Cylinder block 10 102 7 Cooler compressor x V ribbed belt tensioner 25 255 18 Suction hose sub assy 8 0 82 71 in lbf VVT sensor x Cylin...

Page 205: ... IGNITION 2UZ FE SERVICE DATA Firing order 1 8 4 3 6 5 7 2 Spark plug Recommended spark plug DENSO made NGK made Electrode gap SK20R11 IFR6A11 1 0 to 1 1 mm 0 039 to 0 043 in Crankshaft position sensor Resistance Cold Hot 1 630 to 2 740 Ω 2 065 to 3 225 Ω ...

Page 206: ...ECIFICATION Part tightened N m kgf cm ft lbf Spark plug x Cylinder head 17 5 180 13 Ignition coil with igniter x Cylinder head cover 7 5 76 66 in lbf Camshaft position sensor x LH cylinder head 7 5 76 66 in lbf Crankshaft position sensor x Oil pump 6 5 65 58 in lbf ...

Page 207: ... 0 354 in 4 0 mm 0 158 in 5 0 mm 0 197 in Starter 2 0 kW type Rated voltage and output power No load characteristics Current Starter armature assy Circle runout Maximum Commutator diameter Standard Minimum Undercut depth Standard Minimum Starter yoke Shunt coil resistance at 20 C 68 F Brush Brush length Standard Minimum Starter brush holder assy Brush spring load Standard Minimum 12 V 2 0 kW 100 A...

Page 208: ...ousing assy x Repair service starter kit Starter Assy 1 6 kW 7 5 76 66 in lbf Lead wire x Repair service starter kit Starter Assy 1 6 kW 10 102 7 4 Commutator end frame x Brush holder Starter Assy 2 0 kW 3 8 39 34 in lbf Starter drive housing assy x Magnetic Starter Switch Starter Assy 2 0 kW 9 3 95 82 in lbf Commutator end frame x Starter drive housing assy Starter Assy 2 0 kW 9 3 95 82 in lbf Le...

Page 209: ... kgf 2 7 lbf 30 0 mm 1 181 in 29 0 mm 1 142 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 0 0020 in 0 9 mm 0 035 in Starter 2 0 kW type Rated voltage and output power No load characteristics Current rpm Brush length Standard Minimum Spring installed load Standard Minimum Commutator Diameter Standard Minimum Undercut depth Standard Minimum Circle runout Maximum Field frame Shunt coil resistance at 20 ...

Page 210: ... 22 in lbf 32 in lbf End cover x Brush holder 1 4 kW type 2 0 kW type 1 5 3 8 15 39 13 in lbf 34 in lbf Starter hosing x Magnetic switch 1 4 kW type 2 0 kW type 5 9 9 3 60 95 52 in lbf 82 in lbf End cover with field frame x Magnetic switch 1 4 kW type 2 0 kW type 5 9 9 3 60 95 52 in lbf 82 in lbf Lead wire of field coil x Terminal C 5 9 60 52 in lbf Wire clamp Starter wire x Starter 9 81 100 84 in...

Page 211: ...dard specific gravity 12 5 to 12 9 V 1 25 to 1 29 at 20 C 68 F Voltage regulator Regulating voltage 13 2 to 14 8 V Generator brush holder assy Brush length Standard Minimum 10 5 mm 0 413 in 4 5 mm 0 177 in Generator rotor assy Resistance at 20 C 68 F Slip ring diameter Standard Minimum 2 3 to 2 7 Ω 14 2 to 14 4 mm 0 559 to 0 567 in 14 0 mm 0 551 in ...

Page 212: ...in lbf V bank cover x Intake air surge tank sub assy and Air cleaner assy 7 5 76 66 in lbf Engine under cover sub assy No 1 x Frame assy 29 296 21 Engine under cover assy rear x Frame assy 29 296 21 Retainer plate x Drive end frame assy generator 2 6 27 23 in lbf Generator coil assy x Drive frame assy generator 5 8 59 51 in lbf Generator brush holder assy x Generator coil assy 1 8 18 16 in lbf Gen...

Page 213: ...enance free Voltage at 20 C 68 F 1 25 to 1 29 12 5 to 12 9 V Generator Rated output Rotor coil resistance at 20 C 68 F Slip ring diameter Standard Minimum Brush exposed length Standard Minimum 12V 100A 2 1 to 2 5 Ω 14 2 to 14 4 mm 0 559 to 0 567 in 12 8 mm 0 504 in 10 5 mm 0 413 in 1 5 mm 0 059 in Voltage regulator Regulating voltage 13 2 to 14 8 V ...

Page 214: ...erator pulley x Rotor 110 5 1 125 81 Rectifier holder x Lead wire on rectifier end frame 2 94 30 26 in lbf Voltage regulator x Rectifier end frame Rectifier holder 1 96 20 17 in lbf Brush holder x Rectifier holder Voltage regulator 1 96 20 17 in lbf Rear end cover x Rectifier holder 4 4 45 39 in lbf Plate terminal x Rectifier holder Bolt Nut 3 85 4 4 39 45 34 in lbf 39 in lbf Terminal insulator x ...

Page 215: ... to 5 0 mm 0 039 to 0 197 in Pedal freeplay 5 0 to 15 0 mm 0 197 to 0 591 in Clutch release point from pedal full stroke end position Standard 25 mm 0 98 in or more Disc rivet head depth Minimum 0 3 mm 0 012 in Disc runout Maximum 0 7 mm 0 027 in Flywheel runout Maximum 0 1 mm 0 004 in Diaphragm spring for wear Maximum depth Maximum width 0 5 mm 0 020 in 6 0 mm 0 236 in Diaphragm spring tip non al...

Page 216: ... mounting nut 14 143 10 Clutch line union 15 155 11 Bleeder plug x Release cylinder body 11 110 8 Release cylinder installation bolt 12 120 9 Clutch accumulator installation bolt 12 120 9 Clutch housing cover installation bolt 12 120 9 Clutch cover x Flywheel 19 195 14 Release fork support x Transmission 47 479 35 ...

Page 217: ... 50 mm 0 0276 to 0 0591 in 0 70 mm 0 0276 in Synchronizer ring No 3 to 6th gear clearance Standard Minimum 0 70 to 1 50 mm 0 0276 to 0 0591 in 0 70 mm 0 0276 in Wide of the hub sleeve Thickness of the gear shift fork No 2 and No 3 0 26 to 0 84 mm 0 0102 to 0 0331 in Input shaft runout Maximum 0 03 mm 0 0012 in Input shaft journal diameter Part See page MT 34 A Standard Minimum B Standard Minimum C...

Page 218: ... to 2 32 mm 0 0894 to 0 0913 in 2 32 to 2 37 mm 0 0913 to 0 0933 in Clutch hub No 3 snap ring thickness Standard clearance Mark A B C D E F G 0 1 mm 0 0039 in or less 2 10 to 2 15 mm 0 0827 to 0 0846 in 2 15 to 2 20 mm 0 0846 to 0 0866 in 2 20 to 2 25 mm 0 0866 to 0 0886 in 2 25 to 2 30 mm 0 0886 to 0 0906 in 2 30 to 2 35 mm 0 0906 to 0 0925 in 2 35 to 2 40 mm 0 0925 to 0 0945 in 2 40 to 2 45 mm 0...

Page 219: ... 34 002 to 34 015 mm 1 3387 to 1 3392 in 34 002 mm 1 3387 in Gear inside diameter 1st gear Standard Maximum 2nd gear Standard Maximum Reverse gear Standard Maximum 54 015 to 54 040 mm 2 1266 to 2 1276 in 54 040 mm 2 1276 in 60 015 to 60 040 mm 2 3628 to 2 3638 in 60 040 mm 2 3638 in 51 015 to 51 040 mm 2 0085 to 2 0094 in 51 040 mm 2 0094 in Clutch hub No 1 snap ring thickness Standard Mark A B C ...

Page 220: ... 0984 in 2 50 to 2 55 mm 0 0984 to 0 1004 in 2 55 to 2 60 mm 0 1004 to 0 1024 in 2 60 to 2 65 mm 0 1024 to 0 1043 in 2 65 to 2 70 mm 0 1043 to 0 1063 in 2 70 to 2 75 mm 0 1063 to 0 1083 in 2 75 to 2 80 mm 0 1083 to 0 1102 in 2 80 to 2 85 mm 0 1102 to 0 1122 in 2 85 to 2 90 mm 0 1122 to 0 1142 in 2 90 to 2 95 mm 0 1142 to 0 1161 in Oil seal drive in depth Front case oil seal Extension housing oil s...

Page 221: ...exhaust manifold 48 490 35 RH front exhaust pipe x Exhaust pipe support 43 440 32 Manifold stay x Front exhaust pipe and transmission 40 408 30 Propeller shaft x Differential 88 897 65 Center support bearing x Body 40 410 30 Drain plug x Transmission 37 380 27 Control sub assembly x Front case 21 214 15 Back up lamp switch x Front case 44 449 32 Plug x Front case 39 397 29 Release fork support x C...

Page 222: ... 4 4 position O D OFF Throttle valve fully opened 1 2 2 3 3 4 5 4 4 3 3 2 2 1 3 position Throttle valve fully opened 1 2 2 3 4 3 3 2 2 1 2 position Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 2 1 47 60 km h 29 37 mph 89 101 km h 55 62 mph 126 145 km h 78 90 mph 171 188 km h 106 117 mph 166 183 km h 103 114 mph 116 130 km h 72 81 mph 78 87 km h 48 54 mph 36 43 km ...

Page 223: ...le valve fully opened 1 2 2 3 3 4 5 4 4 3 3 2 2 1 3 position Throttle valve fully opened 1 2 2 3 4 3 3 2 2 1 2 position Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 2 1 47 60 km h 29 37 mph 88 101 km h 55 62 mph 126 145 km h 78 90 mph 170 188 km h 106 117 mph 165 182 km h 103 113 mph 116 130 km h 72 81 mph 78 87 km h 48 54 mph 36 43 km h 22 27 mph 46 53 km h 29 33...

Page 224: ...tle valve fully opened 1 2 2 3 3 4 5 4 4 3 3 2 2 1 3 position Throttle valve fully opened 1 2 2 3 4 3 3 2 2 1 2 position Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 2 1 47 60 km h 29 37 mph 92 105 km h 57 65 mph 133 153 km h 83 95 mph 170 188 km h 106 117 mph 163 180 km h 101 112 mph 118 133 km h 73 83 mph 79 88 km h 49 55 mph 37 44 km h 23 27 mph 44 51 km h 27 3...

Page 225: ...alve body 10 100 7 Parking lock pawl bracket x Transmission case 7 4 75 65 in lbf Oil cooler x Body 11 110 8 Transmission oil cooler bracket x Oil cooler 4 9 50 43 in lbf Oil cooler tube clamp x Body 5 0 50 48 in lbf Shift lever x Shift lever housing 18 180 13 Shift lever housing x Steering column assemby 12 120 9 Parking lock cable No 1 x Shift lever housing 2 9 29 25 in lbf Parking lock cable No...

Page 226: ...2 25 to 2 30 mm 0 0886 to 0 0906 in 2 30 to 2 35 mm 0 0906 to 0 0925 in 2 35 to 2 40 mm 0 0925 to 0 0945 in 2 40 to 2 45 mm 0 0945 to 0 0965 in 2 45 to 2 50 mm 0 0965 to 0 0984 in 2 50 to 2 55 mm 0 0984 to 0 1004 in 2 55 to 2 60 mm 0 1004 to 0 1024 in 2 60 to 2 65 mm 0 1024 to 0 1043 in 2 65 to 2 70 mm 0 1043 to 0 1063 in 2 70 to 2 75 mm 0 1063 to 0 1083 in 2 75 to 2 80 mm 0 1083 to 0 1102 in 2 80...

Page 227: ...0 0807 in 2 05 to 2 10 mm 0 0807 to 0 0827 in 2 10 to 2 15 mm 0 0827 to 0 0846 in 2 15 to 2 20 mm 0 0846 to 0 0866 in 2 20 to 2 25 mm 0 0866 to 0 0886 in 2 25 to 2 30 mm 0 0886 to 0 0906 in 2 30 to 2 35 mm 0 0906 to 0 0925 in 2 35 to 2 40 mm 0 0925 to 0 0945 in 2 40 to 2 45 mm 0 0945 to 0 0965 in 2 45 to 2 50 mm 0 0965 to 0 0984 in 2 50 to 2 55 mm 0 0984 to 0 1004 in Planetary gear Pinion gear thr...

Page 228: ...er 16 164 12 Front exhaust pipe x Exhaust manifold 62 630 46 Filler plug x Transfer 37 380 27 Head screw plug x Transfer 19 190 14 Oil pump body x Front case 7 5 76 66 in lbf Separator with oil strainer x Front case 7 5 76 66 in lbf Transfer 4WD position switch 37 377 27 Transfer for L4 position switch 37 377 27 Actuator assembly set bolt 20 204 15 Shift fork shaft stopper set bolt 19 190 14 Strai...

Page 229: ... mm 0 0921 to 0 0929 in 2 36 to 2 38 mm 0 0929 to 0 0937 in 2 38 to 2 40 mm 0 0937 to 0 0945 in 2 40 to 2 42 mm 0 0945 to 0 0953 in 2 42 to 2 44 mm 0 0953 to 0 0961 in 2 18 to 2 20 mm 0 0858 to 0 0866 in 2 20 to 2 22 mm 0 0866 to 0 0874 in 2 22 to 2 24 mm 0 0874 to 0 0882 in 2 24 to 2 26 mm 0 0882 to 0 0890 in 2 26 to 2 28 mm 0 0890 to 0 0898 in 2 48 to 2 50 mm 0 0976 to 0 0984 in 2 50 to 2 52 mm ...

Page 230: ...nter support bearing x Center yoke 1st 181 1 845 133 2nd Loosen nut 3rd 82 835 60 PROPELLER SHAFT ASSEMBLY 4WD Rear propeller shaft x Rear differential 88 897 65 Rear propeller shaft x Transfer 88 897 65 Front propeller shaft x Front differential 88 897 65 Front propeller x Transfer 88 897 65 Center support bearing x Body 40 410 30 Intermediate shaft x Center support bearing x Companion flange 1st...

Page 231: ...for U S A GSK30L TRFDKA Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 75 2 mm 2 961 in 50 8 mm 2 055 in GSK30L TRBDKA Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 77 9 mm 3 067 in 50 2 mm 1 976 in UCK30L TRBDKA Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 77 2 mm 3 039 in 54 5 mm 2 146 in UCK40L TRBDKA Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 53 5 mm 2 106 in 68 1 mm 2 681 in Front ...

Page 232: ...3 D 4 Tire size P265 70R16 Front A 1 B 2 Rear C 3 D 4 64 9 mm 2 555 in 62 4 mm 2 457 in 65 0 mm 2 559 in 62 3 mm 2 453 in UCK30L ARBSKA Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 70R16 B2BB ORP Front A 1 B 2 Rear C 3 D 4 Tire size P265 65R17 Front A 1 B 2 Rear C 3 D 4 Tire size P265 65R17 B2BC SPORT Front A 1 B 2 Rear C 3 D 4 73 2...

Page 233: ...e size P265 65R17 Front A 1 B 2 Rear C 3 D 4 48 0 mm 1 890 in 67 1 mm 2 642 in 48 1 mm 1 894 in 66 9 mm 2 634 in 74 3 mm 2 925 in 62 3 mm 2 453 in 47 7 mm 1 878 in 67 9 mm 2 673 in UCK40L ARBLKA Tire size P265 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 70R16 B2BB ORP Front A 1 B 2 Rear C 3 D 4 Tire size P265 65R17 Front A 1 B 2 Rear C 3 D 4 47 3 mm 1 862 in 71 8 mm 2 827 in 73 3 mm 2 886 in 6...

Page 234: ...UCK40L ARBLKK Tire size P265 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 70R16 B2BB ORP Front A 1 B 2 Rear C 3 D 4 Tire size P265 65R17 Front A 1 B 2 Rear C 3 D 4 48 5 mm 1 909 in 78 7 mm 3 098 in 74 7 mm 2 941 in 74 0 mm 2 913 in 48 1 mm 1 894 in 79 7 mm 3 138 in UCK31L PRBSKK Tire size P245 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 70R16 Front A 1 B 2 Rear C 3 D 4 Tire size P265 65R17 ...

Page 235: ...ar C 3 D 4 Tire size P265 65R17 Front A 1 B 2 Rear C 3 D 4 57 4 mm 2 260 in 54 1 mm 2 130 in 55 0 mm 2 165 in 55 7 mm 2 193 in 56 9 mm 2 240 in 55 5 mm 2 185 in 1 Ground clearance of the front drive shaft center 2 Ground clearance of the front adjusting cam bolt center 3 Ground clearance of the rear axle shaft center 4 Ground clearance of the leaf spring front side bushing center ...

Page 236: ...5 0 75 0 08 45 0 13 0 75 Front wheel alignment UCK41L PRBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 0 08 45 0 13 0 75 0 09 45 0 15 0 75 0 08 45 0 13 0 75 Camber C cab for U S A 2WD models Right left error 30 0 5 or less GSK30L ARFSKA Tire size P245 70R16 Tire size P265 70R16 0 04 45 0 07 0 75 0 04 45 0 07 0 75 GSK30L ARBSKA Tire size P245 70R16 Tire size P265 70R16...

Page 237: ...6 45 0 26 0 75 Camber For CANADA Right left error 30 0 5 or less GSK30L TRBDKK Tire size P245 70R16 0 08 45 0 14 0 75 Front wheel alignment UCK40L TRBDKK Tire size P245 70R16 0 13 45 0 21 0 75 UCK30L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 65R17 0 08 45 0 14 0 75 0 08 45 0 14 0 75 0 08 45 0 14 0 75 UCK40L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 70R16...

Page 238: ...6 0 75 1 54 45 1 90 0 75 Front wheel alignment UCK41L PRBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 1 47 45 1 79 0 75 1 51 45 1 85 0 75 1 53 45 1 89 0 75 Caster C cab for U S A 2WD models Right left error 30 0 5 or less GSK30L ARFSKA Tire size P245 70R16 Tire size P265 70R16 1 32 45 1 54 0 75 1 41 45 1 68 0 75 GSK30L ARBSKA Tire size P245 70R16 Tire size P265 70R16...

Page 239: ...9 45 1 98 0 75 Caster For CANADA Right left error 30 0 5 or less GSK30L TRBDKK Tire size P245 70R16 2 00 45 2 00 0 75 Front wheel alignment UCK40L TRBDKK Tire size P245 70R16 1 23 45 1 39 0 75 UCK30L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 65R17 2 04 45 2 07 0 75 2 07 45 2 12 0 75 2 42 45 2 70 0 75 UCK40L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 70R16...

Page 240: ...0 21 0 75 10 14 45 10 24 0 75 Front wheel alignment UCK41L PRBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 10 14 45 10 24 0 75 10 13 45 10 21 0 75 10 14 45 10 24 0 75 Steering axis inclination C cab for U S A 2WD models Right left error 30 0 5 or less GSK30L ARFSKA Tire size P245 70R16 Tire size P265 70R16 10 18 45 10 30 0 75 10 18 45 10 30 0 75 GSK30L ARBSKA Tire si...

Page 241: ...0 10 0 75 Steering axis inclination For CANADA Right left error 30 0 5 or less GSK30L TRBDKK Tire size P245 70R16 10 31 45 10 51 0 75 Front wheel alignment UCK40L TRBDKK Tire size P245 70R16 10 09 45 10 15 0 75 UCK30L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 65R17 10 31 45 10 51 0 75 10 30 45 10 50 0 75 10 30 45 10 50 0 75 UCK40L ARBSKK Tire size P245 70R16 Tire size P265 70...

Page 242: ...ment UCK41L PRBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 0 06 45 0 11 0 2 1 78 2 mm 0 07 0 08 in 0 07 45 0 11 0 2 1 90 2 mm 0 07 0 08 in 0 06 45 0 11 0 2 1 78 2 mm 0 07 0 08 in Toe in total C cab for U S A 2WD models Rack end length difference 1 5 mm 0 059 in or less GSK30L ARFSKA Tire size P245 70R16 Tire size P265 70R16 0 08 45 0 14 0 2 2 29 2 mm 0 09 0 08 in 0 ...

Page 243: ...difference 1 5 mm 0 059 in or less GSK30L TRBDKK Tire size P245 70R16 0 05 45 0 08 0 2 1 38 2 mm 0 05 0 08 in Front wheel alignment UCK40L TRBDKK Tire size P245 70R16 0 03 45 0 04 0 2 1 11 2 mm 0 04 0 08 in UCK30L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 65R17 0 05 45 0 08 0 2 1 38 2 mm 0 05 0 08 in 0 05 45 0 09 0 2 1 42 2 mm 0 06 0 08 in 0 05 45 0 09 0 2 1 42 2 mm 0 06 0 08...

Page 244: ...2 35 34 35 56 32 21 32 35 35 32 35 53 32 19 32 32 Front wheel alignment UCK31L PRBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 35 32 35 53 32 19 32 32 35 34 35 57 32 22 32 36 35 32 35 53 32 19 32 32 UCK41L PRBSKA Tire size P245 70R16 Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 35 49 35 81 32 28 32 47 35 49 35 81 32 28 32 47 35 51 35 85 32 ...

Page 245: ...30 35 50 32 18 32 30 35 28 35 47 32 16 32 27 35 16 35 26 32 04 32 07 Front wheel alignment UCK30L ASBSKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 Tire size P265 65R17 B2BC SPORT 35 26 35 44 32 14 32 24 35 28 35 47 32 16 32 26 35 26 35 44 32 14 32 24 35 13 35 22 32 02 32 02 UCK30L ASBLKA Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 Tire size...

Page 246: ...4 35 40 32 13 32 21 Wheel angle For CANADA Front wheel GSK30L TRBDKK Tire size P245 70R16 35 24 35 40 32 13 32 21 Front wheel alignment UCK40L TRBDKK Tire size P245 70R16 36 01 36 02 32 32 32 54 UCK30L ARBSKK Tire size P245 70R16 Tire size P265 70R16 Tire size P265 65R17 35 24 35 40 32 13 32 21 36 24 35 40 32 13 32 21 35 24 35 40 32 13 32 21 USK40L ARBSKK Tire size P245 70R16 Tire size P265 70R16 ...

Page 247: ... 30 32 50 35 49 35 81 32 28 32 47 UCK41L PRBLKK Tire size P265 70R16 Tire size P265 70R16 B2BB ORP Tire size P265 65R17 35 48 35 80 32 28 32 46 35 50 35 84 32 29 32 49 35 48 35 80 32 28 32 46 Front drive shaft Front drive shaft length 523 5 2 0 mm 20 610 0 079 in Front suspension Upper ball joint turning torque 0 7 4 4 N m 7 45 kgf cm 6 39 in lbf Lower ball joint excessive play Maximum 0 5 mm 0 02...

Page 248: ...6 1 24 mm 0 0457 0 0488 in 1 26 1 34 mm 0 0496 0 0528 in 2 00 2 02 mm 0 0787 0 0795 in 2 03 2 05 mm 0 0799 00807 in 2 06 2 08 mm 0 0811 0 0819 in 2 09 2 11 mm 0 0823 0 0831 in 2 12 2 14 mm 0 0835 0 0843 in 2 15 2 17 mm 0 0846 0 0854 in Front differential 2 18 2 20 mm 0 0858 0 0866 in 2 21 2 23 mm 0 0870 0 0878 in 2 24 2 26 mm 0 0882 0 0890 in 2 27 2 29 mm 0 0894 0 0902 in 2 30 2 32 mm 0 0906 0 091...

Page 249: ...le bearing press in depth 0 3 0 3 mm 0 012 0 012 in Axle shaft bearing backlash Maximum 0 7 mm 0 028 in R l h ft Axle shaft deviation Maximum 0 1 mm 0 004 in Rear axle shaft Shaft runout Maximum 2 0 mm 0 079 in Flange runout Maximum 0 1 mm 0 004 in Companion flange runout Maximum 0 09 mm 0 0035 in Ring gear runout Maximum 0 05 mm 0 0020 in Drive pinion to ring gear backlash 0 13 0 18 mm 0 0051 0 0...

Page 250: ...05 mm 0 0020 in Drive pinion oil seal drive in depth 0 mm 0 in 1 80 mm 0 0709 in 1 86 mm 0 0732 in 1 92 mm 0 0756 in 1 98 mm 0 0780 in Rear differential 2 04 mm 0 0803 in Rear differential Sid th t h thi k 2 10 mm 0 0827 in Side gear thrust washer thickness 2 22 mm 0 0850 in 2 28 mm 0 0874 in 2 34 mm 0 0898 in 2 34 mm 0 0921 in 2 40 mm 0 0945 in 2 46 mm 0 0969 in ...

Page 251: ... 96 mm 0 1165 in 98 2 98 mm 0 1173 in 00 3 00 mm 0 1181 in R diff ti l Sid b i dj ti h thi k 02 3 02 mm 0 1189 in Rear differential Side bearing adjusting washer thickness 04 3 04 mm 0 1197 in 06 3 06 mm 0 1205 in 08 3 08 mm 0 1213 in 10 3 10 mm 0 1220 in 12 3 12 mm 0 1228 in 14 3 14 mm 0 1236 in 16 3 16 mm 0 1244 in 18 3 18 mm 0 1252 in 20 3 20 mm 0 1260 in 22 3 22 mm 0 1268 in 24 3 24 mm 0 1276 ...

Page 252: ... 0 0803 in 05 2 05 mm 0 0807 in 06 2 06 mm 0 0811 in R diff ti l D i i i b i dj ti h thi k 07 2 07 mm 0 0815 in Rear differential Drive pinion bearing adjusting washer thickness 08 2 08 mm 0 0819 in 09 2 09 mm 0 0823 in 10 2 10 mm 0 0827 in 11 2 11 mm 0 0831 in 12 2 12 mm 0 0835 in 13 2 13 mm 0 0839 in 14 2 14 mm 0 0843 in 15 2 15 mm 0 0846 in 16 2 16 mm 0 0850 in 17 2 17 mm 0 0854 in 18 2 18 mm 0...

Page 253: ...t mounting cushion x Chassis frame 137 1 400 101 Differential rear mounting cushion x Chassis frame 87 890 64 Differential front mounting cushion x Differential 157 1 600 116 Differential rear mounting cushion x Differential 108 1 100 80 Ring gear x Differential case 97 985 71 Differential carrier x Differential tube 78 800 58 Differential carrier x Side bearing retainer 69 700 51 Differential x F...

Page 254: ...ENTIAL LH differential case x RH differential case 47 480 35 Differential carrier x Bearing cap 113 1 150 83 Differential case x Ring gear 125 1 270 92 Differential carrier x Axle housing 73 740 54 Drive pinion x Companion flange See page SA 133 REAR SUSPENSION Shock absorber x Chassis frame 20 200 15 Shock absorber x Axle housing 87 890 64 U bolt x Spring seat 133 1 350 98 Leaf spring front side ...

Page 255: ...n Front brake pad thickness STD 11 5 mm 0 453 in Minimum 1 0 mm 0 039 in Front brake disc thickness STD 28 0 mm 1 102 in Minimum 26 0 mm 1 024 in Front brake disc runout Maximum 0 07 mm 0 0028 in Rear brake drum inside diameter STD 295 0 mm 11 614 in Maximum 297 0 mm 11 693 in Rear brake shoe lining thickness STD 6 0 mm 0 236 in Minimum 1 0 mm 0 039 in Rear brake drum to shoe clearance 0 5 mm 0 02...

Page 256: ...c brake booster x Pump motor bracket 7 8 80 69 in lbf Hydraulic brake booster x Master cylinder solenoid 31 9 325 24 Clevis lock nut w VSC 25 5 260 19 Clevis lock nut w o VSC 25 255 11 Brake booster accumulator assembly x Pump motor assembly 57 4 585 42 Yaw rate sensor x Body 12 5 128 9 Brake line union nut 15 155 11 Front disc brake caliper x Steering knuckle 123 1 250 90 Rear drum brake wheel cy...

Page 257: ... or less PS VANE PUMP 2UZ FE Pump shaft and front housing bushing oil clearance STD 0 03 0 05 mm 0 0012 0 0020 in Pump shaft and front housing bushing oil clearance Maximum 0 07 mm 0 0028 in Vane plate height Minimum 8 6 mm 0 339 in Vane plate thickness Minimum 1 397 mm 0 0550 in Vane plate length Minimum 14 991 mm 0 5902 in Vane plate and pump rotor groove clearance Maximum 0 033 mm 0 0013 in Van...

Page 258: ...port x Column tube assembly 19 195 14 STEERING COLUMN Double Cab Steering wheel pad set screw Torx screw 8 8 90 78 in lbf Steering wheel set nut 50 510 37 Control valve shaft x No 2 intermediate shaft assembly 35 360 26 No 2 intermediate shaft assembly x Sliding yoke 35 360 26 No 2 universal joint assembly x Sliding yoke 35 360 26 No 2 universal joint assembly x Main shaft assembly 35 360 26 Steer...

Page 259: ... 69 520 700 38 51 Rack housing cap 59 600 43 Self locking nut 30 300 22 Control valve housing set bolt 18 185 13 PS gear assembly set bolt 165 1 700 123 PS gear assembly set bolt and nut 130 1 350 96 Bracket x Body Bolt and nut 165 1 700 123 Bracket x Body Stud bolt 20 200 15 Pressure feed and return tubes x Control valve housing 22 25 227 250 16 18 Control valve shaft x No 2 intermediate shaft as...

Page 260: ...AIRBAG ASSEMBLY Passenger Side of Split Type Front seat x Body 37 377 27 Front seat center belt x Front seat 42 428 31 Seatback cover bracket x Seatback frame 5 5 56 49 in lbf Armrest assembly x Front seat 20 204 15 CURTAIN SHIELD AIRBAG ASSEMBLY Curtain shield airbag assembly x Body 9 8 100 7 AIRBAG SENSOR ASSEMBLY Airbag sensor assembly x Body 17 5 179 13 FRONT AIRBAG SENSOR Front airbag sensor ...

Page 261: ...ETER On vehicle DC 13 5 V 25 C at 77 F 2UZ FE Standard indication Allowable range 700 630 770 1 000 900 1 100 2 000 1 875 2 125 3 000 2 850 3 150 4 000 3 850 4 150 5 000 4 850 5 150 6 000 5 820 6 180 TACHOMETER On vehicle DC 13 5 V 25 C at 77 F 1GR FE Standard indication Allowable range 700 630 770 1 000 900 1 000 2 000 1 850 2 150 3 000 2 800 3 200 4 000 3 800 4 200 5 000 4 800 5 100 6 000 5 750 ...

Page 262: ...ICATIONS BODY ELECTRICAL SE Approx 100 3 90 2 5 0 10 Approx 110 0 2 5 ENGINE COOLANT TEMPERATURE RECEIVER GAUGE Temperature C F Resistance kΩ 20 4 13 54 to 16 63 20 68 2 28 to 2 63 80 176 0 31 to 0 33 110 230 0 138 to 0 15 ...

Page 263: ...Rear bumper bar x Rear bumper reinforcement 29 310 22 w Towing hitch Rear bumper reinforcement x Body 100 1020 74 Receiver hitch bracket x Rear bumper reinforcement 160 1632 118 HOOD Hood hinge x Hood 13 133 10 Hood lock x Body 7 8 80 69 in lbf HOOD SUPPORT Hood support x Hood 22 224 16 Hood support x Body 22 224 16 FRONT DOOR Door hinge x Body 23 235 17 Door hinge x Door panel 23 235 17 Door chec...

Page 264: ... lbf Window regulator x Door panel 8 0 82 71 in lbf Door glass x Window regulator 8 0 82 71 in lbf ACCESS DOOR Door hinge x Body 23 235 17 Door hinge x Door panel 23 235 17 Door check x Body 27 275 20 Door check x Door panel 5 0 51 44 in lbf Cancel lever x Door panel 5 0 51 44 in lbf Outside handle x Door panel 5 5 56 49 in lbf Upper door lock x Door panel 12 5 128 9 Lower door lock x Door panel 5...

Page 265: ...back cover bracket x Seat frame assembly 5 5 56 49 in lbf Front seat x Body 37 380 27 Bench type Outer track assembly x Seat cushion frame 20 204 15 Seatback frame x Armrest 18 185 13 Seatback assembly x Seat cushion assembly 42 430 32 Seat track lower rear bracket x Outer track assembly 20 204 15 Seat position sensor for driver seat x RH Outer track assembly 8 0 82 71 in lbf Seat position sensor ...

Page 266: ...nge x Body 37 380 27 Rear No 1 seat outer adjuster x Seat cushion frame 43 440 32 Rear No 1 seat outer adjuster x Seatback frame 43 440 32 Rear No 1 seat inner adjuster x Seat cushion frame 43 440 32 Rear No 1 seat inner adjuster x Seatback frame 43 440 32 Rear No 1 seat inner adjuster x Seat inner bracket 43 440 32 Rear seat shoulder belt guide x Seatback frame 42 430 32 REAR SEAT RH Rear seat cu...

Page 267: ...retractor x Body Upper bolt Lower bolt 8 5 42 87 430 75 in lbf 32 CRS tether anchor bracket x Body 20 204 15 Double cab Front seat outer belt shoulder anchor x Adjustable anchor 42 430 32 Front seat outer belt floor anchor x Body 42 430 32 Front seat outer belt retractor x Body 42 430 32 Adjustable anchor x Body 42 430 32 Front seat inner belt x Front seat 42 430 32 Front seat inner belt x Body 42...

Page 268: ...6 1 76 oz Double cab 530 50 g 18 69 1 76 oz Idle up speed 1GR FE Magnetic clutch not engaged 700 50 rpm Magnetic clutch engaged 700 50 rpm Idle up speed 2UZ FE Magnetic clutch not engaged 750 50 rpm Magnetic clutch engaged 800 50 rpm Magnetic clutch clearance 1GR FE engine 0 35 to 0 60 mm 0 013 to 0 023 in 2UZ FE engine 0 5 0 15 mm 0 020 0 0059 in ...

Page 269: ... 475 34 Idle pulley lock nut 39 400 29 Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Cooling unit x Suction tube 32 330 24 Expansion valve x Evaporator 5 4 55 48 in lbf Receiver x Liquied tube 5 4 55 48 in lbf Condenser x Liquid tube 10 100 7 Condenser x Discharge hose 10 100 7 Pressure switch x Liquied tube 10 100 7 Pressure plate x Compressor 1GR FE engine 18 183 13 2UZ...

Page 270: ...INE 1GR FE PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transaxle assembly engine assembly or ECM see page DI 961 HINT RESET MEMORY AT initialization can not be completed by only removing the battery ...

Page 271: ...nd components that are used by the ECM to detect malfunctions Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle Once per driving cycle means that the ECM detects the malfunction only one time during a single driving cycle Continuous means that the ECM detects malfunction every time an enabling condition is met Duration The minimum time that the ECM m...

Page 272: ...ion Sensor Heated Oxygen Sensor Bank 1 Knock Sensor Bank 1 Camshaft Position Sensor Bank 1 Engine Coolant Temperature Sensor VSV for ACIS Air Fuel Ratio Sensor Bank 1 Crankshaft Position Sensor Camshaft Position Sensor Bank 2 Camshaft Timing Oil Control Valve Assy Bank 1 Camshaft Timing Oil Control Valve Assy Bank 2 Combination Meter Assy Air Fuel Ratio Sensor Bank 2 Air Injection Driver Park Neut...

Page 273: ...IL To Battery To Battery To Battery To Battery To Starter ST Relay PNP SW EFI No 1 EFI No 1 Relay Accelerator Pedal Position Sensor Combination Meter VVT OCV Bank 1 VVT OCV Bank 2 Knock Sensor Bank 1 Knock Sensor Bank 2 To VC Terminal Crankshaft Position Sensor VVT Sensor Bank 1 VVT Sensor Bank 2 To VC Terminal DI 6 DIAGNOSTICS ENGINE 1GR FE SYSTEM DIAGRAM ...

Page 274: ...Sensor Bank 2 Sensor 2 To EFI Relay To EFI No 2 Fuse VSV EVAP VSV ACIS Mass Air Flow Meter ECT Sensor Pump Module To VC Terminal To Battery Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Fuel Injector 5 Fuel Injector 6 Ignition Coil and Igniter No 1 Ignition Coil and Igniter No 2 Ignition Coil and Igniter No 3 Ignition Coil and Igniter No 4 Ignition Coil and Igniter No 5 Ignition ...

Page 275: ...EOM TC CANL CANH IMI IMO DLC3 TC CANL CANH To Battery To Battery To E2 Terminal To IG SW Throttle Body C OPN Relay Fuel Pump Relay Fuel Pump Resister Fuel Pump Transponder Key Computer Stop Light SW To IGN Fuse To EFI Relay ACC Cut Relay To Battery DI 8 DIAGNOSTICS ENGINE 1GR FE ...

Page 276: ...tom Simulation P IN 19 Basic Inspection P DI 12 DTC Chart P DI 57 Problem Symptoms Table P DI 33 Circuit Inspection P DI 70 Adjustment Repair DTC Check P DI 42 Items inside are titles of pages in in the bottom portion See the indicated pages for detailed explanations this manual with the page number Malfunction occurs Malfunction does not occur Parts Inspection Check for Intermittent Problems P DI...

Page 277: ...ng from N to D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Rainy Snowy Various Other Hot Warm Cool Cold approx C F Highway Suburbs Inner city Uphill Downhill Rough road Other Cold Warming up After warming up Any temp Other Starting Just ...

Page 278: ...when the ECM is in check mode In check mode the ECM uses 1trip detection logic which is more sensitive to malfunctions than normal mode default which uses 2trip detection logic c Clear DTCs see page DI 42 d Switch the ECM from normal mode to check mode using a hand held tester see page DI 43 e Perform a simulation test see page IN 19 f Check and wiggle the harness es connector s and terminal s see...

Page 279: ... cases by carrying out the basic engine check shown in the following flowchart the location causing the problem can be found quickly and efficiently There fore using this check is essential in the engine troubleshooting 1 Is battery voltage 11 V or more when engine stopped NO Charge or replace battery YES 2 Is engine cranked NO Proceed to page ST 1 and continue to trouble shoot YES 3 Does engine s...

Page 280: ...ily NG Repair or replace air filter OK 5 Check idle speed See page EM 25 NG Proceed to problem symptoms table on page DI 33 OK 6 Check fuel pressure See page SF 5 NG Proceed to page SF 5 and continue to trouble shoot OK 7 Check for spark See page IG 1 NG Proceed to page IG 1 and continue to trouble shoot OK Proceed to problem symptoms table on page DI 33 ...

Page 281: ...VIN do not match the VIN can be registered or over written in the ECM by following this procedure 2 INPUT INSTRUCTIONS a Hand held tester The arrow buttons UP DOWN RIGHT and LEFT and numerical buttons 0 to 9 are used in order to input the VIN b Cursor Operation To move the cursor around the tester screen press the RIGHT and LEFT buttons c Alphabetical Character Input 1 Press the UP and DOWN button...

Page 282: ...0 VIN Not Programmed or Mismatch ECM PCM Please input the VIN PRESS EXIT Possible cause To Menu Screen 17 digitVIN displayed 3 Select VIN DTC P0630 Set VIN Previously Stored VIN Not Stored EXIT EXIT EXIT 2 VIN WRITE VIN Select VIN READ 1 VIN READ 1 VIN READ ERROR ECM does not respond the VIN 1 VIN is not written yet 2 Vehicle does not support this function DIAGNOSTICS ENGINE 1GR FE DI 15 3 READ VI...

Page 283: ...o Menu Screen Continuedon next page NOTICE Do you wish to continue YES NO 1 Select DIAGNOSIS 2 Select ENHANCED OBD ll 3 Select VIN 1 VIN READ 1 VIN READ VIN Select VIN WRITE YES or NO YES 2 VIN WRITE To Menu Screen NO CONFIRMATION This function will erase the DTCs automatically after writing the VIN Do you wish to continue YES 17 digit VIN displayed VIN Previously Stored DI 16 DIAGNOSTICS ENGINE 1...

Page 284: ...IT Writing Error SET NEW VIN Press RIGHT LEFT to shift the cursor right left Press UP DOWN to increase decrease value Or input digit with the 10 key PRESS ENTER CONFIRMATION PRESS ENTER Vehicle is stopped New Registration ENTER ENTER PRESS ENTER Communication Error ENTER COMMUNICATION ERROR PRESS EXIT Turn IG OFF then ON VIN input method The following VIN has been written correctly The DTCs have b...

Page 285: ...ABLE A MONITOR HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed ...

Page 286: ...A21571 DIAGNOSTICS ENGINE 1GR FE DI 19 ...

Page 287: ...A21572 DI 20 DIAGNOSTICS ENGINE 1GR FE ...

Page 288: ...A21573 DIAGNOSTICS ENGINE 1GR FE DI 21 ...

Page 289: ...A21575 DI 22 DIAGNOSTICS ENGINE 1GR FE ...

Page 290: ...A21576 DIAGNOSTICS ENGINE 1GR FE DI 23 ...

Page 291: ... of the O2S TEST RESULT for O2S related DTCs are written in a table This table consists of 5 items 1 TEST ID a code applied to each TEST DATA 2 Description of TEST DATA 3 Conversion Factor When Conversion Factor has a value written in the table multiply the TEST DATA value appearing on the scan tool by the Conversion Factor value The result will be the required value 4 Unit 5 Standard Value If the...

Page 292: ...s a value of the TIME 81 see the illustration on the left 2 Find the Conversion Factor value of TIME 81 in the O2S TEST RESULT chart below 0 3906 is spe cified for 81 in this chart 3 Multiply 17 in step 1 by 0 3906 Conversion Fac tor in the step 2 17 x 0 3906 6 6 4 If the answer is within the standard value the TIME 81 can be confirmed to be normal O2S TEST RESULT Chart TEST ID Description of TEST...

Page 293: ...ssions related DTC sections Thermostat MID Monitor Identification Data is assigned to each emissions related component TID Test Identification Data is assigned to each test value Scaling is used to calculate the test value indicated on generic hand held tester 3 PROCEDURE USING HAND HELD TESTER a Connect the hand held tester to the DLC3 b Turn the ignition switch and hand held tester ON c Clear DT...

Page 294: ... performance tests for the related Readiness Monitor The Readiness Monitor will be reset to incomplete if ECM has lost power battery or fuse DTCs have been cleared The conditions for running the Readiness Monitor have not been met In the event that any Readiness Monitor shows incomplete follow the appropriate Readiness Monitor Drive Pattern to activate the monitor and change the readiness status t...

Page 295: ... MONITOR ACTIVE AIR FUEL RATIO CONTROL TYPE a Preconditions The monitor will not run unless The MIL is OFF b Drive Pattern 1 Connect a hand held tester or OBD II scan tool to the DLC3 2 Turn the ignition switch to ON 3 Turn the tester or scan tool ON 4 Clear DTCs where set see page DI 42 5 Start the engine and warm it up 6 Drive the vehicle at between 40 mph and 70 mph 64 km h and 113 km h for at ...

Page 296: ... OFF Fuel level is approximately 1 2 to 3 4 Altitude is 7 800 feet 2 400 m or less b Cold Soak Procedure Let the vehicle cold soak for 8 hours or until the difference between IAT and ECT becomes less than 7 C 13 F HINT Examples Scenario 1 ECT 24 C 75 F IAT 16 C 60 F Difference between ECT and IAT is 8 C 15 F The monitor will not run because difference between ECT and IAT is greater than 7 C 13 F S...

Page 297: ...because difference between ECT and IAT is less than 7 C 13 F The readiness test can be completed in cold ambient conditions less than 40 F 4 4 C and or at high altitudes more than 7 800 feet 2 400 m if the drive pattern is repeated a second time after cycl ing the ignition off b Drive Pattern 1 Connect the OBD II scan tool to DLC3 to check monitor status and preconditions refer to a 2 Release pres...

Page 298: ...2 4 Start the engine and warm it up until the ECT reaches 75 C 167 F or higher 5 Drive the vehicle at 40 mph 64 km h or more for at least 10 minutes 6 Change the transmission to 2nd gear 7 Accelerate the vehicle to 30 mph 48 km h or more by depressing the accelerator pedal for at least 10 seconds 8 Soon after performing step 8 above release the accelerator pedal for at least 4 seconds without depr...

Page 299: ...t the OBD II scan tool to the DLC3 to check monitor status and preconditions refer to a 2 Start the engine and allow it to idle for 500 seconds or more 3 Drive the vehicle at 25 mph 40 km h or more for at least 2 minutes 4 Check the status of the readiness monitor on the scan tool display If readiness status did not switch to complete ensure the preconditions are met turn the ignition off and then...

Page 300: ...it 2 Fuel pump control circuit DI 276 DI 414 Difficult to start with hot engine 1 Starter signal circuit 2 Fuel pump control circuit DI 276 DI 414 High engine idle speed Poor idling 1 A C switch circuit 2 ECM power source circuit DI 409 Low engine idle speed Poor idling 1 A C switch circuit 2 Fuel pump control circuit DI 414 Rough idling Poor idling 1 Compression 2 Fuel pump control circuit DI 414...

Page 301: ... 68 F 0 5 to 3 4 V THW E7 21 E2 E7 28 G Y B W Idling Engine coolant temp 80 C 176 F 0 2 to 1 0 V VTA1 E7 20 E2 E7 28 GR B W IG switch ON Accelerator pedal released 0 5 to 1 2 V VTA1 E7 20 E2 E7 28 GR B W IG switch ON Accelerator pedal depressed 3 2 to 4 8 V VTA2 E7 19 E2 E7 28 R B B W IG switch ON Accelerator pedal released 2 0 to 3 1 V VTA2 E7 19 E2 E7 28 R B B W IG switch ON Accelerator pedal de...

Page 302: ...1 E5 1 IGT5 E7 12 E1 E5 1 IGT6 E7 13 E1 E5 1 B L BR L W BR LG BR V BR L B BR R W BR Idling Pulse generation See waveform 9 IG switch ON 4 5 to 5 5 V IGF1 E7 24 E1 E5 1 B Y BR Idling Pulse generation See waveform 8 HA1A E6 2 E1 E5 1 Y BR Idling Below 3 0 V HA1A E6 2 E1 E5 1 HA2A E6 1 E1 E5 1 Y BR G BR IG switch ON 9 to 14 V A1A E6 22 E1 E5 1 V BR Always Ignition switch ON 3 3 V 1 A1A E6 30 E1 E5 1 ...

Page 303: ...R Ignition switch ON 9 V to 14 V MPMP E3 6 E1 E5 1 R W BR Vacuum pump OFF Vacuum pump ON 0 V to 3 V 9 V to 14 V PPMP E3 22 E1 E5 1 L W BR Ignition switch ON 3 V to 3 6 V 1 M T 2 A T WAVEFORM 1 Fuel injector ECM Terminal Names Between 10 to 60 and E01 Tester Ranges 20 V DIV 20 msec DIV Conditions Idling HINT The wavelength becomes shorter as the engine rpm increases WAVEFORM 2 Knock sensor ECM Term...

Page 304: ...ratio of voltage flowing to the OCV see illustration on left VVT OCV DUTY B1 B2 A B x 100 WAVEFORM 4 a VVT sensor bank 1 b VVT sensor bank 2 c Crankshaft position sensor ECM Terminal Name a Between VV1 and VV1 b Between VV2 and VV2 c Between NE and NE Tester Range 5 V DIV 20 msec DIV Condition Idle after engine warmed up HINT The wavelength becomes shorter as the engine rpm increases WAVEFORM 5 Ve...

Page 305: ...med up HINT The duty ratio varies depending on the throttle opening opera tion WAVEFORM 8 a Igniter IGT signal from ECM to igniter b Igniter IGF1 signal from igniter to ECM ECM Terminal Name a Between IGT1 to IGT6 and E1 b Between IGF1 and E1 Tester Range 2 V DIV 20 msec DIV Condition Idling HINT The wavelength becomes shorter as vehicle speed increases WAVEFORM 9 Heated oxygen sensor ECM Terminal...

Page 306: ...e hand held tester also enables you to erase the DTC and check the freeze frame data and various forms of engine data See the instruction manual for the hand held tester The DTC includes SAE controlled codes and manufacturer controlled codes SAE controlled codes must be set according to the SAE while manufacturer controlled codes can be set by a manufacturer with certain restrictions See the DTC c...

Page 307: ...3 The vehicle s ECM uses the ISO 9141 2 for communica tion protocol The terminal arrangement of the DLC3 com plies with SAE J1962 and matches the ISO 9141 2 for mat Symbol Terminal Description Condition Specified Condition SIL 7 SG 5 Bus line During transmission Pulse generation CG 4 Body ground Chassis ground Always Below 1 Ω SG 5 Body ground Signal ground Always Below 1 Ω BAT 16 Body ground Batt...

Page 308: ...en the ignition switch is turned ON and the engine is not running HINT If the MIL is not illuminated troubleshoot the MIL circuit See page DI 417 b When the engine is started the MIL should not illuminate If the lamp remains on the diagnosis system has de tected a malfunction or abnormality in the system 7 ALL READINESS For this vehicle using the hand held tester allows readiness codes correspondi...

Page 309: ...enus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES or PENDING CODE d Confirm the DTCs and freeze frame data and then write them down e See page DI 57 to confirm the details of the DTCs NOTICE When simulating a symptom with the hand held tester to check the DTCs use the normal mode For DTC chart sub ject to 2 trip detection logic perform either of the follow ing actions Turn the ignition switch ...

Page 310: ...n the illustration NOTICE All DTCs and freeze frame data recorded will be erased if 1 the hand held tester is used to change the ECM from normal mode to check mode or vice versa or 2 during check mode the ignition switch is turned from ON to ACC or OFF f Start the engine The MIL should turn off after the engine starts g Simulate the conditions of the malfunction described by the customer h After s...

Page 311: ...using the hand held tester a Remove the EFI No 1 and ETCS fuses from the engine room J B for more than 60 seconds or disconnect the bat tery terminal for more than 60 seconds After disconnecting the battery terminal perform the INI TIALIZE procedure ...

Page 312: ...20 P0121 P0122 P0123 P0220 P0222 P0223 P0606 P0607 P0657 P2102 P2103 P2111 P2112 P2118 P2119 P2135 If the Electronic Throttle Control System ETCS has a mal function the ECM cuts off current to the throttle control motor The throttle control valve returns to a predetermined opening angle approximately 16 by the force of the return spring The ECM then adjusts the engine output by control ling the fu...

Page 313: ...s the ECM detects the abnormal signal volt age difference between the two sensor circuits and switches to limp mode In limp mode the remaining circuit is used to calculate the accelerator pedal opening to allow the vehicle to continue driving If both circuits malfunction the ECM regards the opening angle of the accelerator pedal to be fully closed In this case the throttle valve will remain closed...

Page 314: ...4 deg Max 63 5 deg BTDC 4 to 17 Idling CALC LOAD Calculated load by ECM Min 0 Max 100 11 to 21 Idling 12 to 22 Running without load 2 500 rpm VEHICLE LOAD Vehicle load Min 0 Max 25700 Actual vehicle load MAF Air flow rate from MAF meter Min 0 g s Max 655 g s 2 0 to 3 9 g s Idling If the value approximately 0 0 g s Mass air flow meter power source circuit open VG circuit open or short If the value ...

Page 315: ...OS 1 APP sensor No 1 voltage Min 0 V Max 4 98 V ETCS freeze data ACCEL POS 2 APP sensor No 2 voltage Min 0 V Max 4 98 V ETCS freeze data ACCEL POS 1 APP sensor No 1 voltage Min 0 V Max 5 V 0 5 to 1 1 V accelerator pedal is released 2 6 to 4 5 V or pedal is fully de pressed ACCEL POS 2 APP sensor No 2 voltage Min 0 V Max 5 V 1 2 to 2 0 V accelerator pedal is released 3 4 to 5 3 V accelerator pedal ...

Page 316: ...y closed 4 6 to 5 5 V Throttle fully open Read the value with intrusive op eration active test THRTL COMND VAL Throttle position command value Min 0 V Max 4 98 V 0 5 to 4 8 V ETCS service data THROTTLE SSR 1 Throttle sensor opener position No 1 Min 0 V Max 4 98 V 0 6 to 0 9 V ETCS service data THROTTLE SSR 2 Throttle sensor opener position No 2 Min 0 V Max 4 98 V 2 2 to 2 6 V ETCS service data THR...

Page 317: ...m of bank 1 Average value for fuel trim system of bank 1 Min 0 5 Max 1 496 0 2 to 0 2 Idling SHORT FT 1 Short term fuel trim of bank 1 Min 100 Max 99 2 0 20 This item the short term fuel com pensation used to maintain the air fuel ratio at stoichiometric air fuel ratio SHORT FT 2 Short term fuel trim of bank 1 Min 100 Max 99 2 0 20 This item the short term fuel com pensation used to maintain the a...

Page 318: ...AF FT B2 S1 Short term fuel trim associated with the bank 1 sensor 1 Min 0 Max 1 999 Value less than 1 0 000 to 0 999 Lean Stoichiometric air fuel ratio 1 Value greater than 1 1 001 to 1 999 RICH CAT TEMP B1S1 Catalyst temperature Bank 1 Sensor 1 Min 40 Max 6 513 5 C CAT TEMP B2S1 Catalyst temperature Bank 1 Sensor 1 Min 40 Max 6 513 5 C CAT TEMP B1S2 Catalyst temperature Bank 1 Sensor 2 Min 40 Ma...

Page 319: ...sure ACT VSV A C cut status for Active Test ON or OFF Active Test support data ACIS VSV VSV for ACIS control ON or OFF Active Test support data EVAP Purge VSV VSV status for EVAP control ON or OFF Active Test support data FUEL PUMP SPD Fuel pump speed status ON or OFF Active Test support data FUEL SP CTL Fuel pump speed control status ON or OFF Active Test support data VVT CTRL B1 VVT control stat...

Page 320: ...ire 0 MISFIRE LOAD Engine load for first misfire range Min 0 g rev Max 3 98 g rev 0 g rev Misfire 0 MISFIRE MARGIN Misfire monitoring MIn 100 Max 99 22 100 to 99 2 Misfire detecting margin CODES Codes Min 0 Max 255 Number of detected DTCs CHECK MODE Check mode 0 ON 1 OFF ON Check mode ON See page DI 43 SPD TEST Check mode result for vehicle speed sensor 0 COMPL 1 INCOMPL See page DI 43 MISFIRE TES...

Page 321: ...C cleared MODEL CODE Model code Identifying the model code GSK3 ENGINE TYPE Engine type Identifying the engine type 1GRFE CYLINDER NUMBER Cylinder number Min 0 Max 255 Identifying the cylinder number 6 TRANSMISSION Transmission type Identifying the transmission type ECT 5AT M T DESTINATION Destination Identifying the destination A America MODEL YEAR Model year Min 0 Max 255 Identifying the model y...

Page 322: ...n 3 000 rpm A F CONTROL enables checking and graphing of A F Air Fuel Ra tio sensor and Heated Oxygen HO2 sensor voltage outputs To conduct test select following menu items ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S B1S2 and press YES and ENTER followed by F4 FUEL PMP SP CTL Fuel pump speed control ON low speed OFF high speed Test possible when following conditions met Engine switch on IG ...

Page 323: ...s test is possible during idle VVT B2 Control the VVT bank 2 Between 128 and 127 Same as above VENT VALVE ALONE Activate vent valve built into pump module ON OFF VCUUM PUMP Activate vacuum pump built into pump module ON OFF 3 SYSTEM CHECK HINT Performing a SYSTEM CHECK enables the system which consists of multiple actuators to be operated without removing any parts In addition it can show whether ...

Page 324: ...n VVT sensor circuit VVT sensor ECM P0018 DI 81 Crankshaft Position Camshaft Position Correlation Bank 2 Sensor A Open or short in VVT sensor circuit VVT sensor ECM P0020 DI 70 Camshaft Position A Actuator Circuit Bank 2 Open or short in OCV circuit OCV ECM P0021 DI 76 Camshaft Position A Timing Over Advanced or System Per formance Bank 2 Valve timing OCV VVT controller assembly ECM P0022 DI 76 Ca...

Page 325: ...re Circuit Open or short in intake air temperature sensor circuit Intake air temperature sensor built in mass air flow meter ECM P0112 DI 109 Intake Air Temperature Circuit Low Input Open or short in intake air temperature sensor circuit Intake air temperature sensor built in mass air flow meter ECM P0113 DI 109 Intake Air Temperature Circuit High Input Open or short in intake air temperature sens...

Page 326: ... Open in heated oxygen sensor circuit Heated oxygen sensor Heated oxygen sensor sensor heater EFI relay Gas leakage from exhaust system P0138 DI 142 Oxygen Sensor Circuit High Volt age Bank 1 Sensor 2 Short in heated oxygen sensor circuit Short in heated oxygen sensor ECM internal circuit malfunction P0156 DI 142 Oxygen Sensor Circuit Malfunc tion Bank 2 Sensor 2 Open or short in heated oxygen sen...

Page 327: ...DI 160 System too Rich Bank 2 Injector leak blockage Mass air flow meter Engine coolant temperature sensor Ignition system Fuel pressure Gas leakage in exhaust system Open or short in heated oxygen sensor bank 2 sensor 1 circuit Heated oxygen sensor bank 2 sensor 1 ECM P0220 DI 123 Throttle Pedal Position Sensor Switch B Circuit Throttle control motor and sensor ECM P0222 DI 123 Throttle Pedal Pos...

Page 328: ...ure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P0302 DI 179 Cylinder 2 Misfire Detected Open or short in engine wire Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P...

Page 329: ...ed Open or short in engine wire Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P0327 DI 197 Knock Sensor 1 Circuit Low In put Bank 1 or Single Sensor Short in knock sensor circuit Knock sensor ECM P0328 DI 197 Knock Sensor 1 Circuit High In pu...

Page 330: ...ith igniter Ignition system ECM P0352 DI 216 Ignition Coil B Primary Second ary Circuit Open or short in IGF 1 and IGT 2 circuit from No 2 ignition coil with igniter to ECM No 2 ignition coil with igniter Ignition system ECM P0353 DI 216 Ignition Coil C Primary Second ary Circuit Open or short in IGF 1 and IGT 3 circuit from No 3 ignition coil with igniter to ECM No 3 ignition coil with igniter Ig...

Page 331: ...een pump module and ECM ECM P0453 DI 243 Evaporative Emission Control System Pressure Sensor Switch High Input Pump module include pressure sensor Connector Wire harness between pump module and ECM ECM P0455 DI 252 Evaporative Emission Control System Leak Detected Gross Leak Fuel tank cap loose Leakage from EVAP line between canister and fuel tank Leakage from EVAP line between purge valve and can...

Page 332: ...ure Sensor A Circuit Low Input Electronic control automatic transmission ECT P0713 DI 999 Transmission Fluid Temperature Sensor A Circuit High Input Electronic control automatic transmission ECT P0717 DI 1008 Input Turbine Speed Sensor A Circuit No Signal Electronic control automatic transmission ECT P0722 DI 1013 Output Speed Sensor Circuit No Signal Electronic control automatic transmission ECT ...

Page 333: ...uator Control System Stuck Open Throttle control motor and sensor circuit Throttle control motor and sensor Throttle valve Throttle body P2112 DI 287 Throttle Actuator Control System Stuck Closed Throttle control motor and sensor circuit Throttle control motor and sensor Throttle valve Throttle body P2118 DI 291 Throttle Actuator Control Motor Current Range Performance Open in throttle control mot...

Page 334: ...or 1 A F sensor heater sensor 1 A F relay A F sensor heater and EFI relay circuits Air induction system Fuel pressure Injector ECM P2196 DI 312 Oxygen A F Sensor Signal Stuck Rich Bank 1 Sensor 1 Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 A F relay A F sensor heater and EFI relay circuits Air induction system Fuel pressure Injector ECM P2197 DI 312 ...

Page 335: ...Ground Current Circuit Low For A F Sensor Bank 2 Sensor 1 Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 A F relay A F sensor heater and EFI relay circuits P2256 DI 330 Oxygen Sensor Reference Cur rent Circuit High For A F Sen sor Bank 2 Sensor 1 Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 A F relay A F se...

Page 336: ...d Valve SLU Electronic control automatic transmission ECT P2A00 DI 359 A F Sensor Circuit Slow Re sponse Bank 1 Sensor 1 Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 EFI relay A F sensor heater and EFI relay circuits Air induction system Fuel pressure Injector PCV valve and hose PCV hose connections ECM P2A03 DI 359 A F Sensor Circuit Slow Re sponse B...

Page 337: ...re supplied to the VVT controller Camshaft timing control is performed based on en gine operation conditions such as intake air volume throttle position and engine coolant temperature The ECM controls the OCV based on the signals output from the sensors The VVT controller regulates the intake camshaft angle using oil pressure through the OCV As a result the relative position between the cam shaft ...

Page 338: ...c MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 18 Battery voltage 11 V 13 V Target duty ratio 70 Starter OFF Current cut status Not cut TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following conditions is met Condition 1 or 2 1 Outpu...

Page 339: ... check left bank OCV circuit If DTC P0020 displayed check right bank OCV circuit Read freeze frame data using hand held tester Because freeze frame records the engine conditions when the malfunction is detected When troubleshooting it is useful for determining whether the ve hicle 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 malf...

Page 340: ...TRL B1 or VVT CTRL B2 b Using the hand held tester operate the OCV and check the engine speed OK Standard Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK Check for intermittent problems See page DI 11 NG 2 Check operation of OCV PREPARATION a Start the engine and warmed it up b Disconnect the OCV connector c Apply battery positive voltage...

Page 341: ...tage between terminals OC1 and OC1 OC2 and OC2 of ECM con nector CHECK a Inspection using the oscilloscope b During idling check the waveform between the specified terminals of the E5 ECM connector HINT The waveform frequency A is lengthened as the engine speed becomes higher OK Standard The correct waveform is as shown NG Replace ECM See page SF 66 OK ...

Page 342: ...onnec tors OK Standard Check for open Symbols Terminal No Specified condition OCV C20 1 OC1 E5 17 Below 1 Ω OCV C20 2 OC1 E5 16 Below 1 Ω OCV C19 1 OC2 E5 15 Below 1 Ω OCV C19 2 OC2 E5 14 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition OCV C20 1 or OC1 E5 17 E1 E5 1 10 kΩ or higher OCV C20 1 or OC1 E5 16 E1 E5 1 10 kΩ or higher OCV C19 1 or OC2 E5 15 E1 E5 1 10 kΩ or hig...

Page 343: ...tion a continues 2 trip detection logic a Valve timing does not change from current valve timing OCV VVT controller assembly ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT Variable Valve Timing system to control the intake valve camshaft The VVT system includes the ECM the OCV Oil Control Valve and the VVT controller The ECM sends a target duty cycle control signal to the...

Page 344: ...tection Criteria Threshold P0011 P0021 Advance Deviation of actual valve timing and target valve timing More than 5 CA Crankshaft angle Valve timing No change at advanced valve timing P0012 P0022 Retard Deviation of actual valve timing and target valve timing More than 5 CA Crankshaft angle Valve timing No change at retarded valve timing WIRING DIAGRAM Refer to DTCs P0010 on page DI 70 INSPECTION ...

Page 345: ...peed OK Standard Tester operation Specified condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK VVT system is OK DTC P0011 P0012 P0021 or P0022 is also output when a foreign object is detected in some parts of the system in the en gine oil and then the system returns to normal in a short time As ECM is controlled to eject a foreign object there is no prob lem on the VV...

Page 346: ...scilloscope b During idling check the waveform between the specified terminals of the E5 ECM connector HINT The waveform frequency A is lengthened as the engine speed becomes higher OK Standard The correct waveform is as shown NG Replace ECM See page SF 66 OK 4 Check OCV See page EM 70 NG Replace OCV and then go to step 6 OK 5 Check camshaft timing gear assembly See page EM 70 NG Replace camshaft ...

Page 347: ... is stored See page DI 42 OK Standard DTC P0011 P0012 P0021 or P0022 is not stored OK VVT system is OK DTC P0011 P0012 P0021 or P0022 is also output when a foreign object is detected in some parts of the system in the en gine oil and then the system returns to normal in a short time As ECM is controlled to eject a foreign object there is no prob lem on the VVT There is also no problem on the VVT a...

Page 348: ...018 Deviation in crankshaft position sensor signal and VVT sensor 2 signal 2 trip detection logic stretched ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing VVT system to control the intake valve camshaft The VVT system includes the ECM the Oil Control Valve OCV and the VVT controller The ECM sends a target duty cycle control signal to the OCV This control...

Page 349: ...sor Frequency of operation Once per drive cycle Duration 60 sec MIL operation 2 drive cycles Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 18 Engine RPM 500 rpm 1 000 rpm TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold One of the following condition is met Condition a or b a...

Page 350: ...me records the engine conditions when the malfunction is detected When troubleshooting it is useful for determining whether the ve hicle 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 1 Check valve timing Check for loose and jumping teeth of timing chain See page EM 44 NG Adjust valve timing Repair or replace timing cha...

Page 351: ...nsor 1 HINT Although each DTC title DTC description says oxygen sensor these DTCs are related to the A F sensor CIRCUIT DESCRIPTION Refer to DTC P2195 on page DI 312 HINT The ECM provides a pulse width modulated control circuit to adjust current through the heater The A F sen sor heater circuit uses a relay on the B side of the circuit DTC No DTC Detection Condition Trouble Area P0031 P0051 Heated...

Page 352: ...ions of the exhaust and the outside air The platinum coating amplifies the voltage generation When heated the sensor becomes very efficient If the temperature of the exhaust is low the sensor will not generate useful voltage signals without supplemental heating The ECM regulates the sup plemental heating using a duty cycle approach to regulate the average current in the heater element If the heate...

Page 353: ...ion The test value and test limit information are described as shown in the following table Check the monitor result and test values after performing the monitor drive pattern see page DI 27 TID Test Identification Data is assigned to each emissions related component TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the co...

Page 354: ... from the time the malfunction occurred 1 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the air fuel ratio A F sensor connector CHECK Measure resistance between the terminals of the A F sensor connector OK Standard Tester Connection Specified Condition HT 1 B 2 1 8 Ω to 3 4 Ω at 20 C 68 F HT 1 AF 4 10 kΩ or higher NG Replace air fuel ratio A F sensor OK 2 Check A F re...

Page 355: ...e ignition switch to ON CHECK Measure the voltage between terminals of the ECM connectors and body ground HINT Connect terminal HA1A to the bank 1 sensor 1 Connect terminal HA2A to the bank 2 sensor 1 OK Standard Tester Connection Specified Condition HA1A E6 2 Body ground 9 V to 14 V HA2A E6 1 Body ground 9 V to 14 V NG Replace ECM See page SF 66 NG ...

Page 356: ...1 Ω Standard Check for short Symbols Terminal No Specified condition HT A10 1 or HA1A E6 2 Body ground 10 kΩ or higher HT A30 1 or HA2A E6 1 Body ground 10 kΩ or higher PREPARATION a Disconnect the A10 or A30 A F sensor connector b Remove the A F sensor heater relay from the engine room R B CHECK Check for resistance between the wire harness side connec tors OK Standard Check for open Symbols Term...

Page 357: ...r Heater Control Circuit Low Bank 1 Sensor 2 DTC P0038 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 2 DTC P0057 Oxygen Sensor Heater Control Circuit Low Bank 2 Sensor 2 DTC P0058 Oxygen Sensor Heater Control Circuit High Bank 2 Sensor 2 DIDT7 01 ...

Page 358: ...e air fuel ratio When the air fuel ratio becomes LEAN the oxygen concentration in the exhaust increases and the heated oxygen sensor informs the ECM of the LEAN condition low voltage i e less than 0 45 V When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentration in the ex haust gas is reduced and the heated oxygen sensor informs the ECM of the RICH condition ...

Page 359: ...d difference of the oxy gen concentration between the inside and outside surface of sensor is large the zirconia element will gener ate voltage signals In order to increase the oxygen concentration detecting capacity in the zirconia element the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor When current in the sensor is out of the standard operating ra...

Page 360: ... 5 V Engine Running Starter OFF Intrusive heating Not operating Case 2 Battery voltage 10 5 V All heater is turned OFF and intrusive heating is operated when the following conditions are met Condition a and b a Heater ON b Heater current 2 A TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0037 P0057 Low current HO2S heater current during intrusive heating Less than 0 3 A when battery ...

Page 361: ...component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit CID Component Identification Data is assigned to each test value TID 04 HO2S heater TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 02 Multiply by 0 000076 A Maximum HO2S heater current Bank 1 Sensor ...

Page 362: ... R B W 1 2 2 24 7 R R R R 22 J26 J27 A A EFI No 2 W L B J1 J C B W L R 2 2 2 2 EFI Relay 1 2 5 3 Engine Room R B GR G H6 Heated Oxygen Sensor Bank 2 Sensor 2 B HT E1 OX 1 2 4 3 B W B G B 1 1 E J65 J C E E W B B R 2 2 1 2 EFI No 1 Engine Room R B GR G B A A BR B W J18 J C W B GR G J C 26 9 J26 J27 EA EV Battery 1 Shielded DIAGNOSTICS ENGINE 1GR FE DI 95 WIRING DIAGRAM ...

Page 363: ...n occurred 1 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the H4 or H6 heated oxygen sensor connector CHECK Measure resistance between terminals of the heated oxygen sensor OK Standard Tester Connection Specified Condition HT H4 1 B H4 2 11 to 16 Ω at 20 C 68 F HT H6 1 B H6 2 11 to 16 Ω at 20 C 68 F NG Replace heated oxygen sensor OK 2 Check EFI relay PREPARATION Remove t...

Page 364: ...nals of the ECM connectors and body ground OK Standard Tester Connection Specified Condition HT1B E7 1 Body ground 9 to 14 V HT2B E6 5 Body ground 9 to 14 V HINT Connect terminal HT1B to the bank 1 sensor 2 Connect terminal HT2B to the bank 2 sensor 2 NG Replace ECM See page SF 66 NG Check and repair harness or connector between EFI relay and heated oxygen sensor and heated oxygen sensor and ECM S...

Page 365: ...g air cools the wire and an internal thermistor affecting their resistance To maintain a constant current value the ECM varies the voltage applied to these components in the MAF meter The voltage level is pro portional to the airflow through the sensor The ECM interprets this voltage as the intake air amount The circuit is constructed so that the platinum hot wire and temperature sensor provide a ...

Page 366: ...d if either the condition contin ues for more than 3 sec MONITOR STRATEGY P0100 Mass air flow meter circuit range check Fluttering Related DTCs P0102 Mass air flow meter circuit range check Low voltage P0103 Mass air flow meter circuit range check High voltage Required sensors components Mass air flow meter Frequency of operation Continuous Duration 3 sec MIL operation Immediate When engine speed ...

Page 367: ... B Engine Room R B 2 2 EFI No 2 2 2 2 2 EFI Relay 1 2 5 3 Engine Room R B B R 2 2 1 2 EFI No 1 Engine Room R B B Battery EA A A J18 J C W B 2 1 B VG E2G R 1 3 2 M1 Mass Air Flow Meter W B R DI 100 DIAGNOSTICS ENGINE 1GR FE COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0 4 to 2 2 V WIRING DIAGRAM ...

Page 368: ...function occurred 1 Connect hand held tester and read value of mass air flow rate PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF CHECK Read the mass air flow rate on the hand held tester RESULT Ai...

Page 369: ...w meter connector and body ground OK Standard Tester Connection Specified Condition B M1 1 Body ground 9 to 14 V NG Go to step 5 OK 3 Check voltage between terminal VG of ECM connector and body ground PREPARATION Start the engine CHECK Measure the voltage between the specified terminal of the E7 ECM connector HINT The shift position should be P or N and the A C switch should be turned OFF OK Stand...

Page 370: ...meter and ECM PREPARATION a Disconnect the M1 mass air flow meter connector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VG M1 3 VG E7 30 Below 1 Ω E2G M1 2 E2G E7 29 Below 1 Ω VG M1 3 or VG E7 30 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Replace mass air flow ...

Page 371: ...or resistance in the EFI No 1 fuse OK Standard Below 1 Ω PREPARATION a Install the EFI No 1 fuse b Disconnect the M1 mass air flow meter connector c Remove the EFI relay from the engine room J B CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition B M1 1 Engine Room J B EFI relay terminal 1 Below 1 Ω B M1 1 or Engine room J B EFI re...

Page 372: ... Body ground Below 1 Ω NG Replace ECM See page SF 66 OK 7 Check for open in harness and connector between mass air flow meter and ECM PREPARATION a Disconnect the M1 mass air flow meter connector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VG M1 3 VG E7 30 Below 1 Ω E2G M1 2 E2G E7 29 Below...

Page 373: ...he flow of intake air By applying a specific current to the wire the ECM heats this wire to a given temperature The flow of incoming air cools the wire and an internal thermistor affecting their resistance To maintain a constant current value the ECM varies the volt age applied to these components in the MAF meter The voltage level is proportional to the air flow through the MAF meter The ECM inte...

Page 374: ...0 rpm MAF meter voltage 4 9 V Engine coolant temperature 70 C 158 F Low voltage Engine speed 300 rpm MAF meter voltage 0 2 V Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Mass air flow meter voltage High voltage More than 2 2 V varies with throttle position sensor voltage Mass air flow meter voltage Low voltage Less than 0 83 V varies with throttle position sensor voltag...

Page 375: ...lfunction occurred 1 Are there any other codes besides DTC P0101 being output PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC output Proceed to P0...

Page 376: ...THAR via 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 voltage at terminal THA THAR also changes Based on this signal the ECM increases the fuel in jection volume to improve the driveability during cold engine op erati...

Page 377: ...ents Intake air temperature sensor Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page DI 18 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0110 Intake air temperature sensor voltage Intake air...

Page 378: ...as the ground terminal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as oth...

Page 379: ...ng menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR CHECK Read the temperature value on the hand held tester OK Same as actual intake air temperature RESULT Displayed Temperature Proceed to 40 C 40 F A 140 C 284 F or more B OK Same as present temperature C HINT If there is an open circuit the hand held tester indicates 40 C 40 F If there is a short circuit the hand held tester indicates 140...

Page 380: ...IN TAKE AIR CHECK Read the temperature value on the hand held tester OK Standard 140 C 284 F OK Confirm good connection at sensor If OK re place mass air flow meter NG 3 Check for open in harness or ECM PREPARATION a Connect terminals THA and E2 of the E7 ECM connector HINT Before checking do a visual and contact pressure check for the ECM connector b Turn the ignition switch to ON c When using ha...

Page 381: ...CED OBD II DATA LIST ALL IN TAKE AIR CHECK Read the temperature value on the hand held tester OK Standard 40 C 40 F OK Replace mass air flow meter NG 5 Check for short in harness or ECM PREPARATION a Disconnect the E7 ECM connector b Turn the ignition switch to ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read the temperature v...

Page 382: ... circuit Engine coolant temperature sensor ECM P0118 Step 2 Open in engine coolant tem perature sensor circuit for 0 5 sec HINT After confirming DTC P0115 P0117 or P0118 use the OBD II scan tool or the hand held tester to confirm the engine coolant temperature from the DIAGNOSIS ENHANCED OBD II DATA LIST ALL Displayed Temperature Malfunction 40 C 40 F Open circuit 140 C 284 F or more Short circuit...

Page 383: ...peration Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page DI 18 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0115 Engine coolant temperature sensor voltage Coolant temperature Less than 0 14 V or more than 4 91 V More than 140 C 284 F or less than 40 C ...

Page 384: ...inal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the t...

Page 385: ... menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read the temperature value on the the hand held tester OK Same value as actual engine coolant temperature RESULT Displayed Temperature Proceed to 40 C 40 F A 140 C 284 F or more B OK Same as present temperature C HINT If there is an open circuit hand held tester indicates 40 C 40 F If there is a short circuit hand held tester indicat...

Page 386: ...NT TEMP CHECK Read the temperature value on the hand held tester OK Standard 140 C 284 F OK Confirm good connection at sensor If OK re place engine coolant temperature sensor NG 3 Check for open in harness or ECM PREPARATION a Disconnect the E2 engine coolant temperature sensor connector b Connect terminals THW and E2 of the E7 ECM connector HINT Before checking do a visual and contact pressure ch...

Page 387: ...tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read the temperature value on the hand held tester OK Standard 40 C 40 F OK Replace engine coolant temperature sensor NG 5 Check for short in harness or ECM PREPARATION a Disconnect the E7 ECM connector b Turn the ignition switch to ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED...

Page 388: ...e thermistor increases When the temperature is high the resistance drops The variations in resistance are reflected in the voltage output from the sensor The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature When the sen sor output voltage deviates from the normal operating range the ECM interprets this as a fault in the ECT sensor and sets a DTC Examp...

Page 389: ... or less within 35 sec and stopped for 10 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case1 When temperature is fixed between 35 C 95 F and 60 C 140 F Change of engine coolant temperature value Less than 3 C 5 4 F Case2 When temperature is fixed at 60 C 140 F or more Change of engine coolant temperature value 1 C 1 8 F or less COMPONENT OPERATING RANGE Standard Value Engine coo...

Page 390: ...edal Position Sensor Switch A Circuit High Input DTC P0220 Throttle Pedal Position Sensor Switch B Circuit DTC P0222 Throttle Pedal Position Sensor Switch B Circuit Low Input DTC P0223 Throttle Pedal Position Sensor Switch B Circuit High Input DTC P2135 Throttle Pedal Position Sensor Switch A B Voltage Correlation HINT This is the purpose for the throttle position sensor DIDTD 01 ...

Page 391: ...e throttle position sensor is mounted on the throttle body It detects the opening angle of the throttle valve This sensor is electronically controlled and uses Hall effect elements so that accurate control and reliability can be obtained The throttle position sensor has 2 sensor elements signal outputs VTA1 and VTA2 VTA1 used to detect the throttle opening angle and VTA2 is used to detect malfunct...

Page 392: ...ndition a is satisfied a VTA2 is 1 75 V or less or VTA2 is 4 8 V or more Throttle control motor and sensor ECM P0222 a VTA2 is 1 75 V or less Throttle control motor and sensor Short in VTA2 circuit Open in VC circuit ECM P0223 a VTA2 is 4 8 V or more and VTA1 is 0 2 V or more and VTA1 is 2 02 V or less Throttle control motor and sensor Open in VTA2 circuit Open in E2 circuit VC and VTA2 circuit ar...

Page 393: ...pring The ECM then adjusts the engine output by controlling the fuel infection inter mittent fuel cut and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimum speed If the accelerator pedal is depressed firmly and slowly the vehicle can be driven slowly If a pass condition is detected and then the ignition switch is turned OFF the fa...

Page 394: ...VTA2 voltage 1 75 V or less or 4 8 V or more P0222 VTA2 voltage 1 75 V or less P0223 Both of the following conditions are met for 2 sec or more Condition 1 and 2 1 VTA1 voltage 0 2 to 2 02 V 2 VTA2 voltage 4 8 V or more P2135 Different between VTA1 and VTA2 voltage 0 02 V or less Both of the following conditions are met Condition 1 and 2 1 VTA1 voltage 0 2 V or less 2 VTA2 voltage 1 75 V or less C...

Page 395: ...at have terminal E2 as the ground terminal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or...

Page 396: ...depressed Trouble area Proceed to THROTTLE POS VTA1 THROTTLE POS 2 VTA2 THROTTLE POS VTA1 THROTTLE POS 2 VTA2 Trouble area Proceed to 0 0 to 0 2 V 0 0 to 0 2 V VC circuit open 100 4 5 to 5 5 V 100 4 5 to 5 5 V E2 circuit open 0 or 100 2 1 to 3 1 V Fail safe 0 or 100 2 1 to 3 1 V Fail safe VTA1 circuit open or ground short A about 16 Fail safe 0 to 0 2 or 4 5 to 5 5 V about 16 Fail safe 0 to 0 2 or...

Page 397: ...rol motor and sensor con nector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VC T14 5 VC E7 23 Below 1 Ω VTA1 T14 6 VTA1 E7 20 Below 1 Ω VTA2 T14 4 VTA2 E7 19 Below 1 Ω E2 T14 3 E2 E7 28 Below 1 Ω VC T14 5 or VC E7 23 Body ground 10 kΩ or higher VTA1 T14 6 or VTA1 E7 20 Body ground 10 kΩ or ...

Page 398: ...a Disconnect the T14 throttle control motor and sensor con nector b Turn the ignition switch to ON CHECK Measure the voltage between the specified terminals of the E7 ECM connector OK Standard Tester Connection Specified Condition VC E7 23 E2 E7 28 4 5 to 5 5 V NG Replace ECM See page SF 66 OK 4 Replace throttle body See page SF 40 NEXT ...

Page 399: ...lear the DTC See page DI 42 b Start the engine c Run the engine at idle for 15 seconds or more CHECK Read the DTC RESULT Display DTC Output Proceed to P0120 P0122 P0123 P0220 P0222 P0223 and or P2135 are output again A No DTC output B B System is OK A Replace ECM See page SF 66 ...

Page 400: ...viates from the normal operating range the ECM interprets this as a malfunction of the throttle position sensor The ECM will turn on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle control valve returns to a predetermined opening angle approximately 16 by the force of the return ...

Page 401: ...ON THRESHOLDS Detection Criteria Threshold Different between VTA1 and VTA2 VTA1 VTA2 0 8 Corrected by learning value Less than 0 8 V and more than 1 6 V INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stop...

Page 402: ...t time has passed the sensor still reports that the engine is not warmed up enough for closed loop fuel control after sufficient time has passed the ECM interprets this as a fault in the sensor or cooling system and sets a DTC Example The engine coolant temperature was 0 C 32 F at engine start After 5 min running time the ECT sensor still indicates that the engine is not warmed up enough to begin ...

Page 403: ...CTION PROCEDURE HINT If DTC P0115 P0116 P0117 P0118 and P0125 are output simultaneously engine coolant tempera ture sensor circuit may be open or short Perform the troubleshooting of DTC P0115 P0117 or P0118 first Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine...

Page 404: ... F HINT Also check that the valve is completely closed under opening temperature as above NG Replace thermostat See page CO 11 OK 3 Check cooling system CHECK Check that there is detect in the cooling system which causes overcool such as abnormal radiator fan opera tion modified cooling system and so on NG Repair or replace cooling system OK Replace engine coolant temperature sensor ...

Page 405: ...le Area P0128 Condition a b and c are met a Cold start b After sufficient warm up time has elapsed c Engine coolant temperature greater than 75 C 167 F Thermostat Cooling system Engine coolant temperature sensor ECM MONITOR DESCRIPTION The ECM estimates the coolant temperature based on starting temperature engine loads and engine speeds The ECM then compares the estimated temperature with the actu...

Page 406: ...n 1 or 2 1 All of the following conditions are met Condition a b and c a ECT at engine start IAT at engine start 15 to 7 C 27 to 12 6 F b ECT at engine start 10 to 56 C 14 to 133 F c IAT at engine start 10 to 56 C 14 to 133 F 2 All of the following conditions are met Condition a b and c a ECT at engine start IAT at engine start 7 C 44 6 F b ECT at engine start 56 C 133 F c IAT at engine start 10 C...

Page 407: ...tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC Output Proceed to P0128 A P0128 and other DTCs B HINT If any other codes besides P0128 are output perform the troubleshooting for those DTCs first B Go to DTC chart See page DI 57 A 2 Check cooling system CHEC...

Page 408: ...OSTICS ENGINE 1GR FE DI 141 3 Inspect thermostat See page CO 11 CHECK Check the valve lift OK Valve lift 10 mm 0 39 in or more at 95 C 203 F NG Replace thermostat See page CO 11 OK Replace ECM See page SF 66 ...

Page 409: ...eated Oxygen HO2 sensor is used The HO2 sensor is located behind the TWC and detects the oxygen concentration in the exhaust gas Since the sensor is integrated with the heater that heats the sensing portion it is possible to detect the oxygen concentration even when the intake air volume is low the exhaust gas temperature is low When the air fuel ratio becomes lean the oxygen concentration in the ...

Page 410: ...age from exhaust system P0137 P0157 The rear heated oxygen sensor voltage during active control is 0 2 V or less 2 trip detection logic Open or short in HO2 sensor sensor 2 circuit HO2 sensor sensor 2 HO2 sensor heater sensor 2 Air Fuel Ratio A F sensor sensor 1 EFI relay Gas leakage from exhaust system P0137 P0157 a and b is met for more than 90 seconds a Estimated rear oxygen sensor temperature ...

Page 411: ...am below Active air fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine During active air fuel ratio control the air fuel ratio is forcibly regulated to become lean or rich by the ECM If the ECM detects a malfunction one of the following DTCs is set DTC P0136 P0156 abnormal voltage output P0137 P0157 open circuit and P0138 P0158 short circuit Abnorma...

Page 412: ...ensor noticeably decreases the OSC indicates an extraordinarily high value Even if the ECM attempts to continue regulating the air fuel ratio to become rich or lean the HO2 sensor output does not change While performing active air fuel ratio control when the target air fuel ratio is rich and the HO2 sensor voltage output is 0 21 V or less lean the ECM interprets this as an abnormally low sensor ou...

Page 413: ... while the engine is running the impedance of the sensor is measured by the ECM The ECM determines that there is a malfunction in the sensor when the measured impedance devi ates from the standard range The effective resistance in an alternating current electrical cir cuit HINT The impedance can not be measured using an ohmme ter DTC P0136 or P0156 indicates the deterioration of the HO2 sensor The...

Page 414: ...xygen sensor Bank 2 output volt age Extremely high R i d t Main sensors components Heated rear oxygen sensor Required sensors components Related sensors components Mass air flow meter Frequency of operation Once per driving cycle Active air fuel ratio control detection Continuous Others Duration 20 sec Heated oxygen sensor output Output voltage High voltage Low voltage 30 sec Heated oxygen sensor ...

Page 415: ... OSC Oxygen Strage Capacity of catalyst 2 5 g or more 2 All of the following conditions are met Condition a b and c a Commanded air fuel ratio 14 9 or more b Rear HO2S voltage 0 21 to 0 59 V c OSC Oxygen Strage Capacity of catalyst 2 5 g or more Heated oxygen sensor output voltage Low voltage All of the following conditions are met Condition 1 2 and 3 1 Commanded air fuel ratio 14 3 or less 2 Rear...

Page 416: ... Test ID Test Item Description Unit Conversion Unit Standard Value 07 Output Voltage Minimum rear HO2 sensor output volt age Multiply by 0 005 V Less than TEST LIMIT 08 Output Voltage Maximum rear HO2 sensor output volt age Multiply by 0 005 V More than TEST LIMIT 91 OSC Maximum OSC in catalytic converter Multiply by 0 0156 g Less than TEST LIMIT If the sensor voltage is outside the standard value...

Page 417: ...perates j On the tester select the following menu items DIAGNO SIS ENHANCED OBD II DTC INFO PENDING CODES and check if any DTCs any pending DTCs are set HINT If O2S EVAL does not change to COMPL and any pending DTCs fail to set extend the driving time INSPECTION PROCEDURE HINT Hand held tester only Narrowing down the trouble area is possible by performing ACTIVE TEST of the following A F CONTROL H...

Page 418: ...action DIAGNOSTICS ENGINE 1GR FE DI 151 RESULT Heated oxygen sensor reacts in accordance with increase and decrease of injection volume 25 rich output More than 0 5 V 12 5 lean output Less than 0 4 V NOTICE There is a few seconds delay in the sensor 1 front sensor output And there is approximately 20 seconds delay in the sensor 2 rear sensor The following A F CONTROL procedure enables the technici...

Page 419: ...r codes besides P0136 P0137 P0138 P0156 P0157 and or P0158 are output perform the trou bleshooting for those DTCs first B Go to step 14 C Go to step 7 A 2 Check output voltage of heated oxygen sensor PREPARATION a Connect the hand held tester to the DLC3 b After warming up the engine run the engine at 2 500 rpm for 3 minutes c When using hand held tester enter the following menu DIAGNOSIS ENHANCED...

Page 420: ...dard Tester Connections Specified Conditions HT1B E7 1 OX1B E7 18 10 kΩ or higher HT2B E6 5 OX2B E6 33 10 kΩ or higher NG Replace ECM See page SF 66 NG 4 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the heated oxygen sensor connector CHECK Measure resistance between terminals of the heated oxygen sensor OK Standard Tester Connection Specified Condition HT 1 B 2 11 to 16 Ω...

Page 421: ... PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Start the engine d Select the following menu items DIAGNOSIS ENHANCED OBD II DATA LIST ALL O2S B1S2 e After warming up the engine run the engine at an engine speed of 2 500 rpm for 3 minutes CHECK Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased HINT ...

Page 422: ... Proceed To P0136 or P0156 A No output B B Check for intermittent problems See page DI 11 A 10 Replace heated oxygen sensor NEXT 11 Perform confirmation driving pattern NEXT 12 Check whether DTC output recurs DTC P0136 P0156 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES b Read DTCs RESULT Display DTC Output Proceed To P0136 or P015...

Page 423: ...on volume within the range of 12 and 12 The injection volume can be changed in 1 graduations within the range The A F sensor is displayed as AFS B1S1 and the HO2 sensor is displayed as O2S B1S2 on hand held testers RESULT Tester Display Sensor Voltage Variations Proceed To AFS B1S1 AFS B2S1 A F Alternates between more and less than 3 3 V OK AFS B1S1 AFS B2S1 A F Remains at more than 3 3 V NG AFS B...

Page 424: ...for exhaust gas leakage from the exhaust manifold and pipe OK No exhaust gas leakage NG Repair or replace exhaust gas leakage point OK 15 Inspect heated oxygen sensor PREPARATION Disconnect the HO2 sensor connector CHECK Measure the resistance between the terminals of the HO2 sen sor connector OK Standard Tester Connections Specified Conditions HT 2 B 1 11 to 16 Ω at 20 C 68 F HT 2 E 3 10 kΩ or hi...

Page 425: ...Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Standard Terminal No Condition Specified Condition 3 5 Usually 10 KΩ or higher 3 5 Apply B between terminals 1 and 2 Below 1 Ω NG Replace EFI relay OK ...

Page 426: ... Disconnect the heated oxygen sensor connector b Disconnect the E6 and E7 ECM connectors CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition OX H4 3 OX1B E7 18 Below 1 Ω HT H4 1 HT1B E7 1 Below 1 Ω OX H6 3 OX2B E6 33 Below 1 Ω HT H6 1 HT2B E6 5 Below 1 Ω OX H4 3 or OX1B E7 18 Body ground 10 kΩ or higher HT H4 1 or HT1B E7 1 Body ...

Page 427: ...e air fuel ratio is rich or lean compared to the stoichiometric ratio This triggers a reduction in the fuel injection volume if the air fuel ratio is rich and an increase in the fuel injection volume if it is lean Factors such as individual engine differences wear over time and changes in operating environment cause short term fuel trim to vary from the central value The long term fuel trim which ...

Page 428: ...rming up the engine fuel trim is considered to be in error on RICH side 2 trip detection logic Injector leak blockage Mass air flow meter Engine coolant temperature sensor Ignition system Fuel pressure Gas leakage in exhaust system Open or short in heated oxygen sensor bank 1 2 sensor 1 circuit Heated oxygen sensor bank 1 2 sensor 1 ECM HINT When DTC P0171 or P0174 is recorded the actual air fuel ...

Page 429: ...feedback compensation value and the average long term fuel trim learning value of the air fuel ratio If the average fuel trim learning value exceeds the malfunction thresholds the ECM interprets this a fault in the fuel system and sets a DTC Example The average fuel trim leaning value is more than 35 or less than 35 the ECM interprets this as a fuel system malfunction MONITOR STRATEGY P0171 Fuel s...

Page 430: ...ming the A F CONTROL function provided in the ACTIVE TEST The A F CONTROL function can help to determine whether the Air Fuel Ratio A F sensor Heated Oxygen HO2 sensor and other potential trouble areas are malfunctioning The following instructions describe how to conduct the A F CONTROL operation using a hand held tester 1 Connect a hand held tester to the DLC3 2 Start the engine and turn the test...

Page 431: ...O2 sensor circuit HO2 sensor heater Air fuel ratio extremely lean or rich Injector Gas leakage from exhaust system Fuel pressure DI 164 DIAGNOSTICS ENGINE 1GR FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 AFS B2S1 A F 25 Rich Less than 3 0 AFS B1S1 AFS B2S1 A F 12 5 Lean More than 3 35 O2S B1S2 O2S B2S2 HO2 25 Rich More than 0 55 O2S B1S2 O2S B2S2 HO2 12 5 Lean Less ...

Page 432: ...voltage could be caused by a lean air fuel mixture Check for conditions that would cause the engine to run lean 1 Check any other DTCs output in addition to DTC P0171 P0172 P0174 or P0175 PREPARATION a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read DTCs Resu...

Page 433: ...F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume f Monitor the voltage outputs of A F and HO2 sensors AFS B1S1 AFS B2S1 and O2S B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowers the fuel injection volume by 12 5 or increases the injection volume by 25 Each sensor reacts in accordance with increas...

Page 434: ...sensor B Rich Lean Rich A F sensor malfunction A F sensor B Lean During A F CONTROL the A F sensor output voltage AFS is consistently more than 3 35 V and the HO2 sensor output voltage O2S is consistently less than 0 4 V Rich During A F CONTROL the AFS is consistently less than 3 0 V and the O2S is consistently more than 0 55 V B Go to step 11 C Go to step 15 A 5 Read value of coolant temperature ...

Page 435: ...and at an engine speed of 2 500 rpm Standard MAF while engine idling Between 1 4 gm s and 2 3 gm s shift position N A C OFF MAF at engine speed of 2 500 rpm Between 5 4 gm s and 7 9 gm s shift position N A C OFF NG Replace mass air flow meter OK 7 Check fuel pressure See page SF 5 CHECK Check the fuel pressure high or low pressure NG Check and replace fuel pump pressure regula tor fuel pipe line a...

Page 436: ...eck injector injection See page SF 26 HINT If the injectors malfunction engine misfires may occur The misfire counter can be read with the hand held tester Enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST MISFIRE CYL 1 to CYL 8 NG Replace injector OK 11 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the A10 or A30 air fuel ratio A F sensor connec tor CHECK...

Page 437: ...eck for open and short in harness and connector between ECM and A F sen sor PREPARATION a Disconnect the A10 or A30 A F sensor connector b Turn the ignition switch to ON CHECK Measure the voltage between the B terminal of the A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground 9 to 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect ...

Page 438: ...ard Check for short Tester Connections Specified Conditions HT A10 1 or HA1A E6 2 Body ground HT A30 1 or HA2A E6 1 Body ground 10 kΩ or higher AF A10 3 or A1A E6 22 Body ground AF A30 3 or A2A E6 23 Body ground 10 kΩ or higher AF A10 4 or A1A E6 30 Body ground AF A30 4 or A2A E6 31 Body ground 10 kΩ or higher NG Replace or replace harness or connector OK 14 Replace air fuel ratio sensor NEXT ...

Page 439: ...ON c Clear DTCs see page DI 42 d Switch the ECM from normal mode to check mode using the tester see page DI 43 e Start the engine and warm it up with all the accessories switched OFF f Drive the vehicle at 38 mph to 75 mph 60 km h to 120 km h and at an engine speed of between 1 400 rpm and 3 200 rpm for 3 to 5 minutes HINT If the system is still malfunctioning the MIL will be illuminated during st...

Page 440: ... recurs DTC P0171 P0172 P0174 or P0175 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES b Read DTCs RESULT Display DTC Output Proceed To P0171 P0172 P0174 or P0175 A No output B B Go to step 5 A END ...

Page 441: ...lows to the coil of the circuit opening relay the relay switches on power is supplied to the fuel pump and the fuel pump oper ates While the NE signal is generated engine running the ECM keeps the Tr1 ON circuit opening relay ON and the fuel pump also keeps operating The fuel pump speed is controlled at two levels high speed or low speed by the condition of the engine starting light load heavy loa...

Page 442: ...TICS ENGINE 1GR FE DI 175 DTC No DTC Detecting Condition Trouble Area P0230 Open or short in fuel pump relay circuit Open or short in fuel pump relay circuit Fuel pump relay Circuit opening relay Fuel pump ECM ...

Page 443: ...oom R B L O L O F5 Fuel Pump Resistor W R B R B W B W Y L O L O J C 19 2 J26 J27 W B W B 3 7 BB4 BB4 J26 J27 Y 11 28 J C 2 2 2 1 2 1 2 Engine Room R B EFI No 1 AM2 W B 7 6 I23 Ignition SW AM2 IG2 J18 J C A A W B B Battery J3 J C A EA IF 4 5 F10 Fuel Pump Y DI 176 DIAGNOSTICS ENGINE 1GR FE WIRING DIAGRAM HINT This diagnostic chart is based on premise that engine is started If the engine is not star...

Page 444: ...ccurred 1 Check voltage between terminal FPR and E1 of ECM CHECK Measure the voltage between terminals of E5 ECM connectors OK Tester Connection Condition Specified Condition FPR E5 30 E1 E5 1 STA signal ON 9 to 14 V FPR E5 30 E1 E5 1 STA signal OFF 0 to 3 V OK Replace ECM See page SF 66 NG 2 Check fuel pump relay PREPARATION Remove the fuel pump relay from the engine room R B CHECK Inspect the fu...

Page 445: ...he fuel pump relay from the engine room J B b Disconnect the E5 ECM connector CHECK Measure the resistance between wire harness side connectors OK Standard Tester Connection Specified Condition Engine Room J B Fuel pump relay ter minal 1 FPR E5 30 Below 1 Ω Engine Room J B Fuel pump relay ter minal 1 or FPR E5 30 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Replace ECM ...

Page 446: ... of the catalyst to increase possibly damaging the catalyst To prevent this increase in emissions and limit the possibility of thermal damage the ECM monitors the misfire rate When the temperature of the catalyst reaches a point of thermal degradation the ECM will blink the MIL For monitoring misfire the ECM uses both the camshaft position sensor and the crankshaft position sensor The camshaft pos...

Page 447: ...P0306 Misfiring of each cylinder is detected Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM HINT When several codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded it indicates that the misfires have been detected and recorded at different times Ref...

Page 448: ...percentage of misfire causing catalyst damage is reached 3 time MONITOR STRATEGY P0300 Random Multiple cylinder misfire detected P0301 Cylinder 1 misfire detected P0302 Cylinder 2 misfire detected Related DTCs P0303 Cylinder 3 misfire detected Related DTCs P0304 Cylinder 4 misfire detected P0305 Cylinder 5 misfire detected P0306 Cylinder 6 misfire detected R i d t Main sensors components Camshaft ...

Page 449: ...st 1 000 revolutions after engine start or check mode Crankshaft 1 000 revolutions Except above Crankshaft 1 000 revolutions x 4 Catalyst damage misfire MIL blinks All of the following conditions 1 2 and 3 are met Crankshaft 200 revolutions 1 Driving cycle 1st 2 Check mode OFF 3 Engine RPM 2 800 rpm Except above Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Thres...

Page 450: ... 1 2 1 2 1 2 1 2 B R B R B R W R W R I14 Injector No 1 I19 Injector No 6 I17 Injector No 4 I15 Injector No 2 I18 Injector No 5 I16 Injector No 3 Battery B IE1 13 1I 1J 4 7 I23 Ignition Switch Driver Side J B 6 7 IG2 AM2 8 IA9 DIAGNOSTICS ENGINE 1GR FE DI 183 WIRING DIAGRAM Refer to DTC P0351 on page DI 216 for the wiring diagram of the ignition system ...

Page 451: ...y troubleshoot the non misfire DTCs first If the misfire does not occur when the vehicle is brought to the workshop the misfire can be confirmed by reproducing the condition of the freeze frame data Also after finishing the repair confirm that there is no misfire See confirmation driving pattern On 6 or 8 cylinder engines misfiring cylinder identification is disabled at high engine speed and only ...

Page 452: ...er RESULT Display DTC Output Proceed to P0300 P0301 P0302 P0303 P0304 P0305 and or P0306 A P0300 P0301 P0302 P0303 P0304 P0305 or P0306 and other DTCs B HINT If any other codes besides P0300 P0301 P0302 P0303 P0304 P0305 or P0306 are output perform the troubleshooting for those DTCs B Go to DTC chart See page DI 57 A 2 Check wire harness connector and vacuum hose in engine room CHECK a Check the c...

Page 453: ...DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL CYL 1 to CYL 6 CHECK Read the number of misfire on the hand held tester HINT When a misfire is not reproduced be sure to branch below based on the stored DTC RESULT High Misfire Rate Cylinder Proceed to ...

Page 454: ...ECK a Check the electrode for carbon deposits b Check the spark plug type See page IG 1 c Check electrode gap OK No large carbon deposit present Not wet with gasoline or oil Electrode gap 1 0 to 1 1 mm 0 039 to 0 043 in NOTICE If adjusting the gap of a new spark plug bend only the base ground electrode Do not touch the tip Never at tempt to adjust the gap of a used plug NG Replace spark plug OK ...

Page 455: ...may be faulty from the ignition coil assembly 2 Install another spark plug to the ignition coil assem bly b Disconnect the injector connectors c Ground the spark plug CHECK Check if spark occurs while the engine is being cranked CAUTION Always disconnect each injector connector NOTICE Do not crank the engine for more than 2 seconds OK Spark jumps across electrode gap OK Go to step 8 NG ...

Page 456: ...cified Condition Ignition coil I3 2 IGF1 E7 24 Below 1 Ω Ignition coil I4 2 IGF1 E7 24 Below 1 Ω Ignition coil I5 2 IGF1 E7 24 Below 1 Ω Ignition coil I6 2 IGF1 E7 24 Below 1 Ω Ignition coil I7 2 IGF1 E7 24 Below 1 Ω Ignition coil I8 2 IGF1 E7 24 Below 1 Ω Ignition coil I3 2 or IGF1 E7 24 Body ground 10 kΩ or higher Ignition coil I4 2 or IGF1 E7 24 Body ground 10 kΩ or higher Ignition coil I5 2 or...

Page 457: ...Below 1 Ω Ignition coil I5 3 IGT3 E7 10 Below 1 Ω Ignition coil I6 3 IGT4 E7 11 Below 1 Ω Ignition coil I7 3 IGT5 E7 12 Below 1 Ω Ignition coil I8 3 IGT6 E7 13 Below 1 Ω Ignition coil I3 3 or IGT1 E7 8 Body ground 10 kΩ or higher Ignition coil I4 3 or IGT2 E7 9 Body ground 10 kΩ or higher Ignition coil I5 3 or IGT3 E7 10 Body ground 10 kΩ or higher Ignition coil I6 3 or IGT4 E7 11 Body ground 10 k...

Page 458: ...age between the terminals of the E5 and E7 ECM connectors OK Standard Tester Connection Specified Condition 10 E5 2 E01 E7 7 9 to 14 V 20 E5 3 E01 E7 7 9 to 14 V 30 E5 4 E01 E7 7 9 to 14 V 40 E5 5 E01 E7 7 9 to 14 V 50 E5 6 E01 E7 7 9 to 14 V 60 E5 7 E01 E7 7 9 to 14 V OK Go to step 11 NG 9 Check injector resistance of misfiring cylinder See page SF 21 NG Replace injector OK ...

Page 459: ...ide connectors be tween the ECM and injector OK Standard Tester Connection Specified Condition Injector I14 1 10 E5 2 Below 1 Ω Injector I15 1 20 E5 3 Below 1 Ω Injector I16 1 30 E5 4 Below 1 Ω Injector I17 1 40 E5 5 Below 1 Ω Injector I18 1 50 E5 6 Below 1 Ω Injector I19 1 60 E5 7 Below 1 Ω Injector I14 1 or 10 E5 2 Body ground 10 kΩ or higher Injector I15 1 or 20 E5 3 Body ground 10 kΩ or higher...

Page 460: ... I23 6 Below 1 Ω Injector I15 2 IG2 I23 6 Below 1 Ω Injector I16 2 IG2 I23 6 Below 1 Ω Injector I17 2 IG2 I23 6 Below 1 Ω Injector I23 2 IG2 I23 6 Below 1 Ω Injector I19 2 IG2 I23 6 Below 1 Ω Injector I14 2 or IG2 I23 6 Body ground 10 kΩ or higher Injector I15 2 or IG2 I23 6 Body ground 10 kΩ or higher Injector I16 2 or IG2 I23 6 Body ground 10 kΩ or higher Injector I17 2 or IG2 I23 6 Body ground ...

Page 461: ...page EM 4 NG Adjust valve clearance OK 14 Check result of step 4 and proceed to each step RESULT High misfire rate cylinder Proceed to 1 or 2 cylinders A More than 3 cylinders B B Check for intermittent problems See page DI 11 A 15 Check valve timing Check for looseness or a jumped tooth of timing chain See page EM 44 NG Adjust valve timing Repair or replace timing belt OK ...

Page 462: ...ld tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR 2 Read its value displayed on the hand held tester OK Equivalent to ambient temperature CHECK Check the air flow rate 1 When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF 2 Read its value displayed on the hand held tester OK Condition Air Flow Rate g s Ignition switch...

Page 463: ...olant temperature sensor in the water be careful not to allow water to go into the ter minals After checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor Compare these values to the resistance temperature gr...

Page 464: ...sensor contains a piezoelectric element which generates voltage when it becomes deformed Generation of the voltage occurs when the cylinder block vibrates due to knocking If engine knocking oc curs the ignition timing is retarded in order to suppress the knocking DTC No DTC Detection Condition Trouble Area P0327 P0332 Output voltage of the knock sensor 1 or 2 is 0 5 V or less Short in knock sensor...

Page 465: ...lt age R l t d DTC P0328 Knock sensor Bank 1 range check High volt age Related DTCs P0332 Knock sensor Bank 2 range check Low volt age P0333 Knock sensor Bank 2 range check High volt age Main sensors components Knock sensor Required sensors components Related sensors components Crankshaft position sensor Camshaft position sensor Engine coolant temperature sensor Mass air flow meter Frequency of op...

Page 466: ... PROCEDURE HINT DTC P0327 and P0328 are for the bank 1 knock sensor circuit DTC P0332 and P0333 are for the bank 2 knock sensor circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if t...

Page 467: ... 2 Terminal 4 Terminal 6 Terminal 5 Terminal 4 Terminal 2 c Warm up the engine d Run the engine at 3 000 rpm for 10 seconds or more CHECK a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and turn the hand held tes ter ON c Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES d Read DTCs Result Display Proceed to DTCs same as when vehicle brought in P0327 P032...

Page 468: ... between terminals KNK1 and EKNK KNK2 and EKN2 of ECM PREPARATION a Disconnect the E6 ECM connector b Turn the ignition switch to ON CHECK Measure the voltage between the specified ECM terminals OK Standard Tester Connection Specified Condition KNK1 E6 29 EKNK E6 28 4 5 to 5 5 V KNK2 E6 21 EKN2 E6 20 4 5 to 5 5 V a Reconnect the ECM connector NG Replace ECM See page SF 66 OK Check for intermittent...

Page 469: ... kΩ EF2 male connector 4 6 120 to 280 kΩ b Reconnect the EF2 connector OK Check for intermittent problems See page DI 11 NG 5 Check for open and short in harness and connector between EF2 connector and knock sensor See page IN 30 HINT If DTC P0327 or P0328 has changed to P0332 or P0333 check the knock sensor circuit on the right bank side If DTC P0332 or P0333 has changed to P0327 or P0328 check t...

Page 470: ...l injection time and igni tion timing are controlled DTC No DTC Detecting Condition Trouble Area P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more 1 trip detection logic Open or short in crankshaft position sensor circuit Crankshaft position sensor Signal plate ECM P0339 In condition a b and c when no crankshaft position sensor NE signal is input for 0 05 sec or m...

Page 471: ...on Case 1 0 016 sec Case 2 3 times MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 18 Case 1 Engine speed 600 rpm Starter OFF Time after starter ON to OFF 3 sec Case 2 Time after starter ON to OFF 0 3 sec Number of camshaft position sensor sig nal pulse 6 Ignition ...

Page 472: ...5 VV1 VVT Sensor LH V 16 E5 E5 E5 E7 E5 E5 VV1 VV2 VV2 VC NE NE 19 29 18 28 23 21 20 1 L Y G B 2 3 L G R G 1 2 1 2 3 G B D D BR BR EV C2 Crankshaft Position Sensor Shielded J65 J C G B DIAGNOSTICS ENGINE 1GR FE DI 205 WIRING DIAGRAM ...

Page 473: ... II DATA LIST ALL ENGINE SPD The engine speed can be confirmed in DATA LIST using the hand held tester If there are no NE sig nals from the crankshaft position sensor despite the engine revolving the engine speed will be indi cated as zero If voltage output of the crankshaft position sensor is insufficient the engine speed will be indicated as lower RPM than the actual RPM 1 Check resistance of cr...

Page 474: ... the wire harness side connec tors OK Standard Tester Connection Specified Condition Crankshaft position sensor C2 1 NE E5 21 Below 1 Ω Crankshaft position sensor C2 2 NE E5 20 Below 1 Ω Crankshaft position sensor C2 1 or NE E5 21 Body ground 10 kΩ or higher Crankshaft position sensor C2 2 or NE E5 20 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK 3 Check sensor installat...

Page 475: ...OSTICS ENGINE 1GR FE 4 Inspect teeth of sensor plate PREPARATION Remove the crankshaft angle sensor plate See page EM 111 CHECK Check the teeth of sensor plate NG Replace sensor plate OK Replace ECM See page SF 66 ...

Page 476: ... pickup coil The change affects the magnetic field and result in change in the resistance of the MRE element The crankshaft angle sensor plate has 32 teeth and output 32 signals every engine revolution The ECM detects the standard crankshaft angle based on the G signal and actual crankshaft angle and engine speed by NE signal DTC No DTC Detection Condition Trouble Area P0340 P0345 No camshaft posi...

Page 477: ... timing pulley Jumping teeth of timing belt ECM P0343 P0348 Input voltage to ECM remains 4 7 V or higher for more than 5 seconds when 2 or more seconds have elapsed after turning the ignition switch ON 1 trip detection logic Open or short in camshaft position sensor circuit Camshaft position sensor Camshaft timing pulley Jumping teeth of timing belt ECM Inspection using the oscilloscope The correc...

Page 478: ...quency of operation Continuous Duration 4 sec P0340 Camshaft position sensor range check P0345 VVT sensor range check While starting engine 5 sec Others MIL operation 2 driving cycles P0340 Camshaft position sensor range check P0345 VVT sensor range check While starting engine Immediate Others Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor ...

Page 479: ...is aligned Camshaft position sensor range check Fluctuating Camshaft position sensor voltage Less than 0 3 V or more than 4 7 V Camshaft position sensor range check Low voltage Camshaft position sensor voltage Less than 0 3 V Camshaft position sensor range check High voltage Camshaft position sensor voltage More than 4 7 V VVT sensor range check While starting engine VVT sensor signal No signal VV...

Page 480: ...ccurred 1 Check camshaft position sensor power source PREPARATION Disconnect the camshaft position sensor connector CHECK Measure the voltage between terminal 3 of the camshaft posi tion sensor wire harness side connector and body ground OK Standard 4 5 to 5 5 V NG Check and repair harness and connector OK 2 Check signal of camshaft position sensor PREPARATION Start the engine CHECK Using oscillos...

Page 481: ...1 VV1 E5 19 Below 1 Ω Camshaft position sensor V17 2 VV1 E5 29 Below 1 Ω Camshaft position sensor V16 1 VV2 E5 18 Below 1 Ω Camshaft position sensor V16 2 VV2 E5 28 Below 1 Ω Camshaft position sensor V17 1 or VV1 E5 19 Body ground 10 kΩ or higher Camshaft position sensor V16 2 or VV1 E5 29 Body ground 10 kΩ or higher Camshaft position sensor V16 1 or VV2 E5 18 Body ground 10 kΩ or higher Camshaft ...

Page 482: ...nspect teeth of camshaft timing belt pulley PREPARATION Remove the camshaft timing belt pulley See page EM 53 CHECK Check the camshaft timing belt pulley NG Replace camshaft timing pulley OK Replace Camshaft position sensor See page IG 11 ...

Page 483: ...econdary Circuit HINT These DTCs indicate a malfunction related to primary circuit If DTC P0351 is displayed check No 1 ignition coil with igniter circuit If DTC P0352 is displayed check No 2 ignition coil with igniter circuit If DTC P0353 is displayed check No 3 ignition coil with igniter circuit If DTC P0354 is displayed check No 4 ignition coil with igniter circuit If DTC P0355 is displayed che...

Page 484: ...nition coil In the 1 cylinder ignition system the one spark plug is connected to the end of the secondary winding High voltage generated in the secondary winding is applied directly to the spark plug The spark of the spark plug passes from the center electrode to the ground electrode The ECM determines the ignition timing and outputs the ignition signals IGTs for each cylinder Using the IGT the EC...

Page 485: ...P0355 P0356 No IGF1 signal to ECM while engine is running Open or short in IGF1 and IGT1 to IGT6 circuit from ignition coil with igniter to ECM No 1 to No 6 ignition coil with igniter primary ignition Ignition system ECM Reference Inspection using the oscilloscope During cranking or idling check the waveform between termi nals IG1 to IG6 and E1 and terminal IGF1 and E1 of the E5 and E7 ECM connect...

Page 486: ...peration Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 18 Engine speed 1 500 rpm Either of the following conditions is met Condition 1 or 2 1 Following conditions are met Condition a and b a Engine speed 500 rpm b Battery voltage 6 V 2 Following conditions are met Condition...

Page 487: ... Assy with igniter No 1 I4 Ignition Coil Assy with igniter No 2 I5 Ignition Coil Assy with igniter No 3 I6 Ignition Coil Assy with igniter No 4 I7 Ignition Coil Assy with igniter No 5 I8 Ignition Coil Assy with igniter No 6 Battery N1 Noise Filter Engine Room R B AM2 1 2 2 2 IA9 8 W R W R AM2 IG2 6 7 I23 Ignition Switch 4 7 1 2 1J 1I IE1 5 1 2 3 4 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 Driver Sid...

Page 488: ...CM and ignition coil with igniter PREPARATION a Disconnect the I3 I4 I5 I6 I7 or I8 ignition coil will igniter connector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition Ignition coil I3 2 IGF1 E7 24 Below 1 Ω Ignition coil I4 2 IGF1 E7 24 Below 1 Ω Ignition coil I5 2 IGF1 E7 24 Below 1 Ω Igniti...

Page 489: ...een ter minals IGF1 and E1 of ECM connector PREPARATION a Disconnect the I3 I4 I5 I6 I7 or I8 ignition coil with igniter connector b Turn the ignition switch ON CHECK Measure the voltage between the E8 and E6 ECM connectors OK Standard Tester Connection Specified Condition IGF1 E7 24 E1 E5 1 4 5 to 5 5 V NG Replace ECM See page SF 66 OK Replace ignition coil with igniter ...

Page 490: ...r Connection Specified Condition Ignition coil I3 3 IGT1 E7 8 Below 1 Ω Ignition coil I4 3 IGT2 E7 9 Below 1 Ω Ignition coil I5 3 IGT3 E7 10 Below 1 Ω Ignition coil I6 3 IGT4 E7 11 Below 1 Ω Ignition coil I7 3 IGT5 E7 12 Below 1 Ω Ignition coil I8 3 IGT6 E7 13 Below 1 Ω Ignition coil I3 3 or IGT1 E7 8 Body ground 10 kΩ or higher Ignition coil I4 3 or IGT2 E7 9 Body ground 10 kΩ or higher Ignition ...

Page 491: ...r I8 ignition coil with igniter con nector CHECK Measure the voltage between terminals the E5 and E7 ECM connectors when the engine is cranked OK Standard Tester Connection Specified Condition IGT1 E7 8 E1 E5 1 IGT2 E7 9 E1 E5 1 IGT3 E7 10 E1 E5 1 M th 0 1 V l th 4 5 V IGT4 E7 11 E1 E5 1 More than 0 1 V or less than 4 5 V IGT5 E7 12 E1 E5 1 IGT6 E7 13 E1 E5 1 NG Replace ECM See page SF 66 OK ...

Page 492: ...I8 ignition coil with igniter connector b Turn the ignition switch to ON CHECK Measure the voltage between terminals the E5 and E7 ECM connectors when the engine is cranked OK Standard Tester Connection Specified Condition IGT1 E7 8 E1 E5 1 4 5 V or more IGT2 E7 9 E1 E5 1 4 5 V or more IGT3 E7 10 E1 E5 1 4 5 V or more IGT4 E7 11 E1 E5 1 4 5 V or more IGT5 E7 12 E1 E5 1 4 5 V or more IGT6 E7 13 E1 ...

Page 493: ... ignition coil with igniter connector b Turn the ignition switch to ON CHECK Measure the voltage between the terminal of the wire harness side connector and body ground OK Standard Tester Connection Specified Condition I3 1 Body ground 9 to 14 V I4 1 Body ground 9 to 14 V I5 1 Body ground 9 to 14 V I6 1 Body ground 9 to 14 V I7 1 Body ground 9 to 14 V I8 1 Body ground 9 to 14 V OK Repair ignition ...

Page 494: ... Specified Condition Ignition coil I3 1 IG2 I23 6 Below 1 Ω Ignition coil I4 1 IG2 I23 6 Below 1 Ω Ignition coil I5 1 IG2 I23 6 Below 1 Ω Ignition coil I6 1 IG2 I23 6 Below 1 Ω Ignition coil I7 1 IG2 I23 6 Below 1 Ω Ignition coil I8 1 IG2 I23 6 Below 1 Ω Ignition coil I3 1 or IG2 I23 6 Body ground 10 kΩ or higher Ignition coil I4 1 or IG2 I23 6 Body ground 10 kΩ or higher Ignition coil I5 1 or IG2...

Page 495: ...nning the ECM measures the signal lengths of both sensors 1 and 2 and calculates the ratio of the signal lengths to determine the extent of the TWC deterioration If the deterioration level exceeds the preset threshold the ECM interprets this as the TWC malfunction The ECM then illumi nates the MIL and sets the DTC DTC No DTC Detecting Condition Trouble Area P0420 P0430 After engine and catalyst ar...

Page 496: ...and test limit information are described as shown in the following table Check the monitor result and test values after performing the monitor drive pattern see page DI 27 TID Test Identification Data is assigned to each emissions related component TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunct...

Page 497: ...ll the accessories switched OFF until the engine coolant temper ature stabilizes c Run the engine at an engine speed of between 2 500 rpm and 3 000 rpm for at least 3 minutes d After confirming that the waveform of the heated oxygen sensor bank 1 2 sensor 1 OX1A OX2A oscillate around 0 5 V during feedback to the ECM check the waveform of the heated oxygen sensor bank 1 2 sensor 2 OX1B OX2B HINT If...

Page 498: ...tio A F sensor Heated Oxygen HO2 sensor and other potential trouble areas are malfunctioning The following instructions describe how to conduct the A F CONTROL operation using a hand held tester 1 Connect a hand held tester to the DLC3 2 Start the engine and turn the tester ON 3 Warm up the engine at an engine speed of 2 500 rpm for approximately 90 seconds 4 On the tester select the following men...

Page 499: ...eater HO2 sensor HO2 sensor circuit HO2 sensor heater Air fuel ratio extremely lean or rich Injector Gas leakage from exhaust system Fuel pressure DI 232 DIAGNOSTICS ENGINE 1GR FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 A F 25 Rich Less than 3 0 AFS B1S1 A F 12 5 Lean More than 3 35 O2S B1S2 HO2 25 Rich More than 0 55 O2S B1S2 HO2 12 5 Lean Less than 0 4 NOTICE Th...

Page 500: ... hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC Output Proceed to P0420 and or P0430 A P0420 or P0430 and other DTCs B HINT If any other codes besides P0420 and or P0430 a...

Page 501: ... distinguished a Perform ACTIVE TEST by hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST which changes the injection volume to 12 5 or 25 1 Connect the hand held tester to the DLC3 on the vehicle 2 Turn the ignition switch to ON 3 Warm up the engine with the engine speed at 2 500 rpm for approximately 90 seconds 4 Select the menu DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 ...

Page 502: ...sensor 2 rear sensor The following A F CONTROL procedure enables the technician to check and graph the voltage output of the heated oxygen sensors sensor 1 and 2 For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button NOTICE If the vehicle is short of fuel the air fuel ratio...

Page 503: ...ned ON open and atmospheric air introduced into EVAP system 0 02 inch leak pressure standard is measured at the start and at the end of the leak check If pressure does not return to near atmo spheric pressure ECM determines that purge valve stuck closed Purge VSV Connector wire harness Purge VSV ECM ECM Pump module Leakage from EVAP system While ignition Switch OFF 2 trip P0441 Purge flow While en...

Page 504: ...to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C...

Page 505: ...60 Within 15 minutes sec ON First 0 02 inch B C D OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 Standard sec 60 E EVAP Pressure when Purge VSV Stuck Open Leak Pressure Second 0 02 inch Standard x 0 2 DI 238 DIAGNOSTICS ENGINE 1GR FE a Purge VSV stuck open In operation C the vacuum pump creates negative pressure vacuum in the EVAP Evaporative Emission system The EVAP system pressure is th...

Page 506: ...not increase the ECM interprets this as the purge VSV being stuck closed The ECM illuminates the MIL and sets the DTC 2 trip detection logic 2 PURGE FLOW MONITOR The purge flow monitor consists of the two step monitors The 1st monitor is conducted every time and the 2nd monitor is acti vated if necessary The 1st monitor While the engine is running and the purge VSV Vacuum Switching Valve is ON ope...

Page 507: ...ure sensor malfunction P0450 P0452 P0453 Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF Condition 1 and 2 1 Duration that vehicle is driven 5 min 2 EVAP purge operation Performed ECT 4 4 to 35 C 40 to 95 F IAT 4 4 to 3...

Page 508: ... and 4 1 EVAP pressure just after reference pressure measurement 1 kPa 7 5 mmHg 2 Reference pressure 4 85 to 1 057 kPa 36 4 to 7 92 mmHg 3 Reference pressure Saturated 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following condition is set EVAP pressure when vacuum introduction is complete Less than second r...

Page 509: ...anister purge valve is open Less than 0 3 kPa 2 25 mmHg Purge flow Both of the following conditions are met Condition 1 or 2 1 EVAP pressure change when purge flow is started Less than 0 1 kPa 0 75 mmHg 2 FTP change during purge operation when vent valve is closed Less than 0 5 kPa 3 75 mmHg MONITOR RESULT MODE 06 DATA Refer to page DI 26 for detailed information on Monitor Result INSPECTION PROCE...

Page 510: ...nsor noising Sensor output voltage fluctuates fre quently in certain time period Pump module Connector Wire harness Pump module ECM ECM EVAP monitor ing ignition OFF Engine running 2 trip P0451 Pressure sensor stuck Sensor output voltage does vary in cer tain time period Pump module Connector Wire harness Pump module ECM ECM EVAP monitor ing ignition OFF 2 trip P0452 Pressure sensor voltage low Se...

Page 511: ...he ECM interprets this as noise from the pressure sen sor and stops the EVAP system monitor The ECM then illuminates the MIL and sets the DTC Alternatively if the sensor voltage output does not change for 10 seconds the ECM interprets this as the sensor being stuck and stops the monitor The ECM then illuminates the MIL and sets the DTC Both the malfunctions are detected by 2 trip detection logic c...

Page 512: ...les P0451 Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 18 Pressure sensor noise Atmospheric pressure 70 to 110 kPa 525 to 825 mmHg Battery voltage 10 5 V IAT 4 4 to 35 C 40 to 95 F EVAP pressure sensor malfunction P0450 P0452 P0453 Not detected Either of the following conditions is ...

Page 513: ...r more for 10 sec Pressure sensor stuck EVAP pressure change during reference pressure measure ment Less than 0 65 kPa 4 9 mmHg Pressure sensor chattering EVAP pressure Less than 42 11 kPa 315 90 mmHg or more than 123 761 kPa 928 440 mmHg Pressure sensor low voltage EVAP pressure Less than 42 11 kPa 315 90 mmHg Pressure sensor high voltage EVAP pressure More than 123 761 kPa 928 440 mmHg ...

Page 514: ...ine c Turn the tester ON CHECK a Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES b Read DTCs c Select the following menu items DIAGNOSIS ENHANCED OBD II DATA LIST ALL VAPOR PRESS d Read the EVAP Evaporative Emission pressure displayed on the tester RESULT Display DTC Output Test Results Suspected Trouble Areas Proceed To P0451 Pressure sensor C P0452 Less than 45 k...

Page 515: ...isconnect the E3 ECM connector CHECK Measure the resistance between PPMP terminal of the ECM connector and the body ground RESULT Test Results Suspected Trouble Areas Proceed To 10 Ω or less Wire harness connector ECM pressure sensor Short in pressure sensor circuit A 10 kΩ or more Wire harness connector ECM pressure sensor Short in ECM circuit B B Go to step 7 A ...

Page 516: ...the L4 canister connector b Disconnect the E3 ECM connector CHECK Check the resistance between PPMP terminal of the ECM con nector and the body ground Result Test Results Suspected Trouble Areas Proceed To 10 kΩ or more Short in pressure sensor circuit A 10 Ω or less Short in wire harness connector ECM pressure sensor B A Go to step 5 B Go to step 6 ...

Page 517: ... ground Between 4 5 V and 5 5 V L4 3 Body ground Between 4 5 V and 5 5 V L4 2 Body ground 100 Ω or less RESULT Test Results Suspected Trouble Areas Proceed To Voltage and resistance within standard ranges Open in pressure sensor circuit A Voltage and resistance outside standard ranges Open in wire harness connector ECM pressure sensor B B Go to step 6 A 5 Replace charcoal canister assembly NEXT Go...

Page 518: ...he hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Wait for at least 60 seconds CHECK On the tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES HINT If no pending DTC is displayed on the tester the repair has been successfully completed NEXT Completed ...

Page 519: ...ure standard x 0 2 ECM determines that EVAP system has large leakage Fuel tank cap loose Leakage from EVAP line Canister Fuel tank Leakage from EVAP line Purge VSV Canister Pump module Leakage from fuel tank Leakage from canister While ignition switch OFF 2 trip P0456 EVAP small leak Vacuum pump creates negative pressure vacuum in EVAP system and EVAP sys tem pressure measured 0 02 inch leak press...

Page 520: ... pressure measured by ECM in order to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and them ECM checks if vacuum pump and vent ...

Page 521: ...ets the DTC 2 trip detection logic b P0456 EVAP very small leak In operation C the vacuum pump creates negative pressure vacuum in the EVAP system and the EVAP system pressure is measured If the stabilized system pressure is higher than second 0 02 inch leak pres sure standard the ECM determines that the EVAP system has a small leakage illuminates the MIL and sets the DTC 2 trip detection logic MO...

Page 522: ...llowing condition is set Atmospheric pressure change 0 3 kPa 2 25 mmHg for 1 sec 2 First reference pressure measure ment Next sequence is run if all of the following conditions are set Condition 1 2 and 3 1 EVAP pressure just after reference pressure measurement start 1 kPa 7 5 mmHg 2 Reference pressure 4 85 to 1 057 kPa 36 38 to 7 93 mmHg 3 Reference pressure Saturated 3 EVAP canister vent valve ...

Page 523: ... when vacuum introduction is complete Less than second reference pressure 8 Atmospheric pressure EVAP monitor is complete is the following condition is set Atmospheric pressure difference between sequence 1 and 8 0 3 kPa 2 25 mmHg TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Small leak 0 020 inch malfunction detection EVAP pressure when vacuum introduction is complete Between refere...

Page 524: ...TC No Proceed to DTC Detection Condition Trouble Area P0500 Step 1 No vehicle speed sensor sig nal to ECM under following conditions 1 trip detection logic Vehicle is being driven Combination meter Open or short in vehicle speed sensor circuit Vehicle speed sensor ECM P0503 DI 11 Intermittent problem in the ve hicle speed sensor circuit Combination meter Open or short in vehicle speed sensor circu...

Page 525: ...1 500 times Case 2 8 sec MIL operation Case 1 Immediate Case 2 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 18 Case 1 Vehicle speed is 5 59 mph 9 km h or more 4 sec Park neutral position switch OFF Case 2 ECT 70 C 158 F Fuel cut at high engine speed Not executing Engin...

Page 526: ...function occurred 1 Check operation of speedometer PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST PRIMARY VEHICLE SPD CHECK Read the mass air flow rate on the hand held tester RESULT Vehicle speed Proceed...

Page 527: ...itch to ON CHECK Measure the voltage between the specified terminal of the E4 and E5 ECM connectors when the wheel is turned slowly OK Standard Tester Connection Specified Condition SPD E4 8 E1 E5 1 Generated intermittently HINT The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly NG Check and repair harness and connector be tween com...

Page 528: ...designed with two complementary signal outputs STP and STI The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch HINT Normal condition is as shown in the table Signal Brake pedal released In transition Brake pedal depressed STP OFF ON ON STI ON ON OFF DTC No DTC Detection Condition Trouble Area P0504 Conditions a b and c continue for 0 5 sec or more a Ignition switch...

Page 529: ... G W G W G W G W W B 1 2 4 IC2 8 BB5 G W G W 1D 1D 1H 4 5 3 Driver Side J B To Skid Control ECU G W 3 V G W 4 C C C C G W 3 4 1 5 2 3 G W J10 J C G W 4 3 2 1 B G Y 3 W W R W G W W R 7 6 G Y 4 Driver Side J B Driver Side J B S4 Stop Light SW 4 2 13 11 1I 1I 1G 1F H H B O B O J66 J C GR G 3 J9 J C I23 Ignition SW Driver Side J B ECU IG IGN GR G 3 G Y 3 2 R4 Stop Light LH E E 2 1 S31 Stop Light Relay...

Page 530: ...determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check operation of stop light CHECK Check if the stop lights come on and go off normally when the brake pedal is depressed and released NG Check and repair stop light circuit OK 2 Check stop light switch See page...

Page 531: ... II DATA LIST ALL STOP LIGHT SW CHECK Read the signal displayed on the hand held tester OK Standard Brake Pedal Specified Condition Depressed STP Signal ON Released STP Signal OFF CHECK Measure the voltage between the specified terminals of the E3 and E5 ECM connectors OK Standard Tester Connection Brake Pedal Specified Condition STI E3 16 E1 E5 1 Depressed Below 1 5 V STI E3 16 E1 E5 1 Released 7...

Page 532: ...nnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition Stop light switch S4 1 STP E3 15 Below 1 Ω Stop light switch S4 4 STI E3 16 Below 1 Ω Stop light switch S4 1 or STP E3 15 Body ground 10 kΩ or higher Stop light switch S4 4 or STI E3 16 Body ground 10 kΩ or higher NG Repair or replace harness or connec...

Page 533: ...on Condition Trouble Area P0505 Idle speed continues to vary greatly from target speed 2 trip detection logic ETCS Air induction system PCV hose connection ECM MONITOR DESCRIPTION The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS The ECM con cludes that the idle speed control ECM function is malfunctioning if 1 the actual idle RPM varies more than the specif...

Page 534: ...onitor will run whenever this DTC is not present See page DI 18 Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following conditions is met Condition 1 or 2 1 Frequency that both of the following conditions a and b are met 5 times or more a Engine RPM target engine RPM Less than 100 rpm or more than 150 rpm b Vehicle condition Stop after vehicle was driven ...

Page 535: ... engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides P0505 being output PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II...

Page 536: ...1GR FE DI 269 3 Check air induction system See page SF 1 CHECK Check for vacuum leaks in air induction system OK No leakage NG Repair or replace air induction system OK Check electric throttle control system See page SF 39 ...

Page 537: ...djusts the intake air amount to achieve the target idling speed In addition the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly increase the catalyst temperature at cold start DTC No DTC Detection Conditions Trouble Areas P050A Accumulated intake air amount during 10 seconds of idling after cold start less than threshold 2 trip detection logic Throttle body ...

Page 538: ...e engine idles for 13 seconds after engine start 3 The accumulated intake air amount is below the threshold If a malfunction is not repaired successfully the ECM sets the DTC and illuminates the MIL 13 seconds after the engine is next started NOTICE When the negative battery terminal is disconnected during inspection or repairs the ISC Iearning values are cleared The ISC Iearning must be performed...

Page 539: ...e speed 1 875 mph 3 km h Time after shift position changed 1 second P050B Battery voltage 8 V Time after engine start 3 seconds Starter OFF ECT at engine start 10 C 14 F ECT 10 C 14 F 50 C 122 F Engine idling time 3 seconds Fuel cut OFF Vehicle speed 1 875 mph 3 km h TYPICAL MALFUNCTION THRESHOLDS P050A Accumulated air flow amount M T Varies with ECT Example Less than 42 5 g Accumulated air flow a...

Page 540: ...menu items DIAGNOSIS EN HANCED OBD II DTC INFO CURRENT CODES e Read the DTCs Result Display DTC Output Proceed To P050A and or P050B A P050A and or P050B and other DTCs B HINT If any DTCs other than P050A and P050B are output trouble shoot those DTCs first B Go to DTC chart A 2 Read value using intelligent tester Fuel trim HINT Calculate the total fuel trim values to check the characteristic devia...

Page 541: ...ed NG Go to step 5 OK 4 Check air induction system a Check the air induction system for vacuum leakage OK No leakage from the air induction system OK Go to step 6 NG Go to step 7 5 Repair or replace PCV hose NEXT Go to step 11 6 Replace mass air flow meter NEXT Go to step 11 7 Repair or replace air induction system NEXT Go to step 11 ...

Page 542: ... output recurs DTC P050A and or P050B NOTICE In this operation the engine must be cold the same level as the engine coolant temperature recorded in the freeze frame data a Connect the intelligent tester to the DLC3 b Turn the ignition switch ON c Turn the tester ON d Clear DTCs See page DI 42 e Switch the ECM from normal mode to check mode using the tester See page DI 43 f Start the engine to idle...

Page 543: ...e Area P0560 Open in back up power source circuit Open in back up power source circuit EFI No 1 fuse ECM HINT If DTC P0560 present the ECM will not store another DTC MONITOR STRATEGY Related DTCs P0560 System voltage malfunction Required sensors components ECM Frequency of operation Continuous Duration 3 sec MIL operation Immediate 1 Sequence of operation None 1 The DTC is set immediate The MIL wi...

Page 544: ...ze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check battery voltage PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON c Select the item DIAGNOSIS ENHANCED OBD II DATA LIST ALL BATTERY VOLTAGE CHECK...

Page 545: ...tance of the EFI No 1 fuse OK Standard Below 1 Ω NG Check for short in all harness and components connected to EFI No 1 fuse and replace the fuse OK 3 Check voltage between terminal BATT and E1 of ECM connector CHECK Measure the voltage between terminals of the E5 and E3 ECM connectors OK Standard Tester Connection Specified Condition BATT E3 3 E1 E5 1 9 to 14 V OK Check for intermittent problems ...

Page 546: ... the engine room J B b Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tor OK Standard Tester Connection Specified Condition Engine Room J B EFI No 1 fuse terminal 2 BATT E3 3 Below 1 Ω Engine Room J B EFI No 1 fuse terminal 2 or BATT E3 3 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK 5 Check the battery See page CH 1 NG ...

Page 547: ...Us also perform continuous mutual monitoring The ECM sets a DTC if 1 outputs from the 2 CPUs are different and deviate from the standards 2 the sig nals to the throttle actuator deviate from the standards 3 a malfunction is found in the throttle actuator sup ply voltage and 4 any other ECM malfunction is found DTC No DTC Detecting Condition Trouble Area P0604 P0606 P0607 P0657 ECM malfunction ECM ...

Page 548: ...n a b and c a CPU reset 1 time or more b Difference between TP and APP learned 0 4 V or more c Electronic throttle actuator OFF 2 CPU reset 2 times or more P0657 ECTS power supply when ignition switch OFF to ON 7 V or more INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting f...

Page 549: ...b Engine revolution 1 000 rpm c STA signal ON Park neutral position switch Starter relay circuit Ignition switch ECM MONITOR STRATEGY Related DTCs P0617 Starter signal error R i d t Main sensors components Starter signal Required sensors components Related sensors components Vehicle speed sensor Engine speed sensor Frequency of operation Continuous Duration 20 sec MIL operation Immediate Sequence ...

Page 550: ...Engine Room R B Engine Room R B W R IA9 8 2 3 5 1 B W G R G R 3 8 ST SRLY T13 TVIP ECU 2 1 C10 Clutch Start SW G B G B B W G B 8 7 34 17 27 29 17 34 10 12 B P W B A J3 J C IF EB2 6 B W 1 1 S2 S1 Starter Battery B B L 1 B 2 1 Towing Package 2 Except Towing Package MT AM2 ST2 W R 2 1 J C ST Relay B W DIAGNOSTICS ENGINE 1GR FE DI 277 WIRING DIAGRAM ...

Page 551: ...ion SW B 7 2 3 8 AM2 AM1 ACC ST2 3 4 L O 1 2 C C L R B W 3 6 R L R L IE1 15 IA9 IA9 8 7 J C 25 17 27 29 12 10 34 8 G Y G Y G R G R W B G R L R P N J C A A E P P J23 J C W B A A B W EB2 6 B W S1 S2 1 1 8 3 2 2 2 2 1 1 1 1 B W W T13 TVIP ECU G STA W R W R 2 1 ECU B 3 2 1 5 ST Relay ST3 AM2 AM1 Short Pin P1 Park Neutral Position SW ST SRLY P Starter IE B L 1 B 2 1 Towing Package 2 Except Towing Packa...

Page 552: ... check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter operates OK Standard Ignition Switch Position ON START STARTER SIG OFF ON ...

Page 553: ...the hand held tester while the starter operates OK Standard Ignition Switch Position ON START STARTER SIG OFF ON NG Repair or replace harness or connector OK 5 Check DTC reoccur PREPARATION a Connect the hand held tester b Turn the ignition switch to ON and hand held tester main switch ON c Clear DTC See page DI 42 d Drive the vehicle more than 25 mph 40 km h for 20 seconds or more CHECK Check DTC...

Page 554: ...MONITOR STRATEGY Related DTCs P0630 VIN not programmed R i d t Main sensors components ECM Required sensors components Related sensors components Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 18 Battery voltage 8...

Page 555: ...CE If P0630 is present the VIN must be input to the ECM using the hand held tester However all DTCs are cleared automatically by the tester when inputting the VIN If DTCs other than P0630 are present check them first NEXT 2 Input VIN with hand held tester See page DI 14 NEXT END ...

Page 556: ...ttle body ECM MONITOR DESCRIPTION The ECM monitors the current through the electronic throttle motor and detects malfunctions or open circuit in the throttle motor based on the voltage of the current When the current deviates from the standard the ECM concludes that there is a fault in the throttle motor Or if the throttle valve is not functioning properly for example stuck ON the ECM concludes th...

Page 557: ...are not present See page DI 18 P2102 Throttle motor ON Duty cycle ratio to open throttle actuator 80 Throttle actuator power supply 8 V Current motor current Motor current at 0 016 sec before 0 2 A P2103 Throttle motor ON Either of the following conditions is met Condition 1 or 2 1 Throttle actuator power supply 8 V 2 Throttle actuator power ON Battery voltage 8 V Starter OFF TYPICAL MALFUNCTION T...

Page 558: ...itions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check throttle control motor PREPARATION Disconnect the throttle control motor and sensor connector CHECK Measure the resistan...

Page 559: ...s side connec tors OK Standard Tester Connection Specified Condition M T14 2 M E7 5 Below 1 Ω M T14 1 M E7 4 Below 1 Ω M T14 2 or M E7 5 Body ground 10 kΩ or higher M T14 1 or M E7 4 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK 3 Visually check throttle valve CHECK Check the area between the throttle valve and the housing for foreign objects Also check if the valve can ...

Page 560: ...1 trip detection logic Throttle control motor and sensor Throttle body Throttle valve MONITOR DESCRIPTION The ECM concludes that there is a malfunction of the ETCS Electronic Throttle Control System when the throttle valve remains at a fixed angle despite high drive current from the ECM The ECM will turn on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a mal...

Page 561: ...ent 2 A Throttle actuator duty to open side 80 All System guard is ON when the following conditions are met Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current cut operation Not executing Throttle actuator power supply 4 V Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold TP...

Page 562: ...oceed To P2111 and or P2112 A P2111 and or P2112 and other DTCs B HINT If any DTCs other than P2111 and or P2112 are output troubleshoot those DTCs first B Go to DTC chart See page DI 57 A 2 Visually check throttle valve PREPARATION Remove the air cleaner assy CHECK Check whether or not a foreign body is caught between the throttle valve and housing Also check if the valve can open and close smoot...

Page 563: ... M T14 1 0 3 to100 Ω 20 C 68 F NG Replace throttle body See page SF 40 OK 4 Check for open and short in harness and connector between ECM and throttle control motor PREPARATION a Disconnect the T14 throttle control motor and sensor con nector b Disconnect the E7 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition M ...

Page 564: ...e For this reason when the voltage is low the current to the motor is cut If repairs are made and the system has returned to normal turn the ignition switch OFF The ECM then allows current to flow to the motor and the motor can be restarted HINT This Electrical Throttle Control System ETCS does not use a throttle cable DTC No DTC Detection Condition Trouble Area P2118 Open in ETCS power source cir...

Page 565: ...ass condition is detected and then the ignition switch is turned OFF the fail safe operation will stop and the system will return to normal condition MONITOR STRATEGY Related DTCs P2118 Throttle actuator motor power supply line range check Low voltage Required sensors components Throttle actuator motor Frequency of operation Continuous Duration 0 8 sec MIL operation Immediate Sequence of operation...

Page 566: ...cmc0490 BM E3 7 Battery J26 18 ETCS 2 1 Engine Room R B 1 2 2 4 B J27 DIAGNOSTICS ENGINE 1GR FE DI 293 WIRING DIAGRAM ...

Page 567: ... air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check ETCS fuse PREPARATION Remove the ETCS fuse from the engine room J B CHECK Check the resistance of the ETCS fuse OK Below 1 Ω NG Check for short in all harness and components connected to ETCS fuse OK 2 Check voltage between terminal BM and E1 of ECM connector CHECK Measure the voltage between t...

Page 568: ...pecified Condition Engine Room J B ETCS fuse terminal 2 BM E3 7 Below 1 Ω Engine Room J B ETCS fuse terminal 2 or BM E3 7 Body ground 10 kΩ or higher PREPARATION Disconnect the battery cable from the battery positive terminal CHECK Measure the resistance between the battery cable and engine room J B OK Standard Tester Connection Specified Condition Engine Room J B ETCS fuse terminal 1 Battery posi...

Page 569: ...s compared to the target throttle position commanded by the ECM If the difference of these two values exceeds a specified limit the ECM interprets this as a fault in the ETCS Electronic Throttle Control System The ECM turns on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle contr...

Page 570: ...ition a or b a Commanded closed throttle position current throttle position 0 3 V or more b Commanded open throttle position current throttle posi tion 0 3 V or more COMPONENT OPERATING RANGE Standard Value Commanded throttle position and current throttle position are nearly the same WIRING DIAGRAM Refer to DTC P2102 and P2103 on page DI 283 INSPECTION PROCEDURE HINT Read freeze frame data using t...

Page 571: ...INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC Output Proceed to P2119 A P2119 and other DTC B HINT If any other codes besides P2119 are output perform the troubleshooting for those DTCs first B Go to DTC chart See page DI 57 A 2 Check throttle control motor PREPARATION Disconnect the throttle control motor and sensor connector CHECK Measure the resistance betw...

Page 572: ...C outputs reoccur PREPARATION a Replace ECM b Clear the DTC See page DI 42 c Start and warm up the engine d Run the engine at idle for 15 seconds or more CHECK Read the DTC using the hand held tester See page DI 42 OK No DTC output OK System is normal NG Replace throttle body ...

Page 573: ...tion Sensor Switch D Circuit High Input DTC P2125 Throttle Pedal Position Sensor Switch E Circuit DTC P2127 Throttle Pedal Position Sensor Switch E Circuit Low Input DTC P2128 Throttle Pedal Position Sensor Switch E Circuit High Input DTC P2138 Throttle Pedal Position Sensor Switch D E Voltage Correlation HINT This is the repair procedure for the accelerator pedal position sensor DIDU3 01 ...

Page 574: ... type The accelerator pedal position sensor is mounted in the accelerator pedal to detect the angle of the accelera tor pedal This sensor is electronically controlled and uses Hall effect elements In the accelerator pedal position sensor the voltage applied to terminals VPA and VPA2 of the ECM changes between 0 V and 5 V in proportion to the angle of the accelerator pedal The VPA is a signal to in...

Page 575: ... Accelerator pedal position expressed as voltage Trouble area Accelerator pedal completely released Accelerator pedal fully depressed Trouble area ACCEL POS 1 ACCEL POS 2 ACCEL POS 1 ACCEL POS 2 VC circuit open 0 to 0 2 V 0 to 0 2 V 0 to 0 2 V 0 to 0 2 V VPA circuit open or ground short 0 to 0 2 V 1 2 to 2 0 V 0 to 0 2 V 3 4 to 5 3 V VPA2 circuit open or ground short 0 5 to 1 1 V 0 to 0 2 V 2 6 to...

Page 576: ...Accelerator position sensor 2 VPA2 range check Low voltage P2128 Accelerator position sensor 2 VPA2 range check High voltage P2138 Accelerator position sensor correlation range check Required sensors components Accelerator position sensor Frequency of operation Continuous Duration 2 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Max...

Page 577: ... V or more 1 2 V or less 2 VPA2 voltage when VPA1 voltage is 0 4 to 3 45 V 4 8 V or more P2127 VPA2 voltage when VPA1 voltage is 0 04 V or more 1 2 V or less P2128 VPA2 voltage when VPA1 voltage is 0 4 to 3 45 V 4 8 V or more P2138 Either of the following condition is met Condition 1 or 2 1 Difference between VPA1 and VPA2 voltage 0 02 V or less 2 Both of the following conditions are met a and b a...

Page 578: ...on Sensor ECM E3 E3 E3 E3 E3 E3 18 20 26 19 21 27 R G V R P G L LG R G R 6 1 5 2 5 1 1 2 4 1 4 2 3 1 2 2 2 1 3 2 1 1 6 2 1 A T 2 M T VPA EPA VCPA VPA2 EPA2 VCP2 VCPA VPA EPA VPA2 EPA2 VCP2 DI 304 DIAGNOSTICS ENGINE 1GR FE WIRING DIAGRAM ...

Page 579: ...l as other data from the time when a malfunction occurred 1 Connect hand held tester and read the voltage for accelerator pedal position sensor data PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ETCS ACCEL POS 1 and ACCEL POS 2 CHECK Read the voltage...

Page 580: ...PA A20 1 EPA E3 20 1 Below 1 Ω EPA A20 5 EPA E3 20 2 Below 1 Ω VCPA A20 4 VCPA E3 26 Below 1 Ω VPA2 A20 2 VPA2 E3 19 1 Below 1 Ω VPA2 A20 3 VPA2 E3 19 2 Below 1 Ω EPA2 A20 3 EPA2 E3 21 1 Below 1 Ω EPA2 A20 2 EPA2 E3 21 2 Below 1 Ω VCP2 A20 6 VCP2 E3 27 1 Below 1 Ω VCP2 A20 1 VCP2 E3 27 2 Below 1 Ω VPA A20 5 or VPA E3 18 Body ground 1 10 kΩ or higher VPA A20 6 or VPA E3 18 Body ground 2 10 kΩ or hi...

Page 581: ... and EPA2 of ECM terminals PREPARATION a Disconnect the A20 accelerator pedal position sensor connector b Turn the ignition switch to ON CHECK Measure the voltage between the specified terminals of the E3 ECM connector OK Standard Tester Connection Specified Condition VCPA E3 26 EPA E3 20 4 5 to 5 5 V VCP2 E3 27 EPA2 E3 21 4 5 to 5 5 V NG Replace ECM See page SF 66 OK 4 Replace accelerator pedal a...

Page 582: ...minals or remove the EFI No 1 fuse and ETCS fuse Clear DTCs c Start the engine d Drive the engine at idle for 15 seconds or more e On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES CHECK Read the DTC output RESULT Display DTC Output Proceed To P2120 P2122 P2123 P2125 P2127 P2128 or P2138 A No output B B System is OK A Replace ECM See page SF 6...

Page 583: ...dard the ECM con cludes the accelerator pedal position sensor has a malfunction The ECM turns on the MIL and a DTC is set FAIL SAFE The accelerator pedal position sensor has two main and sub sensor circuits If a malfunction occurs in ei ther of the sensor circuits the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode In limp mode the remai...

Page 584: ...he engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Connect hand held tester and read the voltage for accelerator pedal position sensor data PREPARATION a Connect t...

Page 585: ...elow 1 Ω EPA A20 5 EPA E3 20 2 Below 1 Ω VCPA A20 4 VCPA E3 26 Below 1 Ω VPA2 A20 2 VPA2 E3 19 1 Below 1 Ω VPA2 A20 3 VPA2 E3 19 2 Below 1 Ω EPA2 A20 3 EPA2 E3 21 1 Below 1 Ω EPA2 A20 2 EPA2 E3 21 2 Below 1 Ω VCP2 A20 6 VCP2 E3 27 1 Below 1 Ω VCP2 A20 1 VCP2 E3 27 2 Below 1 Ω VPA A20 5 or VPA E3 18 Body ground 1 10 kΩ or higher VPA A20 6 or VPA E3 18 Body ground 2 10 kΩ or higher EPA A20 1 or EPA ...

Page 586: ...DI 311 1 DIAGNOSTICS ENGINE 1GR FE NG Repair or replace harness or connector OK Replace accelerator pedal pedal assembly ...

Page 587: ... DTC P2197 Oxygen A F Sensor Signal Stuck Lean Bank 2 Sensor 1 DTC P2198 Oxygen A F Sensor Signal Stuck Rich Bank 2 Sensor 1 HINT Although the DTC titles say oxygen sensor these DTCs relate to the Air Fuel Ratio A F sensor Sensor 1 refers to the sensor mounted in front of the Three Way Catalytic Converter TWC and lo cated near the engine assembly DIDU5 01 ...

Page 588: ...facilitate accurate air fuel ratio detection In addition the sensor and heater portions are narrower than the conventional type The heat generated by the heater is conducted to the solid electrolyte though the alumina therefore the sensor activa tion is accelerated In order to obtain a high purification rate of the carbon monoxide CO hydrocarbon HC and nitrogen oxide NOx components in the exhaust ...

Page 589: ... acceleration and the sensor becomes low during deceleration The ECM monitors the air fuel ratio sensor current during fuel cut and detects an unusual current value If the cumulative time the sensor output is out of range exceeds more than 3 seconds the ECM interprets a malfunction in the air fuel ratio sensor and sets a DTC MONITOR STRATEGY P2195 A F sensor Bank 1 signal stuck lean P2195 A F sens...

Page 590: ...ed Fuel system status Closed loop Engine Running P2195 P2197 A F sensor current High side Battery voltage 11 V ECT 75 C 167 F Atmospheric pressure 760 mmHg 0 75 A F sensor status Activated Continuous time of fuel cut 3 to 10 sec P2196 P2198 A F sensor current Low side Battery voltage 11 V ECT 75 C 167 F Atmospheric pressure 760 mmHg 0 75 A F sensor status Activated Continuous time of fuel cut 3 to...

Page 591: ...sor Active A F control method TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 01 Multiply by 0 0003 V Cumulative A F sensor locus length Bank 1 Lower malfunction criterion for A F sensor 0 01 Multiply by 0 0003 V Cumulative A F sensor locus length Bank 1 Upper malfunction criterion for A F sensor 1 11 Multiply by 0 0003 V Cumulative A F sensor locus length Bank 2 Lower...

Page 592: ... W B W R W B J26 J27 EFI No 1 2 1 Engine Room R B J18 J C B Battery A A W B EA ET 26 12 9 W R IE1 W R W R 2 1 EV BR D D D J65 J C P V 3 4 HT AF B AF A10 A F Ratio Sensor Bank1 Sensor1 A30 A F Ratio Sensor Bank2 Sensor1 G G L Shielded W R 2 1 3 4 HT AF B AF ECM MREL HA2A A2A A2A HA1A A1A A1A 23 1 31 2 22 30 Shielded J C Y 1 2 DIAGNOSTICS ENGINE 1GR FE DI 317 WIRING DIAGRAM ...

Page 593: ... at least 10 minutes g Change the transmission to 2nd gear h Drive the vehicle at proper vehicle speed to perform fuel cut operation HINT Fuel cut is performed under following conditions met Accelerator pedal fully released Engine speed 2 500 rpm or more fuel injection returns at 1 000 rpm i Accelerate the vehicle to 30 mph 48 km h or more by depressing the accelerator pedal for at least 10 second...

Page 594: ...he tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume 6 Monitor the voltage outputs of the A F and HO2 sensors AFS B1S1 AFS B2S1 and OS2 B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowers the fue...

Page 595: ...nsor has an output delay of a few seconds and the Heated Oxygen HO2 sensor has a maximum output delay of approximately 20 seconds Following the A F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A F and HO2 sensors To display the graph select the following menu items on the tester DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S...

Page 596: ... to DTC chart See page DI 57 A 2 Check A F sensor output current PREPARATION a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Clear DTC See page DI 42 d On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II MON ITOR INFO MONITOR STATUS e Check that the status of O2S MON is COMPL f On the hand held tester select the follo...

Page 597: ... 500 rpm without any sudden changes in engine speed 3 Raise the engine speed to 4 000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed Standard Conditions A F Sensor Voltage Variations Reference 1 and 2 Changes at approx 0 66 V Between 0 62 V and 0 7 V 3 Increases to 0 76 V or more This occurs during engine deceleration when fuel cut performed For more ...

Page 598: ...rator pedal fully depressed when trying to over take another vehicle The A F sensor is functioning normally The A F sensor is a current output element therefore the current is converted into a voltage inside the ECM Measuring the voltage at the connectors of the A F sensor or ECM will show a constant volt age result NG Go to step 9 OK 4 Perform confirmation driving pattern NEXT 5 Check whether DTC...

Page 599: ...or P2198 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A No output B B Go to step 5 A 9 Confirm whether vehicle has run out of fuel in past NO Check for intermittent problems See page DI 11 YES DTC caused by running out of fuel ...

Page 600: ...between the terminals of the A F sensor connector OK Tester Connection Specified Condition HT 1 B 2 Between 1 8 Ω and 3 4 Ω at 20 C 68 F HT 1 AF 4 10 kΩ or higher NG Replace air fuel ratio A F sensor OK 11 Check A F relay PREPARATION Remove the A F relay from the engine room J B CHECK Inspect the A F relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5 Apply B...

Page 601: ...the A F sensor connector and body ground Standard Tester Connections Specified Conditions B 2 Body ground Between 9 V and 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω AF A...

Page 602: ...k the air induction system for vacuum leaks NG Repair or replace air induction system OK 14 Check fuel pressure See page SF 5 CHECK Check the fuel pressure high or low pressure NG Check and replace fuel pump pressure regula tor fuel pipe line and filter See page SF 1 OK 15 Check injector injection See page SF 26 NG Replace injector OK ...

Page 603: ...nd held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A No output B B Replace ECM See page SF 66 and perform confirmation driving pattern A 19 Confirm whether vehicle has run out of fuel in past NO Check for intermittent problems See page DI 11 YES DTC caused by running out of fuel...

Page 604: ...rn NEXT 22 Check whether DTC output recurs DTC P2195 P2196 P2197 or P2198 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A No output B A Replace ECM See page SF 66 B END ...

Page 605: ...TC P2252 Oxygen Sensor Reference Ground Circuit Low For A F Sensor Bank 1 Sensor1 DTC P2253 Oxygen Sensor Reference Ground Circuit High For A F Sensor Bank 1 Sensor1 DTC P2255 Oxygen Sensor Reference Ground Circuit Low For A F Sensor Bank 2 Sensor1 DTC P2256 Oxygen Sensor Reference Ground Circuit High For A F Sensor Bank 2 Sensor1 HINT Although the DTC titles say oxygen sensor these DTCs relate to...

Page 606: ...or 1 A F sensor heater EFI relay A F sensor heater and relay circuits ECM P2252 P2255 AF voltage 0 5 V or less for 5 0 seconds or more 1 trip detection logic Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater EFI relay A F sensor heater and relay circuits ECM P2253 P2256 AF voltage more than 4 5 V for 5 0 seconds or more 1 trip detection logic Open or short in A F s...

Page 607: ...n AF and AF Related DTCs A F sensor Bank 2 short circuit between AF and GND P2242 A F sensor Bank 2 short circuit between AF and B P2252 A F sensor Bank 1 short circuit between AF and GND P2253 A F sensor Bank 1 short circuit between AF and B P2255 A F sensor Bank 2 short circuit between AF and GND P2256 A F sensor Bank 2 short circuit between AF and B Required sensors components A F sensor Freque...

Page 608: ...rs Battery voltage 11 V Ignition switch ON Time after ignition switch is OFF to ON 5 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2238 P2241 A F sensor open circuit between AF and AF A F sensor admittance Bellow 0 022 1 ohm P2238 P2241 A F sensor short circuit between AF and GND A F terminal voltage 0 5 V or less P2238 P2241 A F sensor short circuit between AF and AF Difference...

Page 609: ...nds 4 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume 6 Monitor the voltage outputs of the A F and HO2 sensors AFS B1S1 AFS B2S1 and OS2 B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowe...

Page 610: ...mely lean or rich Injector Gas leakage from exhaust system Fuel pressure DIAGNOSTICS ENGINE 1GR FE DI 335 NOTICE The Air Fuel Ratio A F sensor has an output delay of a few seconds and the Heated Oxygen HO2 sensor has a maximum output delay of approximately 20 seconds Following the A F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A F and HO2 sensors To di...

Page 611: ...ce between the terminals of the A F sensor connector OK Tester Connection Specified Condition HT 1 B 2 1 8 Ω to 3 4 Ω at 20 C 68 F HT 1 AF 4 10 kΩ or higher NG Replace air fuel ratio A F sensor OK 2 Check A F relay PREPARATION Remove the A F relay from the engine room J B CHECK Inspect the A F relay OK Terminal No Condition Specified Condition 3 5 Usually 10 kΩ or higher 3 5 Apply B between termin...

Page 612: ... the A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground 9 V to 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance OK Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω AF A10...

Page 613: ...DI 338 DIAGNOSTICS ENGINE 1GR FE NG Replace or replace harness or connector OK Replace ECM See page SF 66 ...

Page 614: ...iming Detection Logic P2401 Vacuum pump stuck OFF One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high low Vacuum pump ON stuck Vacuum pump OFF stuck Pump module Connector Wire harness While ignition 2 trips P2402 Vacuum pump stuck ON Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Connector...

Page 615: ...First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C EVAP system pres sure measurement Vent valve turned ON closed to shut EVAP system Negative pressure vacuum created in EVAP system and EVAP system pres...

Page 616: ...p EVAP Pressure sec OFF Sequence Time A 10 sec 60 Within 15 minutes sec ON Specified Range B C D EVAP Pressure during EVAP Monitor OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 sec 60 E Malfunction OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DIAGNOSTICS ENGINE 1GR FE DI 341 In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the c...

Page 617: ...ge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF Condition 1 and 2 1 Duration that vehicle is driven 5 min 2 EVAP purge operation Performed ECT 4 4 to 35 C 40 to 95 F IAT 4 4 to 35 C 40 to 95 F Time after key off 5 or 7 or 9 5 hours EVAP key off moni...

Page 618: ...5 to 1 057 kPa 36 4 to 7 92 mmHg 3 Reference pressure Saturated 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following condition is set EVAP pressure when vacuum introduction is complete Less than second reference pressure 8 Atmospheric pressure measurement EVAP monitor is complete if the following condition...

Page 619: ...DI 344 DIAGNOSTICS ENGINE 1GR FE MONITOR RESULT MODE 06 DATA Refer to the EVAP Inspection Procedure see page DI 368 INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure see page DI 368 ...

Page 620: ...tion Timing Detection Logic P2419 Vent valve stuck ON Closed One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high flow Vacuum pump ON stuck Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Pump module Connector Wire harness Pump module ECM ECM While Ignition switch OFF 2 trips P2420 Vent valv...

Page 621: ... pressure measured by ECM in order to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and them ECM checks if vacuum pump and vent ...

Page 622: ...function OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DIAGNOSTICS ENGINE 1GR FE DI 347 a P2419 Vent valve stuck ON Closed In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the canister pump module through the 0 02 inch orifice If the pressure is out of specified range or is not saturated the ECM illuminates the MIL and sets DTCs P043E P043...

Page 623: ...as the vent valve being stuck OFF vent The ECM illuminates the MIL and sets the DTC MONITOR STRATEGY R l t d DTC P2419 Vent valve stuck open Related DTCs P2420 Vent valve stuck closed Required sensors components Vent valve Frequency of operation Once per driving cycle Duration Within 2 minutes MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification It...

Page 624: ...6 38 to 7 93 mmHg 3 Reference pressure Saturated 3 EVAP canister vent valve close stuck check Next sequence is run if the following condition is set EVAP pressure change after vent valve is ON 0 3 kPa 2 25 mmHg 4 Vacuum introduction Next sequence is run if the following con dition is set Condition 1 and 2 EVAP pressure Saturated within 12 minutes 5 EVAP canister purge valve close stuck check Next ...

Page 625: ...llowing conditions is set Condition 1 2 3 4 or 5 1 EVAP pressure just after reference pressure measure ment start 1 kPa 7 5 mmHg or more 2 Reference pressure 4 85 kPa 36 38 mmHg or less 3 Reference pressure 1 057 kPa 7 93 mmHg or more 4 Reference pressure Not saturated 5 Difference between first reference pressure and second reference pressure More than 0 7 kPa 5 25 mmHg Vent valve stuck closed EV...

Page 626: ...rom when the ignition switch is turned OFF before the moni tor is run This allows the fuel to cool down which stabilizes the Fuel Tank Pressure FTP When 5 hours have elapsed the ECM turns on MONITOR DESCRIPTION 5 hours after the ignition switch is turned OFF the soak timer activates the ECM to begin the EVAP system monitor While the engine is running the ECM monitors the synchronization of the soa...

Page 627: ...frame data using a hand held tester or OBD II scan tool Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Replace ECM See page SF 66 NEXT Check w...

Page 628: ...43E 0 02 inch orifice clogged One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high flow Vacuum pump ON stuck Vacuum pump OFF stuck Pump module Connector Wire harness While ignition 2 trips P043F 0 02 inch orifice high flow Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Connector Wire harnes...

Page 629: ...em monitor 10 seconds B 0 02 inch leak pres sure measurement In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C EVAP system pres sure measurement Vent valve turned ON closed to shut EVAP system Negative pressure vacuum created in EVAP system an...

Page 630: ...p EVAP Pressure sec OFF Sequence Time A 10 sec 60 Within 15 minutes sec ON Specified Range B C D EVAP Pressure during EVAP Monitor OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 sec 60 E Malfunction OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DIAGNOSTICS ENGINE 1GR FE DI 355 In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the c...

Page 631: ...cted EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF Condition 1 and 2 1 Duration that vehicle is driven 5 min 2 EVAP purge operation Performed ECT 4 4 to 35 C 40 to 95 F IAT 4 4 to 35 C 40 to 95 F Time after key off 5 or 7 or 9 5 h...

Page 632: ... to 1 057 kPa 36 4 to 7 92 mmHg 3 Reference pressure Saturated 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following condition is set EVAP pressure when vacuum introduction is complete Less than second reference pressure 8 Atmospheric pressure measurement EVAP monitor is complete if the following condition ...

Page 633: ...DI 358 DIAGNOSTICS ENGINE 1GR FE MONITOR RESULT MODE 06 DATA Refer to page DI 26 for detailed information on Monitor Result INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure see page DI 368 ...

Page 634: ... is warmed up the ECM performs air fuel ratio feedback control to regulate the air fuel ratio at stoichiomentric ratio In addition this vehicle performs Active A F Ratio Control for approximately 10 se conds after preconditions met in order to measure the A F sensor response rate During active air fuel ratio control the ECM forcibly increases and decreases the injection volume for certain amount b...

Page 635: ... h and 120km h for 3 minutes However the vehicle should be driven at constant speed i When detection is complete Response rate of MONITOR RESULT changes If the value does not change perform step h once more j Notes the value of the Monitor Result k Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES l Check if any DTCs any pending DTCs are set MONITOR STRATEGY R l t d ...

Page 636: ...erformed when the following conditions are set Battery voltage 11 V ECT 75 C 167 F Idle OFF Engine RPM 4 000 rpm A F sensor status Activated Fuel cut OFF Engine load 10 to 70 Shift position 2nd Catalyst monitor Not yet MAF 3 to 10 5 g sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Response rate deterioration level Less than 0 2 V WIRING DIAGRAM Refer to DTC P2195 on page DI 312 ...

Page 637: ...nds 4 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume 6 Monitor the voltage outputs of the A F and HO2 sensors AFS B1S1 AFS B2S1 and OS2 B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowe...

Page 638: ...nd the Heated Oxygen HO2 sensor has a maximum output delay of approximately 20 seconds Following the A F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A F and HO2 sensors To display the graph select the following menu items on the tester DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S B1S2 and press the YES but ton and then th...

Page 639: ...DTCs Result Display DTC Output Proceed To P2A00 and or P2A03 A P2A00 and or P2A03 and other DTCs B HINT If any DTCs other than P2A00 and or P2A03 are output troubleshoot those DTCs first B Go to DTC chart See page DI 57 A 2 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the air fuel ratio A F sensor connector CHECK Measure resistance between the terminals of the A F se...

Page 640: ... the A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground 9 V to 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance OK Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω AF A10...

Page 641: ...t recurs DTC P2A00 or P2A03 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2A00 or P2A03 A No output B B Check for intermittent problems See page DI 11 A 6 Replace air fuel ratio sensor NEXT 7 Perform confirmation driving pattern NEXT ...

Page 642: ...P2A00 or P2A03 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2A00 or P2A03 A No output B A Check air fuel ratio extremely lean or rich See page DI 160 B END ...

Page 643: ...ensor built into pump module voltage abnormal fluctuation DI 243 P0451 Pressure sensor built into pump module noise Pressure sensor built into pump module signal becomes fixed flat DI 243 P0452 Pressure sensor built into pump module voltage low DI 243 P0453 Pressure sensor built into pump module voltage high DI 243 P0455 EVAP gross leak DI 252 P0456 EVAP small leak DI 252 P2401 Vacuum pump stuck O...

Page 644: ...OSTICS ENGINE 1GR FE DI 369 CIRCUIT DESCRIPTION HINT The canister is located near the fuel tank underneath the body While the engine is running if a predetermined condition closed loop etc is met the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume The purge flo...

Page 645: ...ow 35 C 5 hours after the ignition switch is turned off the moni tor check starts 2 hours later If it is still not below 35 C 7 hours after the ignition switch is turned off the monitor check starts 2 5 hours later Purge flow monitor The purge flow monitor consists of the two monitors The 1st monitor is always conducted every time and the 2nd monitor is activated if necessary The 1st monitor While...

Page 646: ...ecting EVAP system Soak timer Built into ECM To ensure accurate EVAP monitor measures 5 hours after ignition switch turned to OFF This allows fuel to cool down stabilizing Fuel Tank Pressure FTP When approx 5 hours elapsed ECM activates Pump module Consists of a to d below Pump module cannot be disassembled a Vent valve Vents and closes EVAP system When ECM turns valve ON EVAP system closed When E...

Page 647: ...Valve ON closed A23495 Pressure Sensor Specification fig 2 Output Voltage Usable Range 4 900 V 4 150 V 1 425 V 0 450 V Malfunction Area Pressure 60 kPa 450 mmHg 110 kPa 825 mmHg Malfunction Area HINT Standard atmospheric pressure is 101 3 kPa 760 mmHg A23496 Soak Timer Circuit fig 3 Ignition Switch IGSW Power ECM EFI MAIN MREL B 15 A Source IC Soak Timer IC Main Relay Control IC Battery DI 372 DIA...

Page 648: ... R R R J8 J C 22 R V4 VSV EVAP G W 34 IE1 A A R 1 2 A BB3 9 R 9 L4 Leak Detection Pump Assy BB3 BB3 BB3 L W L B R W L W L B R W 7 5 10 22 5 6 3 8 1 2 4 6 BB3 BB3 IE1 IE1 G B B W 8 6 18 24 23 28 G B B W G B B W BB4 IE1 4 19 W B W B W B A A EA EU J18 J C Battery W B W B ECM MREL PRG PPMP VPMP MPMP VC E2 B R 2 1 EFI No 1 B EFI Relay DIAGNOSTICS ENGINE 1GR FE DI 373 WIRING DIAGRAM ...

Page 649: ...ne condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Confirm DTC a Turn the ignition switch to OFF and wait for 10 seconds b Turn the ignition switch to ON c Turn the ignition switc...

Page 650: ...e fuel is 35 C 95 F or more a large amount of vapor forms and any check results become inaccurate When performing the EVAP SYSTEM CHECK keep the tem perature below 35 C 95 F a Clear DTC See page DI 42 b On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II SYS TEM CHECK EVAP SYS CHECK AUTO OPERATION c After the EVAP SYSTEM CHECK is completed check for pending DTCs by se...

Page 651: ...NUAL OPERATION the series of 5 EVAP SYSTEM CHECK steps is performed manually by the hand held tester Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 full because the cut off valve may be closed and making the leak check of the fuel tank unavailable Do not run the engine in this step When the temperature of the fuel is 35 C 95 F or more a large amount of vapor forms and any ...

Page 652: ... DIAGNOSTICS ENGINE 1GR FE DI 377 4 Perform EVAP system step 1 5 check a Check the EVAP pressure in step 1 5 Result DTCs Test Results Suspected Trouble Areas Proceed To Virtually no variation in EVAP pressure Not yet determined A P0451 EVAP pressure fluctuates by 0 3 kPa 2 25 mmHg or more Pressure sensor noising B The DTCs relating to the EVAP system displayed on a hand held tester when checking B...

Page 653: ...heck the EVAP pressure in step 1 5 and 2 5 Result DTCs Test Results Suspected Trouble Areas Proceed To Virtually no variation in EVAP pressure during step 1 5 Then decreases to 0 02 inch leak pressure standard Not yet determined A P2402 Small difference between EVAP pressures during steps 1 5 and 2 5 Vacuum pump stuck ON B The DTCs relating to the EVAP system displayed on a hand held tester when c...

Page 654: ... pressure again when it has stabilized This pressure is the 0 02 inch leak pressure standard The vacuum pump begins to operate as step 1 5 is proceeded to step 2 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure in step b between 4 85 kPa and 1 06 kPa 36 38 mmHg and 7 95 mmHg Not yet determined A P043F and P2401 EVAP pressure in step b 1 06 kPa 7 95 mmHg or more 0 02 inch...

Page 655: ...crease in step 3 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 2 5 to step 3 5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2 5 to step 3 5 Vent valve stuck open vent B P0451 No variation in EVAP pressure during steps 1 5 through 3 5 Pressure senso...

Page 656: ... Vent ON Closed Time Standard DIAGNOSTICS ENGINE 1GR FE DI 381 8 Perform EVAP system step 3 5 check a Wait until the EVAP pressure change is less than 0 1 kPa 0 75 mmHg for 30 seconds b Measure the EVAP pressure and record it HINT A few minutes are required for the EVAP pressure to become saturated When there is little fuel in the fuel tank it takes up to 12 minutes NEXT ...

Page 657: ... To EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 3 5 to step 4 5 Not yet determined A P0441 EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 3 5 to step 4 5 Problems in EVAP hose between pure VSV and throttle body B P0441 Variation in EVAP pressure is less than 0 3 kPa 2 25 mmHg for 10 seconds after pro...

Page 658: ...d the second 0 02 inch leak pressure standard step 5 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure step 3 5 lower than the second 0 02 inch leak pressure standard step 5 5 Not yet determined no leakage from EVAP system A P0441 and P0455 EVAP pressure step 3 5 higher than second 0 02 inch leak pressure standard step 5 5 x 0 2 Purge VSV stuck open EVAP gross leak B P045...

Page 659: ...VAP system step 3 5 check a Check the EVAP pressure in step 3 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure less than 0 02 inch leak pressure standard x 0 2 0 02 inch orifice high flow A EVAP pressure more than 0 02 inch leak pressure standard x 0 2 Vacuum pump stuck OFF B The DTCs relating to the EVAP system displayed on a hand held tester when checking HINT The 0 02...

Page 660: ...SV OFF b Use your finger to confirm that the purge VSV has no suc tion c Using the tester turn on the purge VSV EVAP VSV ON d Use your finger to confirm that the purge VSV has suction RESULT Test Results Suspected Trouble Areas Proceed To No suction when purge VSV turned OFF and suction applied when tuned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suc...

Page 661: ...r 3 Connect an EVAP tester pump hose to the adaptor and pressurize to 3 2 to 3 7 kPa 24 to 28 mmHg using an EVAP tester pump 4 Seal the adaptor and wait for 2 minutes 5 Check the pressure If the pressure is 2 kPa 15 mmHg or more the fuel tank cap is normal PREPARATION Test Results Suspected Trouble Areas Proceed To Fuel tank cap correctly installed A Fuel tank cap loose Fuel tank cap improperly in...

Page 662: ...sults Suspected Trouble Areas Proceed To No suction ECM A Suction applied Purge VSV B A Go to step 34 B Go to step 30 15 Check EVAP hose between purge VSV and throttle body PREPARATION a Disconnect the hose connected to the throttle body from the purge VSV b Start the engine CHECK a Use your finger to confirm that the hose has suction RESULT Test Results Suspected Trouble Areas Proceed To Suction ...

Page 663: ...n applied EVAP hose between purge VSV and throttle body normal A No suction Throttle body EVAP hose between purge VSV and throttle body B B Go to step 31 A 17 Measure purge VSV terminal voltage PREPARATION a Disconnect the V4 purge VSV connector b Turn the ignition switch to ON CHECK a Measure the voltage between terminal 1 of the purge VSV connector and the body ground RESULT Test Results Suspect...

Page 664: ...kΩ or higher V4 1 Body ground 10 kΩ or higher OK Go to step 35 NG Go to step 32 19 Perform active test for vent valve PREPARATION a Turn the ignition switch to ON b On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VENT VALVE ALONE CHECK Measure the voltage between terminal VPMP of the ECM con nector and the body ground when the vent valve is turned ON c...

Page 665: ...ST VENT VALVE ALONE CHECK Measure the voltage between terminal VPMP of the ECM con nector and the body ground when the vent valve is turned ON close and OFF vent using the tester RESULT Test Results Suspected Trouble Areas Proceed To Below 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF Below 3 V when ON Vent valve B Between 9 V and 14 V when OFF and ON ECM C B Go to...

Page 666: ...Turn the ignition switch to OFF b Disconnect the L4 canister connector c Turn the ignition switch to ON CHECK Measure the voltage between terminal 9 of the canister connec tor and the body ground RESULT Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Power source wire harness of vent valve B B Go to step 32 A ...

Page 667: ... harness between vent valve and ECM A Not operating Vent valve B A Go to step 32 B Go to step 30 23 Perform active test for vacuum pump PREPARATION On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VACUUM PUMP ALONE CHECK Measure the voltage between terminal MPMP of the ECM con nector and the body ground when the vacuum pump is turned ON and OFF using th...

Page 668: ...e L4 canister connector c Turn the ignition switch to ON d On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VACUUM PUMP ALONE e Turn the vacuum pump ON CHECK Measure the voltage between terminal 1 of the canister connec tor and the body ground RESULT Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Wire h...

Page 669: ...LT Test Results Suspected Trouble Areas Proceed To Below 1 Ω Vacuum pump A 10 kΩ or more Wire harness between vacuum pump and body ground B A Go to step 30 B Go to step 32 26 Inspect throttle body PREPARATION a Stop the engine b Disconnect the EVAP hose from the throttle body c Start the engine CHECK a Use your finger to confirm that the port of the throttle body has suction RESULT Test Results Su...

Page 670: ...cap tighten it until a few click sounds are heard When replacing the fuel tank cap use a fuel tank cap that meets OEM specifications and install it until a few click sounds are heard NEXT Go to step 37 28 Replace fuel tank cap HINT When installing the fuel tank cap tighten it until a few click sounds are heard NEXT Go to step 37 29 Locate EVAP leak a Disconnect the vent hose ...

Page 671: ...connecting parts of the EVAP system e Look for areas where bubbles appear This indicates leak point f Repair or replace the leak point NEXT Go to step 37 30 Replace charcoal canister NEXT Go to step 37 31 Replace EVAP VSV a Disconnect the connector and the hoses from the purge VSV b Remove the purge VSV c Install a new purge VSV d Reconnect the connector and hoses NEXT Go to step 37 32 Repair or r...

Page 672: ...is performed automatically by the hand held tester It takes a maximum of approximately 15 minutes Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 full because the cut off valve may be closed and making the leak check of the fuel tank unavailable Do not run the engine in this step When the temperature of the fuel is 35 C 95 F or more a large amount of vapor forms and any che...

Page 673: ...ed the steps described above must be repeated c Monitor Status 1 Connect a hand held tester to the DLC3 2 Turn the ignition switch to ON and turn the tester ON 3 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II MONITOR STATUS 4 Check the Monitor Status displayed on the tester HINT If INCMP is displayed the monitor is not completed Make sure that the preconditions have been m...

Page 674: ...m pump stuck OFF P2401 Refer to pressure A Minimum test limit for vacuum pump stuck OFF Maximum test limit for vacuum pump stuck OFF 3D CD Multiply by 0 01 kPa Test value for vacuum pump stuck ON P2402 Refer to pressure A Minimum test limit for vacuum pump stuck ON Maximum test limit for vacuum pump stuck ON 3D CE Multiply by 0 01 kPa Test value for vent valve stuck OFF vent P2420 Refer to pressur...

Page 675: ... 4 E F Criterion 6 0 3 kPa 2 25 mmHg 10 60 Purge Flow Monitor Sequence Purge VSV Vent Valve Criterion 7 0 1 kPa 0 75 mmHg EVAP Pressure Reference Criterion 8 1 kPa 7 5 mmHg If pressure change in sequence 1 is greater than criterion 7 purge flow moni tor is completed functioning normally ON Close 1 2 ON Open If pressure change in sequence 1 is smaller than criterion 7 sequence 2 is run If pressure ...

Page 676: ...8 GR G E3 26 J C A A J18 J C W B EA DIAGNOSTICS ENGINE 1GR FE DI 401 IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the Intake Air Control Valve IACV in response to the engine load in order to increase the intake efficiency ACIS Acoustic Control Induction System When the engine speed is between 2 200 and 4 100 rpm and the throttle valve opening angle is 60 or more the E...

Page 677: ...urn the ignition switch to ON and hand held tester main switch ON c Select the item DIAGNOSIS ENHANCED OBD II AC TIVE TEST INTAKE CTL VSV1 Operate the VSV for AICS CHECK Check operation of VSV when VSV is operated by the hand held tester OK VSV is ON Air from pipe E is flowing out through pipe F VSV is OFF Air from pipe E is flowing out through the air filter OK Check for ACIS system See page SF 4...

Page 678: ...ectors Standard Check for open Symbols Terminal No Specified condition VSV for ACIS V13 2 ACIS E7 33 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition VSV for ACIS V13 2 or ACIS E7 33 E1 E5 1 10 kΩ or higher b Check the wire harness between the VSV for ACIS con nector and the EFI relay 1 Disconnect the VSV for ACIS connector 2 Remove the EFI relay from the engine room R B ...

Page 679: ...tch s starting signal STSW signal and then supplies current to the starter until the ECM judges that the engine has started successfully The purpose is to reduce the holding time of the ignition key WIRING DIAGRAM Refer to DTC P0617 on page DI 276 INSPECTION PROCEDURE 1 Check operation of engine cranking CHECK When turning the ignition switch to the START position check whether the starter motor s...

Page 680: ...ster while the starter operates OK Standard Ignition Switch Position ON START STARTER SIG OFF ON NG Repair or replace harness or connector OK 3 Check voltage between terminals STSW and STAR NSW of ECM connector a Measure the voltage between the terminals of the E6 and E5 ECM connectors while cranking the engine ignition switch START position Standard Symbols Terminal No Specified condition NSW E6 ...

Page 681: ...ch range Standard Shift range Terminal No Specified condition P 1 3 6 9 Below 1 Ω R 2 3 Below 1 Ω N 3 5 6 9 Below 1 Ω D 3 7 Below 1 Ω 3 3 4 Below 1 Ω 2 L 3 8 Below 1 Ω NG Check and repair harness and connector OK 5 Check starter relay a Remove the starter relay from the engine room R B b Inspect the starter relay Standard Terminal No Specified condition 3 5 10 kΩ or higher 3 5 Below 1 Ω Apply batt...

Page 682: ... Check for open Symbols Terminal No Specified condition Park Neutral position switch N1 6 Starter relay 1 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition Park Neutral position switch N1 6 or Starter relay 1 Body ground 10 kΩ or higher b Check the harness and the connector between the starter relay and the body ground 1 Remove the starter relay from the engine room R B 2 ...

Page 683: ...cified condition Starter relay 5 Body ground 9 to 14 V NG Check for short in all harness and components connected to STA fuse and replace fuse OK 9 Check ignition switch a Check for resistance between the connector terminals shown in the chart below Standard Switch position Terminal No Specified condition LOCK All terminal to terminal 10 kΩ or higher ACC 2 3 Below 1 Ω ON 2 3 2 4 3 4 6 7 Below 1 Ω ...

Page 684: ... J C B B EA ECM IGSW MREL B E1 W R W B DIAGNOSTICS ENGINE 1GR FE DI 409 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON battery positive voltage is applied to terminal IGSW of the ECM and the EFI relay control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI relay This signal causes current to flow to the coil closing the contact...

Page 685: ... 14 V OK Proceed to next circuit inspection shown in the Problem symptoms table See page DI 33 NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminal IGSW of ECM connector and body ground PREPARATION Turn the ignition switch to ON CHECK Measure the voltage between terminal ...

Page 686: ...ed to IGN fuse and replace the fuse OK 5 Check ignition switch See page BE 37 NG Replace ignition switch OK Check and repair harness and connector be tween battery and ignition switch and igni tion switch and ECM 6 Check voltage between terminal MREL of ECM connector and body ground PREPARATION Turn the ignition switch to ON CHECK Measure the voltage between terminal MREL of the ECM con nector and...

Page 687: ...and components connected to EFI No 1 fuse and replace the fuse OK 8 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5 Apply B between terminals 1 and 2 Below 1 Ω NG Replace EFI relay OK 9 Check for open and short in harness and connector between terminal MREL of ...

Page 688: ... DIAGNOSTICS ENGINE 1GR FE DI 413 Check and repair harness or connector be tween EFI No 1 fuse and battery ...

Page 689: ...hand held tester and check operation of fuel pump relay PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II ACTIVE TEST FUEL PUMP SPD CHECK Check the operation of the fuel pump relay when it is switched ON and OFF by the hand held tester OK Operating noise can be he...

Page 690: ...Always Below 1 Ω 3 5 Always 10 KΩ or higher 3 5 Apply B between terminals 1 and 2 Below 1 Ω NG Replace fuel pump relay OK 4 Check fuel pump See page SF 13 NG Repair or replace fuel pump OK 5 Check circuit opening relay PREPARATION Remove the C OPN relay from the engine room J B CHECK Inspect the C OPN relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5 Apply ...

Page 691: ...e ignition switch to ON CHECK Measure the voltage between terminal FC of the ECM connec tor and body ground OK Voltage 9 to 14 V NG Check for open in harness and connector be tween battery and FC terminal of ECM See page SF 66 OK Proceed to problem symptoms table See page DI 33 8 Check fuel pump resistor See page SF 57 NG Replace fuel pump resistor OK Check and repair harness and connector between...

Page 692: ... 1I 1F IGN Driver Side J B B O 24 C12 C11 18 V G IJ1 10 V G 30 E4 ECM W Malfunction Indicator Lamp Combination Meter DIAGNOSTICS ENGINE 1GR FE DI 417 MIL Circuit CIRCUIT DESCRIPTION If the ECM detects a trouble the MIL lights up At this time the ECM records a DTC in the memory WIRING DIAGRAM DIDUG 01 ...

Page 693: ...tion switch to ON and push the hand held tester main switch ON c Read the DTC See page DI 42 d Clear the DTC See page DI 42 CHECK a Check for DTCs OK DTC is not output NG Repair circuit indicated by output code See page DI 57 OK 2 Check Harness and connector Check for short in wire harness PREPARATION a Disconnect the E4 ECM connector b Turn the ignition switch ON CHECK Check that MIL goes off OK ...

Page 694: ...he ignition switch to ON OK MIL lights up Engine stopped OK System OK NG 4 Inspect combination meter assy MIL circuit See the combination meter troubleshooting on page BE 86 NG Repair or replace bulb or combination meter as sembly OK Check and repair harness and connector be tween combination meter and ECM ...

Page 695: ... FE ENGINE 2UZ FE PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transmission assem bly engine assembly or ECM See page DI 1126 HINT Initialization can not be completed by only removing the battery ...

Page 696: ...nished Required sensor compo nents The sensors and components that are used by the ECM to detect malfunctions Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle Once per driving cycle means that the ECM detects the malfunction only one time during a single driving cycle Continuous means that the ECM detects malfunction every time an enabling condition...

Page 697: ...Crankshaft Position Sensor Heated Oxygen Sensor Bank 1 Sensor 2 DLC3 Air Injector Driver AID Accelerator Pedal Assembly Accelerator Pedal Position Sensor Fuel Pump VVT Sensor Bank 2 VVT Sensor Bank 1 OCV Bank 2 OCV Bank 1 Air Pump Air Switching Valve No 2 ASV No 2 Bank 1 Air Switching Valve ASV Air Switching Valve No 2 ASV No 2 Bank 2 VSV for Air Injection Control Bank 1 VSV for Air Injection Cont...

Page 698: ...o Battery To Battery To Battery To Battery To Starter ST Relay PNP SW EFI No 1 EFI No 1 Relay Acclererator Pedal Position Sensor Combination Meter VVT OCV Bank 1 VVT OCV Bank 2 Knock Sensor Bank 1 Knock Sensor Bank 2 Camshaft Position Sensor To VC Terminal Crankshaft Position Sensor VVT Sensor Bank 1 VVT Sensor Bank 2 DIAGNOSTICS ENGINE 2UZ FE DI 425 SYSTEM DIAGRAM ...

Page 699: ...2 Fuse VSV EVAP VSV ACIS VSV AI Control VSV AI Control Mass Air Flow Meter ECT Sensor Pump Modul To VC Terminal To IG SW Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Fuel Injector 5 Fuel Injector 6 Fuel Injector 7 Fuel Injector 8 Ignition Coil and Igniter No 1 Ignition Coil and Igniter No 2 Ignition Coil and Igniter No 3 Ignition Coil and Igniter No 4 Ignition Coil and Igniter N...

Page 700: ...NL CANH ASV AI Driver To EFI Relay To Battery To Battery To Battery To E2 Terminal To E2 Terminal To IG SW Air Pump Pressure Sensor Throttle Body C OPN Relay Fuel Pump Relay Fuel Pump Resister Fuel Pump Transponder Key Computer Stop Light SW To IGN Fuse To EFI Relay ACC Cut Relay To Battery To ACC Fuse DIAGNOSTICS ENGINE 2UZ FE DI 427 ...

Page 701: ...ptom Simulation P IN 19 Basic Inspection P DI 431 DTC Chart P DI 477 Problem Symptoms Table P DI 452 Circuit Inspection P DI 452 Adjustment Repair DTC Check P DI 462 Items inside are titles of pages in in the bottom portion See the indicated pages for detailed explanations this manual with the page number Malfunction occurs Malfunction does not occur Parts Inspection Check for Intermittent Problem...

Page 702: ...g from N to D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Rainy Snowy Various Other Hot Warm Cool Cold approx C F Highway Suburbs Inner city Uphill Downhill Rough road Other Cold Warming up After warming up Any temp Other Starting Just a...

Page 703: ...hen the ECM is in check mode In check mode the ECM uses 1trip detection logic which is more sensitive to malfunctions than normal mode default which uses 2 trip detection logic a Clear DTCs see page DI 462 b Switch the ECM from normal mode to check mode using a hand held tester see page DI 463 c Perform a simulation test see page IN 19 d Check and wiggle the harness es connector s and terminal s s...

Page 704: ... cases by carrying out the basic engine check shown in the following flowchart the location causing the problem can be found quickly and efficiently There fore using this check is essential in the engine troubleshooting 1 Is battery voltage 11 V or more when engine stopped NO Charge or replace battery YES 2 Is engine cranked NO Proceed to page ST 18 and continue to trouble shoot YES 3 Does engine ...

Page 705: ...ly NG Repair or replace air filter OK 5 Check idle speed See page EM 11 NG Proceed to problem symptoms table on page DI 452 OK 6 Check fuel pressure See page SF 7 NG Proceed to page SF 7 and continue to trouble shoot OK 7 Check for spark See page IG 1 NG Proceed to page IG 1 and continue to trouble shoot OK Proceed to problem symptoms table on page DI 452 ...

Page 706: ...VIN do not match the VIN can be registered or over written in the ECM by following this procedure 2 INPUT INSTRUCTIONS a Hand held tester The arrow buttons UP DOWN RIGHT and LEFT and numerical buttons 0 to 9 are used in order to input the VIN b Cursor Operation To move the cursor around the tester screen press the RIGHT and LEFT buttons c Alphabetical Character Input 1 Press the UP and DOWN button...

Page 707: ...0 VIN Not Programmed or Mismatch ECM PCM Please input the VIN PRESS EXIT Possible cause To Menu Screen 17 digitVIN displayed 3 Select VIN DTC P0630 Set VIN Previously Stored VIN Not Stored EXIT EXIT EXIT 2 VIN WRITE VIN Select VIN READ 1 VIN READ 1 VIN READ ERROR ECM does not respond the VIN 1 VIN is not written yet 2 Vehicle does not support this function DI 434 DIAGNOSTICS ENGINE 2UZ FE 3 READ V...

Page 708: ... Menu Screen Continuedon next page NOTICE Do you wish to continue YES NO 1 Select DIAGNOSIS 2 Select ENHANCED OBD ll 3 Select VIN 1 VIN READ 1 VIN READ VIN Select VIN WRITE YES or NO YES 2 VIN WRITE To Menu Screen NO CONFIRMATION This function will erase the DTCs automatically after writing the VIN Do you wish to continue YES 17 digit VIN displayed VIN Previously Stored DIAGNOSTICS ENGINE 2UZ FE D...

Page 709: ...T Writing Error SET NEW VIN Press RIGHT LEFT to shift the cursor right left Press UP DOWN to increase decrease value Or input digit with the 10 key PRESS ENTER CONFIRMATION PRESS ENTER Vehicle is stopped New Registration ENTER ENTER PRESS ENTER Communication Error ENTER COMMUNICATION ERROR PRESS EXIT Turn IG OFF then ON VIN input method The following VIN has been written correctly The DTCs have be...

Page 710: ...SABLE A MONITOR HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed ...

Page 711: ...A21571 DI 438 DIAGNOSTICS ENGINE 2UZ FE ...

Page 712: ...A21572 DIAGNOSTICS ENGINE 2UZ FE DI 439 ...

Page 713: ...A21573 DI 440 DIAGNOSTICS ENGINE 2UZ FE ...

Page 714: ...A21575 DIAGNOSTICS ENGINE 2UZ FE DI 441 ...

Page 715: ...A21576 DI 442 DIAGNOSTICS ENGINE 2UZ FE ...

Page 716: ...l the description of the O2S TEST RESULT for O2S related DTCs are written in a table This table consists of 5 items 1 TEST ID a code applied to each TEST DATA 2 Description of TEST DATA 3 Conversion Factor When Conversion Factor has a value written in the table multiply the TEST DATA value appearing on the scan tool by the Conversion Factor value The result will be the required value 4 Unit 5 Stan...

Page 717: ...s a value of the TIME 81 see the illustration on the left 2 Find the Conversion Factor value of TIME 81 in the O2S TEST RESULT chart below 0 3906 is spe cified for 81 in this chart 3 Multiply 17 in step 1 by 0 3906 Conversion Fac tor in the step 2 17 x 0 3906 6 6 4 If the answer is within the standard value the TIME 81 can be confirmed to be normal O2S TEST RESULT Chart TEST ID Description of TEST...

Page 718: ...sions related DTC sections Thermostat MID Monitor Identification Data is assigned to each emissions related component TID Test Identification Data is assigned to each test value Scaling is used to calculate the test value indicated on generic OBD II scan tools 3 PROCEDURE USING HAND HELD TESTER a Connect the hand held tester to the DLC3 b Turn the ignition switch and hand held tester ON c Clear DT...

Page 719: ... performance tests for the related Readiness Monitor The Readiness Monitor will be reset to incomplete if ECM has lost power battery or fuse DTCs have been cleared The conditions for running the Readiness Monitor have not been met In the event that any Readiness Monitor shows incomplete follow the appropriate Readiness Monitor Drive Pattern to activate the monitor and change the readiness status t...

Page 720: ... MONITOR ACTIVE AIR FUEL RATIO CONTROL TYPE a Preconditions The monitor will not run unless The MIL is OFF b Drive Pattern 1 Connect a hand held tester or OBD II scan tool to the DLC3 2 Turn the ignition switch to ON 3 Turn the tester or scan tool ON 4 Clear DTCs where set see page DI 462 5 Start the engine and warm it up 6 Drive the vehicle at between 40 mph and 70 mph 64 km h and 113 km h for at...

Page 721: ... OFF Fuel level is approximately 1 2 to 3 4 Altitude is 7 800 feet 2 400 m or less b Cold Soak Procedure Let the vehicle cold soak for 8 hours or until the difference between IAT and ECT becomes less than 7 C 13 F HINT Examples Scenario 1 ECT 24 C 75 F IAT 16 C 60 F Difference between ECT and IAT is 8 C 15 F The monitor will not run because difference between ECT and IAT is greater than 7 C 13 F S...

Page 722: ... because difference between ECT and IAT is less than 7 C 13 F The readiness test can be completed in cold ambient conditions less than 40 F 4 4 C and or at high altitudes more than 7 800 feet 2 400 m if the drive pattern is repeated a second time after cycl ing the ignition off b Drive Pattern 1 Connect the OBD II scan tool to DLC3 to check monitor status and preconditions refer to a 2 Release pre...

Page 723: ...62 4 Start the engine and warm it up until the ECT reaches 75 C 167 F or higher 5 Drive the vehicle at 40 mph 64 km h or more for at least 10 minutes 6 Change the transmission to 2nd gear 7 Accelerate the vehicle to 30 mph 48 km h or more by depressing the accelerator pedal for at least 10 seconds 8 Soon after performing step 8 above release the accelerator pedal for at least 4 seconds without dep...

Page 724: ...ct the OBD II scan tool to the DLC3 to check monitor status and preconditions refer to a 2 Start the engine and allow it to idle for 500 seconds or more 3 Drive the vehicle at 25 mph 40 km h or more for at least 2 minutes 4 Check the status of the readiness monitor on the scan tool display If readiness status did not switch to complete ensure the preconditions are met turn the ignition off and the...

Page 725: ...rcuit 2 Fuel pump control circuit DI 723 DI 937 Difficult to start with hot engine 1 Starter signal circuit 2 Fuel pump control circuit DI 723 DI 937 High engine idle speed Poor idling 1 A C switch circuit 2 ECM power source circuit DI 918 Low engine idle speed Poor idling 1 A C switch circuit 2 Fuel pump control circuit DI 937 Rough idling Poor idling 1 Compression 2 Fuel pump control circuit EM ...

Page 726: ...28 G B B W IG switch ON 4 5 to 5 5 V VG E7 30 E2G E7 29 R Y B Y Idling P or N position A C switch OFF 0 5 to 3 0 V THA E7 22 E2 E7 28 Y G B W Idling Intake air temp 20 C 68 F 0 5 to 3 4 V THW E7 21 E2 E7 28 G B W Idling Engine coolant temp 80 C 176 F 0 2 to 1 0 V VTA1 E7 20 E2 E7 28 GR B W IG switch ON Accelerator pedal released 0 5 to 1 2 V VTA1 E7 20 E2 E7 28 GR B W IG switch ON Accelerator peda...

Page 727: ...neration See waveform 5 PRG E7 34 E1 E5 1 W G BR IG switch ON 9 to 14 V SPD E4 8 E1 E5 1 G O BR IG switch ON Rotate driving wheel slowly Pulse generation See waveform 6 M E7 5 E1 E5 1 R BR Idling Pulse generation See waveform 7 M E7 4 E1 E5 1 W BR Idling Pulse generation See waveform 8 FPR E5 30 E1 E5 1 R G BR IG switch ON 0 to 3 0 V FC E3 10 E1 E5 1 Y BR IG switch ON 9 to 14 V IGT1 E7 8 E1 E5 1 I...

Page 728: ...14 V W E4 30 E1 E5 1 V G BR IG switch ON Below 3 0 V TACH E4 1 E1 E5 1 L W BR 2 B BR 3 Idling Pulse generation See waveform 11 ACIS E7 33 E1 E5 1 G W BR IG switch ON 9 to 14 V VPMP E3 5 E1 E5 1 L B BR Ignition switch ON 9 V to 14 V MPMP E3 6 E1 E5 1 R W BR Vacuum pump OFF Vacuum pump ON 0 V to 3 V 9 V to 14 V PPMP E3 22 E1 E5 1 L W BR Ignition switch ON 3 V to 3 6 V AIV1 E7 27 E1 E5 1 B L BR Ignit...

Page 729: ...isplayed differ slightly depending on the vehicle WAVEFORM 3 VVT OCV ECM Terminal Name Between OC1 and OC1 Between OC2 and OC2 Tester Range 0 2 V DIV 200 msec DIV Condition Accelerate slowly after engine warmed up HINT In the DATA LIST the items VVT OCV DUTY B1 and B2 show the duty ratio of voltage flowing to the OCV see illustration on left VVT OCV DUTY B1 B2 A B x 100 WAVEFORM 4 a VVT sensor ban...

Page 730: ...0 km h 25 mph HINT The wavelength becomes shorter as vehicle speed increases WAVEFORM 7 Throttle actuator positive terminal ECM Terminal Name Between M and ME01 Tester Range 5 V DIV 1 msec DIV Condition Idle after engine warmed up HINT The duty ratio varies depending on the throttle opening opera tion WAVEFORM 8 Throttle actuator negative terminal ECM Terminal Name Between M and ME01 Tester Range ...

Page 731: ...ges 0 2 V DIV 200 msec DIV Conditions Engine speed maintained 2 500 rpm for 2 minutes after warming up sensor HINT In the DATA LIST item O2S B1S2 shows the ECM input values from the heated oxygen sensor WAVEFORM 11 Engine speed signal ECM Terminal Names Between TACH and E1 Tester Ranges 5 V DIV 10 msec DIV Conditions Idling HINT The wavelength becomes shorter as vehicle speed increases ...

Page 732: ... tester or OBD II scan tool also enables you to erase the DTC and check the freeze frame data and various forms of engine data See the instruction manual for the hand held tes ter The DTC includes SAE controlled codes and manufacturer controlled codes SAE controlled codes must be set according to the SAE while manufacturer controlled codes can be set by a manufacturer with certain restrictions See...

Page 733: ...3 The vehicle s ECM uses the ISO 9141 2 for communica tion protocol The terminal arrangement of the DLC3 com plies with SAE J1962 and matches the ISO 9141 2 for mat Symbol Terminal Description Condition Specified Condition SIL 7 SG 5 Bus line During transmission Pulse generation CG 4 Body ground Chassis ground Always Below 1 Ω SG 5 Body ground Signal ground Always Below 1 Ω BAT 16 Body ground Batt...

Page 734: ...hen the ignition switch is turned ON and the engine is not running HINT If the MIL is not illuminated troubleshoot the MIL circuit See page DI 940 b When the engine is started the MIL should not illuminate If the lamp remains on the diagnosis system has de tected a malfunction or abnormality in the system 7 ALL READINESS For this vehicle using the hand held tester allows readiness codes correspond...

Page 735: ...OSIS ENHANCED OBD II DTC INFO CURRENT CODES or PENDING CODE d Confirm the DTCs and freeze frame data and then write them down e See page DI 477 to confirm the details of the DTCs NOTICE When simulating a symptom with the hand held tester to check the DTCs use the normal mode For DTC chart sub ject to 2 trip detection logic perform either of the follow ing actions Turn the ignition switch OFF after...

Page 736: ...ashes as shown in the illustration NOTICE All DTCs and freeze frame data recorded will be erased if 1 the hand held tester is used to change the ECM from normal mode to check mode or vice versa or 2 during check mode the ignition switch is turned from ON to ACC or OFF f Start the engine The MIL should turn off after the engine starts g Simulate the conditions of the malfunction described by the cu...

Page 737: ... using the hand held tester a Remove the EFI No 1 and ETCS fuses from the engine room J B for more than 60 seconds or disconnect the bat tery terminal for more than 60 seconds After disconnecting the battery terminal perform the INI TIALIZE procedure ...

Page 738: ...t by control ling the fuel injection intermittent fuel cut and ignition tim ing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed If the accelerator pedal is depressed firmly and slowly the vehicle can be driven slowly If the accelerator pedal is depressed quickly the vehicle may speed up and slow down erratically Pass condition is detected...

Page 739: ... and or P1444 Restrict the throttle opening angle Ga 30 g s P1441 and P1444 Restrict the throttle opening angle Ga 50 g s P1441 P1444 Restrict the throttle opening angle Ga 100 g s P2430 P2431 P2432 P2433 Restrict the throttle opening angle Ga 50 g s ...

Page 740: ...in 64 deg Max 63 5 deg BTDC 4 to 17 Idling CALC LOAD Calculated load by ECM Min 0 Max 100 11 to 21 Idling 12 to 22 Running without load 2 500 rpm VEHICLE LOAD Vehicle load Min 0 Max 25700 Actual vehicle load MAF Air flow rate from MAF meter Min 0 g s Max 655 g s 2 0 to 3 9 g s Idling If the value approximately 0 0 g s Mass air flow meter power source circuit open VG circuit open or short If the va...

Page 741: ...released 66 to 98 The accelerator pedal is fully depressed ACCEL POS 1 APP sensor No 1 voltage Min 0 V Max 4 98 V ETCS freeze data ACCEL POS 2 APP sensor No 2 voltage Min 0 V Max 4 98 V ETCS freeze data ACCEL POS 1 APP sensor No 1 voltage Min 0 V Max 5 V 0 5 to 1 1 V accelerator pedal is released 2 6 to 4 5 V or pedal is fully de pressed ACCEL POS 2 APP sensor No 2 voltage Min 0 V Max 5 V 1 2 to 2...

Page 742: ...tle position No 2 Min 0 V Max 5 V 2 0 to 2 9 V Throttle fully closed 4 6 to 5 5 V Throttle fully open Read the value with intrusive op eration active test THRTL COMND VAL Throttle position command value Min 0 V Max 4 98 V 0 5 to 4 8 V ETCS service data THROTTLE SSR 1 Throttle sensor opener position No 1 Min 0 V Max 4 98 V 0 6 to 0 9 V ETCS service data THROTTLE SSR 2 Throttle sensor opener positio...

Page 743: ...to 0 2 Idling TOTAL FT 2 Total fuel trim of bank 2 Average value for fuel trim system of bank 2 Min 0 5 Max 1 496 0 2 to 0 2 Idling SHORT FT 1 Short term fuel trim of bank 1 Min 100 Max 99 2 0 20 This item the short term fuel com pensation used to maintain the air fuel ratio at stoichiometric air fuel ratio SHORT FT 2 Short term fuel trim of bank 2 Min 100 Max 99 2 0 20 This item the short term fu...

Page 744: ...2 sensor 1 Min 0 Max 1 999 Value less than 1 0 000 to 0 999 Lean Stoichiometric air fuel ratio 1 Value greater than 1 1 001 to 1 999 RICH CAT TEMP B1S1 Catalyst temperature Bank 1 Sensor 1 Min 40 Max 6 513 5 C CAT TEMP B2S1 Catalyst temperature Bank 2 Sensor 1 Min 40 Max 6 513 5 C CAT TEMP B1S2 Catalyst temperature Bank 1 Sensor 2 Min 40 Max 6 513 5 C CAT TEMP B2S2 Catalyst temperature Bank 2 Sens...

Page 745: ...RL B1 VVT control status Bank 1 ON or OFF Active Test support data VVT CTRL B2 VVT control status Bank 2 ON or OFF Active Test support data VACUUM PUMP Key off EVAP system pump sta tus ON or OFF Active Test support data EVAP VENT VAL Key off EVAP system vent valve status ON or OFF Active Test support data TC TE1 TC and TE1 terminal of DLC3 ON or OFF VVTL AIM ANGL 1 VVT aim angle bank 1 Min 0 Max 1...

Page 746: ...de ON See page DI 463 SPD TEST Check mode result for vehicle speed sensor 0 COMPL 1 INCOMPL AS TEST Check mode result for secondary air injection system 0 COMPL 1 INCOMPL MISFIRE TEST Check mode result for misfire monitor 0 COMPL 1 INCOMPL OXS1 TEST Check mode result for HO2 sen sor Bank 1 0 COMPL 1 INCOMPL OXS2 TEST Check mode result for HO2 sen sor Bank 2 0 COMPL 1 INCOMPL A F SSR TEST B1 Check ...

Page 747: ...UZFE CYLINDER NUMBER Cylinder number Min 0 Max 255 Identifying the cylinder number 8 TRANSMISSION Transmission type Identifying the transmission type ECT 5AT DESTINATION Destination Identifying the destination A America MODEL YEAR Model year Min 0 Max 255 Identifying the model year 200 SYSTEM System identification Identifying the engine system GASLIN gasoline engine AI STATUS AI operation prohibit...

Page 748: ...el Ra tio sensor and Heated Oxygen HO2 sensor voltage outputs To conduct test select following menu items ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S B1S2 and press YES and ENTER followed by F4 EVAP VSV ALONE Activate EVAP VSV control ON OFF VVT CTRL B1 Turn on and off OCV Oil Control Valve ON OFF Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV off...

Page 749: ...he SYSTEM CHECK can be performed with a hand held tester a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON c Turn the tester ON d Select the following menu items DIAGNOSIS ENHANCED OBD II SYSTEM CHECK e Perform the SYSTEM CHECK by referring to the table below Hand heldTester Displays Test Details Recommended Fuel Temperatures Diagnostic Notes EVAP SYS CHECK AUTO OPERATION P...

Page 750: ...VVT sensor circuit VVT sensor ECM P0018 DI 504 Crankshaft Position Camshaft Position Correlation Bank 2 Sensor A Open or short in VVT sensor circuit VVT sensor ECM P0020 DI 492 Camshaft Position A Actuator Circuit Bank 2 Open or short in OCV circuit OCV ECM P0021 DI 498 Camshaft Position A Timing Over Advanced or System Per formance Bank 2 Valve timing OCV VVT controller assembly ECM P0022 DI 498 ...

Page 751: ...rature Circuit Open or short in intake air temperature sensor circuit Intake air temperature sensor built in mass air flow meter ECM P0112 DI 534 Intake Air Temperature Circuit Low Input Open or short in intake air temperature sensor circuit Intake air temperature sensor built in mass air flow meter ECM P0113 DI 534 Intake Air Temperature Circuit High Input Open or short in intake air temperature ...

Page 752: ...ensor 2 circuit HO2 sensor sensor 2 HO2 sensor heater sensor 2 Air Fuel Ratio A F sensor sensor 1 EFI relay Gas leakage from exhaust system P0137 DI 567 Oxygen Sensor Circuit Low Volt age Bank 1 Sensor 2 Open in HO2 sensor sensor 2 circuit HO2 sensor sensor 2 HO2 sensor heater sensor 2 EFI relay Gas leakage from exhaust system P0138 DI 567 Oxygen Sensor Circuit High Volt age Bank 1 Sensor 2 Short ...

Page 753: ...coolant temperature sensor Fuel pressure Gas leakage on exhaust system Open or short in heated oxygen sensor bank 2 sensor 1 circuit Heated oxygen sensor bank 2 sensor 1 Heated oxygen sensor heater EFI relay PCV piping ECM P0175 DI 586 System too Rich Bank 2 Injector leak blockage Mass air flow meter Engine coolant temperature sensor Ignition system Fuel pressure Gas leakage in exhaust system Open...

Page 754: ...nection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P0302 DI 605 Cylinder 2 Misfire Detected Open or short in engine wire Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Co...

Page 755: ...s air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P0306 DI 605 Cylinder 6 Misfire Detected Open or short in engine wire Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM 2 P0307 DI...

Page 756: ...on sensor Signal plate ECM P0339 DI 632 Crankshaft Position Sensor A Circuit Intermittent Open or short in crankshaft position sensor circuit Crankshaft position sensor Signal plate ECM P0340 DI 637 Camshaft Position Sensor A Circuit Bank 1 or Single Sensor Open or short in camshaft position sensor circuit Camshaft position sensor LH camshaft timing pulley Jumping teeth of timing belt ECM P0341 DI...

Page 757: ...I 642 Ignition Coil G Primary Second ary Circuit Open or short in IGF 1 and IGT 7 circuit from No 7 ignition coil with igniter to ECM No 7 ignition coil with igniter Ignition system ECM P0358 DI 642 Ignition Coil H Primary Second ary Circuit Open or short in IGF 2 and IGT 8 circuit from No 8 ignition coil with igniter to ECM No 8 ignition coil with igniter Ignition system ECM P0412 DI 656 Air Inje...

Page 758: ...ross Leak Fuel tank cap loose Leakage from EVAP line between canister and fuel tank Leakage from EVAP line between purge valve and canister Leakage from pump module Leakage from fuel tank Leakage from canister P0456 DI 696 Evaporative Emission Control System Leak Detected Very Small Leak Same as DTC No P0445 P0500 DI 701 Vehicle Speed Sensor A Combination meter Open or short in vehicle speed senso...

Page 759: ...ctronic control automatic transmission ECT P0748 DI 1188 Pressure Control Solenoid A Electrical Shift Solenoid Valve SL1 Electronic control automatic transmission ECT P0751 DI 1193 Shift Solenoid A Performance Shift Solenoid Valve S1 Electronic control automatic transmission ECT P0756 DI 1199 Shift Solenoid B Performance Shift Solenoid Valve S2 Electronic control automatic transmission ECT P0771 D...

Page 760: ...d Air switching valve No 2 Bank 1 VSV for air injection control Bank 1 ECM P1443 DI 735 Scondary Air Injection System Control Valve Circuit Bank 2 Open or short in VSV for air injection control circuit ECM P1444 DI 739 Scondary Air Injection System Switching Valve No 2 Bank 2 Stuck Open VSV for air injection control circuit Bank 2 Air switching valve No 2 Bank 2 VSV for air injection system Bank 2...

Page 761: ...Pedal Position Sensor Switch E Circuit Accelerator pedal position sensor ECM P2127 DI 794 Throttle Pedal Position Sensor Switch E Circuit Low Input Accelerator pedal position sensor VCP2 circuit open VPA2 circuit open or ground short ECM P2128 DI 794 Throttle Pedal Position Sensor Switch E Circuit High Input Accelerator pedal position sensor EPA circuit open ECM P2135 DI 548 Throttle Pedal Positio...

Page 762: ...rt in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 A F relay A F sensor heater and EFI relay circuits P2242 DI 826 Oxygen Sensor Pumping Cur rent Circuit High For A F Sen sor Bank 2 Sensor 1 Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater sensor 1 A F relay A F sensor heater and EFI relay circuits P2252 DI 826 Oxygen Sensor Reference...

Page 763: ... ECM P2432 DI 846 Secondary Air Injection System Air Flow Pressure Sensor Circuit Low Bank 1 Pressure sensor Open or short in pressure sensor circuit Vacuum hose Check valve ECM P2433 DI 846 Secondary Air Injection System Air Flow Pressure Sensor Circuit High Bank 1 Pressure sensor Open or short in pressure sensor circuit Vacuum hose Check valve ECM P2440 DI 739 Secondary Air Injection System Swit...

Page 764: ... Temperature Sensor B Circuit Low Input Electronic control automatic transmission ECT 2743 DI 1251 Transmission Fluid Temperature Sensor B Circuit High Input Electronic control automatic transmission ECT P2757 DI 1257 Torque Converter clutch Pres sure Control Solenoid Perfor mance Shift Solenoid Valve SLU Electronic control automatic transmission ECT P2759 DI 1265 Torque Converter clutch Pres sure...

Page 765: ...ure supplied to the VVT controller Camshaft timing control is performed based on en gine operation conditions such as intake air volume throttle position and engine coolant temperature The ECM controls the OCV based on the signals output from the sensors The VVT controller regulates the intake camshaft angle using oil pressure through the OCV As a result the relative position between the cam shaft...

Page 766: ... run whenever this DTC not present See page DI 437 All of the following conditions are met Starter OFF Ignition switch ON Time after ignition switch OFF to ON 0 5 seconds TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold One of the following conditions is met Condition A B or C A All of the following conditions are met Condition a b and c a Battery voltage 11 V or more and less than 13 V...

Page 767: ...d check left bank OCV circuit If DTC P0020 displayed check right bank OCV circuit Read freeze frame data using hand held tester Because freeze frame records the engine conditions when the malfunction is detected When troubleshooting it is useful for determining whether the ve hicle 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 mal...

Page 768: ...TRL B1 or VVT CTRL B2 b Using the hand held tester operate the OCV and check the engine speed OK Standard Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK Check for intermittent problems See page DI 430 NG 2 Check operation of OCV PREPARATION a Start the engine and warmed it up b Disconnect the OCV connector c Apply battery positive voltag...

Page 769: ...tage between terminals OC1 and OC1 OC2 and OC2 of ECM con nector CHECK a Inspection using the oscilloscope b During idling check the waveform between the specified terminals of the E5 ECM connector HINT The waveform frequency A is lengthened as the engine speed becomes higher OK Standard The correct waveform is as shown NG Replace ECM See page SF 82 OK ...

Page 770: ...con nectors OK Standard Check for open Symbols Terminal No Specified condition OCV C19 1 OC1 E5 17 Below 1 Ω OCV C19 2 OC1 E5 16 Below 1 Ω OCV C20 1 OC2 E5 15 Below 1 Ω OCV C20 2 OC2 E5 14 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition OCV C19 1 or OC1 E5 17 E1 E5 1 10 kΩ or higher OCV C19 1 or OC1 E5 16 E1 E5 1 10 kΩ or higher OCV C20 1 or OC2 E5 15 E1 E5 1 10 kΩ or hi...

Page 771: ...ition a continues 2 trip detection logic a Valve timing does not change from current valve timing OCV VVT controller assembly ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT Variable Valve Timing system to control the intake valve camshaft The VVT system includes the ECM the OCV Oil Control Valve and the VVT controller The ECM sends a target duty cycle control signal to th...

Page 772: ...0 C 212 F TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0011 P0021 advance Duration of valve timing More than 5 CA Crankshaft angle Valve timing No change at advanced valve timing P0012 P0022 retard Duration of valve timing More than 5 CA Crankshaft angle Valve timing No change at retarded valve timing WIRING DIAGRAM Refer to DTCs P0010 on page DI 492 INSPECTION PROCEDURE HINT Bank ...

Page 773: ...speed OK Standard Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK VVT system is OK DTC P0011 P0012 P0021 or P0022 is also output when a foreign object is detected in some parts of the system in the en gine oil and then the system returns to normal in a short time As ECM is controlled to eject a foreign object there is no prob lem on the V...

Page 774: ...ween the specified terminals of the E5 ECM connector HINT The waveform frequency A is lengthened as the engine speed becomes higher OK Standard The correct waveform is as shown NG Replace ECM See page SF 82 OK 4 Check OCV PREPARATION a Remove the V bank cover b Remove the air cleaner inlet and intake air connector c Disconnect the oil control valve connector CHECK a Using an Ohmmeter measure the r...

Page 775: ...ssembly See page EM 46 CHECK Check whether the oil in VVT controller assembly is drained or not OK Standard The oil in VVT controller assembly is drained NG Replace VVT controller assembly and then go to step 6 OK 6 Check oil control valve filter PREPARATION a Remove the cylinder head cover b Remove the camshaft bearing cap and OCV filter CHECK Check that the filter is not clogged OK The filter is...

Page 776: ... Standard DTC P0011 P0012 P0021 or P0022 is not stored OK VVT system is OK DTC P0011 P0012 P0021 or P0022 is also output when a foreign object is detected in some parts of the system in the en gine oil and then the system returns to normal in a short time As ECM is controlled to eject a foreign object there is no prob lem on the VVT There is also no problem on the VVT as the oil filter should catc...

Page 777: ... VVT sensor ECM P0018 While the crankshaft rotates twice VVT sensor signal will be input to ECM 5 times ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT Variable Valve Timing system to control the intake valve camshaft The VVT system includes the ECM the OCV Oil Control Valve and the VVT controller The ECM sends a target duty cycle control signal to the OCV This control sig...

Page 778: ...on sensor Frequency of operation Once per drive cycle Duration within 60 sec MIL operation 2 drive cycles Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 437 Engine RPM 400 rpm 1 400 rpm TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold One of the following conditions is met Con...

Page 779: ...ze frame records the engine conditions when the malfunction is detected When troubleshooting it is useful for deter mining 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 1 Check valve timing Check for loose and jumping teeth of timing belt See page EM 9 NG Adjust valve timing Repair or replace timing...

Page 780: ...1 HINT Although each DTC title DTC description says oxygen sensor these DTCs are related to the A F sensor CIRCUIT DESCRIPTION Refer to DTC P2195 on page DI 806 HINT The ECM provides a pulse width modulated control circuit to adjust current through the heater The A F sen sor heater circuit uses a relay on the B side of the circuit DTC No DTC Detection Condition Trouble Area P0031 P0051 Heated curr...

Page 781: ...s very efficient If the temperature of the exhaust is low the sensor will not generate useful voltage signals without supplemental heating The ECM regulates the sup plemental heating using a duty cycle approach to regulate the average current in the heater element If the heater current is out of the normal range the sensor s output signals will be inaccurate and the ECM can not regulate the air fu...

Page 782: ...OCEDURE HINT Read freeze frame data using a hand held tester Freeze frame data record the engine condition when mal functions are detected When troubleshooting freeze frame data can help determine if the vehicle was mov ing or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Check resistance of air fuel rat...

Page 783: ...nd 2 Below 1 Ω NG Replace A F relay OK 3 Check voltage between terminals HA1A HA2A of ECM connectors and body ground PREPARATION Turn the ignition switch ON CHECK Measure the voltage between terminals of the ECM connectors and body ground HINT Connect terminal HA1A to the bank 1 sensor 1 Connect terminal HA2A to the bank 2 sensor 1 OK Standard Tester Connection Specified Condition HA1A E6 2 Body g...

Page 784: ...E6 2 HT A30 1 HA2A E6 1 Below 1 Ω Standard Check for short Tester Connections Specified Conditions HT A10 1 or HA1A E6 2 Body ground HT A30 1 or HA2A E6 1 Body ground 10 kΩ or higher PREPARATION a Turn the ignition switch to OFF b Disconnect the A10 or A30 A F sensor connector c Remove A F relay from engine room R B No 2 CHECK Check the resistance OK Standard Check for open Tester Connections Spec...

Page 785: ...r Heater Control Circuit Low Bank 1 Sensor 2 DTC P0038 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 2 DTC P0057 Oxygen Sensor Heater Control Circuit Low Bank 2 Sensor 2 DTC P0058 Oxygen Sensor Heater Control Circuit High Bank 2 Sensor 2 DIDRB 01 ...

Page 786: ...e air fuel ratio When the air fuel ratio becomes LEAN the oxygen concentration in the exhaust increases and the heated oxygen sensor informs the ECM of the LEAN condition low voltage i e less than 0 45 V When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentration in the ex haust gas is reduced and the heated oxygen sensor informs the ECM of the RICH condition ...

Page 787: ...xy gen concentration between the inside and outside surface of sensor is large the zirconia element will gener ate voltage signals In order to increase the oxygen concentration detecting capacity in the zirconia element the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor When current in the sensor is out of the standard operating range the ECM interpret...

Page 788: ...t Condition a b c d and e a Learned heater current during heater OFF Completed b Intrusive heating Not operating c Heating is OFF 0 1 sec d Heater current 0 3 A e Intrusive heating for high current moni tor Not operating 2 Following condition is met Time after heaters are OFF 1 sec P0038 P0058 High current When the following conditions are met 0 3 sec 1 All of the following conditions are met Cond...

Page 789: ...or detailed information The test value and test limit information are described as shown in the following table Check the monitor result and test values after performing the monitor drive pattern see page DI 446 TID Test Identification Data is assigned to each emissions related component TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test lim...

Page 790: ...7 24 J C R R R A A IE1 22 A A J18 J C B L 1 B 2 Battery EA W B EW EC H6 Heated Oxygen Sensor Bank 2 Sensor 2 R R B W 2 1 4 3 E6 E6 E7 E7 E7 E5 B HT E OX H4 Heated Oxygen Sensor Bank1 Sensor2 B HT E OX 2 4 3 1 B W R L Y B 5 33 Shielded B 1 18 B W 28 OX2B HT1B OX1B E2 E1 1 Towing Package 2 Except Towing Package 1 BR BR E E E J64 J C J8 J C Shielded W EFI No 1 2 1 DIAGNOSTICS ENGINE 2UZ FE DI 517 WIR...

Page 791: ...xygen Sensor Bank2 Sensor2 EFI No 1 B HT E OX B HT E OX E3 E6 E6 E7 E7 E7 E5 A J34 J C A 2 1 5 3 2F 2D 1 1 2 1 4 3 2 1 4 3 8 33 1 18 28 1 5 J48 J47 R R J C C A 2 R R IA10 B W B W B W B W B W Y B Shielded W B R L E E E J64 J C IE1 R BR BR EY EC Battery W B W B B 10 12 F13 FL Block B Double Cab 22 11 Shielded EA DI 518 DIAGNOSTICS ENGINE 2UZ FE ...

Page 792: ...r rich etc when a malfunction occurred 1 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the H4 or H6 heated oxygen sensor connector CHECK Measure resistance between terminals of the heated oxygen sensor OK Standard Tester Connection Specified Condition HT H4 1 B H4 2 11 to 16 Ω 20 C HT H6 1 B H6 2 11 to 16 Ω 20 C NG Replace heated oxygen sensor OK 2 Check EFI relay PREPARAT...

Page 793: ...rn the ignition switch ON CHECK Measure the voltage between terminals of the ECM connectors and body ground HINT Connect terminal HT1B to the bank 1 sensor 2 Connect terminal HT2B to the bank 2 sensor 2 OK Standard Tester Connection Specified Condition HT1B E7 1 Body ground 9 to 14 V HT2B E6 5 Body ground 9 to 14 V OK Replace ECM See page SF 82 NG ...

Page 794: ... HT H4 1 HT1B E7 1 Below 1 Ω HT H6 1 HT2B E6 5 Below 1 Ω Standard Check for short Tester Connections Specified Conditions HT H4 1 or HT1B E7 1 Body ground 10 kΩ or higher HT H6 1 or HT2B E6 5 Body ground 10 kΩ or higher PREPARATION a Turn the ignition switch to OFF b Disconnect the H4 or H6 oxygen sensor connector c Remove EFI relay from engine room R B CHECK Check the resistance OK Standard Check...

Page 795: ... wire and an internal thermistor affecting their resistance To maintain a constant current value the ECM varies the voltage applied to these components in the MAF meter The voltage level is pro portional to the airflow through the sensor The ECM interprets this voltage as the intake air amount The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit ...

Page 796: ... than 4 9 V and if either the condition contin ues for more than 3 sec MONITOR STRATEGY P0100 Mass air flow meter circuit range check Fluttering Related DTCs P0102 Mass air flow meter circuit range check Low voltage P0103 Mass air flow meter circuit range check High voltage Required sensors components Mass air flow meter Frequency of operation Continuous Duration 3 sec MIL operation Immediate When...

Page 797: ...8 E3 E7 E7 30 29 2 2 2 1 J26 J27 J C 7 24 A A R R R J8 J C 22 IE1 R 1 2 3 W L J1 J C B B J18 J C B L 1 B 2 Battery EA W L B VG E2G R Y B Y VG E2G ECM MREL 1 Towing Packege 2 Except Towing Package M1 Mass Air Flow Meter EFI No 1 DI 524 DIAGNOSTICS ENGINE 2UZ FE COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0 4 to 2 2 V WIRING DIAGRAM ...

Page 798: ... 30 29 B J34 J C B Y VG E2G ECM MREL E3 1 3 B VG M1 Mass Air Flow Meter R Y R R 2 EFI No 1 W B W B F13 Fusible Link Block Battery B A A W B EA 10 12 R 2 IA4 B W IA10 IE1 22 11 J48 J47 J C A C 2 6 1 1 2A 2H 2D 2F 3 2 1 5 E2G B W R DIAGNOSTICS ENGINE 2UZ FE DI 525 ...

Page 799: ...unction occurred 1 Connect hand held tester and read value of mass air flow rate PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF CHECK Read the mass air flow rate on the hand held tester RESULT Air...

Page 800: ...meter connector and body ground OK Standard Tester Connection Specified Condition B M1 1 Body ground 9 to 14 V NG Go to step 5 OK 3 Check voltage between terminal VG of ECM connector and body ground PREPARATION Start the engine CHECK Measure the voltage between the specified terminal of the E7 ECM connector HINT The shift position should be P or N and the A C switch should be turned OFF OK Standar...

Page 801: ...meter and ECM PREPARATION a Disconnect the M1 mass air flow meter connector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VG M1 3 VG E7 30 Below 1 Ω E2G M1 2 E2G E7 29 Below 1 Ω VG M1 3 or VG E7 30 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Replace mass air flow ...

Page 802: ...he resistance in the EFI No 2 fuse OK Standard Below 1 Ω PREPARATION a Install the EFI No 2 fuse b Disconnect the M1 mass air flow meter connector c Remove the EFI relay from the engine room J B CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition B M1 1 Engine Room J B EFI relay terminal 1 Below 1 Ω B M1 1 or Engine room J B EFI re...

Page 803: ... Body ground Below 1 Ω NG Replace ECM See page SF 82 OK 7 Check for open in harness and connector between mass air flow meter and ECM PREPARATION a Disconnect the M1 mass air flow meter connector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VG M1 3 VG E7 30 Below 1 Ω E2G M1 2 E2G E7 29 Below...

Page 804: ...intake air By applying a specific current to the wire the ECM heats this wire to a given temperature The flow of incoming air cools the wire and an internal thermistor affecting their resistance To maintain a constant current value the ECM varies the volt age applied to these components in the MAF meter The voltage level is proportional to the air flow through the MAF meter The ECM interprets this...

Page 805: ...oltage Engine speed 2 000 rpm Engine coolant temperature 70 C 158 F Low voltage Engine speed 300 rpm Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Mass air flow meter voltage High voltage More than 2 2 V varies with throttle position sensor voltage Mass air flow meter voltage Low voltage Less than 1 0 V varies with throttle position sensor voltage ...

Page 806: ...malfunction occurred 1 Are there any other codes besides DTC P0101 being output PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC output Proceed to P01...

Page 807: ...THAR via 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 voltage at terminal THA THAR also changes Based on this signal the ECM increases the fuel in jection volume to improve the driveability during cold engine op erati...

Page 808: ...onents Intake air temperature sensor Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page DI 437 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0110 Intake air temperature sensor voltage Intake air...

Page 809: ...as the ground terminal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as oth...

Page 810: ...g menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR CHECK Read the temperature value on the hand held tester OK Same as actual intake air temperature RESULT Displayed Temperature Proceed to 40 C 40 F A 140 C 284 F or more B OK Same as present temperature C HINT If there is an open circuit the hand held tester indicates 40 C 40 F If there is a short circuit the hand held tester indicates 140 ...

Page 811: ...erature value on the hand held tester OK Standard Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK re place mass air flow meter NG 3 Check for open in harness or ECM PREPARATION a Connect terminals THA and E2 of the E7 ECM connector HINT Before checking do a visual and contact pressure check for the ECM connector b Turn the ignition switch ON c When using hand held ...

Page 812: ...ST ALL IN TAKE AIR CHECK Read the temperature value on the hand held tester OK Standard Temperature value 40 C 40 F OK Replace mass air flow meter NG 5 Check for short in harness or ECM PREPARATION a Disconnect the E7 ECM connector b Turn the ignition switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read the temperature valu...

Page 813: ...sor circuit Engine coolant temperature sensor ECM P0118 Step 2 Open in engine coolant tem perature sensor circuit for 0 5 sec HINT After confirming DTC P0115 P0117 or P0118 use the OBD II scan tool or the hand held tester to confirm the engine coolant temperature from the DIAGNOSIS ENHANCED OBD II DATA LIST ALL Displayed Temperature Malfunction 40 C 40 F Open circuit 140 C 284 F or more Short circ...

Page 814: ... operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page DI 437 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0115 Engine coolant temperature sensor voltage Coolant temperature Less than 0 14 V or more than 4 91 V More than 140 C 284 F or less than 40 C ...

Page 815: ...nal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the ti...

Page 816: ...menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read the temperature value on the the hand held tester OK Same value as actual engine coolant temperature RESULT Displayed Temperature Proceed to 40 C 40 F A 140 C 284 F or more B OK Same as present temperature C HINT If there is an open circuit hand held tester indicates 40 C 40 F If there is a short circuit hand held tester indicate...

Page 817: ...re value on the hand held tester OK Standard Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK re place engine coolant temperature sensor NG 3 Check for open in harness or ECM PREPARATION a Disconnect the E2 engine coolant temperature sensor connector b Connect terminals THW and E2 of the E7 ECM connector HINT Before checking do a visual and contact pressure checks f...

Page 818: ...ollowing menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read the temperature value on the hand held tester OK Standard Temperature value 40 C 40 F OK Replace engine coolant temperature sensor NG 5 Check for short in harness or ECM PREPARATION a Disconnect the E7 ECM connector b Turn the ignition switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OB...

Page 819: ...e thermistor increases When the temperature is high the resistance drops The variations in resistance are reflected in the voltage output from the sensor The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature When the sen sor output voltage deviates from the normal operating range the ECM interprets this as a fault in the ECT sensor and sets a DTC Examp...

Page 820: ...ph 70 km h 2 the vehicle is decelerated from 40 4 mph 65 km h to 1 86 mph 3 km h or less within 35 seconds and 3 the vehicle is stopped for 10 seconds TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case1 When temperature is fixed between 35 C 95 F and 60 C 140 F Change of engine coolant temperature value Less than 3 C 5 4 F Case2 When temperature is fixed at 60 C 140 F or more Change ...

Page 821: ...edal Position Sensor Switch A Circuit High Input DTC P0220 Throttle Pedal Position Sensor Switch B Circuit DTC P0222 Throttle Pedal Position Sensor Switch B Circuit Low Input DTC P0223 Throttle Pedal Position Sensor Switch B Circuit High Input DTC P2135 Throttle Pedal Position Sensor Switch A B Voltage Correction HINT This is the purpose for the throttle position sensor DIDRD 01 ...

Page 822: ...e throttle position sensor is mounted on the throttle body It detects the opening angle of the throttle valve This sensor is electronically controlled and uses Hall effect elements so that accurate control and reliability can be obtained The throttle position sensor has 2 sensor elements signal outputs VTA1 and VTA2 VTA1 used to detect the throttle opening angle and VTA2 is used to detect malfunct...

Page 823: ...satisfied a VTA2 is 1 75 V or less or VTA2 is 4 8 V or more Throttle control motor and sensor ECM P0222 a VTA2 is 1 75 V or less Throttle control motor and sensor Short in VTA2 circuit Open in VC circuit ECM P0223 a VTA2 is 4 8 V or more and VTA1 is 0 2 V or more and VTA1 is 2 02 V or less Throttle control motor and sensor Open in VTA2 circuit Open in E2 circuit VC and VTA2 circuit are short circu...

Page 824: ...pring The ECM then adjusts the engine output by controlling the fuel infection inter mittent fuel cut and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimum speed If the accelerator pedal is depressed firmly and slowly the vehicle can be driven slowly If a pass condition is detected and then the ignition switch is turned OFF the fa...

Page 825: ...more P0220 VTA2 voltage 1 75 V or less or 4 8 V or more P0222 VTA2 voltage 1 75 V or less P0223 Both of the following conditions are met Condition 1 and 2 1 VTA1 voltage 0 2 to 2 02 V 2 VTA2 voltage 4 8 V or more P2135 Different between VTA1 and VTA2 voltage 0 02 V or less Both of the following conditions are met Condition 1 and 2 1 VTA1 voltage 0 2 V or less 2 VTA2 voltage 1 75 V or less COMPONEN...

Page 826: ...ferent system that have terminal E2 as the ground terminal are output simulta neously terminal E2 may have an open circuit Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel r...

Page 827: ... depressed Trouble area Proceed to THROTTLE POS VTA1 THROTTLE POS 2 VTA2 THROTTLE POS VTA1 THROTTLE POS 2 VTA2 Trouble area Proceed to 0 0 to 0 2 V 0 0 to 0 2 V VC circuit open 100 4 5 to 5 5 V 100 4 5 to 5 5 V E2 circuit open 0 or 100 2 1 to 3 1 V Fail safe 0 or 100 2 1 to 3 1 V Fail safe VTA1 circuit open or ground short A about 16 Fail safe 0 to 0 2 or 4 5 to 5 5 V about 16 Fail safe 0 to 0 2 o...

Page 828: ...rol motor and sensor con nector b Disconnect the E7 ECM connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VC T14 5 VC E7 23 Below 1 Ω VTA1 T14 6 VTA1 E7 20 Below 1 Ω VTA2 T14 4 VTA2 E7 19 Below 1 Ω E2 T14 3 E2 E7 28 Below 1 Ω VC T14 5 or VC E7 23 Body ground 10 kΩ or higher VTA1 T14 6 or VTA1 E7 20 Body ground 10 kΩ or ...

Page 829: ...terminals of the E7 ECM connector OK Standard Tester Connection Specified Condition VC E7 23 E2 E7 28 4 5 to 5 5 V NG Replace ECM See page SF 82 OK 4 Replace throttle body See page SF 43 Go 5 Check if DTC output recur PREPARATION a Clear DTCs see page DI 462 b Start the engine c Run the engine at idle for 15 seconds or more CHECK Read the DTC RESULT Display DTC Output Proceed to P0120 P0122 P0123 ...

Page 830: ... DIAGNOSTICS ENGINE 2UZ FE DI 557 Replace ECM See page SF 82 ...

Page 831: ...2 deviates from the normal operating range the ECM interprets this as a malfunction of the throttle position sensor The ECM will turn on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle control valve returns to a predetermined opening angle approximately 16 by the force of the ret...

Page 832: ...S Detection Criteria Threshold Different between VTA1 and VTA2 VTA1 VTA2 0 8 to 1 2 Corrected by learning value Less than 0 8 V or more than 1 6 V INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if...

Page 833: ...t time has passed the sensor still reports that the engine is not warmed up enough for closed loop fuel control after sufficient time has passed the ECM interprets this as a fault in the sensor or cooling system and sets a DTC Example The engine coolant temperature was 0 C 32 F at engine start After 5 min running time the ECT sensor still indicates that the engine is not warmed up enough to begin ...

Page 834: ...ON PROCEDURE HINT If DTC P0115 P0116 P0117 P0118 and P0125 are output simultaneously engine coolant tempera ture sensor circuit may be open or short Perform the troubleshooting of DTC P0115 P0117 or P0118 first Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if...

Page 835: ...F HINT Also check that the valve is completely closed under opening temperature as above NG Replace thermostat See page CO 12 OK 3 Check cooling system CHECK Check that there is detect in the cooling system which causes overcool such as abnormal radiator fan opera tion modified cooling system and so on NG Repair or replace cooling system OK Replace engine coolant temperature sensor ...

Page 836: ...le Area P0128 Condition a b and c are met a Cold start b After sufficient warm up time has elapsed c Engine coolant temperature greater than 75 C 167 F Thermostat Cooling system Engine coolant temperature sensor ECM MONITOR DESCRIPTION The ECM estimates the coolant temperature based on starting temperature engine loads and engine speeds The ECM then compares the estimated temperature with the actu...

Page 837: ...or 2 1 All of the following conditions are met Condition a b and c a ECT at engine start IAT at engine start 15 to 7 C 5 to 44 6 F b ECT at engine start 10 to 56 C 14 to 133 F c IAT at engine start 10 to 56 C 14 to 133 F 2 All of the following conditions are met Condition d e and f d ECT at engine start IAT at engine start 7 C 44 6 F e ECT at engine start 56 C 133 F f IAT at engine start 10 C 14 F...

Page 838: ...in switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC Output Proceed to P0128 A P0128 and other DTCs B HINT If any other codes besides P0128 are output perform the troubleshooting for those DTCs first B Check for intermittent problems See page DI 430 A 2 Check cooling sys...

Page 839: ...DI 566 DIAGNOSTICS ENGINE 2UZ FE 3 Check thermostat See page CO 12 CHECK Check the valve lift OK Valve lift 10 mm 0 39 in or more at 95 C 203 F NG Replace thermostat OK Replace ECM See page SF 82 ...

Page 840: ... the TWC and detects the oxygen concentration in the exhaust gas Since the sensor is integrated with the heater that heats the sensing portion it is possible to detect the oxygen concentration even when the intake air volume is low the exhaust gas temperature is low When the air fuel ratio becomes lean the oxygen concentration in the exhaust gas is rich The HO2 sensor informs the ECM that the post...

Page 841: ...Ratio A F sensor sensor 1 EFI relay Gas leakage from exhaust system P0137 P0157 During active air fuel ratio control following conditions a and b met for certain period of time 2 trip detection logic a HO2 sensor voltage output less than 0 21 V b Target air fuel ratio rich Open in HO2 sensor sensor 2 circuit HO2 sensor sensor 2 HO2 sensor heater sensor 2 P0137 P0157 High impedance Sensor impedance...

Page 842: ...am below Active air fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine During active air fuel ratio control the air fuel ratio is forcibly regulated to become lean or rich by the ECM If the ECM detects a malfunction one of the following DTCs is set DTC P0136 P0156 abnormal voltage output P0137 P0157 open circuit and P0138 P0158 short circuit Abnorma...

Page 843: ...ensor noticeably decreases the OSC indicates an extraordinarily high value Even if the ECM attempts to continue regulating the air fuel ratio to become rich or lean the HO2 sensor output does not change While performing active air fuel ratio control when the target air fuel ratio is rich and the HO2 sensor voltage output is 0 21 V or less lean the ECM interprets this as an abnormally low sensor ou...

Page 844: ...nal while the engine is running the impedance of the sensor is measured by the ECM The ECM determines that there is a malfunction in the sensor when the measured impedance devi ates from the standard range The effective resistance in an alternating current electrical cir cuit HINT The impedance can not be measured using an ohmme ter DTC P0136 or P0156 indicates the deterioration of the HO2 sensor ...

Page 845: ...i d t Main sensors components Heated rear oxygen sensor Required sensors components Related sensors components Mass air flow meter Frequency of operation Once per driving cycle Active air fuel ratio control detection Continuous Others Duration 20 sec Heated oxygen sensor output Output voltage High voltage Low voltage 30 sec Heated oxygen sensor impedance Low 90 sec Heated oxygen sensor impedance H...

Page 846: ...ng conditions is met Condition 1 or 2 1 All of the following conditions are met Condition a b and c a Commanded air fuel ratio 14 3 or less b Rear HO2S voltage 0 21 to 0 59 V c OSC Oxygen Storage Capacity of catalyst 3 g or more 2 All of the following conditions are met Condition d e and f d Commanded air fuel ratio 14 9 or more e Rear HO2S voltage 0 21 to 0 59 V f OSC Oxygen Storage Capacity of c...

Page 847: ...ing the monitor drive pattern see page DI 446 MID Monitor Identification Data is assigned to each emissions related component TID Test Identification Data is assigned to each test value HO2S bank 1 sensor 2 MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit 02 07 Multiply by 0 001 V Minimum sensor voltage Minimum test limit Maximum test limit 02 08 Multiply by 0 001 V ...

Page 848: ...orming this confirmation pattern will activate the Heated Oxygen HO2 sensor monitor The cata lyst monitor is performed simultaneously This is very useful for verifying the completion of a repair a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON c Turn the tester or scan tool ON d Clear DTCs where set see page DI 462 e If using a hand held tester select the following menu it...

Page 849: ... to the DLC3 on the vehicle 2 Turn the ignition switch ON 3 Warm up the engine with the engine speed at 2 500 rpm for approximately 90 seconds 4 Select the menu DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform A F CONTROL with the engine in an idle condition press the right or left button RESULT Heated oxygen sensor reacts in accordance with increase and decrease of injection volume 25 ...

Page 850: ...t system etc OK OK OK Almost no reaction Sensor 2 rear sensor sensor 2 heater sensor 2 circuit Almost no reaction Almost no reaction Almost no reaction DIAGNOSTICS ENGINE 2UZ FE DI 577 The following A F CONTROL procedure enables the technician to check and graph the voltage output of the heated oxygen sensors For displaying the graph indication first enter ACTIVE TEST A F CONTROL USER DATA then se...

Page 851: ... HINT If any other codes besides P0136 are output perform the troubleshooting for those DTCs first B Go to step 14 C Go to step 7 A 2 Check output voltage of heated oxygen sensor PREPARATION a Connect the hand held tester to the DLC3 b After warming up the engine run the engine at 2 500 rpm for 3 minutes c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL...

Page 852: ... resistance OK Standard Tester Connections Specified Conditions HT1B E7 1 OX1B E7 18 10 kΩ or higher HT2B E6 5 OX2B E6 33 10 kΩ or higher OK Replace ECM See page SF 82 NG 4 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the heated oxygen sensor connector CHECK Measure resistance between terminals of the heated oxygen sensor OK Standard Tester Connection Specified Condition ...

Page 853: ...PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Start the engine d Select the following menu items DIAGNOSIS ENHANCED OBD II DATA LIST ALL O2S B1S2 e After warming up the engine run the engine at an engine speed of 2 500 rpm for 3 minutes CHECK a Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased HINT...

Page 854: ...Proceed To P0136 or P0156 A No output B B Check for intermittent problems See page DI 430 A 10 Replace heated oxygen sensor NEXT 11 Perform confirmation driving pattern NEXT 12 Check whether DTC output recurs DTC P0136 P0156 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P0136 or P015...

Page 855: ...e within the range of 12 and 12 The injection volume can be changed in 1 graduations within the range The A F sensor is displayed as AFS B1S1 AFS B2S1 and the HO2 sensor is displayed as O2S B1S2 O2S B2S2 on hand held testers RESULT Tester Display Sensor Voltage Variations Proceed To AFS B1S1 AFS B2S1 A F Alternates between more and less than 3 3 V OK AFS B1S1 AFS B2S1 A F Remains at more than 3 3 ...

Page 856: ...eakage CHECK Check for exhaust gas leakage from the exhaust manifold and pipe OK No exhaust gas leakage NG Repair or replace exhaust gas leakage point OK 15 Inspect heated oxygen sensor PREPARATION Disconnect the HO2 sensor connector CHECK Measure the resistance between the terminals of the HO2 sen sor connector OK Standard Tester Connections Specified Conditions HT 2 B 1 11 to 16 Ω at 20 C 68 F H...

Page 857: ...Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5 Apply B between terminals 1 and 2 Below 1 Ω NG Replace EFI relay OK ...

Page 858: ...PARATION a Disconnect the heated oxygen sensor connector b Disconnect the E6 and E7 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition OX H4 3 OX1B E7 18 Below 1 Ω HT H4 1 HT1B E7 1 Below 1 Ω OX H6 3 OX2B E6 33 Below 1 Ω HT H6 1 HT2B E6 5 Below 1 Ω OX H4 3 or OX1B E7 18 Body ground 10 kΩ or higher HT H4 1 or HT1B E...

Page 859: ...e air fuel ratio is rich or lean compared to the stoichiometric ratio This triggers a reduction in the fuel injection volume if the air fuel ratio is rich and an increase in the fuel injection volume if it is lean Factors such as individual engine differences wear over time and changes in operating environment cause short term fuel trim to vary from the central value The long term fuel trim which ...

Page 860: ...rming up the engine fuel trim is considered to be in error on RICH side 2 trip detection logic Injector leak blockage Mass air flow meter Engine coolant temperature sensor Ignition system Fuel pressure Gas leakage in exhaust system Open or short in heated oxygen sensor bank 1 2 sensor 1 circuit Heated oxygen sensor bank 1 2 sensor 1 ECM HINT When DTC P0171 or P0174 is recorded the actual air fuel ...

Page 861: ...back compensation value and the average long term fuel trim learning value of the air fuel ratio If the average fuel trim learning value exceeds the malfunction thresholds the ECM interprets this a fault in the fuel system and sets a DTC Example The average fuel trim leaning value is more than 35 or less than 35 the ECM interprets this as a fuel system malfunction MONITOR STRATEGY P0171 Fuel syste...

Page 862: ...ing the A F CONTROL function provided in the ACTIVE TEST The A F CONTROL function can help to determine whether the Air Fuel Ratio A F sensor Heated Oxygen HO2 sensor and other potential trouble areas are malfunctioning The following instructions describe how to conduct the A F CONTROL operation using a hand held tester 1 Connect a hand held tester to the DLC3 2 Start the engine and turn the teste...

Page 863: ...O2 sensor circuit HO2 sensor heater Air fuel ratio extremely lean or rich Injector Gas leakage from exhaust system Fuel pressure DI 590 DIAGNOSTICS ENGINE 2UZ FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 AFS B2S1 A F 25 Rich Less than 3 0 AFS B1S1 AFS B2S1 A F 12 5 Lean More than 3 35 O2S B1S2 O2S B2S2 HO2 25 Rich More than 0 55 O2S B1S2 O2S B2S2 HO2 12 5 Lean Less ...

Page 864: ... caused by a lean air fuel mixture Check for conditions that would cause the engine to run lean 1 Check any other DTCs output in addition to DTC P0171 P0172 P0174 or P0175 PREPARATION a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK a Read DTCs Result Display DTC...

Page 865: ...S B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowers the fuel injection volume by 12 5 or increases the injection volume by 25 Each sensor reacts in accordance with increases and decreases in the fuel injection volume Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 AFS B2S1 A F 25 Rich Less than 3 0 AFS B1S1 AFS B2S1 A F 12 5 Lean More than 3 35 O...

Page 866: ...than 0 4 V Rich During A F CONTROL the AFS is consistently less than 3 0 V and the O2S is consistently more than 0 55 V B Go to step 11 C Go to step 15 A 5 Read value of engine coolant temperature PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Select the following menu items DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK...

Page 867: ...h the engine in an idling condition and at an engine speed of 2 500 rpm Standard MAF while engine idling Between 1 4 gm s and 2 3 gm s shift position N A C OFF MAF at engine speed of 2 500 rpm Between 5 4 gm s and 7 9 gm s shift position N A C OFF NG Replace mass air flow meter OK 7 Check fuel pressure See page SF 7 CHECK Check the fuel pressure high or low pressure NG Check and replace fuel pump ...

Page 868: ...Check injector injection See page SF 29 HINT If the injectors malfunction engine misfires may occur The misfire counter can be read with the hand held tester Enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST MISFIRE CYL 1 to CYL 8 NG Replace injector OK 11 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the air fuel ratio A F sensor connector CHECK Measure r...

Page 869: ... for open and short in harness and connector between ECM and A F sen sor PREPARATION a Disconnect the A10 or A30 A F sensor connector b Turn the ignition switch to ON CHECK a Measure the voltage between the B terminal of the A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground 9 to 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect t...

Page 870: ...ard Check for short Tester Connections Specified Conditions HT A10 1 or HA1A E6 2 Body ground HT A30 1 or HA2A E6 1 Body ground 10 kΩ or higher AF A10 3 or A1A E6 22 Body ground AF A30 3 or A2A E6 23 Body ground 10 kΩ or higher AF A10 4 or A1A E6 30 Body ground AF A30 4 or A2A E6 31 Body ground 10 kΩ or higher NG Replace or replace harness or connector OK 14 Replace air fuel ratio sensor NEXT ...

Page 871: ...th all the accessories switched OFF f Drive the vehicle at between 38 mph and 75 mph 60 km h and 120 km h and at an engine speed of between 1 400 rpm and 3 200 rpm for 3 to 5 minutes HINT If the system is still malfunctioning the MIL will be illuminated during step e NOTICE If the conditions in this test are not strictly followed no malfunction will be detected NEXT 16 Check whether DTC output rec...

Page 872: ... DIAGNOSTICS ENGINE 2UZ FE DI 599 END ...

Page 873: ...ows to the coil of the circuit opening relay the relay switches on power is supplied to the fuel pump and the fuel pump oper ates While the NE signal is generated engine running the ECM keeps the Tr1 ON circuit opening relay ON and the fuel pump also keeps operating The fuel pump speed is controlled at two levels high speed or low speed by the condition of the engine starting light load heavy load...

Page 874: ...TICS ENGINE 2UZ FE DI 601 DTC No DTC Detecting Condition Trouble Area P0230 Open or short in fuel pump relay circuit Open or short in fuel pump relay circuit Fuel pump relay Circuit opening relay Fuel pump ECM ...

Page 875: ...L B B R AM2 5 1K 9 2H E5 2C 2D 2F 1J 1C 2F IA1 E3 E3 IA2 IA2 2H 2H 2C 1C 1J FPR FC MREL B O Battery 5 J48 J49 J C F L BB1 G R G R Engine Room J B 4 2F 5 V V V IG3 25 G O G O B 6 IG2 W R J8 J C W B W B A A 1F IE 5 4 G R IG1 B W B W Instrument Panel J B F9 Fuel Pump Resister DI 602 DIAGNOSTICS ENGINE 2UZ FE WIRING DIAGRAM HINT This diagnostic chart is based on premise that engine is started If the e...

Page 876: ...rred 1 Check voltage between terminal FPR and E1 of ECM CHECK Measure the voltage between terminals of E5 and E5 ECM con nectors OK Tester Connection Condition Specified Condition FPR E5 30 E1 E5 1 STA signal ON 9 to 14 V FPR E5 30 E1 E5 1 STA signal OFF 0 to 3 V OK Replace ECM See page SF 82 NG 2 Check fuel pump relay PREPARATION Remove the fuel pump relay from the engine room R B CHECK Inspect t...

Page 877: ...fuel pump relay from the engine room J B b Disconnect the E5 ECM connector CHECK Measure the resistance between wire harness side connectors OK Standard Tester Connection Specified Condition Engine Room J B Fuel pump relay ter minal 1 FPR E5 30 Below 1 Ω Engine Room J B Fuel pump relay ter minal 1 or FPR E5 30 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Replace ECM See...

Page 878: ...s of HC can also cause the temperature of the catalyst to increase possibly damaging the catalyst To prevent this increase in emissions and limit the possibility of thermal damage the ECM monitors the misfire rate When the temperature of the catalyst reaches a point of thermal degradation the ECM will blink the MIL For monitoring misfire the ECM uses both the camshaft position sensor and the crank...

Page 879: ...g of each cylinder is detected Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV piping ECM HINT When several codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded it indicates that the misfires have been detected and recorded at different ...

Page 880: ...lyst damage is reached 3 time MONITOR STRATEGY P0300 Random Multiple cylinder misfire detected P0301 Cylinder 1 misfire detected P0302 Cylinder 2 misfire detected P0303 Cylinder 3 misfire detected Related DTCs P0304 Cylinder 4 misfire detected Related DTCs P0305 Cylinder 5 misfire detected P0306 Cylinder 6 misfire detected P0307 Cylinder 7 misfire detected P0308 Cylinder 8 misfire detected R i d t...

Page 881: ... blinks All of the following conditions 1 2 and 3 are met Crankshaft 200 revolutions 1 Driving cycle 1st 2 Check mode OFF 3 Engine RPM 2 800 rpm Except above Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Emission related misfire Misfire rate 1 2 or more Catalyst damage misfire MIL blinks Number of misfire per 200 revolutions 93 or more varies with intak...

Page 882: ...ling Description of Test Value Minimum Test Limit Maximum Test Limit A4 0B Multiply by 1 time Exponential Weighted Moving Average misfire counts for last 10 driving cycles total 0 65535 A4 0C Multiply by 1 time Misfire counts for last and current driv ing cycles total 0 65535 Misfire monitor Cylinder 4 MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit A5 0B Multiply b...

Page 883: ...iving cycles total 0 65535 A8 0C Multiply by 1 time Misfire counts for last and current driv ing cycles total 0 65535 Misfire monitor Cylinder 8 MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit A9 0B Multiply by 1 time Exponential Weighted Moving Average misfire counts for last 10 driving cycles total 0 65535 A9 0C Multiply by 1 time Misfire counts for last and curre...

Page 884: ...R B R B R B R B R B R R W G R B L Y R W L R B R B R B R B R B R B R B R Driver Side J B I23 Ignition SW B R W R 7 6 Engine Room R B W R Battery 5 IE1 2 2 2 1 AM2 AM2 IG2 8 IA9 4 7 1I 1J B L 1 B 2 Access Cab Standard Cab 1 Towing Package 2 Except Towing Package ECM 2 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 B DIAGNOSTICS ENGINE 2UZ FE DI 611 WIRING DIAGRAM Refer to DTC P0351 on page DI 642 for the wiring diag...

Page 885: ...tor No 6 I20 Injector No 7 I21 Injector No 8 B R B R B R B R B R B R B R B R R W G R B L Y L R R W B R 2 3 4 5 6 7 3 2 B R IE1 5 6 B R 2 1 5 1D 1C IGN2 Driver Side J B I23 Ignition SW AM2 IG2 1C 1J 2C 2D 1 1 3 7 W R W R Driver Side J B Engine Room J B F13 FL Block B B 10 12 Battery 1 2 1 1 1 1 1 1 1 2 2 2 2 2 2 2 AM2 B R B R B R B R B R DI 612 DIAGNOSTICS ENGINE 2UZ FE ...

Page 886: ...ly troubleshoot the non misfire DTCs first If the misfire does not occur when the vehicle is brought to the workshop the misfire can be confirmed by reproducing the condition of the freeze frame data Also after finishing the repair confirm that there is no misfire See confirmation driving pattern On 6 or 8 cylinder engines misfiring cylinder identification is disabled at high engine speed and only...

Page 887: ... Output Proceed to P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0307 and or P0308 A P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0307 or P0308 and other DTCs B HINT If any other codes besides P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0307 or P0308 are output perform the troubleshooting for those DTCs B Go to relevant DTC chart See page DI 477 A 2 Check wire harness connector and vacuum hose in engine...

Page 888: ...the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL CYL 1 to CYL 8 CHECK Read the number of misfire on the hand held tester HINT When a misfire is not reproduced be sure to branch below based on the stored DTC RESULT High Misfire Rate Cylinder Proceed to...

Page 889: ...gasoline or oil Electrode gap 0 8 mm 0 031 in NOTICE If adjusting the gap of a new spark plug bend only the base ground electrode Do not touch the tip Never at tempt to adjust the gap of a used plug PREPARATION a Install the spark plug to the ignition coil assembly b Disconnect the injector connector c Ground spark plug CHECK Check if spark occurs while engine is being cracked CAUTION Always disco...

Page 890: ...y be faulty from the ignition coil assembly 2 Install another spark plug to the ignition coil assem bly b Disconnect the injector connector c Ground the spark plug CHECK Check if spark occurs while the engine is being cranked CAUTION Always disconnect each injector connector NOTICE Do not crank the engine for more than 2 seconds OK Spark jumps across electrode gap OK Replace spark plug NG ...

Page 891: ...4 Below 1 Ω Ignition coil I4 2 IGF2 E7 25 Below 1 Ω Ignition coil I5 2 IGF1 E7 24 Below 1 Ω Ignition coil I6 2 IGF2 E7 25 Below 1 Ω Ignition coil I7 2 IGF1 E7 24 Below 1 Ω Ignition coil I8 2 IGF2 E7 25 Below 1 Ω Ignition coil I9 2 IGF1 E7 24 Below 1 Ω Ignition coil I10 2 IGF2 E7 25 Below 1 Ω Ignition coil I3 2 or IGF1 E7 24 Body ground 10 kΩ or higher Ignition coil I4 2 or IGF2 E7 25 Body ground 1...

Page 892: ...low 1 Ω Ignition coil I6 3 IGT4 E7 10 Below 1 Ω Ignition coil I7 3 IGT5 E7 13 Below 1 Ω Ignition coil I8 3 IGT6 E7 12 Below 1 Ω Ignition coil I9 3 IGT7 E7 14 Below 1 Ω Ignition coil I10 3 IGT8 E7 9 Below 1 Ω Ignition coil I3 3 or IGT1 E7 8 Body ground 10 kΩ or higher Ignition coil I4 3 or IGT2 E7 15 Body ground 10 kΩ or higher Ignition coil I5 3 or IGT3 E7 11 Body ground 10 kΩ or higher Ignition c...

Page 893: ... of the E5 and E7 ECM connectors OK Standard Tester Connection Specified Condition 10 E5 2 E01 E7 7 9 to 14 V 20 E5 3 E01 E7 7 9 to 14 V 30 E5 4 E01 E7 7 9 to 14 V 40 E5 5 E01 E7 7 9 to 14 V 50 E5 6 E01 E7 7 9 to 14 V 60 E5 7 E01 E7 7 9 to 14 V 70 E7 3 E01 E7 7 9 to 14 V 80 E7 2 E01 E7 7 9 to 14 V OK Go to step 11 NG 9 Check injector resistance of misfiring cylinder See page SF 24 NG Replace injec...

Page 894: ...ion Specified Condition Injector I14 2 10 E5 2 Below 1 Ω Injector I15 2 20 E5 3 Below 1 Ω Injector I16 2 30 E5 4 Below 1 Ω Injector I17 2 40 E5 5 Below 1 Ω Injector I18 2 50 E5 6 Below 1 Ω Injector I19 2 60 E5 7 Below 1 Ω Injector I20 2 70 E7 3 Below 1 Ω Injector I21 2 80 E7 2 Below 1 Ω Injector I14 2 or 10 E5 2 Body ground 10 kΩ or higher Injector I15 2 or 20 E5 3 Body ground 10 kΩ or higher Inje...

Page 895: ...Ω Injector I17 1 IG2 I23 6 Below 1 Ω Injector I18 1 IG2 I23 6 Below 1 Ω Injector I19 1 IG2 I23 6 Below 1 Ω Injector I20 1 IG2 I23 6 Below 1 Ω Injector I21 1 IG2 I23 6 Below 1 Ω Injector I14 1 or IG2 I23 6 Body ground 10 kΩ or higher Injector I15 1 or IG2 I23 6 Body ground 10 kΩ or higher Injector I16 1 or IG2 I23 6 Body ground 10 kΩ or higher Injector I17 1 or IG2 I23 6 Body ground 10 kΩ or higher...

Page 896: ... 4 NG Adjust valve clearance OK 14 Switch step by number of misfire cylinder Refer to the result of step 4 High misfire rate cylinder Proceed to 1 or 2 cylinders A More than 3 cylinders B B Check for intermittent problems See page DI 430 A 15 Check valve timing Check for looseness or a jumped tooth of timing belt See page EM 9 NG Adjust valve timing Repair or replace timing belt OK ...

Page 897: ...ester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR 2 Read its value displayed on the hand held tester OK Equivalent to ambient temperature CHECK Check the air flow rate 1 When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF 2 Read its value displayed on the hand held tester OK Condition Air Flow Rate gm s Ignition switch ON...

Page 898: ...ture sensor in the water be careful not to allow water to go into the ter minals After checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor Compare these values to the resistance temperature graph Change th...

Page 899: ...electric element which generates voltage when it becomes deformed Generation of the voltage occurs when the cylinder block vibrates due to knocking If engine knocking oc curs the ignition timing is retarded in order to suppress the knocking DTC No DTC Detection Condition Trouble Area P0327 P0332 Output voltage of the knock sensor 1 or 2 is 0 5 V or less 1 trip detection logic Short in knock sensor...

Page 900: ...olt age R l t d DTC P0328 Knock sensor Bank 1 range check High volt age Related DTCs P0332 Knock sensor Bank 2 range check Low volt age P0333 Knock sensor Bank 2 range check High volt age Main sensors components Knock sensor Required sensors components Related sensors components Crankshaft position sensor Camshaft position sensor Engine coolant temperature sensor Mass air flow meter Frequency of o...

Page 901: ...EC3 EC3 EC3 EC3 20 21 28 29 3 4 7 8 2 2 1 2 1 B W B W R G R G 1 1 1 1 1 1 BR BR E E J64 J C BR K2 Knock Sensor Bank 2 K1 Knock Sensor Bank 1 EY 2 EW 3 1 Shielded 2 Double Cab 3 Access Cab Standard Cab DI 628 DIAGNOSTICS ENGINE 2UZ FE WIRING DIAGRAM ...

Page 902: ... tester and check knock sensor circuit PREPARATION a Disconnect the EC3 connector b Using lead wires connect the EC3 connectors as follows Male Connector Female Connector Terminal 4 Terminal 8 Terminal 3 Terminal 7 Terminal 8 Terminal 4 Terminal 7 Terminal 3 c Warm up the engine d Run the engine at 3 000 rpm for 10 seconds or more CHECK a Connect the hand held tester to the DLC3 b Turn the ignitio...

Page 903: ...isconnect the E6 ECM connector b Turn the ignition switch to ON CHECK a Measure the voltage between the specified ECM termi nals OK Standard Tester Connection Specified Condition KNK1 E6 29 EKNK E6 28 4 5 to 5 5 V KNK2 E6 21 EKN2 E6 20 4 5 to 5 5 V b Reconnect the ECM connector NG Replace ECM See page SF 82 OK Check for intermittent problems See page DI 430 4 Check knock sensor installation CHECK ...

Page 904: ...ector 3 4 120 to 280 kΩ EC3 male connector 7 8 120 to 280 kΩ b Reconnect the EC3 connector OK Check for intermittent problems See page DI 430 NG 6 Check for open and short in harness and connector between EC3 connector and knock sensor See page IN 30 HINT If DTC P0327 or P0328 has changed to P0332 or P0333 check the knock sensor circuit on the right bank side If DTC P0332 or P0333 has changed to P...

Page 905: ...e and igni tion timing are controlled DTC No DTC Detecting Condition Trouble Area P0335 No crankshaft position sensor signal to ECM during crank ing 2 trip detection logic Open or short in crankshaft position sensor circuit Crankshaft position sensor P0335 No crankshaft position sensor signal to ECM with engine speed 450 rpm or more 1 trip detection logic Crankshaft osition sensor Signal plate ECM...

Page 906: ...on Case 1 0 016 sec Case 2 3 times MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 437 Case 1 Engine speed 450 rpm Starter OFF Time after starter ON to OFF 3 sec Case 2 Time after starter OFF to ON 0 3 sec Number of camshaft position sensor sig nal pulse 6 Battery ...

Page 907: ...as running or stopped the engine was warmed up or not the air fuel ratio lean or rich etc at the time of the malfunction READ VALUE ON HAND HELD TESTER a Connect the hand held tester to the DLC3 b Start the engine and push the hand held tester tool main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL ENGINE SPD The engine speed can be confir...

Page 908: ...Cold is form 10 C 14 F to 50 C 122 F and Hot is from 50 C 122 F to 100 C 212 F NG Replace crankshaft position sensor OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor PREPARATION a Disconnect the C2 crankshaft position sensor connector b Disconnect the E5 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard...

Page 909: ... crankshaft position sensor installation OK The crankshaft position sensor is installed properly NG Tighten sensor installation bolt OK 4 Inspect teeth of sensor plate PREPARATION Remove the crankshaft angle sensor plate See page EM 98 CHECK Check the teeth of sensor plate NG Replace sensor plate OK Replace ECM See page SF 82 ...

Page 910: ...uel injection time and ignition timing If there is no signal from the camshaft position sensor even though the engine is turning or the rotation of the camshaft and the crankshaft is not synchronized the ECM interprets this as a malfunction in the sensor and sets a DTC DTC No DTC Detection Condition Trouble Area P0340 No camshaft position sensor signal to ECM during cranking 2 trip detection logic...

Page 911: ...eck or rationality Related DTCs P0345 VVT sensor Bank 2 range check or rationality P0346 VVT sensor Bank 2 range check or rationality R i d t Main sensors components VVT sensor Required sensors components Related sensors components Crankshaft position sensor Engine speed sensor Frequency of operation Continuous Duration P0340 P0345 case 1 4 sec P0340 P0345 case 2 5 sec P0341 P0346 720 CA MIL opera...

Page 912: ...Cab 2 Double Cab J64 J C DIAGNOSTICS ENGINE 2UZ FE DI 639 TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0340 P0345 Case 1 VVT sensor signal No signal P0340 P0345 Case 2 VVT sensor signal No signal P0341 P0346 VVT sensor count 12 or more 720 CA Engine 2 revolutions COMPONENT OPERATING RANGE Parameter Standard Value VVT sensor signal input during every 720 CA 3 WIRING DIAGRAM ...

Page 913: ... 78 NG Replace VVT sensor See page SF 79 OK 2 Check for open and short in harness and connector between ECM and VVT sen sor PREPARATION a Disconnect the VVT sensor connector b Disconnect the E5 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VVT sensor V16 1 VV1 E5 25 Below 1 Ω VVT sensor V16 2 VV1 E5 24 Below 1...

Page 914: ...VT sensor CHECK Check the VVT sensor installation OK The VVT sensor is installed properly NG Tighten sensor installation bolt OK 4 Inspect teeth of camshaft PREPARATION Remove the cylinder head cover See page EM 36 CHECK Check the tooth of the camshaft NG Replace camshaft OK Replace ECM ...

Page 915: ...HINT These DTCs indicate a malfunction related to primary circuit If DTC P0351 is displayed check No 1 ignition coil with igniter circuit If DTC P0352 is displayed check No 2 ignition coil with igniter circuit If DTC P0353 is displayed check No 3 ignition coil with igniter circuit If DTC P0354 is displayed check No 4 ignition coil with igniter circuit If DTC P0355 is displayed check No 5 ignition ...

Page 916: ...mary circuit The DIS is a 1 cylinder ignition system which ignites one cylinder with one ignition coil In the 1 cylinder ignition system the one spark plug is connected to the end of the secondary winding High voltage generated in the secondary winding is applied directly to the spark plug The spark of the spark plug passes from the center electrode to the ground electrode The ECM determines the i...

Page 917: ...P0358 No IGF signal to ECM while engine is running Open or short in IGF1 or IGF2 and IGT1 to IGT8 circuit from ignition coil with igniter to ECM No 1 to No 8 ignition coil with igniter primary ignition Ignition system ECM Reference Inspection using the oscilloscope During cranking or idling check the waveform between termi nals IG1 to IG8 and E1 and IGF1 IGF2 and E1 of the E5 and E7 ECM connectors...

Page 918: ...MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Either of the following conditions is met Condition 1 or 2 1 Engine speed 1 500 rpm 2 Starter OFF Either of the following conditions is met Condition a or b a All of the following conditions are met Engine spee...

Page 919: ...E7 L B L W LG P V W R G R L LG B L Y 24 25 9 14 12 13 10 11 15 8 ECM IGF1 IGF2 IGT8 IGT7 IGT6 IGT5 IGT4 IGT3 IGT2 IGT1 L W L B L B L W L B L W L W L B W B W B W B W B W B W B W B W B W B W B W B W B W B W B L B L B L B 2 3 1 4 4 2 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R W B B R B R B R 1J 2 1 13 7 6 7 W B EC 1 2 W R W R N1 Noise Filter No 1 Driver Side J B I...

Page 920: ...7 E7 L B L W LG P V W R G R L LG B L Y 24 25 9 14 12 13 10 11 15 8 ECM IGF1 IGF2 IGT8 IGT7 IGT6 IGT5 IGT4 IGT3 IGT2 IGT1 L W L B L B L W L B L W L W L B W B W B W B W B W B W B W B W B W B W B W B W B W B W B L B L B L B 2 3 1 4 4 2 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R 2 4 3 1 B R W B B R B R B R B R 1D 2 1 13 2 2 6 5 W B EC 12 10 B B 1 1 3 7 W R W R N1 Noise Filter ...

Page 921: ...open or short Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check spark plug and ...

Page 922: ... 25 Below 1 Ω Ignition coil I5 2 IGF1 E7 24 Below 1 Ω Ignition coil I6 2 IGF2 E7 25 Below 1 Ω Ignition coil I7 2 IGF1 E7 24 Below 1 Ω Ignition coil I8 2 IGF2 E7 25 Below 1 Ω Ignition coil I9 2 IGF1 E7 24 Below 1 Ω Ignition coil I10 2 IGF2 E7 25 Below 1 Ω Ignition coil I3 2 or IGF1 E7 24 Body ground 10 kΩ or higher Ignition coil I4 2 or IGF2 E7 25 Body ground 10 kΩ or higher Ignition coil I5 2 or I...

Page 923: ...nector PREPARATION a Disconnect the I3 I4 I5 I6 I7 I8 I9 or I10 ignition coil with igniter connector b Turn the ignition switch ON CHECK Measure the voltage between the E7 and E5 ECM connectors OK Standard Tester Connection Specified Condition IGF1 E7 24 E1 E5 1 4 5 to 5 5 V IGF2 E7 25 E1 E5 1 4 5 to 5 5 V NG Replace ECM See page SF 82 OK Replace ignition coil with igniter ...

Page 924: ... IGT2 E7 15 Below 1 Ω Ignition coil I5 2 IGT3 E7 11 Below 1 Ω Ignition coil I6 2 IGT4 E7 10 Below 1 Ω Ignition coil I7 2 IGT5 E7 13 Below 1 Ω Ignition coil I8 2 IGT6 E7 12 Below 1 Ω Ignition coil I9 2 IGT7 E7 14 Below 1 Ω Ignition coil I10 2 IGT8 E7 9 Below 1 Ω Ignition coil I3 2 or IGT1 E7 8 Body ground 10 kΩ or higher Ignition coil I4 2 or IGT2 E7 15 Body ground 10 kΩ or higher Ignition coil I5 ...

Page 925: ...andard Tester Connection Specified Condition IGT1 E7 8 E1 E5 1 More than 0 1 V or less than 4 5 V IGT2 E7 15 E1 E5 1 More than 0 1 V or less than 4 5 V IGT3 E7 11 E1 E5 1 More than 0 1 V or less than 4 5 V IGT4 E7 10 E1 E5 1 More than 0 1 V or less than 4 5 V IGT5 E7 13 E1 E5 1 More than 0 1 V or less than 4 5 V IGT6 E7 12 E1 E5 1 More than 0 1 V or less than 4 5 V IGT7 E7 14 E1 E5 1 More than 0 1...

Page 926: ...ter connector b Turn the ignition switch to ON CHECK Measure the voltage between terminals the E5 and E7 ECM connectors when the engine is cranked OK Standard Tester Connection Specified Condition IGT1 E7 8 E1 E5 1 4 5 V or more IGT2 E7 15 E1 E5 1 4 5 V or more IGT3 E7 11 E1 E5 1 4 5 V or more IGT4 E7 10 E1 E5 1 4 5 V or more IGT5 E7 13 E1 E5 1 4 5 V or more IGT6 E7 12 E1 E5 1 4 5 V or more IGT7 E...

Page 927: ... I9 or I10 ignition coil with igniter connector b Turn the ignition switch to ON CHECK Measure the voltage between the terminal of the wire harness side connector and body ground OK Standard Tester Connection Specified Condition I3 1 Body ground I4 1 Body ground I5 1 Body ground I6 1 Body ground 9 t 14 V I7 1 Body ground 9 to 14 V I8 1 Body ground I9 1 Body ground I10 1 Body ground OK Repair ignit...

Page 928: ...w 1 Ω Ignition coil I5 1 IG2 I23 6 Below 1 Ω Ignition coil I6 1 IG2 I23 6 Below 1 Ω Ignition coil I7 1 IG2 I23 6 Below 1 Ω Ignition coil I8 1 IG2 I23 6 Below 1 Ω Ignition coil I9 1 IG2 I23 6 Below 1 Ω Ignition coil I10 1 IG2 I23 6 Below 1 Ω Ignition coil I3 1 or IG2 I23 6 Body ground 10 kΩ or higher Ignition coil I4 1 or IG2 I23 6 Body ground 10 kΩ or higher Ignition coil I5 1 or IG2 I23 6 Body gr...

Page 929: ...y the air pump through the ASV and ASV No 2 The ASV assists the ASV No 2 The ASV No 2 also controls air supply The ECM sends signals to the AID and then the AID operates the air pump and ASV The pressure sensor detects pressure and exhaust pulsation in the system when the system operates and when it does not oper ate and sends the data to the ECM DTC No DTC Detection Condition Trouble Area P0412 A...

Page 930: ...valve circuit malfunction Second ary air injection system Required sensors components Air injection driver Air switching valve Frequency of operation Continuous Duration 3 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 437 Case 1 Air pump Operating Air switchi...

Page 931: ... A A 4 13 13 12 16 30 29 33 4 3 2 6 2 4 3 5 1 1 25 28 11 14 2 1 1 2 3 1 2 5 2 1 P P G B G B GR B GR B R B R R B W W W SIV SIP DI VV VP B BATT E Air Injection Control Driver Engine Room R B EF1 No 2 EFI Relay Engine Room R B Engine Room R B J1 J C Battery B B B W L L 2 2 1 1 AIRP EFI No 1 J18 J C B R W B W B W B W B W B A35 Air Pump A31 Air Switching Valve EA EC EX B L 1 B 2 1 Towing Package 2 Exce...

Page 932: ... EB2 EB2 IA10 IE1 IE1 IA10 EFI No 2 EFI Relay EFI No 1 A Battery J34 J C A Air Pump 13 FL Block 8 27 26 25 4 13 4 3 2 6 2 4 3 5 1 1 6 14 2 1 1 2 EA EC EZ J48 J47 IA4 A C 1 2 1 2 22 2 1 3 5 6 2 3 2H 2A 2F 2F 2D 1 1 10 B 12 B W B W B L B R R R R R R B L G Y SIV SIP VV B BATT E VP DI B R R B W W W BR BR W B B W B W Air Injection Control Driver V15 VSV Air Switching Valve Bank2 11 2 J C 10 9 8 8 DIAGN...

Page 933: ... following menu items DIAGNOSIS ENHANCED OBD II SYSTEM CHECK AIR INJ CHECK MANUAL OPERATION OPERATION 1 and 2 HINT OPERATION 1 AP OFF EASV CLOSE ASV1 CLOSE ASV2 CLOSE OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN 7 Monitor the voltage output of the AID duty ratio sig nal Oscilloscope range Items Contents Terminals CH1 AIDI E1 Equipment Settings 5 V Division 20 to 40 ms Division Conditions Idling...

Page 934: ...t AID Pump Harness connector AID Pump Air Pump AID ECM Short between air pump drive circuit and body ground AID ECM Harness connector AID Pump Air Pump Open in ASV drive circuit AID ASV Harness connector AID ASV ASV AID ECM Short between ASV drive circuit and body ground Harness connector AID ASV AID ECM ECM Normal AID AID or short between air pump drive circuit and B or short between ASV drive ci...

Page 935: ...ir switching valve connector c Connect the hand held tester to the DLC3 d Turn the ignition switch ON and turn the tester ON CHECK a When the air switching valve is operated using the hand held tester measure voltage between terminal A31 1 of the air switching valve connector and body ground b Select the following menu items DIAGNOSIS EN HANCED OBD II SYSTEM CHECK AIR INJ CHECK MANUAL OPERATION OP...

Page 936: ...cified Conditions ASV B13 1 ASV B13 2 4 5 to 5 5 Ω NG Replace air switching valve OK 3 Check for open in harness and connector between air switching valve and body ground PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A31 air switching valve connector CHECK Check the resistance between the wire harness side connec tors and body ground OK Standard Tester Connection Specifi...

Page 937: ...air switching valve PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A32 air injection driver connector c Disconnect the A31 air switching valve connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VV A32 6 A31 1 Below 1 Ω VV A32 6 or A31 1 Body ground 10 kΩ or higher NG Repair or replace harness or...

Page 938: ...dy ground Air injection driver ECM MONITOR DESCRIPTION Air Injection Driver AID detects an open or short in the air pump and Air Switching Valve ASV circuit ac cording to the terminal voltage and sends a signal as diagnostic information to the ECM When the air injection system operation is required while the engine is warming up the ECM transmits com mand signals to the AID to drive the air pump a...

Page 939: ...t operating Air switching valve Not operating Battery voltage 8 V Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case 1 2 Diagnostic signal duty ratio from air injection driver 11 to 29 COMPONENT OPERATING RANGE Parameter Standard Value Diagnostic signal duty ratio from air injection driver 70 to 90 when secondary air injection system operating and 0 whe...

Page 940: ... ENHANCED OBD II SYSTEM CHECK AIR INJ SYSTEM 7 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II SYSTEM CHECK AIR INJ CHECK MANUAL OPERATION OPERATION 1 and 2 HINT OPERATION 1 AP OFF EASV CLOSE ASV1 CLOSE ASV2 CLOSE OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN 8 Monitor the voltage output of the AID duty ratio sig nal Oscilloscope range Items Contents Terminals CH1 AIDI E1...

Page 941: ...t AID Pump Harness connector AID Pump Air Pump AID ECM Short between air pump drive circuit and body ground AID ECM Harness connector AID Pump Air Pump Open in ASV drive circuit AID ASV Harness connector AID ASV ASV AID ECM Short between ASV drive circuit and body ground Harness connector AID ASV AID ECM ECM Normal AID AID or short between air pump drive circuit and B or short between ASV drive ci...

Page 942: ...mp connector c Connect the hand held tester to the DLC3 d Turn the ignition switch ON and turn the tester ON CHECK a When the air pump is operated using the hand held tes ter measure voltage between terminal A35 2 of the air in jection driver connector and body ground b Select the following menu items DIAGNOSIS EN HANCED OBD II SYSTEM CHECK AIR INJ CHECK MANUAL OPERATION OPERATION 1 and 3 HINT OPE...

Page 943: ...er Connections Specified Conditions A35 1 A35 2 0 4 to 1 0 Ω NG Replace air pump assembly OK 3 Check for open in harness and connector between air pump and body ground PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A35 air pump connector CHECK Check the resistance between the wire harness side connec tors and body ground OK Standard Tester Connection Specified Condition A...

Page 944: ...and air pump PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A33 air injection driver connector c Disconnect the A35 air pump connector CHECK Check the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VP A33 2 A35 2 Below 1 Ω VP A33 2 or A35 2 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Repl...

Page 945: ...deteriorates its oxygen storage capacity decreases and the variation in the oxygen concentration in the exhaust gas increases As a result the sensor voltage output fluctuates frequently While the catalyst monitor is running the ECM measures the signal lengths of both sensors 1 and 2 and calculates the ratio of the signal lengths to determine the extent of the TWC deterioration If the deterioration...

Page 946: ...It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Battery voltage 11 V Intake air temperature 10 C 14 F Engine coolant temperature 75 C 167 F Atmospheric pressure coefficient 0 75 Idle OFF Engine RPM 3 200 rpm A F sensor Activated Fuel system status Closed loop Engine load 10 to 70 All of the following conditions are met Condition 1 2 an...

Page 947: ...talyst Maximum test limit for catalyst Catalyst bank 2 Active A F control method MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit 22 A9 Multiply by 0 0003 no dimension Oxygen storage capacity of catalyst Minimum test limit for catalyst Maximum test limit for catalyst WAVEFORMS OF AIR FUEL RATIO A F AND HEATED OXYGEN HO2 SEN SORS HINT Perform the operation with the en...

Page 948: ...er only Malfunctioning areas can be identified by performing the A F CONTROL function provided in the ACTIVE TEST The A F CONTROL function can help to determine whether the Air Fuel Ratio A F sensor Heated Oxygen HO2 sensor and other potential trouble areas are malfunctioning The following instructions describe how to conduct the A F CONTROL operation using a hand held tester 1 Connect a hand held...

Page 949: ...eater HO2 sensor HO2 sensor circuit HO2 sensor heater Air fuel ratio extremely lean or rich Injector Gas leakage from exhaust system Fuel pressure DI 676 DIAGNOSTICS ENGINE 2UZ FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 A F 25 Rich Less than 3 0 AFS B1S1 A F 12 5 Lean More than 3 35 O2S B1S2 HO2 25 Rich More than 0 55 O2S B1S2 HO2 12 5 Lean Less than 0 4 NOTICE Th...

Page 950: ...y DTC Output Proceed to P0420 and or P0430 A P0420 or P0430 and other DTCs B HINT If any other codes besides P0420 and or P0430 are output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 477 A 2 Check A F sensor bank 1 2 sensor 1 a Connect the hand held tester to the DLC3 b Start the engine and turn the tester ON c Warm up the engine with the engine speed at...

Page 951: ...akage from exhaust system Gas leakage from exhaust system Extremely rich or lean actual air fuel ratio Extremely rich or lean actual air fuel ratio DI 678 DIAGNOSTICS ENGINE 2UZ FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 A F 25 Rich Less than 3 0 AFS B1S1 A F 12 5 Lean More than 3 35 O2S B1S2 HO2 25 Rich More than 0 55 O2S B1S2 HO2 12 5 Lean Less than 0 4 RESULT L...

Page 952: ... 2UZ FE DI 679 3 Check gas leakage on exhaust system OK No exhaust gas leakage NG Repair or replace exhaust gas leakage point OK Replace front and rear three way catalytic converter in the bank a malfunction is de tected ...

Page 953: ...ned ON open and atmospheric air introduced into EVAP system 0 02 inch leak pressure standard is measured at the start and at the end of the leak check If pressure does not return to near atmo spheric pressure ECM determines that purge valve stuck closed Purge VSV Connector wire harness Purge VSV ECM ECM Pump module Leakage from EVAP system While ignition Switch OFF 2 trip P0441 Purge flow While en...

Page 954: ...to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C...

Page 955: ... A 10 sec 60 Within 15 minutes sec ON First 0 02 inch B C D OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 Standard sec 60 E EVAP Pressure when Purge VSV Stuck Open Leak Pressure Second 0 02 inch Standard x 0 2 DI 682 DIAGNOSTICS ENGINE 2UZ FE a Purge VSV stuck open In operation C the vacuum pump creates negative pressure vacuum in the EVAP Evaporative Emission system The EVAP system pres...

Page 956: ...not increase the ECM interprets this as the purge VSV being stuck closed The ECM illuminates the MIL and sets the DTC 2 trip detection logic 2 PURGE FLOW MONITOR The purge flow monitor consists of the two step monitors The 1st monitor is conducted every time and the 2nd monitor is acti vated if necessary The 1st monitor While the engine is running and the purge VSV Vacuum Switching Valve is ON ope...

Page 957: ...me after key off 5 or 7 or 9 5 hours EVAP pressure sensor malfunction P0450 P0452 P0453 Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 set before key off 1 Duration that vehicle has been driven 5 min 2 EVAP purge operation Performed ECT 4 ...

Page 958: ...VAP pressure just after reference pressure 1 kPa 7 5 mmHg 2 Reference pressure 4 85 to 1 057 kPa 36 38 to 7 93 mmHg 3 Reference pressure Saturated within 60 seconds 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following con dition is set EVAP pressure when vacuum introduction is complete Second reference pre...

Page 959: ...er purge valve is open Less than 0 3 kPa 2 25 mmHg Purge flow Both of the following conditions are met Condition 1 or 2 1 EVAP pressure change when purge flow is started Less than 0 1 kPa 0 75 mmHg 2 EVAP pressure change during purge flow when EVAP pressure switching valve is ON closed Less than 0 5 kPa 3 75 mmHg MONITOR RESULT MODE 06 DATA Refer to page DI 445 for detailed information INSPECTION ...

Page 960: ...nsor noising Sensor output voltage fluctuates fre quently in certain time period Pump module Connector Wire harness Pump module ECM ECM EVAP monitor ing ignition OFF Engine running 2 trip P0451 Pressure sensor stuck Sensor output voltage does vary in cer tain time period Pump module Connector Wire harness Pump module ECM ECM EVAP monitor ing ignition OFF 2 trip P0452 Pressure sensor voltage low Se...

Page 961: ...he ECM interprets this as noise from the pressure sen sor and stops the EVAP system monitor The ECM then illuminates the MIL and sets the DTC Alternatively if the sensor voltage output does not change for 10 seconds the ECM interprets this as the sensor being stuck and stops the monitor The ECM then illuminates the MIL and sets the DTC Both the malfunctions are detected by 2 trip detection logic c...

Page 962: ...ce of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Pressure sensor noise Atmospheric pressure 70 to 110 kPa 525 to 825 mmHg Battery voltage 10 5 V IAT 4 4 to 35 C 40 to 95 F EVAP pressure sensor malfunction P0450 P0452 P0453 Not detected Either of the following conditions is met Condition 1...

Page 963: ...re for 10 sec Pressure sensor stuck EVAP pressure change during reference pressure measure ment Less than 0 65 kPa 4 9 mmHg Pressure sensor chattering EVAP pressure Less than 42 11 kPa 315 90 mmHg or more than 123 761 kPa 928 440 mmHg Pressure sensor low voltage EVAP pressure Less than 42 11 kPa 315 90 mmHg Pressure sensor high voltage EVAP pressure More than 123 761 kPa 928 440 mmHg ...

Page 964: ...ine c Turn the tester ON CHECK a Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES b Read DTCs c Select the following menu items DIAGNOSIS ENHANCED OBD II DATA LIST ALL VAPOR PRESS d Read the EVAP Evaporative Emission pressure displayed on the tester RESULT Display DTC Output Test Results Suspected Trouble Areas Proceed To P0451 Pressure sensor C P0452 Less than 45 k...

Page 965: ...isconnect the E3 ECM connector CHECK Measure the resistance between PPMP terminal of the ECM connector and the body ground RESULT Test Results Suspected Trouble Areas Proceed To 10 Ω or less Wire harness connector ECM pressure sensor Short in pressure sensor circuit A 10 kΩ or more Wire harness connector ECM pressure sensor Short in ECM circuit B B Go to step 7 A ...

Page 966: ...the L4 canister connector b Disconnect the E3 ECM connector CHECK Check the resistance between PPMP terminal of the ECM con nector and the body ground Result Test Results Suspected Trouble Areas Proceed To 10 kΩ or more Short in pressure sensor circuit A 10 Ω or less Short in wire harness connector ECM pressure sensor B A Go to step 5 B Go to step 6 ...

Page 967: ... ground Between 4 5 V and 5 5 V L4 3 Body ground Between 4 5 V and 5 5 V L4 2 Body ground 100 Ω or less RESULT Test Results Suspected Trouble Areas Proceed To Voltage and resistance within standard ranges Open in pressure sensor circuit A Voltage and resistance outside standard ranges Open in wire harness connector ECM pressure sensor B B Go to step 6 A 5 Replace charcoal canister assembly NEXT Go...

Page 968: ... hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Wait for at least 60 seconds CHECK a On the tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PEND ING CODES HINT If no pending DTC is displayed on the tester the repair has been successfully completed NEXT Completed ...

Page 969: ...ure standard x 0 2 ECM determines that EVAP system has large leakage Fuel tank cap loose Leakage from EVAP line Canister Fuel tank Leakage from EVAP line Purge VSV Canister Pump module Leakage from fuel tank Leakage from canister While ignition switch OFF 2 trip P0456 EVAP small leak Vacuum pump creates negative pressure vacuum in EVAP system and EVAP sys tem pressure measured 0 02 inch leak press...

Page 970: ... pressure measured by ECM in order to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and them ECM checks if vacuum pump and vent ...

Page 971: ...ion logic b P0456 EVAP very small leak In operation C the vacuum pump creates negative pressure vacuum in the EVAP system and the EVAP system pressure is measured If the stabilized system pressure is higher than second 0 02 inch leak pres sure standard the ECM determines that the EVAP system has a small leakage illuminates the MIL and sets the DTC 2 trip detection logic MONITOR STRATEGY R l t d DT...

Page 972: ...tmospheric pressure change 0 3 kPa 2 25 mmHg 2 First reference pressure measure ment Next sequence is run if the following con ditions are set Condition 1 2 and 3 1 EVAP pressure just after reference pressure measurement start 1 kPa 7 5 mmHg 2 Reference pressure 4 85 to 1 057 kPa 36 38 to 7 93 mmHg 3 Reference pressure Saturated within 60 seconds 3 EVAP canister vent valve close stuck check Next s...

Page 973: ...when vacuum introduction is complete Second reference pressure 8 Atmospheric pressure measurement EVAP monitor is complete if the following condition is set Atmospheric pressure difference between sequence 1 and 8 0 3 kPa 2 25 mmHg TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Small leak 0 020 inch malfunction detection EVAP pressure when vacuum introduction is complete Between refer...

Page 974: ...on the frequency of these pulse signals DTC No Proceed to DTC Detection Condition Trouble Area P0500 Step 1 No vehicle speed sensor sig nal to ECM under following conditions 2 trip detection logic Vehicle is being driven Combination meter Open or short in vehicle speed sensor circuit Vehicle speed sensor ECM P0503 DI 430 Intermittent problem in the ve hicle speed sensor circuit ECM MONITOR DESCRIP...

Page 975: ...position switch Engine coolant tem perature sensor Combination meter Frequency of operation Continuous Duration 500 times MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 437 Vehicle speed is 5 59 mph 9 km h or more 4 sec Park neutral position switch OFF TYPICAL MAL...

Page 976: ...r rich as well as other data from the time when a malfunction occurred 1 Check operation of speedometer PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON and push the hand held tester main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST PRIMARY VEHICLE SPD CHECK Read the mass air flow rate...

Page 977: ...ied Condition SPD E4 8 E1 E5 1 Generated intermittently HINT The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly OK Replace ECM See page SF 82 NG 3 Check vehicle speed sensor PREPARATION a Disconnect the vehicle speed sensor connector b Connect the battery positive lead to terminal 1 and the battery negative lead to terminal 2 c Conn...

Page 978: ...or open and short in harness and connector between combination meter and ECM PREPARATION a Disconnect the C11 combination meter connector b Disconnect the E4 ECM connector CHECK Check for resistance between the wire harness side connec tors OK Standard Check for open Symbols Terminal No Specified condition SPD E4 8 C11 23 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition S...

Page 979: ...designed with two complementary signal outputs STP and ST1 The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch HINT Normal condition is as shown in the table Signal Brake pedal released In transition Brake pedal depressed STP OFF ON ON ST1 ON ON OFF DTC No DTC Detection Condition Trouble Area P0504 Conditions a b and c continue for 0 5 sec or more a Ignition switch...

Page 980: ... R W W R AM1 AM2 IG1 IG2 2 7 4 6 B Y B R 1I 1I 2 4 1G 1F 13 11 ECU IG IGN GR R 3 J9 J C E E J66 J C H H B O B O 2 1 4 3 B 16 E3 E3 15 C C C G W 3 G W G W 3 G W 4 V 1 5 2 3 ECU ST1 STP 4 5 3 1D 1H 1D G W G W IC2 BB5 G W G W G W 4 4 8 4 W B G W W B 3 3 R5 Stop Light RH R4 Stop Light LH W B 1 2 W B 1A 1J W B J3 J C J10 J C H10 Hight Mounted Stop Light A IF BL 1 Towing Package 2 Except Towing Package ...

Page 981: ...2 AM2 IG1 AM1 6 5 1 W L 1C 1J 3 7 2C 2D 1 1 AM2 B 1C 1F AM1 STOP 1 2 2 6 1 1L W 2 ALT 10 12 B B Y 1C 1F 4 4 B R 1 3A 3D 4 3 ECU IG B R 1 4A 4A 8 18 B R 1 L B 1 W 1 2 1 5 3 4 J47 J47 J47 J48 J48 J48 J C J C B B B B E D G W 2 W R 1 G W 1 W R B Battery G W J38 J39 E L W R W R 1 E3 15 To Skid Control ECU STP G W G W G W G W G W W B W B J C H10 High Mounted Stop Light W B 1 2 BR BS W B BP3 8 4 3 4 3 R4...

Page 982: ... determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check operation of stop light CHECK Check if the stop lights come on and go off normally when the brake pedal is operated and released NG Check and repair stop light circuit OK 2 Check stop light switch See page...

Page 983: ...I DATA LIST ALL STOP LIGHT SW CHECK Read the signal displayed on the hand held tester OK Standard Brake Pedal Specified Condition Depressed STP Signal ON Released STP Signal OFF CHECK Measure the voltage between the specified terminals of the E3 and E5 ECM connectors OK Standard Tester Connection Brake Pedal Specified Condition ST1 E3 16 E1 E5 1 Depressed Below 1 5 V ST1 E3 16 E1 E5 1 Released 7 5...

Page 984: ...nnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition Stop light switch S4 1 STP E3 15 Below 1 Ω Stop light switch S4 3 ST1 E3 16 Below 1 Ω Stop light switch S4 1 or STP E3 15 Body ground 10 kΩ or higher Stop light switch S4 3 or ST1 E3 16 Body ground 10 kΩ or higher NG Repair or replace harness or connec...

Page 985: ...on Condition Trouble Area P0501 Idle speed continues to vary greatly from target speed 2 trip detection logic ETCS Air induction system PCV hose connection ECM MONITOR DESCRIPTION The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS The ECM con cludes that the idle speed control ECM function is malfunctioning if 1 the actual idle RPM varies more than the specif...

Page 986: ...onitor will run whenever this DTC is not present See page DI 437 Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following conditions is met Condition 1 or 2 1 Frequency that both of the following conditions a and b are met 5 times or more a Engine RPM target engine RPM Less than 100 rpm or more than 150 rpm b Vehicle condition Stop after vehicle was driven...

Page 987: ...e was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides P0505 being output PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO...

Page 988: ...2UZ FE DI 715 3 Check air induction system See page SF 1 CHECK Check for vacuum leaks in air induction system OK No leakage NG Repair or replace air induction system OK Check electric throttle control system See page SF 41 ...

Page 989: ... open and close the throttle valve and adjusts the intake air amount to achieve the target idling speed In addition the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly in crease the catalyst temperature at cold start DTC No DTC Detection Conditions Trouble Areas P050A Accumulated intake air amount during 10 seconds of idling after cold start less than thresh...

Page 990: ...ets the DTC and illuminates the MIL 3 seconds after the engine is next started NOTICE When the negative battery terminal is disconnected during inspection or repairs the ISC learning values are cleared The ISC learning must be performed by warming up the engine and idling for 5 minutes with the engine coolant temperature at 75 C 167 F or more because DTCs cannot be de tected with the ISC learning ...

Page 991: ...ve hicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Check any other DTCs output In addition to DTC P050A a Connect the intelligent tester to the DLC3 b Turn the ignition switch ON c Turn the tester ON d Select the following the menu items DIAGNOSIS EN HANCED OBD II DTC INFO CURRENT CODES...

Page 992: ...S EN HANCED OBD II DATA LIST PRIMARY SHORT FT 1 and LONG FT 1 e Read the values displayed on the tester f Add together the SHORT FT 1 and LONG FT 1 values to obtain the total FUEL TRIM OK Total of the SHORT FT 1 and LONG FT 1 values is between 20 and 20 OK Go to step 8 NG 3 Check PCV hose connections OK PCV hose is connected correctly and is not damaged NG Go to step 5 OK 4 Check air induction sys...

Page 993: ...low meter NEXT Go to step 11 7 Repair or replace air induction system NEXT Go to step 11 8 Check throttle valve a Check for deposits around the throttle valve OK No deposits around the throttle valve OK Go to step 9 NG Go to step 10 9 Replace ECM NEXT Go to step 11 10 Replace throttle body assembly NEXT ...

Page 994: ...coolant temperature recorded in the freeze frame data a Connect the intelligent tester to the DTC3 b Turn the ignition switch ON c Turn the tester ON d Clear DTCs See page DI 462 e Switch the ECM from normal mode to check mode using the tester See page DI 463 f Start the engine to idle for a minute OK Stable fast idling g Read DTCs OK No DTCs output NEXT END ...

Page 995: ...ble Area P0560 Open in back up power source circuit Open in back up power source circuit EFI fuse ECM HINT If DTC P0560 present the ECM will not store another DTC MONITOR STRATEGY Related DTCs P0560 System voltage malfunction Required sensors components ECM Frequency of operation Continuous Duration 3 sec MIL operation Immediate 1 Sequence of operation None 1 The DTC is set immediate The MIL will ...

Page 996: ...7 23 6 B R E3 Battery ECM BATT 3 J C 1 Towing Package 2 Except Towing Package Access Cab Standard Cab A23591 Double Cab Engine Room R B EFI No 1 1 2D 2H 7 B Y Battery ECM BATT B Y 3 E3 B 7 10 12 B F13 FL Block IA10 DIAGNOSTICS ENGINE 2UZ FE DI 717 WIRING DIAGRAM ...

Page 997: ...r data from the time when a malfunction occurred 1 Check battery voltage PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch to ON c Select the item DIAGNOSIS ENHANCED OBD II DATA LIST ALL BATTERY VOLTAGE CHECK Read the battery voltage on the hand held tester RESULT Battery voltage Proceed to 0 V A Except 0 V B B Go to step 5 A 2 Check EFI No 1 fuse of engine room J B...

Page 998: ...termittent problems See page DI 430 NG 4 Check for open and short in harness and connector between ECM and EFI No 1 fuse EFI No 1 fuse and battery PREPARATION a Remove the EFI No 1 fuse from the engine room J B b Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tor OK Standard Tester Connection Specified Condition Engine Room J B EFI No 1 fuse termi...

Page 999: ...DI 720 DIAGNOSTICS ENGINE 2UZ FE 5 Check the battery See page CH 1 NG Replace battery OK Check and replace engine room J B ...

Page 1000: ...Us also perform continuous mutual monitoring The ECM sets a DTC if 1 outputs from the 2 CPUs are different and deviate from the standards 2 the sig nals to the throttle actuator deviate from the standards 3 a malfunction is found in the throttle actuator sup ply voltage and 4 any other ECM malfunction is found DTC No DTC Detecting Condition Trouble Area P0604 P0606 P0607 P0657 ECM malfunction ECM ...

Page 1001: ...tion a b and c a CPU reset 1 time or more b Difference between TP and APP learned 0 4 V or more c Electronic throttle actuator OFF 2 CPU reset 2 times or more P0657 ECTS power supply when ignition switch OFF to ON 7 V or more INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester Freeze frame data records the engine conditions when a malfunction is detected When troubleshootin...

Page 1002: ...icle speed 12 4 mph 20 km h b Engine revolution 1 000 rpm c STA signal ON Park neutral position switch Starter relay circuit Ignition switch ECM MONITOR STRATEGY Related DTCs P0617 Starter signal error R i d t Main sensors components Starter signal Required sensors components Related sensors components Vehicle speed sensor Engine speed sensor Frequency of operation Continuous Duration 20 sec MIL o...

Page 1003: ...8 W R AM1 AM2 ACC I23 Ignition SW 7 IA9 ACCR V W 1 D V W 1 C C J19 J C J27 ST2 8 IA9 7 Driver Side J B 3 6 STA 1I 1F L R R L 12 E5 8 E6 STSW NSW 4 5 P1 Park Neutral Position SW A E A J28 J28 J28 P 11 E5 STA J C P 1 w Engine Immobiliser System 2 w o Engine Immobiliser System DI 724 DIAGNOSTICS ENGINE 2UZ FE WIRING DIAGRAM ...

Page 1004: ...om R B No 2 ECU B 2 1 2 B SHORT PIN 1 2 2 2 2 2 2 2 1 2 1 2 ALT AM1 AM2 1 2 2 2 2 1 2 5 3 ST Relay B W B L 3 B 4 W W R G Y G Y G R G R G Y G R W B J26 J26 J26 J26 J27 J27 J27 J27 8 34 10 12 25 17 27 29 B L S1 1 A ST3 1 2 3 Towing Package 4 Except Towing Package DIAGNOSTICS ENGINE 2UZ FE DI 725 ...

Page 1005: ... 5 1 3C W R E3 W R 3 P ACC A22 ACC Cut Relay W R AM2 ST2 3D Sub J B No 4 19 9 4A 4A W R 5 4 P P1 Park Neutral Position SW L R 8 E6 NSW A J28 A J28 J C E J29 P 11 E5 P W W R W R B W 1 1L 7 1J 3 1J 6 1J 6 1C 3 1C 2 1E 5 1C 2 1 AM1 Driver Side J B Sub J B No 3 DI 726 DIAGNOSTICS ENGINE 2UZ FE ...

Page 1006: ...T Relay B R 2 5 1 3 2 2 2 2 2 1 3 B W W R W R 2D 1 2 ST STA ECU B Short Pin AM2 2E 2C 2C 2 1 8 B W 6 EB2 W B P B P 4 IJ4 B W 8 IJ4 B 12 E5 STSW W F13 FL Block ALT 2 12 10 B B B L A A EA W B J34 J C 1 S1 S2 1 Starter DIAGNOSTICS ENGINE 2UZ FE DI 727 ...

Page 1007: ...eck STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter operates OK Standard Ignition Switch Position ON START STARTER SIG OFF ON OK Go ...

Page 1008: ...the hand held tester while the starter operates OK Standard Ignition Switch Position ON START STARTER SIG OFF ON NG Repair or replace harness or connector OK 5 Check DTC reoccur PREPARATION a Connect the hand held tester b Turn the ignition switch ON and hand held tester main switch ON c Clear DTCs see page DI 462 d Drive the vehicle more than 25 mph 40 km h for 20 seconds or more CHECK Check DTC ...

Page 1009: ...NITOR STRATEGY Related DTCs P0630 VIN not programmed R i d t Main sensors components ECM Required sensors components Related sensors components Frequency of operation Continuous Duration 0 325 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 437 Battery voltage ...

Page 1010: ...CE If P0630 is present the VIN must be input to the ECM using the hand held tester However all DTCs are cleared automatically by the tester when inputting the VIN If DTCs other than P0630 are present check them first NEXT 2 Input VIN with hand held tester See page DI 433 NEXT END ...

Page 1011: ...No camshaft position sensor signal to ECM with engine speed 600 rpm or more Camshaft osition sensor LH camshaft timing pulley ECM MONITOR DESCRIPTION The camshaft position sensor G signal consists of a magnet and MRE element The camshaft drive gear has 5 teeth on its inner circumference When the camshaft gear rotates air gap changes between the protrusion on the gear and the pickup coil The change...

Page 1012: ...y comparing the crankshaft position to the camshaft position Camshaft position sensor signal No input in appropriate timing P1341 Crankshaft Camshaft alignment Mis aligned Camshaft position sensor count 12 or more 720 CA Engine 2 revolutions COMPONENT OPERATING RANGE Parameter Standard Value Camshaft position sensor signal input at every 720 CA 3 WIRING DIAGRAM Refer to DTC P0335 on page DI 632 IN...

Page 1013: ...the Camshaft position sensor connector b Turn the ignition switch to ON CHECK Measure the voltage between terminal 3 of the camshaft posi tion sensor connector and body ground OK Standard 4 5 to 5 5 V NG Repair or replace harness or connector OK 2 Check camshaft position sensor signal PREPARATION Start the engine CHECK Check the waveform between the G2 E5 19 and G2 E5 29 of the ECM connector OK St...

Page 1014: ...s side connectors OK Standard Tester Connection Specified Condition Camshaft position sensor C1 2 G2 E5 19 Below 1 Ω Camshaft position sensor C1 1 G2 E5 29 Below 1 Ω Camshaft position sensor C1 2 or G2 E5 19 Body ground 10 kΩ or higher Camshaft position sensor C1 1 or G2 E5 29 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK 4 Inspect sensor installation and signal plate to...

Page 1015: ...DI 734 DIAGNOSTICS ENGINE 2UZ FE 5 Inspect signal plate tooth of LH camshaft timing pulley NG Replace LH camshaft timing pulley OK Replace camshaft position sensor ...

Page 1016: ...trip detection logic Open or short in VSV for air injection control circuit Bank 2 VSV power source VSV for air injection control Bank 2 ECM MONITOR DESCRIPTION The ECM detects an open or short in the circuit of the VSV for air injection control according to the AIV1 AIV2 terminal voltage stores the DTC and then illuminates the MIL When the AIV1 AIV2 terminal voltage is less than half of the B vol...

Page 1017: ...operating TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P1440 Air switching valve No 2 Bank 1 output terminal level Low P1443 Air switching valve No 2 Bank 2 output terminal level Low WIRING DIAGRAM Refer to DTC P0412 on page DI 656 INSPECTION PROCEDURE 1 Check VSV for air injection control power source PREPARATION a Disconnect the VSV for air injection control connector b Turn the i...

Page 1018: ...nnect the VSV for air injection control connector CHECK Measure the resistance between the VSV connector and ECM OK Standard Tester connection Specified condition E7 27 AIV1 V14 2 Below 1 Ω E7 26 AIV2 V15 2 Below 1 Ω CHECK Measure the resistance between the VSV connector and body ground OK Standard Tester connection Specified condition E7 27 AIV1 or V14 2 and Body ground 10 KΩ or higher E7 26 AIV1...

Page 1019: ...ector from the VSV b Disconnect the 2 vacuum hoses from the VSV CHECK Measure the resistance between the VSV terminals OK Standard Tester Connection Specified Condition 1 2 33 to 39 Ω at 20 C 68 F 1 Body ground 10 kΩ or higher 2 Body ground 10 kΩ or higher NG Replace VSV for air injection control OK Replace ECM See page SF 82 ...

Page 1020: ...or air injection system Bank 1 ECM P1444 Air switching valve No 2 bank 2 stuck open The pressure sensor detects exhaust pulsation when both of air switching valve No 2 OFF and air switching valve ON 2 trip detection logic VSV for air injection control circuit Bank 2 Air switching valve No 2 Bank 2 VSV for air injection system Bank 2 ECM P2440 Air switching valve stuck open The pressure sensor dete...

Page 1021: ...p operates When exhaust pulsation is detected the ECM determines that the ASV is open The ECM determines malfunction parts based on the measured value and stores the DTCs Points A and B ECM detects pressure changes decrease and determines that the ASV No 2 is open Points C and F ECM detects pressure and exhaust pulsation and determines the pressure pattern of the system Point D ECM operate the sys...

Page 1022: ... changed Pressure changed No pulsation detected Normal Pattern 1 Pattern 4 Pressure changed No pressure changed Pulsation detected No pulsation detected Normal Pattern 1 Pattern 4 Pressure changed No pressure changed No pulsation detected No pulsation detected P1444 Pattern 1 Pattern 4 Pressure changed No pressure changed No pulsation detected P1442 Pattern 1 Pattern 4 No pressure changed No press...

Page 1023: ...em Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Conditions for case 1 case 2 and case 4 Atmospheric pressure 45 kPa 338 mmHg Battery voltage 11 5 V Sequence 1 to 6 are performed to monitor AIR Sequence 1 AIR In operation AIR pump ON AIR valve Electric type ON Either of the following conditions is met Condition 1 or 2 1 Both of the following conditions ar...

Page 1024: ...ence 5 AIR Not operating AIR pump OFF AIR valve Electric type OFF AIR valve vacuum type bank 1 OFF AIR valve vacuum type bank 2 OFF Engine RPM 3750 rpm Sequence 6 AIR status Not operating AIR pump OFF AIR valve Electric type ON AIR valve vacuum type bank 1 OFF AIR valve vacuum type bank 2 OFF Engine RPM 3750 rpm Conditions for case 3 Atmospheric pressure 45 kPa 338 mmHg Battery voltage 11 5 V AIR ...

Page 1025: ...e or f d All of the following conditions are met AIR pressure during monitor sequence 1 Change AIR pressure during monitor sequence 2 Change e AIR pressure during monitor sequence 1 when AIR VSV bank 1 is open No change f AIR pressure during monitor sequence 2 when AIR VSV bank 1 is open No change Thresholds for case 2 Both of the following conditions are met Condition 1 or 2 1 One of the followin...

Page 1026: ...ated on generic tools Secondary air injection AIR system MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit 71 E1 Multiply by 0 01 g s Test value of AIR amount insufficient Minimum test limit Maximum test limit 71 E2 Multiply by 0 01 kPa Test value of AIR pump stuck ON Minimum test limit Maximum test limit 71 E3 Multiply by 0 01 kPa Test value of AIR pump stuck OFF Min...

Page 1027: ...DTC Output Proceed To P1441 and or P1444 and P2440 A P1441 and or P1444 B P1441 and or P1444 and or P2440 and other DTCs C HINT If any DTCs other than P1441 P1444 or P2440 are output troubleshoot those DTCs first B Go to step 7 C Go to DTC chart See page DI 462 A 2 Check air switching valve operation PREPARATION a Remove the intake manifold see page EM 36 b Remove the air switching valve CHECK Blo...

Page 1028: ...dy ground PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A31 air switching valve connector c Turn the ignition switch ON CHECK Measure the voltage between terminal 1 of the air switching valve connector and body ground OK Standard Tester Connection Specified Condition A31 1 Body ground Below 1 0 V NG Go to step 4 OK Check for intermittent problems See page DI 430 and go t...

Page 1029: ...r d Disconnect the battery positive terminal cable CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VV A32 6 A31 1 Below 1 Ω VV A32 6 or A31 1 Battery positive terminal cable 10 kΩ or higher NG Repair or replace harness or connector OK 5 Check voltage between SIV terminal of air injection driver and body ground PREPARATION a D...

Page 1030: ...en air injection driver and ECM PREPARATION a Disconnect the air injection driver connector b Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition SIV A32 3 AIRV E3 4 Below 1 Ω SIV A32 3 or AIRV E3 4 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Replace ECM See page SF 82 ...

Page 1031: ...EN ASV1 CLOSE ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand held tester is prohibited the tester displays the prohibition WAIT or ERROR If the ERROR AI STATUS NG is displayed...

Page 1032: ...s time check that no negative pressure generates at port A of the VSV HINT OPERATION 1 AP OFF EASV CLOSE ASV1 CLOSE ASV2 CLOSE NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand held tester...

Page 1033: ... the air switching valve No 2 CHECK Blow air into port B and check that air is not discharged from port C OK Not discharged from port C CHECK Apply vacuum 30 kPa 225 mmHg to port A blow air into port B and check that air is discharged from port C OK Discharged from port C NG Replace air switching valve No 2 OK Check for intermittent problems See page DI 430 ...

Page 1034: ...Disconnect the connector from the VSV for air injection control CHECK Check that air does not flow from the port as shown in the il lustration OK Does not flow from port A CHECK Apply battery positive across the terminals check that air flows from the ports OK Flows from port A NG Replace VSV for air injection control OK ...

Page 1035: ...ct the VSV for air injection system control con nector CHECK Measure the resistance between the VSV connector and ECM OK Standard Tester connection Specified condition E7 27 AIV1 V14 2 Below 1 Ω E7 26 AIV2 V15 2 Below 1 Ω CHECK Measure the resistance between the VSV connector and body ground OK Standard Tester connection Specified condition E7 27 AIV1 or V14 2 and Body ground 10 KΩ or higher E7 26...

Page 1036: ...ter the ECM sends an open air switching valve No 2 bank 2 signal 2 trip detection logic VSV for air injection control circuit Bank 2 Vacuum hose VSV for air injection control air switching valve No 2 Air injector pipe Air switching valve No 2 exhaust manifold Air switching valve No 2 Bank 2 VSV for air injection control Bank 2 ECM P2441 Air switching valve stuck close The pressure sensor does not ...

Page 1037: ... voltage 11 5 V Sequence 1 to 6 are performed to monitor AIR Sequence 1 AIR In operation AIR pump ON AIR valve Electric type ON Either of the following conditions is met Condition 1 or 2 1 Both of the following conditions are met Condition a and b a AIR valve vacuum type bank 1 ON b AIR valve vacuum type bank 2 OFF 2 Both of the following conditions are met Condition c and d c AIR valve vacuum typ...

Page 1038: ...All of the following conditions are met AIR pressure during monitor sequence 3 1 kPa 7 5 mmHg or more and pulse is NOT generated AIR pressure during monitor sequence 6 5 kPa 37 5 mmHg or more and pulse is NOT generated b All of the following conditions are met AIR pressure during monitor sequence 3 1 kPa 7 5 mmHg or more and pulse is NOT generated AIR pressure during monitor sequence 6 Less than 5...

Page 1039: ... generated c All of the following conditions are met AIR pressure during monitor sequence 3 Less than 1 kPa 7 5 mmHg or more and pulse is NOT generated AIR pressure during monitor sequence 6 5 kPa 37 5 mmHg or more and pulse is NOT generated d All of the following conditions are met AIR pressure during monitor sequence 3 Less than 1 kPa 7 5 mmHg or more and pulse is NOT generated AIR pressure duri...

Page 1040: ...imum test limit 71 E5 Multiply by 0 01 kPa Test value of AIR control valve OFF Minimum test limit Maximum test limit 71 E6 Multiply by 0 01 kPa Test value of AIR pressure change for AIR valve Minimum test limit Maximum test limit 71 E7 Multiply by 0 01 kPa Test value of AIR pressure change for AIR VSV bank 1 Minimum test limit Maximum test limit 71 E8 Multiply by 0 01 kPa Test value of AIR pressur...

Page 1041: ...or replace vacuum hoses OK 3 Check voltage between terminal 1 of air switching valve and body ground PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A31 air switching valve connector c Connect the hand held tester to the DLC3 d Turn the ignition switch ON and turn the tester ON CHECK a When the air switching valve is operated using the hand held tester measure voltage betw...

Page 1042: ...engine for 10 minutes and then try again OK Standard Tester operation Tester Connection Specified Condition Operation 4 A31 1 Body ground 10 V or more Operation 1 A31 1 Body ground Below 1 0 V NG Go to step 12 OK 4 Check all air injection pipes and hoses of air injection system CHECK a Remove the intake manifold see page EM 36 b Check all pipes and hoses of the air injection system OK All the air ...

Page 1043: ...ve the intake manifold see page EM 36 b Remove the air switching valve CHECK Blow air into port A and check that air is not discharged from port B OK Not discharged CHECK a Apply battery positive across the terminals b Blow air into port A and check that air is discharged from port B OK Discharged NG Replace air switching valve and go to step 6 OK ...

Page 1044: ...N EASV OPEN ASV1 CLOSE ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand held tester is prohibited the tester displays the prohibition WAIT or ERROR If the ERROR AI STATUS NG is ...

Page 1045: ...owing menu items DIAGNOSIS EN HANCED OBD II SYSTEM CHECK AIR INJ CHECK MANUAL OPERATION OPERATION 2 HINT OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation ...

Page 1046: ...se s are securely connected CHECK a Check the vacuum hoses for blockages and damage OK The vacuum hoses no blockages and damages NG Repair or replace vacuum hose OK 9 Check air switching valve No 2 operation PREPARATION Remove the air switching valve No 2 CHECK Blow air into port B and check that air is not discharged from the port C OK Not discharged from port C CHECK Apply vacuum 30 kPa 225 mmHg...

Page 1047: ...Check the air injection pipe for blockages and damage OK The air injection pipe no blockages and damages NG Repair or replace air injection pipe OK Check for intermittent problems See page DI 430 11 Check VSV for air injection control PREPARATION Disconnect the 2 vacuum hoses CHECK Check that air does not flow from the port A as shown in the il lustration OK Not flow from port A CHECK Apply batter...

Page 1048: ...r c Disconnect the VSV for air injection system control con nector CHECK Measure the resistance between the VSV connector and ECM OK Standard Tester connection Specified condition E7 27 AIV1 V14 2 Below 1 Ω E7 26 AIV2 V15 2 Below 1 Ω CHECK Measure the resistance between the VSV connector and body ground OK Standard Tester connection Specified condition E7 27 AIV1 or V14 2 and Body ground 10 KΩ or ...

Page 1049: ...tor CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VV A32 6 A31 1 Below 1 Ω VV A32 6 or A31 1 Body ground 10 kΩ or higher NG Repair or replace harness or connector and go to step 6 OK 14 Check for open in harness and connector between air switching valve and body ground PREPARATION a Remove the intake manifold see page EM 36...

Page 1050: ...er and ECM PREPARATION a Disconnect the air injection driver connector b Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition SIV A32 3 AIRV E3 4 Below 1 Ω SIV A32 3 or AIRV E3 4 Body ground 10 kΩ or higher NG Repair or replace harness or connector and go to step 6 OK Replace ECM See page SF 82 ...

Page 1051: ... ECM P1613 Air injection driver outputs abnormal duty signal 100 duty signal 1 trip detection logic Open or short in AID power source circuit Open in diagnostic information signal circuit AID ECM Air injection driver AID ECM MONITOR DESCRIPTION When the air injection system operation is required while the engine is warming up the ECM transmits com mand signals to the Air Injection Driver AID to dr...

Page 1052: ...r 2 1 Air pump Not operating 2 Air switching valve Not operating Battery voltage 8 V Ignition switch ON Starter OFF Case 3 Air pump Operating Air switching valve Operating Battery voltage 8 V Ignition switch ON Starter OFF Case 4 Battery voltage 8 V Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case 1 One of the following conditions is met Condition 1 2...

Page 1053: ...INT The diagnostic information output from the AID can be confirmed by connecting an oscilloscope to the diag nostic information terminal of the AID It narrows a trouble area search to read the waveform on the oscillo scope when performing the AI system intrusive operation function provided in the SYSTEM CHECK a Start the engine and warm it up b Turn the ignition switch to OFF c Connect a hand hel...

Page 1054: ...thermore the check can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between checks While the AI system operation using the hand held tester is prohibited the tester displays the prohibition WAIT or ERROR If the ERROR AI STATUS NG is displayed on the tester stop the engine for 10 minutes and then try again Performing the AIR INJ CHECK over and ov...

Page 1055: ...t AID Pump Harness connector AID Pump Air Pump AID ECM Short between air pump drive circuit and body ground AID ECM Harness connector AID Pump Air Pump Open in ASV drive circuit AID ASV Harness connector AID ASV ASV AID ECM Short between ASV drive circuit and body ground Harness connector AID ASV AID ECM ECM Normal AID AID or short between air pump drive circuit and B or short between ASV drive ci...

Page 1056: ... When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Check any other DTCs output In addition to air injection system DTCs PREPARATION a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tes...

Page 1057: ...rouble Areas Proceed To Fixed at Low 1 6 V or less even when AI system ON Air pump ON ASV ON Short between air pump or air switching valve command signal circuit and body ground Open in air pump command signal circuit be tween ECM and AID Open in ASV command signal circuit between ECM and AID Open in AID ground circuit between AID and body ground Diagnostic signal circuit ground short AID ECM A Fi...

Page 1058: ...ce ECM See page SF 82 OK 4 Check for short in harness and connector between SIP terminal of air injection driver and SIRP of ECM PREPARATION a Disconnect the A32 air injection driver connector b Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition SIP A32 4 or AIRP E3 25 Body ground 10 kΩ or higher ...

Page 1059: ...he voltage between the terminal B A32 5 and E A32 1 of the air injection driver connector OK Standard Tester Connection Specified Condition A32 5 B E A32 1 10 V or more NG Repair or replace harness or connector OK 6 Check voltage between DI terminals of air injection driver and body ground PREPARATION a Disconnect the A32 air injection driver connector b Turn the ignition switch to ON CHECK Measur...

Page 1060: ...he resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition DI A32 2 AIDI E3 13 Below 1 Ω DI A32 2 or AIDI E3 13 B A32 5 10 kΩ or higher NG Repair or replace harness or connector OK Replace ECM See page SF 82 8 Inspect air injection driver ground circuit PREPARATION Disconnect the A32 air injection driver connector CHECK Measure the resistance between ...

Page 1061: ... Perform ACTIVE TEST to operate the air injection system Select the following menu items DIAGNOSIS ENHANCED OBD II SYSTEM CHECK AIR INJ CHECK AUTOMATIC OPERATION b After operating the secondary air injection system confirm the pending codes of the secondary air in jection system by selecting the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES OK DTC P1613 for the secondary ai...

Page 1062: ...NITOR DESCRIPTION The ECM monitors the current through the electronic throttle motor and detects malfunctions or open circuit in the throttle motor based on the voltage of the current When the current deviates from the standard the ECM concludes that there is a fault in the throttle motor Or if the throttle valve is not functioning properly for example stuck ON the ECM concludes that there is a fa...

Page 1063: ... DI 437 P2102 Throttle motor ON Duty cycle ratio to open throttle actuator 80 Throttle actuator power supply 8 V Current motor current Motor current at 0 016 sec before 0 2 A P2103 Throttle motor ON Either of the following conditions is met Condition 1 or 2 1 Throttle actuator power supply 8 V 2 Throttle actuator power ON Battery voltage 8 V Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection Cri...

Page 1064: ...lp determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check throttle control motor PREPARATION Disconnect the throttle control motor and sensor connector CHECK Measure the resistance between terminals of the throttle con trol motor OK Standard Tester Connection S...

Page 1065: ...s side connec tors OK Standard Tester Connection Specified Condition M T14 2 M E7 5 Below 1 Ω M T14 1 M E7 4 Below 1 Ω M T14 2 or M E7 5 Body ground 10 kΩ or higher M T14 1 or M E7 4 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK 3 Visually check throttle valve CHECK Check the area between the throttle valve and the housing for foreign objects Also check if the valve can ...

Page 1066: ... trip detection logic Throttle control motor and sensor Throttle body Throttle valve MONITOR DESCRIPTION The ECM concludes that there is a malfunction of the ETCS Electronic Throttle Control System when the throttle valve remains at a fixed angle despite high drive current from the ECM The ECM will turn on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malf...

Page 1067: ...ent 2 A Throttle motor duty to open side 80 System guard is ON when the following conditions are set Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current cut operation Not executing Throttle actuator power supply 4 V Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold TP sensor...

Page 1068: ...o P2111 and or P2112 A P2111 and or P2112 and other DTCs B HINT If any DTCs other than P2111 and or P2112 are output troubleshoot those DTCs first B Go to relevant DTC chart See page DI 477 A 2 Visually check throttle valve PREPARATION Remove the intake air connector CHECK Check whether or not a foreign body is caught between the throttle valve and housing Also check if the valve can open and clos...

Page 1069: ...M T14 1 0 3 to100 Ω 20 C 68 F NG Replace throttle body See page SF 44 OK 4 Check for open and short in harness and connector between ECM and throttle control motor PREPARATION a Disconnect the T14 throttle control motor and sensor con nector b Disconnect the E7 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition M T...

Page 1070: ...e For this reason when the voltage is low the current to the motor is cut If repairs are made and the system has returned to normal turn the ignition switch OFF The ECM then allows current to flow to the motor and the motor can be restarted HINT This Electrical Throttle Control System ETCS does not use a throttle cable DTC No DTC Detection Condition Trouble Area P2118 Open in ETCS power source cir...

Page 1071: ...ass condition is detected and then the ignition switch is turned OFF the fail safe operation will stop and the system will return to normal condition MONITOR STRATEGY Related DTCs P2118 Throttle actuator motor power supply line range check Low voltage Required sensors components Throttle actuator motor Frequency of operation Continuous Duration 0 8 sec MIL operation Immediate Sequence of operation...

Page 1072: ... Package 2 Except Towing Package Battery ETCS ECM BM E3 J C B B L 1 2 2 J26 G Y 2 2 1 J27 G Y 1 18 7 A23591 Double Cab Engine Room R B Battery ETCS ECM BM E3 B 2D F13 FL Block 2H W G 12 7 10 12 W G 3 1 B IA10 DI 788 DIAGNOSTICS ENGINE 2UZ FE WIRING DIAGRAM ...

Page 1073: ...ir fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check ETCS fuse PREPARATION Remove the ETCS fuse from the engine room J B CHECK Check the resistance of the ETCS fuse OK Below 1 Ω NG Check for short in all harness and components connected to ETCS fuse OK 2 Check voltage between terminal BM and E1 of ECM connector CHECK Measure the voltage between the...

Page 1074: ...tion Engine Room J B ETCS fuse terminal BM E3 7 Below 1 Ω Engine Room J B ETCS fuse terminal or BM E3 7 Body ground 10 kΩ or higher PREPARATION a Remove the ETCS fuse from the engine room J B b Disconnect the battery positive terminal CHECK Measure the resistance of the wire harness side connector be tween the ETCS fuse and battery OK Standard Tester Connection Specified Condition Engine Room J B ...

Page 1075: ...s compared to the target throttle position commanded by the ECM If the difference of these two values exceeds a specified limit the ECM interprets this as a fault in the ETCS Electronic Throttle Control System The ECM turns on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle contr...

Page 1076: ...Condition a or b a Commanded closed throttle position current closed throttle position 0 3 V or more b Commanded open throttle position current open throttle position 0 3 V or more COMPONENT OPERATING RANGE Standard Value Commanded throttle position and current throttle position are nearly the same WIRING DIAGRAM Refer to DTC P0120 on page DI 548 INSPECTION PROCEDURE HINT Read freeze frame data us...

Page 1077: ...FO CURRENT CODES CHECK Read the DTC using the hand held tester RESULT Display DTC Output Proceed to P2119 A P2119 and other DTC B HINT If any other codes besides P2119 are output perform the troubleshooting for those DTCs first B Go to DTC chart See page DI 462 A 2 Check throttle control motor PREPARATION Disconnect the throttle control motor and sensor connector CHECK Measure the resistance betwe...

Page 1078: ...ts reoccur PREPARATION a Replace ECM b Clear DTCs see page DI 462 c Start and warm up the engine d Run the engine at idle for 15 seconds or more CHECK Read the DTC using the hand held tester See page DI 462 OK No DTC output OK System is normal NG Replace throttle body See page SF 44 ...

Page 1079: ...n Sensor Switch D Circuit High Input DTC P2125 Throttle Pedal Position Sensor Switch E Circuit DTC P2127 Throttle Pedal Position Sensor Switch E Circuit Low Input DTC P2128 Throttle Pedal Position Sensor Switch E Circuit High Input DTC P2138 Throttle Pedal Position Sensor Switch D E Voltage Correlation HINT This is the repair procedure for the Accelerator Pedal Position APP sensor DICNE 02 ...

Page 1080: ... type The accelerator pedal position sensor is mounted in the accelerator pedal to detect the angle of the accelera tor pedal This sensor is electronically controlled and uses Hall effect elements In the accelerator pedal position sensor the voltage applied to terminals VPA and VPA2 of the ECM changes between 0 V and 5 V in proportion to the angle of the accelerator pedal The VPA is a signal to in...

Page 1081: ... Accelerator pedal position expressed as voltage Trouble area Accelerator pedal completely released Accelerator pedal fully depressed Trouble area ACCEL POS 1 ACCEL POS 2 ACCEL POS 1 ACCEL POS 2 VC circuit open 0 to 0 2 V 0 to 0 2 V 0 to 0 2 V 0 to 0 2 V VPA circuit open or ground short 0 to 0 2 V 1 2 to 2 0 V 0 to 0 2 V 3 4 to 5 3 V VPA2 circuit open or ground short 0 5 to 1 1 V 0 to 0 2 V 2 6 to...

Page 1082: ...Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Ignition switch ON Throttle control motor power ON TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2120 Either of the following conditions is met Condition 1 or 2 1 VPA1 voltage when VPA2 is 0 04 V or more 0 4 V...

Page 1083: ...E P2138 Either of the following condition is met Condition 1 or 2 1 Difference between VPA1 and VPA2 voltage 0 02 V or less 2 Both of the following conditions are met a and b a VPA1 voltage 0 4 V or less b VPA2 voltage 1 2 V or less COMPONENT OPERATING RANGE Parameter Standard Value VPA voltage More than 0 4 V and less than 4 8 V VPA2 voltage More than 1 2 V and Less than 4 8 V Difference between ...

Page 1084: ...ll as other data from the time when a malfunction occurred 1 Connect hand held tester and read the voltage for accelerator pedal position sensor data PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tes ter main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ETCS ACCEL POS 1 and ACCEL POS 2 CHECK Read the voltage ...

Page 1085: ...ance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VPA A20 6 VPA E3 18 Below 1 Ω EPA A20 5 EPA E3 20 Below 1 Ω VCPA A20 4 VCPA E3 26 Below 1 Ω VPA2 A20 3 VPA2 E3 19 Below 1 Ω EPA2 A20 2 EPA2 E3 21 Below 1 Ω VCP2 A20 1 VCP2 E3 27 Below 1 Ω VPA A20 6 or VPA E3 18 Body ground 10 kΩ or higher EPA A20 5 or EPA E3 20 Body ground 10 kΩ or higher VCPA A20 4 or...

Page 1086: ...REPARATION a Turn the ignition switch ON b Disconnect the A20 accelerator pedal position sensor connector CHECK Measure the voltage between the specified terminals of the E3 ECM connector OK Standard Tester Connection Specified Condition VCPA E3 26 EPA E3 20 4 5 to 5 5 V VCP2 E3 27 EPA2 E3 21 4 5 to 5 5 V NG Replace ECM See page SF 82 OK 4 Replace accelerator pedal assembly See page SF 80 Go ...

Page 1087: ...minals or remove the EFI No 1 fuse and ETCS fuse Clear DTCs c Start the engine d Drive the engine at idle for 15 seconds or more e On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES CHECK Read the DTC output RESULT Display DTC Output Proceed To P2120 P2122 P2123 P2125 P2127 P2128 or P2138 A No output B B System is OK A Replace ECM See page SF 8...

Page 1088: ...dard the ECM con cludes the accelerator pedal position sensor has a malfunction The ECM turns on the MIL and a DTC is set FAIL SAFE The accelerator pedal position sensor has two main and sub sensor circuits If a malfunction occurs in ei ther of the sensor circuits the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode In limp mode the remai...

Page 1089: ... the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Connect hand held tester and read the voltage for accelerator pedal position sensor data PREPARATION a Connect...

Page 1090: ...Connection Specified Condition VPA A20 6 VPA E3 18 Below 1 Ω EPA A20 5 EPA E3 20 Below 1 Ω VCPA A20 4 VCPA E3 26 Below 1 Ω VPA2 A20 3 VPA2 E3 19 Below 1 Ω EPA2 A20 2 EPA2 E3 21 Below 1 Ω VCP2 A20 1 VCP2 E3 27 Below 1 Ω Standard Check for short Tester Connection Specified Condition VPA A20 6 or VPA E3 18 Body ground 10 kΩ or higher EPA A20 5 or EPA E3 20 Body ground 10 kΩ or higher VCPA A20 4 or VC...

Page 1091: ... DTC P2197 Oxygen A F Sensor Signal Stuck Lean Bank 2 Sensor 1 DTC P2198 Oxygen A F Sensor Signal Stuck Rich Bank 2 Sensor 1 HINT Although the DTC titles say oxygen sensor these DTCs relate to the Air Fuel Ratio A F sensor Sensor 1 refers to the sensor mounted in front of the Three Way Catalytic Converter TWC and lo cated near the engine assembly DIDS4 01 ...

Page 1092: ... zirconia element This heater is controlled by the ECM When the intake air volume is low the exhaust gas tempera ture is low a current flows into the heater to heat the sensor in order to facilitate accurate air fuel ratio detection In addition the sensor and heater portions are narrower than the conventional type The heat generated by the heater is conducted to the solid electrolyte though the al...

Page 1093: ...d relay circuits Air induction system Fuel pressure Injector ECM HINT When any of these DTCs are set check the A F sensor voltage output by selecting the following menu items on a hand held tester DIAGNOSIS ENHANCED OBD II DATA LIST ALL AFS B1S1 Short term fuel trim values can also be read using a hand held tester The ECM regulates the voltage at the A1A and A1A terminals of the ECM at a constant ...

Page 1094: ...ent during fuel cut and detects unusual current value If the cumulative time the sensor output is out of range exceeds 3 seconds the ECM interprets a mal function in the air fuel ratio sensor and sets a DTC MONITOR STRATEGY P2195 A F sensor Bank 1 signal stuck lean P2195 A F sensor Bank 1 current high side P2196 A F sensor Bank 1 signal stuck rich R l t d DTC P2196 A F sensor Bank 1 current low si...

Page 1095: ...ted Fuel system status Closed loop Engine Running P2195 P2197 A F sensor current High side Battery voltage 11 V ECT 75 C 167 F Atmospheric pressure 760 mmHg 0 75 A F sensor status Activated Continuous time of fuel cut 3 to 10 sec P2196 P2198 A F sensor current Low side Battery voltage 11 V ECT 75 C 167 F Atmospheric pressure 760 mmHg 0 75 A F sensor status Activated Continuous time of fuel cut 3 t...

Page 1096: ...itor Identification Data is assigned to each emissions related component TID Test Identification Data is assigned to each test value A F sensor bank 1 sensor 1 MID TID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit 01 91 Multiply by 0 003906 mA A F current Minimum test limit Maximum test limit A F sensor bank 2 sensor 1 MID TID Scaling Description of Test Value Minimum Tes...

Page 1097: ...HTR Relay 2 1 5 3 2 1 5 3 W R B R L B W B A A J18 J C EA W B Battery Engine Room R B 2 2 2 EFI No 1 2 1 B B L 1 2 ET W B EW E J64 J C E BR BR C J64 J C C J26 J C J27 9 26 W R W R W R IE1 12 4 3 2 1 A30 A F Sensor Bank 2 Sensor 1 A10 A F Sensor Bank 1 Sensor 1 B HT AF 4 3 2 1 B HT AF P V G L Y C G 3 3 1 Towing Package 2 Except Towing Package 3 Shielded AF AF W R 2 1 DI 812 DIAGNOSTICS ENGINE 2UZ FE...

Page 1098: ...Sensor 1 A10 Air Fuel Ratio Sensor Bank 1 Sensor 1 4 3 2 1 P V G L Y C G W R Shielded Shielded IE1 12 2 2 Engine Room J B R 2 2 2 A F 2 1 5 3 2 1 2H 2D 2F 2H EFI No 1 EFI Relay 1 1 6 B W B B Engine Room R B Engine Room R B B R 2 2 2 A F Relay W L W L W W B Battery A J34 J C A A 1 2 5 3 EA B HT AF AF B HT AF AF 10 12 7 R B W R F13 FL Block IA10 IA10 DIAGNOSTICS ENGINE 2UZ FE DI 813 ...

Page 1099: ...east 10 minutes g Change the transmission to 2nd gear h Drive the vehicle at an appropriate speed to perform fuel cut operation HINT Fuel cut is performed when the following conditions met Accelerator pedal is fully released Engine speed is 2 500 rpm or more fuel injection returns at 1 000 rpm i Accelerate the vehicle to 30 mph 48 km h or more by depressing the accelerator pedal for at least 10 se...

Page 1100: ...he tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume 6 Monitor the voltage outputs of the A F and HO2 sensors AFS B1S1 AFS B2S1 and OS2 B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowers the fue...

Page 1101: ...nsor has an output delay of a few seconds and the Heated Oxygen HO2 sensor has a maximum output delay of approximately 20 seconds Following the A F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A F and HO2 sensors To display the graph select the following menu items on the tester DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S...

Page 1102: ...levant DTC chart See page DI 477 A 2 Check A F sensor output current PREPARATION a Connect a hand held tester to the DLC3 b Turn the ignition switch to ON and turn the tester ON c Clear DTCs see page DI 462 d On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II MON ITOR INFO MONITOR STATUS e Check that the status of O2S MON is COMPL f On the hand held tester select the...

Page 1103: ... 500 rpm without any sudden changes in engine speed 3 Raise the engine speed to 4 000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed Standard Conditions A F Sensor Voltage Variations Reference 1 and 2 Changes at approx 0 66 V Between 0 62 V and 0 7 V 3 Increases to 0 76 V or more This occurs during engine deceleration when fuel cut performed For more ...

Page 1104: ...ator pedal fully depressed when trying to over take another vehicle The A F sensor is functioning normally The A F sensor is a current output element therefore the current is converted into a voltage inside the ECM Measuring the voltage at the connectors of the A F sensor or ECM will show a constant volt age result NG Go to step 9 OK 4 Perform confirmation driving pattern NEXT 5 Check whether DTC ...

Page 1105: ...or P2198 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A No output B B Go to step 5 A 9 Confirm whether vehicle has run out of fuel in past NO Check for intermittent problems See page DI 430 YES DTC caused by running out of fuel ...

Page 1106: ...between the terminals of the A F sensor connector OK Tester Connection Specified Condition HT 1 B 2 Between 1 8 Ω and 3 4 Ω at 20 C 68 F HT 1 AF 4 10 kΩ or higher NG Replace air fuel ratio A F sensor OK 11 Check A F relay PREPARATION Remove the A F relay from the engine room J B CHECK Inspect the A F relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5 Apply B...

Page 1107: ...the A F sensor connector and body ground Standard Tester Connections Specified Conditions B 2 Body ground Between 9 V and 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω AF A...

Page 1108: ...k the air induction system for vacuum leaks NG Repair or replace air induction system OK 14 Check fuel pressure See page SF 7 CHECK Check the fuel pressure high or low pressure NG Check and replace fuel pump pressure regula tor fuel pipe line and filter See page SF 1 OK 15 Check injector injection See page SF 29 NG Replace injector OK ...

Page 1109: ...nd held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A No output B B Replace ECM See page SF 82 and perform confirmation driving pattern A 19 Confirm whether vehicle has run out of fuel in past NO Check for intermittent problems See page DI 430 YES DTC caused by running out of fue...

Page 1110: ...heck whether DTC output recurs DTC P2195 P2196 P2197 or P2198 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2195 P2196 P2197 or P2198 A F sensor pending DTCs A No output B B Replace ECM See page SF 82 A END ...

Page 1111: ...TC P2252 Oxygen Sensor Reference Ground Circuit Low For A F Sensor Bank 1 Sensor1 DTC P2253 Oxygen Sensor Reference Ground Circuit High For A F Sensor Bank 1 Sensor1 DTC P2255 Oxygen Sensor Reference Ground Circuit Low For A F Sensor Bank 2 Sensor1 DTC P2256 Oxygen Sensor Reference Ground Circuit High For A F Sensor Bank 2 Sensor1 HINT Although the DTC titles say oxygen sensor these DTCs relate to...

Page 1112: ...or 1 A F sensor heater EFI relay A F sensor heater and relay circuits ECM P2252 P2255 AF voltage 0 5 V or less for 5 0 seconds or more 1 trip detection logic Open or short in A F sensor sensor 1 circuit A F sensor sensor 1 A F sensor heater EFI relay A F sensor heater and relay circuits ECM P2253 P2256 AF voltage more than 4 5 V for 5 0 seconds or more 1 trip detection logic Open or short in A F s...

Page 1113: ...between AF and B P2255 A F sensor Bank 2 short circuit between AF and GND P2256 A F sensor Bank 2 short circuit between AF and B Required sensors components A F sensor Frequency of operation Once per driving cycle Duration 10 sec A F sensor open circuit between AF and AF 5 sec Others MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximu...

Page 1114: ...only Malfunctioning areas can be identified by performing the A F CONTROL function provided in the ACTIVE TEST The A F CONTROL function can help to determine whether the Air Fuel Ratio A F sensor Heated Oxygen HO2 sensor and other potential trouble areas are malfunctioning The following instructions describe how to conduct the A F CONTROL operation using a hand held tester 1 Connect a hand held te...

Page 1115: ...O2 sensor circuit HO2 sensor heater Air fuel ratio extremely lean or rich Injector Gas leakage from exhaust system Fuel pressure DI 830 DIAGNOSTICS ENGINE 2UZ FE Standard Tester Display Sensor Injection Volumes Status Voltages AFS B1S1 AFS B2S1 A F 25 Rich Less than 3 0 AFS B1S1 AFS B2S1 A F 12 5 Lean More than 3 35 O2S B1S2 O2S B2S2 HO2 25 Rich More than 0 55 O2S B1S2 O2S B2S2 HO2 12 5 Lean Less ...

Page 1116: ...the malfunction occurred 1 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the air fuel ratio A F sensor connector CHECK Measure resistance between the terminals of the A F sensor connector OK Tester Connection Specified Condition HT 1 B 2 Between 1 8 Ω and 3 4 Ω at 20 C 68 F HT 1 AF 4 10 kΩ or higher NG Replace air fuel ratio A F sensor OK 2 Check A F relay PREPARATION...

Page 1117: ... A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground Between 9 V and 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance OK Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω A...

Page 1118: ... DIAGNOSTICS ENGINE 2UZ FE DI 833 NG Replace or replace harness or connector OK Replace ECM See page SF 82 ...

Page 1119: ...ming Detection Logic P2401 Vacuum pump stuck OFF One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high low Vacuum pump ON stuck Vacuum pump OFF stuck Pump module Connector Wire harness While ignition 2 trips P2402 Vacuum pump stuck ON Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Connector ...

Page 1120: ...First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C EVAP system pres sure measurement Vent valve turned ON closed to shut EVAP system Negative pressure vacuum created in EVAP system and EVAP system pres...

Page 1121: ...p EVAP Pressure sec OFF Sequence Time A 10 sec 60 Within 15 minutes sec ON Specified Range B C D EVAP Pressure during EVAP Monitor OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 sec 60 E Malfunction OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DI 836 DIAGNOSTICS ENGINE 2UZ FE In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the c...

Page 1122: ...sure sensor malfunction P0450 P0452 P0453 Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 set before key off 1 Duration that vehicle has been driven 5 min 2 EVAP purge operation Performed ECT 4 4 to 35 C 40 to 95 F IAT 4 4 to 35 C 40 to 95 ...

Page 1123: ... 93 mmHg 3 Reference pressure Saturated within 60 seconds 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following con dition is set EVAP pressure when vacuum introduction is complete Second reference pressure 8 Atmospheric pressure measurement EVAP monitor is complete if the following condition is set Atmosph...

Page 1124: ... DIAGNOSTICS ENGINE 2UZ FE DI 839 MONITOR RESULT MODE 06 DATA Refer to page DI 445 for detailed information INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure see page DI 884 ...

Page 1125: ...ion Timing Detection Logic P2419 Vent valve stuck ON Closed One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high flow Vacuum pump ON stuck Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Pump module Connector Wire harness Pump module ECM ECM While Ignition switch OFF 2 trips P2420 Vent valve...

Page 1126: ... pressure measured by ECM in order to register atmospheric pressure If EVAP pressure is not between 70 kPa and 110 kPa 525 mmHg and 825 mmHg ECM cancels EVAP system monitor 10 seconds B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and them ECM checks if vacuum pump and vent ...

Page 1127: ...tion OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DI 842 DIAGNOSTICS ENGINE 2UZ FE a P2419 Vent valve stuck ON Closed In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the canister pump module through the 0 02 inch orifice If the pressure is out of specified range or is not saturated the ECM illuminates the MIL and sets DTCs P043E P043F P2...

Page 1128: ...valve being stuck OFF vent The ECM illuminates the MIL and sets the DTC MONITOR STRATEGY R l t d DTC P2419 Vent valve stuck open Related DTCs P2420 Vent valve stuck closed Required sensors components Vent valve Frequency of operation Once per driving cycle Duration Within 2 minutes varies with amount of fuel in tank MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITI...

Page 1129: ...mHg 3 Reference pressure Saturated within 60 seconds 3 EVAP canister vent valve close stuck check Next sequence is run if the following con dition is set EVAP pressure change after vent valve is ON 0 3 kPa 2 25 mmHg 4 Vacuum introduction Next sequence is run if the following con dition is set EVAP pressure Saturated within 15 minutes 5 EVAP canister purge valve close stuck check Next sequence is r...

Page 1130: ... the following conditions set Condition 1 2 3 4 or 5 1 EVAP pressure just after reference pressure measure ment start More than 1 kPa 7 5 mmHg 2 Reference pressure Less than 4 85 kPa 36 38 mmHg 3 Reference pressure 1 057 kPa 7 93 mmHg or more 4 Reference pressure Not saturated 5 Difference between first reference pressure and second reference pressure 0 7 kPa 5 25 mmHg or more Vent valve stuck clo...

Page 1131: ...ore 1 trip detection logic P2431 The pressure sensor indicates less than 45 63 kPa 342 mmHg or more than 135 kPa 1013 mHg 1 trip detection logic Pressure sensor O h t i i it P2432 While the engine is running if voltage output of pressure sen sor remains below 0 1 V 1 trip detection logic Open or short in pressure sensor circuit ECM P2433 While the engine is running if voltage output of the pressur...

Page 1132: ...operation P2430 P2432 P2433 Immediate P2431 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 437 Starter OFF Time after starter turned from ON to OFF 2 sec Battery voltage 8 V Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2430 Air press...

Page 1133: ...s and connector between pressure sensor and ECM See page IN 30 PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A34 pressure sensor connector c Disconnect the E7 ECM connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VC A34 1 VC E7 23 AIP A34 2 AIP E7 32 E2 A34 3 E2 E7 28 Below 1 Ω VC A34 1 or V...

Page 1134: ... vehicle d Turn the ignition switch ON and push the hand held tes ter main switch ON Do not start engine e Select the following items DIAGNOSIS ENHANCED OBD II DATA LIST 2ND AIR PRESS CHECK Check that the pressure displayed on the hand held tester fluc tuates when applying the pressure to the pressure sensor with the pressure gauge OK Pressure fluctuates in response to the pressure ap plied with p...

Page 1135: ... Air pump assembly Air injection driver Open in air pump circuit Air injection system piping Pressure sensor Open or short in pressure sensor circuit ECM MONITOR DESCRIPTION P2444 The ECM observes the pressure in the secondary air passage using the pressure sensor located on the air switching valve in the secondary air injection system The sensor measures the pressure in the secondary air passage ...

Page 1136: ... case 3 Atmospheric pressure 45 kPa 338 mmHg Battery voltage 11 5 V Sequence 1 to 6 are performed to monitor AIR Sequence 1 AIR In operation AIR pump ON AIR valve Electric type ON Either of the following conditions is met Condition 1 or 2 1 Both of the following conditions are met Condition a and b a AIR valve vacuum type bank 1 ON b AIR valve vacuum type bank 2 OFF 2 Both of the following conditi...

Page 1137: ...vacuum type bank 1 OFF AIR valve vacuum type bank 2 OFF Engine RPM 3750 rpm Sequence 6 AIR status Not operating AIR pump OFF AIR valve Electric type ON AIR valve vacuum type bank 1 OFF AIR valve vacuum type bank 2 OFF Engine RPM 3750 rpm Conditions for case 4 ECT at engine start 5 C 41 F IAT at engine start 15 C 5 F Time after ECT is 80 C 176 F or more 10 to 60 minutes Cumulative intake air amount...

Page 1138: ...ID Scaling Description of Test Value Minimum Test Limit Maximum Test Limit 71 E1 Multiply by 0 01 g s Test value of AIR amount insufficient Minimum test limit Maximum test limit 71 E2 Multiply by 0 01 kPa Test value of AIR pump stuck ON Minimum test limit Maximum test limit 71 E3 Multiply by 0 01 kPa Test value of AIR pump stuck OFF Minimum test limit Maximum test limit 71 E4 Multiply by 0 01 kPa ...

Page 1139: ...o the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P2445 A P2444 B P2444 and P2445 B P2444 and P2445 and other DTCs C HINT If any other codes besides P2444 or P2445 is output perform the troubleshooting for those DTCs first B Go to ...

Page 1140: ...K AIR INJ CHECK MANUAL OPERATION OPERATION 1 and 6 HINT OPERATION 1 AP OFF EASV CLOSE ASV1 CLOSE ASV2 CLOSE OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN b Check that the PRESSURE on the hand held tester NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are ...

Page 1141: ...ating the secondary air injection system confirm the pending codes for the secondary air injection system by selecting the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES c Read DTC and check DTC OK DTC P2444 or P2445 for the secondary air injection system is not output NG Go to step 4 OK Check for intermittent problems See page DI 430 4 Check vacuum hose CHECK a Remove the i...

Page 1142: ...sure displayed on the hand held tester fluc tuates when applying the pressure to the pressure sensor with the pressure gauge OK Pressure fluctuates in response to the pressure ap plied with pressure gauge NG Replace pressure sensor OK 6 Check connection of all air injection system piping and hoses CHECK a Remove the intake manifold see page EM 36 b Check that all the pipes and hoses between the ai...

Page 1143: ...ion driver connec tor c Turn the ignition switch to ON CHECK Measure the voltage between terminals A32 5 B and A33 1 BATT of the air injection driver and body ground OK Standard Tester Connection Specified Condition A32 5 B Body ground 10 V or more A33 1 BATT Body ground 10 V or more CHECK Measure the resistance between the terminal A32 1 E of the air injection driver and body ground OK Standard T...

Page 1144: ... AP ON EASV OPEN ASV1 OPEN ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand held tester is prohibited the tester displays the prohibition WAIT or ERROR If the ERROR AI STATUS NG...

Page 1145: ...ASV1 CLOSE ASV2 CLOSE OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand held tester is prohibited the tester displays the prohibition WAIT o...

Page 1146: ...STEM CHECK AIR INJ CHECK MANUAL OPERATION OPERATION 1 and 2 HINT OPERATION 1 AP OFF EASV CLOSE ASV1 CLOSE ASV2 CLOSE OPERATION 2 AP ON EASV OPEN ASV1 OPEN ASV2 OPEN NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI syste...

Page 1147: ...n air pump and body ground PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A35 air pump connector CHECK Measure the resistance between the wire harness side connec tors and body ground OK Standard Tester Connection Specified Condition A35 1 Body ground Below 1 Ω NG Repair or replace harness or connector OK ...

Page 1148: ... is operated using the hand held tes ter measure the air injection system pressure HINT OPERATION 2 AP ON EASV CLOSE ASV1 CLOSE ASV2 CLOSE NOTICE This test only allows technicians to operate the AI system for 5 seconds Furthermore the test can be performed 4 times a trip If the test is repeated intervals of at least 30 seconds are required between tests While the AI system operation using the hand...

Page 1149: ...CTIVE TEST to operate the air injection system Select the following menu items DIAGNOSIS ENHANCED OBD II SYSTEM CHECK AIR INJ CHECK AUTOMATIC OPERATION b After operating secondary air injection system confirm the pending codes of the secondary air injec tion system by selecting the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES c Read DTC and check no DTC OK DTC P2444 or P24...

Page 1150: ...nd air pump PREPARATION a Remove the intake manifold see page EM 36 b Disconnect the A33 air injection driver connector c Disconnect the A35 air pump connector CHECK Measure the resistance between the wire harness side connec tors OK Standard Tester Connection Specified Condition VP A33 2 A35 2 Below 1 Ω VP A33 2 or A35 2 Body ground 10 kΩ or higher NG Repair or replace harness or connector OK Rep...

Page 1151: ...rom when the ignition switch is turned OFF before the moni tor is run This allows the fuel to cool down which stabilizes the Fuel Tank Pressure FTP When 5 hours have elapsed the ECM turns on MONITOR DESCRIPTION 5 hours after the ignition switch is turned OFF the soak timer activates the ECM to begin the EVAP system monitor While the engine is running the ECM monitors the synchronization of the soa...

Page 1152: ...ad freeze frame data using a hand held tester Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Replace ECM See page SF 82 NEXT Check whether DTC...

Page 1153: ...43E 0 02 inch orifice clogged One of following conditions are met 0 02 inch orifice low flow 0 02 inch orifice high flow Vacuum pump ON stuck Vacuum pump OFF stuck Pump module Connector Wire harness While ignition 2 trips P043F 0 02 inch orifice high flow Vacuum pump OFF stuck Vent valve ON Closed stuck NOTE P043E P043F P2401 P2402 and P2419 have same DTC detection conditions Connector Wire harnes...

Page 1154: ... B First 0 02 inch leak pressure measure ment In order to determine 0 02 inch leak pressure standard vacuum pump creates negative pres sure vacuum through 0 02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally 60 seconds C EVAP system pres sure measurement Vent valve turned ON closed to shut EVAP system Negative pressure vacuum created in EVAP system and EVAP system p...

Page 1155: ...p EVAP Pressure sec OFF Sequence Time A 10 sec 60 Within 15 minutes sec ON Specified Range B C D EVAP Pressure during EVAP Monitor OK Malfunction ON Open OFF Closed OFF Vent ON Closed 10 sec 60 E Malfunction OFF OFF ON OFF OK Malfunction Malfunction 1 kPa 4 85 kPa DIAGNOSTICS ENGINE 2UZ FE DI 871 In sequence B and E to determine the leak criterion the vacuum pump creates negative pressure in the c...

Page 1156: ...hours EVAP pressure sensor malfunction P0450 P0452 P0453 Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 set before key off 1 Duration that vehicle has been driven 5 min 2 EVAP purge operation Performed ECT 4 4 to 35 C 40 to 95 F IAT 4 4 to...

Page 1157: ...7 93 mmHg 3 Reference pressure Saturated within 60 seconds 4 Difference between first reference pres sure and second reference pressure 0 7 kPa 5 25 mmHg 7 Leak check Next sequence is run if the following con dition is set EVAP pressure when vacuum introduction is complete Second reference pressure 8 Atmospheric pressure measurement EVAP monitor is complete if the following condition is set Atmosp...

Page 1158: ...DI 874 DIAGNOSTICS ENGINE 2UZ FE MONITOR RESULT MODE 06 DATA Refer to page DI 445 for detailed information INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure see page DI 884 ...

Page 1159: ...e is warmed up the ECM performs air fuel ratio feedback control to regulate the air fuel ratio at stoichiometric ratio In addition this vehicle performs Active A F Ratio Control for approximately 10 se conds after preconditions met in order to measure the A F sensor response rate During active air fuel ratio control the ECM forcibly increases and decreases the injection volume for certain amount b...

Page 1160: ... h and 120km h for 3 minutes However the vehicle should be driven at constant speed i When detection is complete Response rate of MONITOR RESULT changes If the value does not change perform step g once more j Notes the value of the Monitor Result k Select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES l Check if any DTCs any pending DTCs are set MONITOR STRATEGY R l t d ...

Page 1161: ...it information are described as shown in the following table Check the monitor result and test values after performing the monitor drive pattern refer to Confirmation Monitor MID Monitor Identification Data is assigned to each emissions related component TID Test Identification Data is assigned to each test value Scaling is used to calculate the test value indicated on generic OBD ll scan tools A ...

Page 1162: ...nds 4 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine in an idling condition press the RIGHT or LEFT button to change the fuel injection volume 6 Monitor the voltage outputs of the A F and HO2 sensors AFS B1S1 AFS B2S1 and OS2 B1S2 O2S B2S2 displayed on the tester HINT The A F CONTROL operation lowe...

Page 1163: ...conds and the Heated Oxygen HO2 sensor has a maximum output delay of approximately 20 seconds Following the A F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A F and HO2 sensors To display the graph select the following menu items on the tester DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL USER DATA AFS B1S1 and O2S B1S2 and press the YES but ton and ...

Page 1164: ...lt Display DTC Output Proceed To P2A00 and or P2A03 A P2A00 and or P2A03 and other DTCs B HINT If any DTCs other than P2A00 and or P2A03 are output troubleshoot those DTCs first B Go to relevant DTC chart See page DI 477 A 2 Check resistance of air fuel ratio A F sensor heater PREPARATION Disconnect the air fuel ratio A F sensor connector CHECK Measure resistance between the terminals of the A F s...

Page 1165: ... A F sensor connector and body ground OK Standard Tester Connections Specified Conditions B 2 Body ground Between 9 V and 14 V PREPARATION a Turn the ignition switch to OFF b Disconnect the E6 ECM connector CHECK a Check the resistance OK Standard Check for open Tester Connections Specified Conditions HT A10 1 HA1A E6 2 HT A30 1 HA2A E6 1 Below 1 Ω AF A10 3 A1A E6 22 AF A30 3 A2A E6 23 Below 1 Ω A...

Page 1166: ... recurs DTC P2A00 or P2A03 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2A00 or P2A03 A No output B B Check for intermittent problems See page DI 430 A 6 Replace air fuel ratio sensor NEXT 7 Perform confirmation driving pattern NEXT ...

Page 1167: ...P2A00 or P2A03 CHECK a On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II DTC INFO PENDING CODES b Read DTCs RESULT Display DTC Output Proceed To P2A00 or P2A03 A No output B A Check air fuel ratio extremely lean or rich See page DI 586 B END ...

Page 1168: ...ensor built into pump module voltage abnormal fluctuation DI 687 P0451 Pressure sensor built into pump module noise Pressure sensor built into pump module signal becomes fixed flat DI 687 P0452 Pressure sensor built into pump module voltage low DI 687 P0453 Pressure sensor built into pump module voltage high DI 687 P0455 EVAP gross leak DI 696 P0456 EVAP small leak DI 696 P2401 Vacuum pump stuck O...

Page 1169: ...OSTICS ENGINE 2UZ FE DI 885 CIRCUIT DESCRIPTION HINT The canister is located near the fuel tank underneath the body While the engine is running if a predetermined condition closed loop etc is met the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume The purge flo...

Page 1170: ...ow 35 C 5 hours after the ignition switch is turned off the moni tor check starts 2 hours later If it is still not below 35 C 7 hours after the ignition switch is turned off the monitor check starts 2 5 hours later Purge flow monitor The purge flow monitor consists of the two monitors The 1st monitor is always conducted every time and the 2nd monitor is activated if necessary The 1st monitor While...

Page 1171: ...ecting EVAP system Soak timer Built into ECM To ensure accurate EVAP monitor measures 5 hours after ignition switch turned to OFF This allows fuel to cool down stabilizing Fuel Tank Pressure FTP When approx 5 hours elapsed ECM activates Pump module Consists of a to d below Pump module cannot be disassembled a Vent valve Vents and closes EVAP system When ECM turns valve ON EVAP system closed When E...

Page 1172: ...Valve ON closed A23495 Pressure Sensor Specification fig 2 Output Voltage Usable Range 4 900 V 4 150 V 1 425 V 0 450 V Malfunction Area Pressure 60 kPa 450 mmHg 110 kPa 825 mmHg Malfunction Area HINT Standard atmospheric pressure is 101 3 kPa 760 mmHg A23496 Soak Timer Circuit fig 3 Ignition Switch IGSW Power ECM EFI MAIN MREL B 15 A Source IC Soak Timer IC Main Relay Control IC Battery DI 888 DIA...

Page 1173: ...3 BB3 B W G B L W L B R W GR G GR G B W G B B W G B L W L B R W J26 J C J27 9 26 J26 J C J27 7 24 R R W G 2 1 22 A A A J8 J C IE1 V4 VSV EVAP L4 Leak Detection Pump Assembly BB3 9 B B L 1 2 Engine Room R B EFI No 1 2 1 2 2 B R W B W B A A EA 2 2 2 2 EFI Relay 5 3 2 1 B B W L W L J1 J C 2 2 2 1 EFI No 2 R Engine Room R B Engine Room R B E3 E3 R J18 J C DIAGNOSTICS ENGINE 2UZ FE DI 889 WIRING DIAGRA...

Page 1174: ...y IL3 IL3 BP1 BP1 L W L W 5 10 L B R W L B R W 6 9 9 R R R R 8 11 22 BP1 IL3 IE1 BP1 IL3 IE1 G B G B G B B W B W B W 11 2 1 V4 VSV EVAP J47 J48 BP1 IL3 J C J47 A C A IA4 2 2 6 1 1 EFI Relay EFI No 2 EFI No 1 W B W B A A J34 J C F13 FL Block 10 12 Battery EA EC IE1 IL3 B B BP2 W B W B W B W B 19 14 4 2 1 3 5 2D 2F 2A 2H R R W L 1 Engine Room J B E3 E3 IA10 DI 890 DIAGNOSTICS ENGINE 2UZ FE ...

Page 1175: ...ne condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not if the air fuel ratio was lean or rich and other data from the time the malfunction occurred 1 Confirm DTC a Turn the ignition switch to OFF and wait for 10 seconds b Turn the ignition switch to ON c Turn the ignition switc...

Page 1176: ...fuel is 35 C 95 F or more a large amount of vapor forms and any check results become inaccurate When performing the EVAP SYSTEM CHECK keep the tem perature below 35 C 95 F a Clear DTCs see page DI 462 b On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II SYS TEM CHECK EVAP SYS CHECK AUTO OPERATION c After the EVAP SYSTEM CHECK is completed check for pending DTCs by se...

Page 1177: ...UAL OPERATION the series of 5 EVAP SYSTEM CHECK steps is performed manually by the hand held tester Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 full because the cut off valve may be closed and making the leak check of the fuel tank unavailable Do not run the engine in this step When the temperature of the fuel is 35 C 95 F or more a large amount of vapor forms and any c...

Page 1178: ... DI 894 DIAGNOSTICS ENGINE 2UZ FE 4 Perform EVAP system step 1 5 check a Check the EVAP pressure in step 1 5 Result DTCs Test Results Suspected Trouble Areas Proceed To Virtually no variation in EVAP pressure Not yet determined A P0451 EVAP pressure fluctuates by 0 3 kPa 2 25 mmHg or more Pressure sensor noising B The DTCs relating to the EVAP system displayed on a hand held tester when checking B...

Page 1179: ...heck the EVAP pressure in step 1 5 and 2 5 Result DTCs Test Results Suspected Trouble Areas Proceed To Virtually no variation in EVAP pressure during step 1 5 Then decreases to 0 02 inch leak pressure standard Not yet determined A P2402 Small difference between EVAP pressures during steps 1 5 and 2 5 Vacuum pump stuck ON B The DTCs relating to the EVAP system displayed on a hand held tester when c...

Page 1180: ... pressure again when it has stabilized This pressure is the 0 02 inch leak pressure standard The vacuum pump begins to operate as step 1 5 is proceeded to step 2 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure in step b between 4 85 kPa and 1 06 kPa 36 38 mmHg and 7 95 mmHg Not yet determined A P043F and P2401 EVAP pressure in step b 1 06 kPa 7 95 mmHg or more 0 02 inch...

Page 1181: ...crease in step 3 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 2 5 to step 3 5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2 5 to step 3 5 Vent valve stuck open vent B P0451 No variation in EVAP pressure during steps 1 5 through 3 5 Pressure senso...

Page 1182: ... Vent ON Closed Time Standard DI 898 DIAGNOSTICS ENGINE 2UZ FE 8 Perform EVAP system step 3 5 check a Wait until the EVAP pressure change is less than 0 1 kPa 0 75 mmHg for 30 seconds b Measure the EVAP pressure and record it HINT A few minutes are required for the EVAP pressure to become saturated When there is little fuel in the fuel tank it takes up to 12 minutes NEXT ...

Page 1183: ... To EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 3 5 to step 4 5 Not yet determined A P0441 EVAP pressure increases by 0 3 kPa 2 25 mmHg or more within 10 seconds of proceeding from step 3 5 to step 4 5 Problems in EVAP hose between pure VSV and throttle body B P0441 Variation in EVAP pressure is less than 0 3 kPa 2 25 mmHg for 10 seconds after pro...

Page 1184: ...d the second 0 02 inch leak pressure standard step 5 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure step 3 5 lower than the second 0 02 inch leak pressure standard step 5 5 Not yet determined no leakage from EVAP system A P0441 and P0455 EVAP pressure step 3 5 higher than second 0 02 inch leak pressure standard step 5 5 x 0 2 Purge VSV stuck open EVAP gross leak B P045...

Page 1185: ...VAP system step 3 5 check a Check the EVAP pressure in step 3 5 Result DTCs Test Results Suspected Trouble Areas Proceed To EVAP pressure less than 0 02 inch leak pressure standard x 0 2 0 02 inch orifice high flow A EVAP pressure more than 0 02 inch leak pressure standard x 0 2 Vacuum pump stuck OFF B The DTCs relating to the EVAP system displayed on a hand held tester when checking HINT The 0 02...

Page 1186: ...SV OFF b Use your finger to confirm that the purge VSV has no suc tion c Using the tester turn on the purge VSV EVAP VSV ON d Use your finger to confirm that the purge VSV has suction RESULT Test Results Suspected Trouble Areas Proceed To No suction when purge VSV turned OFF and suction applied when tuned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suc...

Page 1187: ...r 3 Connect an EVAP tester pump hose to the adaptor and pressurize to 3 2 to 3 7 kPa 24 to 28 mmHg using an EVAP tester pump 4 Seal the adaptor and wait for 2 minutes 5 Check the pressure If the pressure is 2 kPa 15 mmHg or more the fuel tank cap is normal PREPARATION Test Results Suspected Trouble Areas Proceed To Fuel tank cap correctly installed A Fuel tank cap loose Fuel tank cap improperly in...

Page 1188: ...sults Suspected Trouble Areas Proceed To No suction ECM A Suction applied Purge VSV B A Go to step 34 B Go to step 30 15 Check EVAP hose between purge VSV and throttle body PREPARATION a Disconnect the hose connected to the throttle body from the purge VSV b Start the engine CHECK a Use your finger to confirm that the hose has suction RESULT Test Results Suspected Trouble Areas Proceed To Suction ...

Page 1189: ...n applied EVAP hose between purge VSV and throttle body normal A No suction Throttle body EVAP hose between purge VSV and throttle body B B Go to step 31 A 17 Measure purge VSV terminal voltage PREPARATION a Disconnect the V4 purge VSV connector b Turn the ignition switch to ON CHECK a Measure the voltage between terminal 1 of the purge VSV connector and the body ground RESULT Test Results Suspect...

Page 1190: ...kΩ or higher V4 1 Body ground 10 kΩ or higher OK Go to step 35 NG Go to step 32 19 Perform active test for vent valve PREPARATION a Turn the ignition switch to ON b On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VENT VALVE ALONE CHECK Measure the voltage between terminal VPMP of the ECM con nector and the body ground when the vent valve is turned ON c...

Page 1191: ...ST VENT VALVE ALONE CHECK Measure the voltage between terminal VPMP of the ECM con nector and the body ground when the vent valve is turned ON close and OFF vent using the tester RESULT Test Results Suspected Trouble Areas Proceed To Below 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF Below 3 V when ON Vent valve B Between 9 V and 14 V when OFF and ON ECM C B Go to...

Page 1192: ...Turn the ignition switch to OFF b Disconnect the L4 canister connector c Turn the ignition switch to ON CHECK Measure the voltage between terminal 9 of the canister connec tor and the body ground RESULT Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Power source wire harness of vent valve B B Go to step 32 A ...

Page 1193: ... harness between vent valve and ECM A Not operating Vent valve B A Go to step 32 B Go to step 30 23 Perform active test for vacuum pump PREPARATION On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VACUUM PUMP ALONE CHECK Measure the voltage between terminal MPMP of the ECM con nector and the body ground when the vacuum pump is turned ON and OFF using th...

Page 1194: ...e L4 canister connector c Turn the ignition switch to ON d On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST VACUUM PUMP ALONE e Turn the vacuum pump ON CHECK Measure the voltage between terminal 1 of the canister connec tor and the body ground RESULT Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Wire h...

Page 1195: ...LT Test Results Suspected Trouble Areas Proceed To Below 1 Ω Vacuum pump A 10 kΩ or more Wire harness between vacuum pump and body ground B A Go to step 30 B Go to step 32 26 Inspect throttle body PREPARATION a Stop the engine b Disconnect the EVAP hose from the throttle body c Start the engine CHECK a Use your finger to confirm that the port of the throttle body has suction RESULT Test Results Su...

Page 1196: ...cap tighten it until a few click sounds are heard When replacing the fuel tank cap use a fuel tank cap that meets OEM specifications and install it until a few click sounds are heard NEXT Go to step 37 28 Replace fuel tank cap HINT When installing the fuel tank cap tighten it until a few click sounds are heard NEXT Go to step 37 29 Locate EVAP leak a Disconnect the vent hose ...

Page 1197: ...ng parts of the EVAP system e Look for areas where bubbles appear This indicates leak point f Repair or replace the leak point NEXT Go to step 37 30 Replace charcoal canister NEXT Go to step 37 31 Replace EVAP VSV See page SF 64 a Disconnect the connector and the hoses from the purge VSV b Remove the purge VSV c Install a new purge VSV d Reconnect the connector and hoses NEXT Go to step 37 32 Repa...

Page 1198: ...s performed automatically by the hand held tester It takes a maximum of approximately 15 minutes Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 full because the cut off valve may be closed and making the leak check of the fuel tank unavailable Do not run the engine in this step When the temperature of the fuel is 35 C 95 F or more a large amount of vapor forms and any chec...

Page 1199: ...ed the steps described above must be repeated c Monitor Status 1 Connect a hand held tester to the DLC3 2 Turn the ignition switch to ON and turn the tester ON 3 On the tester select the following menu items DIAGNOSIS ENHANCED OBD II MONITOR STATUS 4 Check the Monitor Status displayed on the tester HINT If INCMP is displayed the monitor is not completed Make sure that the preconditions have been m...

Page 1200: ...m pump stuck OFF P2401 Refer to pressure A Minimum test limit for vacuum pump stuck OFF Maximum test limit for vacuum pump stuck OFF 3D CD Multiply by 0 01 kPa Test value for vacuum pump stuck ON P2402 Refer to pressure A Minimum test limit for vacuum pump stuck ON Maximum test limit for vacuum pump stuck ON 3D CE Multiply by 0 01 kPa Test value for vent valve stuck OFF vent P2420 Refer to pressur...

Page 1201: ...5 mmHg Criterion 4 E F Criterion 6 0 3 kPa 10 60 Purge Flow Monitor Sequence Purge VSV Vent Valve Criterion 7 0 1 kPa EVAP Pressure Reference Criterion 8 1kPa If pressure change in sequence 1 is greater than criterion 7 purge flow moni tor is completed functioning normally ON Close 1 2 ON Open If pressure change in sequence 1 is smaller than criterion 7 sequence 2 is run If pressure change in sequ...

Page 1202: ...IA9 W R W L J26 W L H GR G AM2 IG2 B 1 Towing Package 2 Except Towing Package DI 918 DIAGNOSTICS ENGINE 2UZ FE ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON battery positive voltage is applied to terminal IGSW of the ECM and the EFI relay control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI relay This signal causes current ...

Page 1203: ... 5 1 3 2H EFI No 1 E3 E3 2 6 2 2D W B Engine Room R B B R B R J75 J C Driver Side J B J34 J C B Double Cab IGSW MREL 2H AM2 IG2 2C 1 1 1 A W B 2F 10 B F13 Fusible Link Block 12 Driver Side J B BR B R B O B O 3A 3D 5 5 Sub J B No 3 1C 1J 3 7 A B EA EC B O B A J75 J C A IA10 W R IA10 DIAGNOSTICS ENGINE 2UZ FE DI 919 ...

Page 1204: ...14 V OK Proceed to next circuit inspection shown in the Problem symptoms table See page DI 452 NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminal IGSW of ECM connector and body ground PREPARATION Turn the ignition switch ON CHECK Measure the voltage between terminal IGS...

Page 1205: ... and components connected to IGN1 fuse OK 5 Check ignition switch See page BE 37 PREPARATION a Remove the lower finish panel b Disconnect the ignition switch connector CHECK Check resistance between terminals OK Standard Switch Position Terminal Condition Specified Condition LOCK Always 10 kΩ or more ACC 1 3 Below 1 Ω ON 1 2 3 5 6 Below 1 Ω START 1 2 4 5 6 Below 1 Ω NG Replace ignition switch OK C...

Page 1206: ... switch ON CHECK Measure the voltage between terminal MREL of the ECM con nector and body ground OK Standard 9 to 14 V NG Replace ECM See page SF 82 OK 7 Check EFI No 1 fuse of engine room J B PREPARATION Remove the EFI No 1 fuse from the engine room J B CHECK Check resistance of EFI No 1 fuse OK Below 1 Ω NG Check for short in all harness and components connected to EFI No 1 fuse OK ...

Page 1207: ...Apply B between terminals 1 and 2 Below 1 Ω NG Replace EFI relay OK 9 Check for open and short in harness and connector between terminal MREL of ECM and body ground PREPARATION Disconnect the E3 ECM connector CHECK Measure the resistance between the wire harness side connec tor and body ground OK Standard Tester Connection Specified Condition MREL E3 8 Body ground Below 1 Ω NG Repair or replace ha...

Page 1208: ...PTION This circuit opens and closes the Intake Air Control Valve IACV in response to the engine load in order to increase the intake efficiency ACIS Acoustic Control Induction System When the engine speed is 4 700 rpm or more and the throttle valve opening angle is 60 or more the VSV is OFF so the is IACV open All the other times the ECM turns the VSV ON and closes the IACV DIDSG 01 ...

Page 1209: ...FI No 2 2 1 EFI Relay A A R R R R J8 J C IE1 22 2 1 G W V13 VSV ACIS B R W B W B A A J18 J C EA B B J1 J C W L W L EFI No 1 5 3 2 1 2 1 A23641 Double Cab 8 33 ECM E3 E7 MREL ACIS B W G W B W Battery 2 6 12 2H 2A 2D 2F J47 J C J48 A C Engine Room J B 10 EFI Relay R R R R F13 FL Block IE1 22 2 1 V13 VSV ACIS W B W B A A J34 J C EA B B 5 3 2 1 11 IA4 1 1 2 EFI No 2 EFI No 1 IA10 DIAGNOSTICS ENGINE 2U...

Page 1210: ...the DLC3 b Turn the ignition switch ON and push the hand held tes ter main switch ON c Select the ACTIVE TEST mode on the hand held tester CHECK Check the operation of the VSV when the VSV is operated by the hand held tester OK VSV is ON Air from port E flows out through port F VSV is OFF Air from port E flows out through the air filter OK Check for vacuum tank See page SF 56 NG 2 Check VSV for AC...

Page 1211: ...andard Check for open Symbols Terminal No Specified condition VSV for ACIS V13 2 ACIS E7 33 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition VSV for ACIS V13 2 or ACIS E7 33 E1 E5 1 10 kΩ or higher b Check the wire harness between the VSV for ACIS con nector and the EFI relay 1 Disconnect the VSV for ACIS connector 2 Remove the EFI relay from the engine room R B 3 Check f...

Page 1212: ...CIRCUIT DESCRIPTION The starter is controlled by the ECM when the ECM detects a start signal STSW from the ignition switch this system monitors the engine speed NE and continues to operate the starter until it has determined that the engine has started engine speed reaches approximately 500 rpm If the engine is already running and the ignition switch is turned to START the ECM will not operate the...

Page 1213: ...6 J C J27 B J26 J27 J26 J27 J26 J27 25 29 34 10 G Y W R W 7 8 27 17 8 12 L R IA9 IA9 G R P N 4 5 2 2 2 2 2 2 1 2 1 2 1 2 1 2 1 Short Pin AM1 AM2 ST3 P G R W B 8 3 P A A J28 J29 J28 SRLT ST EB2 6 2 2 2 2 3 2 1 5 ST Relay Engine Room R B Engine Room R B B W J C Battery B B L 1 2 1 Towing Package 2 Except Towing Package B L B W 1 1 S2 Starter S1 J23 J C A A IE W B P1 Park Neutral Position SW G R G Y ...

Page 1214: ...1 2C 1 8 Short Pin AM1 AM2 ST Engine Room J B Driver Side J B Driver Side J B 1L 6 1 3 2C ECU B 3 7 1C 1J 1 B R W R W R W W R W L 3 1 5 4 AM1 ACC ST2 AM2 I23 Ignition SW B W B W 1C 1J Driver Side J B 5 8 P 1J 1E 3 2 W R W R R B B 8 15 IE1 G W R Sub J B No 4 Sub J B No 3 Driver Side J B 10 10 9 19 4A 3D 3C 4A A22 ACC Cut Relay 4 3 2 1 Engine Room R B STA 2 2 1 2 IJ4 P L R R L P1 Park Neutral Positi...

Page 1215: ...ntermittent problems See page DI 430 NG 2 Connect hand held tester and check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter operates OK Ignition Switch Positio...

Page 1216: ...etween the terminals of the E5 ECM con nectors while cranking the engine ignition switch START posi tion OK Standard Tester Connection Specified Condition STA E5 11 E1 E5 1 9 to 14 V STSW E5 12 E1 E5 1 9 to 14 V RESULT Terminal STAR Terminal STSW Proceed to 9 to 14 V 9 to 14 V A 0 V 9 to 14 V B 0 V 0 V C B Replace ECM See page SF 82 C Go to step 9 A ...

Page 1217: ...ange Terminal No to continuity P 1 3 6 9 R 2 3 N 3 5 6 9 D 3 7 2 3 4 L 3 8 OK Below 1 Ω NG Replace the park neutral position switch OK Check and repair harness and connector be tween park neutral position switch and ECM 5 Check starter relay a Remove the starter relay from the engine room R B b Inspect the starter relay Standard Tester Connection Specified Condition 3 5 10 kΩ or higher 3 5 Below 1...

Page 1218: ... for resistance between the wire harness side connectors Standard Check for open Symbols Terminal No Specified condition Park Neutral position switch P1 6 Starter relay 1 Below 1 Ω Standard Check for short Symbols Terminal No Specified condition Park Neutral position switch P1 6 or Starter relay 1 Body ground 10 kΩ or higher b Check the harness and the connector between the starter relay and the b...

Page 1219: ...er relay from the engine room R B No 2 CHECK Measure the voltage between the terminal of the engine room R B and body ground OK Standard Tester Connection Specified Condition Starter relay 5 Body ground 9 to 14 V NG Check and repair harness and connector be tween starter relay and battery OK 8 Check starter See page ST 18 NG Repair or replace starter OK ...

Page 1220: ...h connector CHECK Check resistance between terminals OK Standard Switch Position Terminal Condition Specified Condition LOCK Always 10 kΩ or more ACC 1 3 Below 1 Ω ON 1 2 3 5 6 Below 1 Ω START 1 2 4 5 6 Below 1 Ω NG Replace ignition switch OK Check for open in harness and connector be tween ECM and ignition switch ignition switch and battery See page IN 30 ...

Page 1221: ...onnect hand held tester and check operation of fuel pump relay PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II ACTIVE TEST FUEL PUMP SPD CHECK Check the operation of the fuel pump relay when it is switched ON and OFF by the hand held tester OK Operating noise can b...

Page 1222: ...er 3 4 Always Below 1 Ω 3 5 Always 10 KΩ or higher 3 5 Apply B between terminals 1 and 2 Below 1 Ω NG Replace fuel pump relay OK 4 Check fuel pump See page SF 15 NG Repair or replace fuel pump OK 5 Check circuit opening relay PREPARATION Remove the C OPN relay from the engine room J B CHECK Inspect the C OPN relay OK Standard Terminal No Condition Specified Condition 3 5 Always 10 KΩ or higher 3 5...

Page 1223: ... the ignition switch ON CHECK Measure the voltage between terminal FC of the ECM connec tor and body ground OK Voltage 9 to 14 V NG Check for open in harness and connector be tween battery and FC terminal of ECM See page IN 30 OK Proceed to problem symptoms table See page DI 452 8 Check fuel pump resistor See page SF 63 NG Replace fuel pump resistor OK Check for open in harness and connector betwe...

Page 1224: ...8 Ignition Switch 4 1D 1G 6 B R R GAUGE Combination Meter Malfunction Indicator Lamp AM2 IG2 AM2 DI 940 DIAGNOSTICS ENGINE 2UZ FE MIL Circuit CIRCUIT DESCRIPTION If the ECM detects a trouble the MIL lights up At this time the ECM records a DTC in the memory WIRING DIAGRAM DIDSJ 01 ...

Page 1225: ...and held tester main switch ON c Read the DTC See page DI 462 d Clear DTCs see page DI 462 CHECK a Check that MIL does not light up OK Standard MIL does not light up OK Repair circuit indicated by output code See page DI 477 NG 2 Check Harness and connector Check for short in wire harness PREPARATION a Disconnect the E4 ECM connector b Turn the ignition switch ON CHECK a Check that MIL does not li...

Page 1226: ...ng the ignition switch ON OK Standard MIL lights up OK System OK NG 4 Inspect combination meter assy MIL circuit See the combination meter troubleshooting on page BE 86 NG Repair or replace bulb or combination meter as sembly OK Check and repair harness and connector be tween combination meter and ECM ...

Page 1227: ...43 AUTOMATIC TRANSMISSION A750E for 1GR FE PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transmission assy en gine assy or ECM See page DI 961 HINT RESET MEMORY cannot be completed by only disconnecting the battery terminal ...

Page 1228: ... to detect malfunctions Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle Once per driving cycle means that the ECM detects malfunction only one time during a single driving cycle Continuous means that the ECM detects malfunction every time when enabling condition is met Duration The minimum time that the ECM must sense a continuous deviation in the ...

Page 1229: ...rative emission pressure switching valve Vapor pressure sensor EVAP pressure sensor Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On board refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve IMRV IACV runner valve Intake manifold tuning ...

Page 1230: ...nsor NT Turbine speed sensor Input turbine speed sensor PNP switch NSW Park neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch Shift lock control unit Shift lock control module Engine immobilizer system Immobilizer system Vehicle anti theft system ...

Page 1231: ...enoid Valve SLU Shift Solenoid Valve SL2 ATF Temperature Sensor No 2 Integration Control and Panel Shift Position L Switch MIL Shift Solenoid Valve SL1 Shift Solenoid Valve SLT ATF Temperature Sensor No 1 Shift Solenoid Valve S2 Speed Sensor NT AT Oil Temp Warning Light Shift Lever O D Main Switch DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 947 LOCATION ...

Page 1232: ...D STP TH01 TC Throttle Position Sensor ATF Automatic Transmission Fluid Temperature Sensor No 1 Mass Air Flow Meter Accelerator Pedal Position Sensor VPA VPA2 Shift Lever O D Main Switch Input Speed Sensor NT NT Output Speed Sensor SP2 SP2 TH02 ATF Automatic Transmission Fluid Temperature Sensor No 2 Skid Control ECU NSW Park Neutral Position Switch R D 3 2 VG NE L ODMS Integration Control and Pan...

Page 1233: ... the ECM The ECM detects electrical signals that indicate engine and driving condi tions and controls the shift point based on driver habits and road conditions As a result fuel efficiency and power transmission performance are improved Shift shock has been reduced by controlling the engine and transmission simultaneously In addition the ECT has features such as follows Diagnostic function Fail sa...

Page 1234: ...and held tester inspect DLC3 DI 980 2 3 4 5 6 Symptom does not occur Problem Symptom Confirmation 8 7 Symptom Simulation IN 19 Symptom occurs DTC Check DI 983 OK Code 11 Preliminary Check DI 952 DTC Chart DI 991 Mechanical System Test DI 956 and DI 958 Manual Shifting Test DI 960 OK OK Chapter 1 Electronic Chapter 2 On Vehicle DI 971 OK Chapter 3 Off Vehicle OK Matrix Chart of Problem Symptoms DI ...

Page 1235: ...ny position Particular position No down shift 5th 4th 4th 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive position Slip or shudder No kick down Others DTC Check 1st Time 2nd Time Check Item Normal system code Trouble code DTC Normal system code Trouble code DTC Malfunction Indicator Lamp Normal Remains ON VIN Production Date Licence Pl...

Page 1236: ...ble and temporarily install the control shaft lever nut 6 While holding the shift lever lightly toward the R position side tighten the control shaft lever nut Torque 14 5 N m 148 kgf cm 11 ft lbf 7 Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to the D position and reverses when shifting it to the R position 2 INSPECT AND ADJUST PARK NEUTRAL POSIT...

Page 1237: ...e coolant temperature is 40 C 104 F or less and vehicle speed is at 45 km h 28 mph or less 5th Gear Lock up Prohibition Control Brake pedal is depressed Accelerator pedal is released Engine coolant temperature is 60 C 140 F or less 2 Check for shift shock and slip Check for shock and slip at the 1 2 2 3 3 4 and 4 5th up shifts 3 Check for abnormal noise and vibration Check for abnormal noise and v...

Page 1238: ...d does not change abruptly HINT If there is a big jump in engine speed there is no lock up c 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points 1 Check up shift operation Check that the 1 2 and 2 3 up shifts takes place and that the shift point conforms to the automatic shift schedule See page SS 50 HINT There is no 4th up shift and loc...

Page 1239: ...that there is no up shift to 2nd gear 2 Check engine braking While running in the L position release the accelerator pedal and check the engine braking ef fect 3 Check for abnormal noises during acceleration and deceleration f R position test Shift into the R position lightly depress the accelerator pedal and check that the vehicle moves back ward without any abnormal noise or vibration CAUTION Be...

Page 1240: ...s of wheels or wheel stoppers outside the vehicle while the other is doing the test 1 Chock all 4 wheels 2 Connect a hand held tester to DLC3 3 Fully apply the parking brake 4 Using your left foot keep the brake pedal firmly depressed 5 Start the engine 6 Shift into the D position Press all the way down on the accelerator pedal with your right foot 7 Quickly read the stall speed at this time Stall...

Page 1241: ...onnect a hand held tester to DLC3 2 Fully apply the parking brake 3 Start and warm up the engine and check idle speed Idle speed approx 700 rpm In N position and A C OFF 4 Shift the lever from the N to D position Using a stop watch measure the time from when the lever is shifted until the shock is felt Time lag N D Less than 1 2 seconds 5 In the same manner measure the time lag for N R Time lag N ...

Page 1242: ...conducted after checking and ad justing engine Perform under condition that A C is OFF When conducting stall test do not continue more than 10 seconds 1 Warm up the ATF Automatic Transmission Fluid 2 Lift the vehicle up 3 Remove the test plug on the transmission case cen ter right side and connect SST SST 09992 00095 09992 00231 09992 00271 4 Fully apply the parking brake and chock the 4 wheels 5 ...

Page 1243: ... 4 to 13 6 kgf cm2 177 to 194 psi Evaluation Problem Possible cause Measured values are higher than specified in all positions Shift solenoid valve SLT defective Regulator valve defective Measured values are lower than specified in all positions Shift solenoid valve SLT defective Regulator valve defective Oil pump defective Pressure is low in the D position only D position circuit fluid leak Clutc...

Page 1244: ...ether the shifting condition changes the table below Shift Position Shifting Condition L 2 No Shift Not Change 2 3 Down Shift Up Shift 3 4 Down Shift Up Shift 4 D No Shift Not Change HINT When driving with the transmission wire disconnected the gear position will be as follows When the shift lever is in the L or the 2 position the gear is held in the 1st position When the shift lever is in the 3rd...

Page 1245: ...atic transmission assy and engine assy according to those characteristics Therefore when the automatic transmission assy engine assy or ECM has been replaced it is necessary to reset the memory so that the ECM can memorize the new information Reset procedure is as follows a Turn the ignition switch off b Connect the hand held tester to the DLC3 c Turn the ignition switch to the ON position d Turn ...

Page 1246: ...flow DI 962 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE NOTICE After performing the RESET MEMORY be sure to perform the ROAD TEST See page DI 953 de scribed earlier HINT The ECM learns through use of the ROAD TEST ...

Page 1247: ...I 963 LIST OF DISABLE A MONITOR HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed ...

Page 1248: ...A21571 DI 964 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE ...

Page 1249: ...A21572 A22718 A22768 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 965 ...

Page 1250: ...A21573 DI 966 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE ...

Page 1251: ...A21575 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 967 ...

Page 1252: ...A21576 DI 968 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE ...

Page 1253: ...gher Malfunction is not detected when the atmospheric temperature is 10 C 14 F or less Notice in driving Drive the vehicle through all gears Stop 1st 2nd 3rd 4th 5th 5th lock up ON Repeat the above driving pattern three times or more NOTICE The monitor status can be checked using the OBD II scan tool When using the hand held tes ter monitor status can be found in the ENHANCED OBD II DATA LIST or u...

Page 1254: ...al acceleration with the throttle open for 3 minutes or more 1 DI 970 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE HINT 1 Drive at such a speed in the uppermost gear to engage lock up The vehicle can be driven at a speed lower than that in the above diagram under the lock up condition NOTICE It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 ATF tempera tu...

Page 1255: ...058 DI 1063 IN 30 No up shift 4th 5th 1 O D main switch circuit 2 Engine coolant temp sensor circuit 1 3 Speed sensor NT circuit 1 4 Shift solenoid valve SL1 circuit 1 5 Shift solenoid valve SL2 circuit 1 6 Shift solenoid valve SR circuit 1 7 ECM DI 1102 DI 57 DI 1008 DI 1020 DI 1048 DI 1068 IN 30 No up shift 3rd 4th 1 Engine coolant temp sensor circuit 1 2 Shift solenoid valve S2 circuit 1 3 ECM ...

Page 1256: ...M DI 1105 IN 30 Harsh engagement N D 1 Speed sensor NT circuit 1 2 Shift solenoid valve SL1 circuit 1 3 Shift solenoid valve SLT circuit 1 4 ECM DI 1008 DI 1020 DI 1079 IN 30 Harsh engagement Lock up 1 Speed sensor NT circuit 1 2 Speed sensor SP2 circuit 1 3 Shift solenoid valve SLU circuit 1 4 ECM DI 1008 DI 1013 DI 1097 IN 30 Harsh engagement Any driving position ECM IN 30 Poor acceleration 1 AT...

Page 1257: ...x chart AT 12 No down shift 3rd 2nd 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No down shift 2nd 1st 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No lock up or No lock up off 1 Shift solenoid valve SLU 2 Valve body assy 3 Off vehicle repair matrix chart DI 1089 AT 12 Harsh engagement N D 1 Shift solenoid valve SL1 2 Valve body assy 3 C1 accumulator 4 Off vehicle repair ...

Page 1258: ...ntrol cable 2 Valve body assy 3 Oil strainer 4 Off vehicle repair matrix chart DI 952 AT 12 AT 12 No engine braking 1st L position 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No engine braking 2nd 2 position 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No kick down Valve body assy AT 12 Shift point too high or too low 1 Shift solenoid valve SLT 2 Shift solenoid valve SL1...

Page 1259: ... B4 3 One way clutch No 1 F1 Harsh engagement 1 2 1 Brake No 3 B3 2 One way clutch No 1 F1 3 One way clutch No 2 F2 Harsh engagement 2 3 Clutch No 3 C3 Harsh engagement 3 4 Clutch No 2 C2 Harsh engagement 4 5th 1 Brake No 1 B1 2 Clutch No 1 C1 Harsh engagement Lock up Torque converter clutch AT 39 Slip or shudder Forward and reverse After warm up 1 One way clutch No 1 F1 2 Clutch No 3 C3 3 Torque ...

Page 1260: ...raking 2nd 2 position Brake No 2 B2 No engine braking 3rd 3 position Brake No 1 B1 Poor acceleration All positions Torque converter clutch AT 39 Poor acceleration 5th 1 Clutch No 1 C1 2 Clutch No 3 C3 3 Brake No 1 B1 4 Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch AT 39 ...

Page 1261: ...elow 1 V R E4 11 E1 E5 1 G R BR R shift position switch sig nal IG switch ON and shift lever R posi tion 10 to 14 V IG switch ON and shift lever except R position Below 1 V D E4 21 E1 E5 1 W R BR D shift position switch sig nal IG switch ON and shift lever D posi tion 10 to 14 V IG switch ON and shift lever except D position Below 1 V 3 E4 19 E1 E5 1 G W BR 3 shift position switch sig nal IG switc...

Page 1262: ...emperature 115 C 239 F or more Below 1 5 V THO2 E6 32 E2 E7 28 V B W No 2 ATF temperature sensor signal No 2 ATF temperature 115 C 239 F or more Below 1 5 V SP2 E6 34 SP2 E6 26 Y R W R Speed sensor SP2 sig nal Vehicle speed 20 km h 12 mph Pulse generation See waveform 6 NT E6 35 NT E6 27 G R Speed sensor NT signal Engine idle speed Pulse generation See waveform 5 STAR NSW E6 8 E1 E5 1 L R BR Park ...

Page 1263: ...nal SL2 SL2 Tool setting 5V DIV 1ms DIV Vehicle condition Engine idle speed Waveform 4 Reference Terminal SL1 SL1 Tool setting 5V DIV 1ms DIV Vehicle condition Engine idle speed Waveform 5 Reference Terminal NT NT Tool setting 1V DIV 2ms DIV Vehicle condition Engine idle speed P or N position Waveform 6 Reference Terminal SP2 SP2 Tool setting 2V DIV 20ms DIV Vehicle condition Vehicle speed 20 km h...

Page 1264: ...does not reoccur in 3 consecutive trips the MIL turns off automatically but the DTCs remain recorded in the ECM memory To check DTCs connect the scan tool to the Data Link Connec tor 3 DLC3 of the vehicle The scan tool displays DTCs the freeze frame data and a variety of the engine data The DTCs and freeze frame data can be erased with the scan tool See page DI 983 NORMAL MODE AND CHECK MODE The d...

Page 1265: ...n protocol The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765 4 format HINT Connect the cable of the hand held tester to the DLC3 turn the ignition switch ON and attempt to use the hand held tester If the screen displays UNABLE TO CONNECT TO VEHICLE a problem exists in the vehicle side or the tester side If the communication is normal when the tool is connected ...

Page 1266: ...ch ON If the MIL does not illuminate there is a problem in the MIL cir cuit refer to MIL CIRCUIT on page DI 417 b When the engine is started the MIL should turn off ALL READINESS For this vehicle using the hand held tester allows readiness codes corresponding to all DTCs to be read When diagnosis normal or malfunctioning has been complete readiness codes are set Enter the following menus ENHANCED ...

Page 1267: ...he ignition switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES or PENDING CODE d Confirm the DTCs and freeze frame data and then write them down e See page DI 991 to confirm the details of the DTCs NOTICE When simulating a symptom with the scan tool to check for DTCs use normal mode For codes on DIAGNOSTIC TROUBLE CODE CHART subject to 2 trip detection log ic pe...

Page 1268: ...ogether with the Controller Area Network Vehicle Interface Module CAN VIM to the DLC3 d Turn the ignition switch ON e Enter the following menus DIAGNOSIS ENHANCED OBD II CHECK MODE f Change the ECM to check mode Make sure the MIL flashes as shown in the illustration NOTICE All DTCs and freeze frame data recorded will be erased if 1 the hand held tester is used to change the ECM from normal mode to...

Page 1269: ...e next page Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction up shift to the 5th is prohibited Shift Solenoid Valve SLU During a solenoid valve SLU malfunction the current to the solenoid valve is stopped This stops lock up control and flex lock up control fuel economy de creases Shift Solenoid Valve SLT During a solenoid valve SLT malfunction the current to the sole...

Page 1270: ... 4 th 5 th 5 th 5 th 4 th 3 rd E B 3 rd E B 3 rd E B 3 rd E B 5 th 5 th 2 nd E B 3 rd E B 5 th 5 th 4 th 3 rd E B 3 rd E B 4 th 1 st E B 2 nd 5 th 1 st E B 2 nd Fail 4th 3 rd E B 3 rd E B 4 th 5 th 3 rd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 3 rd E B 3 rd E B 3 rd 3 rd 3 rd 1 st 1 st 1 st 1 st 3 rd 4 th 4 th 4 th 4 th Fail 4 th 3 rd 4 th Position DI 986 DIAGNOSTICS AUTOMATIC TRANSMISSION A75...

Page 1271: ...th 4 th 4 th 4 th 3 rd E B 3 rd E B 3 rd 1 st 1 st 1 st 1 st 1 st 1 st 2nd 1 st 2nd 2nd 1 st E B 2nd 1 st 3 rd E B 3 rd 3 rd 3 rd E B 3 rd 1 st 3 rd 3 rd E B 3 rd 1 st 1 st 1 st 1 st 1 st 1 st 1 st 4 th 3 rd 3 rd E B 3 rd 3 rd E B 3 rd E B 4 th 5 th 4 th 5 th Fail 4 th Fail 4 th Fail 4 th Fail 4 th S1 S2 SR SL1 SL2 S1 S2 SR SL1 S1 S2 SR SL1 S1 S2 SR SL1 SL2 3 rd SL2 SL2 Gear S1 S2 OFF 3 rd 4 th Po...

Page 1272: ...Brake Pedal is depressed ON Brake Pedal is released OFF PNP SW NSW PNP SW Status ON or OFF Shift lever position is P and N ON Except P and N OFF When the shift lever position dis played on the hand held tester dif fers from the actual position ad justment of the PNP switch or the shift cable may be incorrect HINT When the failure still occurs even after adjusting these parts See page DI 993 LOW PN...

Page 1273: ...ak If the value is 40 C 40 F or 215 C 419 F ATF temp sen sor No 1 circuit is open or shorted AT FLUID TEMP 2 ATF Temp Sensor No 2 Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak If the value is 40 C 40 F or 215 C 419 F ATF temp sen sor No 2 circuit is open or shorted SPD SP2 Output shaft Speed min 0 km h 0 mph max 255 km h 158 mph ...

Page 1274: ...f Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possible to check the operation of the shift solenoid valves LOCK UP Test Details Control the shift solenoid SLU to set the automatic transmission to the lock up condition Vehicle Condition Throttle valve opening angle Less than 35 Vehicle Speed 60 km h 37 mph or more Possible to check the SLU opera t...

Page 1275: ...wire ATF temperature sensor No 1 ECM P0713 DI 999 Transmission Fluid Temperature Sensor A Circuit High Input Open in ATF temperature sensor No 1 circuit Transmission wire ATF temperature sensor No 1 ECM P0717 DI 1008 Input Speed Sensor Circuit No Signal Open or short in speed sensor NT circuit Speed sensor NT ECM Automatic transmission clutch brake or gear etc P0722 DI 1013 Output Speed Sensor Cir...

Page 1276: ... ECM P0986 DI 1068 Shift Solenoid E Control Circuit High Shift Solenoid Valve SR Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM P2714 DI 1073 Pressure Control Solenoid D Performance Shift Solenoid Valve SLT Shift solenoid valve SLT remains open or closed Valve body is blocked Automatic transmission clutch brake or gear etc P2716 DI 1079 Pressure Control Solenoid D Electrical S...

Page 1277: ... shift lever position and sends a signal to the ECM For security the park neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position The park neutral position switch sends a signal to the ECM according to the shift position NSW R D 3 or 2 The ECM determines that there is a problem with the switch or related parts if it...

Page 1278: ...Condition A Number of the following signal input at the same time 2 or more NSW switch R switch D switch ON 3 switch ON 2 switch Condition B All of following conditions are met NSW switch R switch D switch OFF 3 switch OFF 2 switch COMPONENT OPERATING RANGE Parameter Standard value Park neutral position switch The park neutral position switch sends only one signal to the ECM ...

Page 1279: ...G W W R LG B G R L Y L Y G R LG B W R G W P L AM1 IG1 E4 E4 E4 E4 11 21 19 10 I23 Ignition SW Cowl Side J B RH E6 8 P N L RB To ABS Actuator with ECM To Skid Control ECM with Acrtuator 1 2 9 2 1 8 3 7 9 1 6 2 4 2 1 2 1 5 4 J28 J28 J28 J28 J28 J28 J29 J29 J29 J29 J29 J29 To ABS Actuator with ECM 2 2 1 w VSC 2 w o VSC Engine Room R B E E DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 995 WIR...

Page 1280: ...NOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition Diagnostic Note PNP SW NSW PNP SW Status ON or OFF Shift lever position is P and N ON Except P and N OFF When the shift lever position dis played on the hand held tester dif fers from the actual position ad justment of the PNP switch or the shift cable may...

Page 1281: ...cording to the value s in the table below when the shift lever is moved to each position OK Shift Position Tester Connection Specified Condition P 2 6 and 4 5 Below 1 Ω Except P 10 kΩ or higher R 2 1 Below 1 Ω Except R 10 kΩ or higher N 2 9 and 4 5 Below 1 Ω Except N 10 kΩ or higher D 2 7 Below 1 Ω Except D 10 kΩ or higher 3 2 3 Below 1 Ω Except 3 10 kΩ or higher 2 2 8 Below 1 Ω Except 2 10 kΩ or ...

Page 1282: ...lever is moved to each position OK Shift Position Tester connection Specified condition P and N E6 8 STAR NSW Body ground Below 2 V Except P and N 10 to 14 V R E4 11 R Body ground 10 to 14 V Except R Below 1 V D E4 21 D Body ground 10 to 14 V Except D Below 1 V 3 E4 19 3 Body ground 10 to 14 V Except 3 Below 1 V 2 and L E4 10 2 Body ground 10 to 14 V Except 2 and L Below 1 V HINT The voltage will ...

Page 1283: ...SION A750E for 1GR FE DI 999 DTC P0710 Transmission Fluid Temperature Sensor A Circuit DTC P0712 Transmission Fluid Temperature Sensor A Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor A Circuit High Input DIDV9 01 ...

Page 1284: ...ire ATF temperature sensor No 1 ECM P0712 ATF temperature sensor No 1 resistance is less than 79 Ω for 0 5 sec or more 1 trip detection logic Short in ATF temperature sensor No 1 circuit Transmission wire ATF temperature sensor No 1 ECM P0713 ATF temperature No 1 sensor resistance is more than 156 kΩ when 15 minutes or more have elapsed after the engine start DTC is detected for 0 5 sec or more 1 ...

Page 1285: ...ll run whenever these DTCs are not present See page DI 963 Range check Fluttering Low resistance The typical enabling condition is not avail able Range check High resistance Time after engine start 15 min or more TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Fluttering TFT transmission fluid temperature sensor resistance Less than 79 Ω or More than 156 kΩ Range check Low ...

Page 1286: ...nd held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 1 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When DTC P0712 is output and hand...

Page 1287: ...istance according to the value s in the table below OK Tester Connection Specified Condition 2 OT 10 OT 79 Ω to 156 kΩ 2 OT Body ground 10 kΩ or higher 10 OT Body ground 10 kΩ or higher HINT If the resistance is out of the specified range with either the ATF temperature shown in the table below the driveability of the ve hicle may decrease ATF Temperature Specified Condition 20 C 68 F 3 to 4 kΩ 11...

Page 1288: ...of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 24 THO1 E7 28 E2 79 Ω to 156 kΩ CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 24 THO1 Body ground 10 kΩ or higher E7 28 E2 Body ground NG Repair or replace the harness or connector See page IN 30 OK Re...

Page 1289: ... or a fault in the ATF temperature sensor After running the vehicle for a certain period the ATF temperature should increase If the ATF temperature is below 20 C 68 F after running the vehicle for a certain period the ECM interprets this as a fault and turns on the MIL MONITOR STRATEGY Related DTCs P0711 ATF temperature sensor Rationality check Required sensors Components ATF temperature sensor TF...

Page 1290: ...D II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 1 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When DTC ...

Page 1291: ...HANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0711 is output A P0711 and other DTCs B HINT If any other codes besides P0711 are output perform troubleshooting for those DTCs first B Go to DTC chart See page DI 991 A 2 Check transmission fluid level See page DI 952 OK Automatic transmission flui...

Page 1292: ...ng to various conditions thus providing smooth gear shift DTC No DTC Detection Condition Trouble Area P0717 All conditions below are detected for 5 secs or more 1 trip detection logic a Gear change is not performed b Gear position 4th or 5th c T M input shaft rpm 300 rpm or less d T M output shaft rpm 1 000 rpm or more e Park neutral position switch NSW input signal is OFF R input signal is OFF L ...

Page 1293: ...e speed is approx 50 km h 31 mph or more MONITOR STRATEGY Related DTCs P0717 Speed sensor NT Verify pulse input R i d C t Main Speed sensor NT Required sensors Components Sub Speed sensor NO Frequency of operation Continuous Duration 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is n...

Page 1294: ...on switch to the ON position e Push the ON button of the OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition SPD NT Input Turbine Speed display 50 r min HINT Lock up ON After warming up the engine Input Turbine ...

Page 1295: ...OK The installation bolt is tightened properly and there is no clearance between the sensor and transmission case Torque 5 4 N m 55 kgf cm 48 in lbf NG Replace speed sensor NT See page AT 8 OK 2 Inspect speed sensor NT PREPARATION Disconnect the speed sensor connector from the transmission CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condi...

Page 1296: ...or CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 35 NT E6 27 NT 560 to 680 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 35 NT Body ground 10 kΩ or higher E6 27 NT Body ground NG Repair or replace harness or connector See page IN 30 OK Replace th...

Page 1297: ...e timing rotor for this sensor 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 DTC No DTC Detection Condition Trouble Area P0722 All conditions below are detected 500 times or more continu ously 1 trip detection logic a No signal from speed sensor SP2 is input to ECM while 4 pulses of No 1...

Page 1298: ...d sensor SP2 The ECM will illuminate the MIL and set a DTC MONITOR STRATEGY Related DTCs P0722 Speed sensor SP2 Verify pulse input Required sensors Components Speed sensor SP2 Frequency of operation Continuous Duration 500 output shaft revolution MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this D...

Page 1299: ...er Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition SPD SP2 Output shaft Speed min 0 km h 0 mph max 255 km h 158 mph Vehicle stopped 0 km h 0 mph HINT Equal to vehicle speed HINT SPD SP2 is always 0 while driving Open or short in the sensor or circuit SPD SP2 is always more than 0 and...

Page 1300: ...ace speed sensor SP2 See page AT 8 OK 3 Check harness and connector ECM speed sensor SP2 PREPARATION a Connect the speed sensor connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 34 SP2 E6 26 SP2 560 to 680 Ω CHECK Measure the resistance according to the value s in the table below O...

Page 1301: ...itch remains ON during stop and go driving the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC The vehicle must stop less than 3 km h 2 mph and go 30 km h 19 mph or more ten times for two driving cycles in order to detect a malfunction MONITOR STRATEGY Related DTCs P0724 Stop light switch Range check Rationality R i d C t Main Stop light swit...

Page 1302: ...LC3 d Turn the ignition switch to the ON position e Push the ON button of the OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Standard Item MeasurementItem Range display Normal Condition Stop Light Switch Stop light SW Status ON or OFF Brake Pedal is depresse...

Page 1303: ...ed in 10 kΩ or higher Switch pin free 3 4 10 kΩ or higher Switch pin pushed in Below 1 Ω NG Replace stop light switch OK 3 Check harness and connector ECM stop light switch PREPARATION Install the stop lamp switch assy CHECK Measure the voltage according to the value s in the table be low when the brake pedal is depressed and released OK Condition Tester Connection Specified Condition Brake pedal ...

Page 1304: ...in the shift solenoid valve SL1 circuit The ECM commands gearshift by turning the shift solenoid valves ON OFF When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores the DTC And the ECM per forms the fail safe function and turns the other normal shift solenoid valves ON OFF In case of an open or short circuit the EC...

Page 1305: ... SL1 12 4 L R E1 SL1 SL1 B CPU E6 SL1 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 1021 TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Output signal duty 100 COMPONENT OPERATING RANGE Parameter Standard value Output signal duty Less than 100 WIRING DIAGRAM ...

Page 1306: ...ve SL1 is turned on off normally when the shift lever is in the D position 1 Inspect transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 12 SL1 4 SL1 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connectio...

Page 1307: ...tor CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 19 SL1 E6 18 SL1 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 19 SL1 Body ground 10 kΩ or higher E6 18 SL1 Body ground NG Repair or replace the harness or connector See page IN 30 OK R...

Page 1308: ...cording to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL1 See page AT 12 OK Repair or replace the ...

Page 1309: ...ed Automatic transmission clutch brake or gear etc MONITOR DESCRIPTION This DTC indicates stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve S1 The ECM commands gear shifts by turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY R l t...

Page 1310: ...F or more Spark advance from Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9...

Page 1311: ...nsition from 4th to 5th gear Less than 150 rpm Vehicle speed After transition from 4th to 5th gear Less than 100 km h 62 2 mph TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold OFF malfunction All of the following conditions are met Conditions A B and C 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction A Turbi...

Page 1312: ...ile driving the shift position can be forcibly changed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 985 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Pre...

Page 1313: ... c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0751 is output A P0751 and other DTCs B HINT If any other codes besides P0751 are output perform troubleshooting for those DTCs first B Go to DTC chart...

Page 1314: ...ter Connection Specified Condition 20 C 68 F Solenoid Connector S1 Solenoid Body S1 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace shift solenoid valve S1 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on each valve NG Repair o...

Page 1315: ...Automatic transmission clutch brake or gear etc MONITOR DESCRIPTION This DTC indicates stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve S2 The ECM commands gear shifts by turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY R l t d ...

Page 1316: ...e from Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 OFF malfunctio...

Page 1317: ...ter transition from 4th to 5th gear Less than 150 rpm Vehicle speed After transition from 4th to 5th gear Less than 100 km h 62 mph TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold OFF malfunction All of the following conditions are met Conditions A B C and D 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction ...

Page 1318: ...ile driving the shift position can be forcibly changed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 985 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Pre...

Page 1319: ... c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0756 is output A P0756 and other DTCs B HINT If any other codes besides P0756 are output perform troubleshooting for those DTCs first B Go to DTC chart...

Page 1320: ...ster Connection Specified Condition 20 C 68 F Solenoid Connector S2 Solenoid Body S2 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace shift solenoid valve S2 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on each valve NG Repair ...

Page 1321: ...ing the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY Related DTCs P0771 Shift solenoid valve SR Rationality check R i d C t Main Shift solenoid valve SR Required sensors Components Sub Speed sensor NT Speed sensor NO Crankshaft position sensor NE Frequency of o...

Page 1322: ...ore at 2 000 rpm Conditions vary with engine speed OFF malfunction B Current ECM selected gear 5th Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec or more OFF malfunction C Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction Current ECM selected gear 2th Last ECM selected gear 1st Throttle valve opening angle During transition from 1st to 2nd gear 5 ...

Page 1323: ...tem DIAGNOSIS ENHANCED OBD II ACTIVE TEST g According to the display on the tester perform the ACTIVE TEST HINT While driving the shift position can be forcibly changed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 985 Item Test Details Diagnostic Note SHIFT Test Details Operate the ...

Page 1324: ... Proceed to Only P0771 is output A P0771 and other DTCs B HINT If any other codes besides P0771 are output perform troubleshooting for those DTCs first B Go to DTC chart See page DI 991 A 2 Inspect shift solenoid valve SR operation PREPARATION Remove the shift solenoid valve SR See page AT 12 CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Co...

Page 1325: ...nection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL1 See page AT 12 OK 4 Inspect valve body See page AT 12 OK There are no foreign objects on each v...

Page 1326: ...hift solenoid valve SL2 remains open or closed Valve body is blocked Automatic transmission clutch brake or gear etc MONITOR DESCRIPTION This DTC indicates stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SL2 The ECM commands gear shifts by turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same th...

Page 1327: ...Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 ON malfunction A ECM ...

Page 1328: ...MALFUNCTION THRESHOLDS Detection criteria Threshold Both of the following conditions are met ON lf ti A d B ON lf ti C ON malfunctions A and B or ON malfunction C ON malfunction D or E ON malfunction A Turbine speed Output speed 3 30 to 7 50 ON malfunction B Turbine speed Output speed 1 28 to 1 53 ON malfunction C Turbine speed Output speed 0 93 to 1 07 ON malfunction D Turbine speed Output speed ...

Page 1329: ...ed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 985 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possible ...

Page 1330: ... c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0776 is output A P0776 and other DTCs B HINT If any other codes besides P0776 are output perform troubleshooting for those DTCs first B Go to DTC chart...

Page 1331: ...nection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL2 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on each v...

Page 1332: ...DTC indicates an open or short in the shift solenoid valve SL2 circuit The ECM commands gear shift by turning the shift solenoid valves ON OFF When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores the DTC And the ECM per forms the fail safe function and turns the other normal shift solenoid valves ON OFF In case of...

Page 1333: ...SL2 11 3 V Y E1 SL2 SL2 B CPU E6 SL2 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 1049 TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Output signal duty 100 COMPONENT OPERATING RANGE Parameter Standard value Output signal duty Less than 100 WIRING DIAGRAM ...

Page 1334: ...e SL2 is turned on off normally when the shift lever is in the D position 1 Inspect transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 11 SL2 3 SL2 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection...

Page 1335: ...tor CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 17 SL2 E6 16 SL2 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 17 SL2 Body ground 10 kΩ or higher E6 16 SL2 Body ground NG Repair or replace the harness or connector See page IN 30 OK R...

Page 1336: ...ording to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL2 See page AT 12 OK Repair or replace the t...

Page 1337: ...and switching oil pressure to the valves in the valve body The ECM calculates the actual transmission gear by comparing the signals from the input speed sensor NCO and the output speed sensor SP2 The ECM can detect many mechanical problems in the shift sole noids valve body and the transmission clutches brakes and gears If the ECM detects that the actual gear position and the commanded gear positi...

Page 1338: ... or more Spark advance from Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 ...

Page 1339: ...th gear ratio NT NO x 4th gear ratio 1 000 rpm or more Condition D Turbine speed Output speed x 5th gear ratio NT NO x 5th gear ratio 1 000 rpm or more INSPECTION PROCEDURE 1 Check other DTCs output in addition to DTC P0781 PREPARATION a Turn the ignition switch off b Connect the OBD II scan tool or hand held tester to the DLC3 c Turn the ignition switch to the ON position d Turn on the tester e S...

Page 1340: ...ion commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 985 Standard Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possible to check the operation of the shift solenoid ...

Page 1341: ...A750E for 1GR FE DI 1057 3 Clear the DTC and running test CHECK Clear the DTC and check DTC again after conducting the MONITOR DRIVE PATTERN FOR ECT TEST See page DI 969 OK No DTC code NG Repair or replace valve body See page AT 12 OK END ...

Page 1342: ...in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated 1 trip detection logic Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores...

Page 1343: ...resent See page DI 963 Range check Low resistance Shift solenoid valve S1 ON Range check High resistance Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve S1 resistance 8 Ω or less Range check High resistance Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Parameter Standard value Shif...

Page 1344: ...TIC TRANSMISSION A750E for 1GR FE INSPECTION PROCEDURE HINT The shift solenoid valve S1 is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 8 Body ground 11 to 15 Ω NG Go to step ...

Page 1345: ...ECM PREPARATION a Connect the transmission wire connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 11 S1 Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 66 ...

Page 1346: ... according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector S1 Solenoid Body S1 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace the shift solenoid valve S1 See page AT 12 OK Repair or replace the transmission wir...

Page 1347: ...in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated 1 trip detection logic Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores...

Page 1348: ...resent See page DI 963 Range check Low resistance Shift solenoid valve S2 ON Range check High resistance Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve S2 resistance 8 Ω or less Range check High resistance Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Parameter Standard value Shif...

Page 1349: ...SMISSION A750E for 1GR FE DI 1065 INSPECTION PROCEDURE HINT The shift solenoid valve S2 is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 15 Body ground 11 to 15 Ω NG Go to step...

Page 1350: ...ECM PREPARATION a Connect the transmission wire connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 10 S2 Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 66 ...

Page 1351: ... according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector S2 Solenoid Body S2 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace the shift solenoid valve S2 See page AT 12 OK Repair or replace the transmission wir...

Page 1352: ...in solenoid valve SR circuit 2 times when solenoid valve SR is not operated 1 trip detection logic Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores...

Page 1353: ...lenoid valve SR ON Battery voltage 8 V or more Ignition switch ON Starter OFF Range check High resistance Shift solenoid valve SR OFF Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve SR resistance 8 Ω or less Range check High resistance Shift solenoid valve SR resistance 100 kΩ or ...

Page 1354: ...ATIC TRANSMISSION A750E for 1GR FE INSPECTION PROCEDURE HINT The shift solenoid valve SR is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 7 Body ground 11 to 15 Ω NG Go to step...

Page 1355: ... PREPARATION a Connect the transmission wire connector b Disconnect the connector of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 9 SR Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 66 ...

Page 1356: ...ing to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector SR Solenoid Body SR 11 to 15 Ω CHECK Connect the battery positive lead to the solenoid connector ter minal and the battery negative lead to the solenoid body ground OK Solenoid sounds an operation noise NG Replace the shift solenoid valve SR See page AT 12 OK Repair or replace the transmissi...

Page 1357: ... continuity in one cycle and B is the period of non continuity then Duty Ratio A A B x 100 DTC No DTC Detection Condition Trouble Area P2714 ECM detects a malfunction on SLT ON side according to the revolution difference of the turbine and the output shaft and also by the oil pressure 2 trip detection logic Shift solenoid valve SLT remains open or closed Valve body is blocked Automatic transmissio...

Page 1358: ...ot circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT Engine coolant temperature sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS Electric throttle control system...

Page 1359: ...ion Solenoid E6 G BR 14 6 SLT SLT B SLT DIAGNOSTICS AUTOMATIC TRANSMISSION A750E for 1GR FE DI 1075 TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Summation of C1 clutch heat generations Turbine speed Output speed x Temporary ratio Specified value WIRING DIAGRAM ...

Page 1360: ...ccording to the display on tester perform the ACTIVE TEST Item Test Details Diagnostic Note LINE PRESS UP Test Details Operate the shift solenoid SLT and raise the line pressure Vehicle Condition Vehicle Stopped IDL ON HINT OFF Line pressure up When the active test of Control the Line Pres sure Up is performed the ECM commands the SLT solenoid to turn off ON No action normal operation LINE PRESS U...

Page 1361: ... c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P2714 is output A P2714 and other DTCs B HINT If any other codes besides P2714 are output perform troubleshooting for those DTCs first B Go to DTC chart...

Page 1362: ...Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLT See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on eac...

Page 1363: ... this as a fault The ECM will turn on the MIL and store the DTC MONITOR STRATEGY Related DTCs P2716 Shift solenoid valve SLT Range check Required sensors Components Shift solenoid valve SLT Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is no...

Page 1364: ...eter Standard value Output signal duty Less than 100 WIRING DIAGRAM INSPECTION PROCEDURE 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 14 SLT 6 SLT 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Test...

Page 1365: ...ector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 13 SLT E6 12 SLT 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 13 SLT Body ground 10 kΩ or higher E6 12 SLT Body ground NG Repair or replace harness or connector See page IN 30 OK Rep...

Page 1366: ...rding to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLT See page AT 12 OK Repair or replace the tr...

Page 1367: ...F temperature Sensor No 2 State Detection Condition Symptom Recovery Condition AT fluid temp more than 150 C 302 F AT Oil Temp warning light re mains on AT fluid temp less than 135 C 275 F 2 AT fluid temp more than 130 C 266 F Shift point too high AT fluid temp less than 110 C 230 F Sensor is normal When the conditions a and b are satisfied a AT fluid temp more than 130 C 266 F b Engine coolant te...

Page 1368: ...ssion wire ATF temperature sensor No 2 ECM MONITOR DESCRIPTION The Automatic Transmission Fluid ATF temperature sensor converts ATF temperature to an electrical re sistance value Based on the resistance the ECM determines the ATF temperature and the ECM detects an open or short in the AFT temperature circuit If the resistance value of the ATF temperature is less than 25 Ω 0 046 V or more than 156 ...

Page 1369: ...hreshold Range check Fluttering TFT transmission fluid temperature sensor voltage Less than 0 046 V or More than 4 915 V Range check Low voltage TFT transmission fluid temperature sensor voltage Less than 0 046 V Range check High voltage TFT transmission fluid temperature sensor voltage More than 4 915 V COMPONENT OPERATING RANGE Parameter Standard value TFT transmission fluid temperature sensor A...

Page 1370: ...BD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 2 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When DTC...

Page 1371: ...istance according to the value s in the table below OK Tester Connection Specified Condition 1 OT2 9 OT2 25 Ω to 156 kΩ 1 OT2 Body ground 10 kΩ or higher 9 OT2 Body ground 10 kΩ or higher HINT If the resistance is out of the specified range with either the ATF temperature shown in the table below the driveability of the ve hicle may decrease ATF Temperature Specified Condition 20 C 68 F 3 to 4 kΩ ...

Page 1372: ...of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 32 THO2 E7 28 E2 25 Ω to 156 kΩ CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 32 THO2 Body ground 10 kΩ or higher E7 28 E2 Body ground NG Repair or replace the harness or connector See page IN 30 OK Re...

Page 1373: ...ndition of the lock up clutch Then the ECM compares the engagement condition of the lock up clutch with the lock up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU valve body and torque converter clutch DTC No DTC Detection Condition Trouble Area P2757 Lock up does not occur when driving in the lock up range normal driving at 80 km h 50 mph or lock up rem...

Page 1374: ...noid valve SLU or lock up system performance The ECM will turn on the MIL and store the DTC Example When any of the following is met the system judges it as a malfunction a There is a difference in rotation between the input side engine speed and output side input turbine speed of the torque converter when the ECM commands lock up Engine speed is at least 70 rpm greater than input turbine speed b ...

Page 1375: ...hicle speed 25 km h 15 5 mph or more Shift solenoid valve S1 circuit Not on malfunction Shift solenoid valve S2 circuit Not on malfunction Shift solenoid valve SL2 circuit Not on malfunction 1 2 Shift valve Not on malfunction Transfer neutral position switch OFF Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit No...

Page 1376: ...ditions are met OFF malfunctions A and B OFF malfunction A Engine speed Turbine speed 70 rpm or more OFF malfunction B Turbine speed Output speed Not 3 30 to 7 50 ON malfunction 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON Vehicle speed must be under 10 km h 6 2 mph once before 2nd detection Difference between engine speed and tur...

Page 1377: ...NOSIS ENHANCED OBD II ACTIVE TEST g According to the display on the tester perform the ACTIVE TEST Item Test Details Diagnostic Note LOCK UP Test Details Control the shift solenoid SLU to set the automatic transmission to the lock up condition Vehicle Condition Throttle valve opening angle Less than 35 Vehicle Speed 60 km h 37 mph or more Possible to check the SLU opera tion HINT This test can be ...

Page 1378: ... c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P2757 is output A P2757 and other DTCs B HINT If any other codes besides P2757 are output perform troubleshooting for those DTCs first B Go to DTC chart...

Page 1379: ...e table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLU See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are n...

Page 1380: ...UTOMATIC TRANSMISSION A750E for 1GR FE 4 Check torque converter clutch See page AT 39 OK The torque converter clutch operates normally NG Replace the torque converter clutch OK Repair or replace transmission See page AT 26 ...

Page 1381: ... if A is the period of continuity in one cycle and B is the period of non continuity then Duty Ratio A A B x 100 DTC No DTC detection condition Trouble Area P2759 Open or short is detected in shift solenoid valve SLU circuit for 1 second or more while driving 1 trip detection logic Open or short in shift solenoid valve SLU circuit Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or sh...

Page 1382: ... run whenever these DTCs are not present See page DI 973 Case 1 Battery voltage 12 V or more Ignition switch ON Starter OFF Case 2 Battery voltage 10 V or more Less than 12 V CPU commanded duty Less than 75 Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Case 1 Output signal duty 100 Case 2 Output signal duty 100 COMPONENT OPERATING RANGE Parameter Standa...

Page 1383: ...ion wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 13 SLU 5 SLU 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 13 SLU Body ground 10 kΩ or higher 5 SLU Body ground NG Go to step 3 OK ...

Page 1384: ...tor CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 15 SLU E6 14 SLU 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 15 SLU Body ground 10 kΩ or higher E6 14 SLU Body ground NG Repair or replace the harness or connector See page IN 30 OK R...

Page 1385: ...cording to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLU See page AT 12 OK Repair or replace the ...

Page 1386: ...main switch transmission control switch is a momentary type switch When pressing the O D main switch once the O D OFF indicator light comes on and the ECM prohibits shifting into O D When pressing it once again the O D OFF indicator light goes off and the ECM allows shifting into O D Turning the IG switch OFF will reset the O D OFF indicator light WIRING DIAGRAM DIDVT 01 ...

Page 1387: ...CK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 1 Body ground Below 1 Ω NG Repair or replace the harness or connector See page IN 30 OK 2 Inspect O D main switch CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition O D main switch pressed and held 1 3 Below 1...

Page 1388: ...ct the connector from the ECM CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition O D main switch pressed and held E3 12 ODMS Body ground Below 1 Ω O D main switch released 10 kΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Proceed to next circuit inspection shown on matrix chart See page DI...

Page 1389: ...IRCUIT DESCRIPTION The shift position L switch is a momentary type switch When the shift position L switch is pressed while driving with the shift lever in the 2 position the L position indicator on the combination meter comes on and the transmission is locked in 1st gear When the switch is pressed again the indicator goes off and the trans mission is released WIRING DIAGRAM DIDVU 01 ...

Page 1390: ... the value s in the table below OK Tester Connection Specified Condition 10 Body ground Below 1 Ω NG Repair or replace the harness or connector See page IN 30 OK 2 Inspect center cluster integration panel shift position L switch CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition Shift position L switch pressed and held...

Page 1391: ...switch b Disconnect the connector from the ECM CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition Shift position L switch pressed and held E4 9 LMS Body ground Below 1 Ω Shift position L switch released 10 kΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Proceed to next circuit inspection sh...

Page 1392: ...FE AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transmission assy en gine assy or ECM See page DI 1126 HINT RESET MEMORY cannot be completed by only disconnecting the battery terminal ...

Page 1393: ...ECM to detect malfunctions Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle Once per driving cycle means that the ECM detects malfunction only one time during a single driving cycle Continuous means that the ECM detects malfunction every time when enabling condition is met Duration The minimum time that the ECM must sense a continuous deviation in t...

Page 1394: ...aporative emission pressure switching valve Vapor pressure sensor EVAP pressure sensor Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On board refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve IMRV IACV runner valve Intake manifold tuni...

Page 1395: ...d sensor NT Turbine speed sensor Input turbine speed sensor PNP switch NSW Park neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch Shift lock control unit Shift lock control module Engine immobilizer system Immobilizer system Vehicle anti theft system ...

Page 1396: ...id Valve SL2 ATF Temperature Sensor No 2 Integration Control and Panel Shift Position L Switch MIL Shift Solenoid Valve SL1 Shift Solenoid Valve SLT ATF Temperature Sensor No 1 Shift Solenoid Valve S2 Speed Sensor NT AT Oil Temp Warning Light Shift Lever O D Main Switch 4WD Indicator Switch Transfer L4 Position Switch DI 1112 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE LOCATION ...

Page 1397: ...ensor ATF Automatic Transmission Fluid Temperature Sensor No 1 Mass Air Flow Meter Accelerator Pedal Position Sensor VPA VPA2 Shift Lever O D Main Switch Input Speed Sensor NT NT Output Speed Sensor SP2 SP2 TH02 ATF Automatic Transmission Fluid Temperature Sensor No 2 Skid Control ECU NSW Park Neutral Position Switch R D 3 2 VG NE L ODMS Integration Control and Panel Shift Position L Switch Indica...

Page 1398: ...sing the ECM The ECM detects electrical signals that indicate engine and driving condi tions and controls the shift point based on driver habits and road conditions As a result fuel efficiency and power transmission performance are improved Shift shock has been reduced by controlling the engine and transmission simultaneously In addition the ECT has features such as follows Diagnostic function Fai...

Page 1399: ... tester inspect DLC3 DI 1145 2 3 4 5 6 Symptom does not occur Problem Symptom Confirmation 8 7 Symptom Simulation IN 19 Symptom occurs DTC Check DI 1148 OK Code 11 Preliminary Check DI 1117 DTC Chart DI 1156 Mechanical System Test DI 1121 and DI 1123 Manual Shifting Test DI 1125 OK OK Chapter 1 Electronic Chapter 2 On Vehicle DI 1136 OK Chapter 3 Off Vehicle OK Matrix Chart of Problem Symptoms DI ...

Page 1400: ...position Particular position No down shift 5th 4th 4th 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive position Slip or shudder No kick down Others DTC Check 1st Time 2nd Time Check Item Normal system code Trouble code DTC Normal system code Trouble code DTC Malfunction Indicator Lamp Normal Remains ON VIN Production Date Licence Plate...

Page 1401: ... cable and temporarily install the control shaft lever nut 6 While holding the shift lever lightly toward the R position side tighten the control shaft lever nut Torque 14 5 N m 148 kgf cm 11 ft lbf 7 Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to the D position and reverses when shifting it to the R position 2 INSPECT AND ADJUST PARK NEUTRAL PO...

Page 1402: ...s at 45 km h 28 mph or less 5th Gear Lock up Prohibition Control Brake pedal is depressed Accelerator pedal is released Engine coolant temperature is 60 C 140 F or less 2 Check for shift shock and slip Check for shock and slip at the 1 2 2 3 3 4 and 4 5th up shifts 3 Check for abnormal noise and vibration Check for abnormal noise and vibration when up shifting from 1 2 2 3 3 4 and 4 5 while drivin...

Page 1403: ...speed does not change abruptly HINT If there is a big jump in engine speed there is no lock up c 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points 1 Check up shift operation Check that the 1 2 and 2 3 up shifts takes place and that the shift point conforms to the automatic shift schedule See page SS 50 HINT There is no 4th up shift and...

Page 1404: ...ck that there is no up shift to 2nd gear 2 Check engine braking While running in the L position release the accelerator pedal and check the engine braking ef fect 3 Check for abnormal noises during acceleration and deceleration f R position test Shift into the R position lightly depress the accelerator pedal and check that the vehicle moves back ward without any abnormal noise or vibration CAUTION...

Page 1405: ...tions of wheels or wheel stoppers outside the vehicle while the other is doing the test 1 Chock all 4 wheels 2 Connect a hand held tester to DLC3 3 Fully apply the parking brake 4 Using your left foot keep the brake pedal firmly depressed 5 Start the engine 6 Shift into the D position Press all the way down on the accelerator pedal with your right foot 7 Quickly read the stall speed at this time S...

Page 1406: ...1 Connect a hand held tester to DLC3 2 Fully apply the parking brake 3 Start and warm up the engine and check idle speed Idle speed approx 700 rpm In N position and A C OFF 4 Shift the lever from the N to D position Using a stop watch measure the time from when the lever is shifted until the shock is felt Time lag N D Less than 1 2 seconds 5 In the same manner measure the time lag for N R Time lag...

Page 1407: ... be conducted after checking and ad justing engine Perform under condition that A C is OFF When conducting stall test do not continue more than 10 seconds 1 Warm up the ATF Automatic Transmission Fluid 2 Lift the vehicle up 3 Remove the test plug on the transmission case cen ter right side and connect SST SST 09992 00095 09992 00231 09992 00271 4 Fully apply the parking brake and chock the 4 wheel...

Page 1408: ... 12 5 to 13 8 kgf cm2 178 to 196 psi Evaluation Problem Possible cause Measured values are higher than specified in all positions Shift solenoid valve SLT defective Regulator valve defective Measured values are lower than specified in all positions Shift solenoid valve SLT defective Regulator valve defective Oil pump defective Pressure is low in the D position only D position circuit fluid leak Cl...

Page 1409: ... whether the shifting condition changes the table below Shift Position Shifting Condition L 2 No Shift Not Change 2 3 Down Shift Up Shift 3 4 Down Shift Up Shift 4 D No Shift Not Change HINT When driving with the transmission wire disconnected the gear position will be as follows When the shift lever is in the L or the 2 position the gear is held in the 1st position When the shift lever is in the ...

Page 1410: ...tomatic transmission assy and engine assy according to those characteristics Therefore when the automatic transmission assy engine assy or ECM has been replaced it is necessary to reset the memory so that the ECM can memorize the new information Reset procedure is as follows a Turn the ignition switch off b Connect the hand held tester to the DLC3 c Turn the ignition switch to the ON position d Tu...

Page 1411: ... DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1127 NOTICE After performing the RESET MEMORY be sure to perform the ROAD TEST See page DI 1118 de scribed earlier HINT The ECM learns through use of the ROAD TEST ...

Page 1412: ...or 2UZ FE LIST OF DISABLE A MONITOR HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed ...

Page 1413: ...A21571 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1129 ...

Page 1414: ...A21572 A22718 A22768 DI 1130 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE ...

Page 1415: ...A21573 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1131 ...

Page 1416: ...A21575 DI 1132 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE ...

Page 1417: ...A21576 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1133 ...

Page 1418: ... higher Malfunction is not detected when the atmospheric temperature is 10 C 14 F or less Notice in driving Drive the vehicle through all gears Stop 1st 2nd 3rd 4th 5th 5th lock up ON Repeat the above driving pattern three times or more NOTICE The monitor status can be checked using the OBD II scan tool When using the hand held tes ter monitor status can be found in the ENHANCED OBD II DATA LIST o...

Page 1419: ...acceleration with the throttle open for 3 minutes or more 1 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1135 HINT 1 Drive at such a speed in the uppermost gear to engage lock up The vehicle can be driven at a speed lower than that in the above diagram under the lock up condition NOTICE It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 ATF temper...

Page 1420: ...1226 DI 1231 IN 30 No up shift 4th 5th 1 O D main switch circuit 2 Engine coolant temp sensor circuit 1 3 Speed sensor NT circuit 1 4 Shift solenoid valve SL1 circuit 1 5 Shift solenoid valve SL2 circuit 1 6 Shift solenoid valve SR circuit 1 7 ECM DI 1274 DI 477 DI 1175 DI 1188 DI 1216 DI 1236 IN 30 No up shift 3rd 4th 1 Engine coolant temp sensor circuit 1 2 Shift solenoid valve S2 circuit 1 3 EC...

Page 1421: ... 2 ECM DI 1277 IN 30 Harsh engagement N D 1 Speed sensor NT circuit 1 2 Shift solenoid valve SL1 circuit 1 3 Shift solenoid valve SLT circuit 1 4 ECM DI 1175 DI 1188 DI 1247 IN 30 Harsh engagement Lock up 1 Speed sensor NT circuit 1 2 Speed sensor SP2 circuit 1 3 Shift solenoid valve SLU circuit 1 4 ECM DI 1175 DI 1180 DI 1265 IN 30 Harsh engagement Any driving position ECM IN 30 Poor acceleration...

Page 1422: ...trix chart AT 12 No down shift 3rd 2nd 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No down shift 2nd 1st 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No lock up or No lock up off 1 Shift solenoid valve SLU 2 Valve body assy 3 Off vehicle repair matrix chart DI 1257 AT 12 Harsh engagement N D 1 Shift solenoid valve SL1 2 Valve body assy 3 C1 accumulator 4 Off vehicle repa...

Page 1423: ... control cable 2 Valve body assy 3 Oil strainer 4 Off vehicle repair matrix chart DI 1117 AT 12 AT 12 No engine braking 1st L position 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No engine braking 2nd 2 position 1 Valve body assy 2 Off vehicle repair matrix chart AT 12 No kick down Valve body assy AT 12 Shift point too high or too low 1 Shift solenoid valve SLT 2 Shift solenoid valve...

Page 1424: ...o 4 B4 3 One way clutch No 1 F1 Harsh engagement 1 2 1 Brake No 3 B3 2 One way clutch No 1 F1 3 One way clutch No 2 F2 Harsh engagement 2 3 Clutch No 3 C3 Harsh engagement 3 4 Clutch No 2 C2 Harsh engagement 4 5th 1 Brake No 1 B1 2 Clutch No 1 C1 Harsh engagement Lock up Torque converter clutch AT 39 Slip or shudder Forward and reverse After warm up 1 One way clutch No 1 F1 2 Clutch No 3 C3 3 Torq...

Page 1425: ...ne braking 2nd 2 position Brake No 2 B2 No engine braking 3rd 3 position Brake No 1 B1 Poor acceleration All positions Torque converter clutch AT 39 Poor acceleration 5th 1 Clutch No 1 C1 2 Clutch No 3 C3 3 Brake No 1 B1 4 Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch AT 39 ...

Page 1426: ... V R E4 11 E1 E5 1 G R 1 BR R B 2 BR R shift position switch sig nal IG switch ON and shift lever R posi tion 10 to 14 V IG switch ON and shift lever except R position Below 1 V D E4 21 E1 E5 1 W R BR D shift position switch sig nal IG switch ON and shift lever D posi tion 10 to 14 V IG switch ON and shift lever except D position Below 1 V 3 E4 19 E1 E5 1 G W 1 BR L W 2 BR 3 shift position switch ...

Page 1427: ...ignal No 2 ATF temperature 115 C 239 F or more Below 1 5 V SP2 E6 34 SP2 E6 26 Y R W R Speed sensor SP2 sig nal Vehicle speed 20 km h 12 mph Pulse generation See waveform 6 NT E6 35 NT E6 27 G R Speed sensor NT signal Engine idle speed Pulse generation See waveform 5 STAR NSW E6 8 E1 E5 1 L R BR Park neutral switch signal IG switch ON and shift lever P and N position Below 2 V IG switch ON and shi...

Page 1428: ...rminal SL2 SL2 Tool setting 5V DIV 1ms DIV Vehicle condition Engine idle speed Waveform 4 Reference Terminal SL1 SL1 Tool setting 5V DIV 1ms DIV Vehicle condition Engine idle speed Waveform 5 Reference Terminal NT NT Tool setting 1V DIV 2ms DIV Vehicle condition Engine idle speed P or N position Waveform 6 Reference Terminal SP2 SP2 Tool setting 2V DIV 20ms DIV Vehicle condition Vehicle speed 20 k...

Page 1429: ...on does not reoccur in 3 consecutive trips the MIL turns off automatically but the DTCs remain recorded in the ECM memory To check DTCs connect the scan tool to the Data Link Connec tor 3 DLC3 of the vehicle The scan tool displays DTCs the freeze frame data and a variety of the engine data The DTCs and freeze frame data can be erased with the scan tool See page DI 1148 NORMAL MODE AND CHECK MODE T...

Page 1430: ...tion protocol The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765 4 format HINT Connect the cable of the hand held tester to the DLC3 turn the ignition switch ON and attempt to use the hand held tester If the screen displays UNABLE TO CONNECT TO VEHICLE a problem exists in the vehicle side or the tester side If the communication is normal when the tool is connect...

Page 1431: ...switch ON If the MIL does not illuminate there is a problem in the MIL cir cuit refer to MIL CIRCUIT on page DI 940 b When the engine is started the MIL should turn off ALL READINESS For this vehicle using the hand held tester allows readiness codes corresponding to all DTCs to be read When diagnosis normal or malfunctioning has been complete readiness codes are set Enter the following menus ENHAN...

Page 1432: ...n the ignition switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES or PENDING CODE d Confirm the DTCs and freeze frame data and then write them down e See page DI 1156 to confirm the details of the DTCs NOTICE When simulating a symptom with the scan tool to check for DTCs use normal mode For codes on DIAGNOSTIC TROUBLE CODE CHART subject to 2 trip detection log i...

Page 1433: ...r together with the Controller Area Network Vehicle Interface Module CAN VIM to the DLC3 d Turn the ignition switch ON e Enter the following menus DIAGNOSIS ENHANCED OBD II CHECK MODE f Change the ECM to check mode Make sure the MIL flashes as shown in the illustration NOTICE All DTCs and freeze frame data recorded will be erased if 1 the hand held tester is used to change the ECM from normal mode...

Page 1434: ... the next page Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction up shift to the 5th is prohibited Shift Solenoid Valve SLU During a solenoid valve SLU malfunction the current to the solenoid valve is stopped This stops lock up control and flex lock up control fuel economy de creases Shift Solenoid Valve SLT During a solenoid valve SLT malfunction the current to the s...

Page 1435: ...h 5 th 5 th 5 th 4 th 3 rd E B 3 rd E B 3 rd E B 3 rd E B 5 th 5 th 2 nd E B 3 rd E B 5 th 5 th 4 th 3 rd E B 3 rd E B 4 th 1 st E B 2 nd 5 th 1 st E B 2 nd Fail 4th 3 rd E B 3 rd E B 4 th 5 th 3 rd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 2 nd 3 rd E B 3 rd E B 3 rd 3 rd 3 rd 1 st 1 st 1 st 1 st 3 rd 4 th 4 th 4 th 4 th Fail 4 th 3 rd 4 th Position DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F fo...

Page 1436: ... th 4 th 4 th 3 rd E B 3 rd E B 3 rd 1 st 1 st 1 st 1 st 1 st 1 st 2nd 1 st 2nd 2nd 1 st E B 2nd 1 st 3 rd E B 3 rd 3 rd 3 rd E B 3 rd 1 st 3 rd 3 rd E B 3 rd 1 st 1 st 1 st 1 st 1 st 1 st 1 st 4 th 3 rd 3 rd E B 3 rd 3 rd E B 3 rd E B 4 th 5 th 4 th 5 th Fail 4 th Fail 4 th Fail 4 th Fail 4 th S1 S2 SR SL1 SL2 S1 S2 SR SL1 S1 S2 SR SL1 S1 S2 SR SL1 SL2 3 rd SL2 SL2 Gear S1 S2 OFF 3 rd 4 th Positi...

Page 1437: ...FF Brake Pedal is depressed ON Brake Pedal is released OFF PNP SW NSW PNP SW Status ON or OFF Shift lever position is P and N ON Except P and N OFF When the shift lever position dis played on the hand held tester dif fers from the actual position ad justment of the PNP switch or the shift cable may be incorrect HINT When the failure still occurs even after adjusting these parts See page DI 1159 LO...

Page 1438: ... soak If the value is 40 C 40 F or 215 C 419 F ATF temp sen sor No 1 circuit is open or shorted AT FLUID TEMP 2 ATF Temp Sensor No 2 Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak If the value is 40 C 40 F or 215 C 419 F ATF temp sen sor No 2 circuit is open or shorted SPD SP2 Output shaft Speed min 0 km h 0 mph max 255 km h 158 m...

Page 1439: ...self Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possible to check the operation of the shift solenoid valves LOCK UP Test Details Control the shift solenoid SLU to set the automatic transmission to the lock up condition Vehicle Condition Throttle valve opening angle Less than 35 Vehicle Speed 60 km h 37 mph or more Possible to check the SLU oper...

Page 1440: ...sion wire ATF temperature sensor No 1 ECM P0713 DI 1166 Transmission Fluid Temperature Sensor A Circuit High Input Open in ATF temperature sensor No 1 circuit Transmission wire ATF temperature sensor No 1 ECM P0717 DI 1175 Input Speed Sensor Circuit No Signal Open or short in speed sensor NT circuit Speed sensor NT ECM Automatic transmission clutch brake or gear etc P0722 DI 1180 Output Speed Sens...

Page 1441: ...e SR ECM P0986 DI 1236 Shift Solenoid E Control Circuit High Shift Solenoid Valve SR Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM P2714 DI 1241 Pressure Control Solenoid D Performance Shift Solenoid Valve SLT Shift solenoid valve SLT remains open or closed Valve body is blocked Automatic transmission clutch brake or gear etc P2716 DI 1247 Pressure Control Solenoid D Electric...

Page 1442: ...DI 1158 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE P2772 DI 1270 Transfer L4 SW Circuit Short in transfer L4 position switch circuit Transfer L4 position switch ECM HINT 4WD ...

Page 1443: ...the shift lever position and sends a signal to the ECM For security the park neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position The park neutral position switch sends a signal to the ECM according to the shift position NSW R D 3 or 2 The ECM determines that there is a problem with the switch or related parts if...

Page 1444: ...ondition A Number of the following signal input at the same time 2 or more NSW switch R switch D switch ON 3 switch ON 2 switch Condition B All of following conditions are met N switch NSW switch R switch OFF D switch OFF 3 switch 2 switch COMPONENT OPERATING RANGE Parameter Standard value Park neutral position switch The park neutral position switch sends only one signal to the ECM ...

Page 1445: ... GAUGE IG1 AM1 7 4 8 7 1C 1L 1 6 AM1 2 1 ALT Battery F13 FL Block Cowl Side J B LH I23 Ignition SW Cowl Side J B RH To 4WD Control ECU To Skid Control ECU with Actuator 1 To Starter Relay P1 Park Neutral Position SW 2 w o VSC 2 1 N 2 12 4 5 6 1 9 7 3 8 D B A E C C G F D B H G 2 RB Double Cab To ABS Actuator with ECU 2 1 w VSC W L DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1161 WI...

Page 1446: ...o ABS Actuator with ECM 2 2 26 IE1 D8 Diode B Y L B J8 J C B Y B Y GAUGE ALT 3 4 AM1 B 4 W 1F 1L 7 IA9 2 2 AM1 IG1 I23 Ignition SW Cowl Side J B RH 2 9 2 1 2 4 2 1 2 1 Engine Room R B Battery 6 J28 J28 J28 J28 J28 J28 J29 J29 J29 J29 J29 J29 W To Starter Relay To ABS Actuator with ECM E E 1 w VSC 2 w o VSC 3 140A Towing Package 4 100A Except Towing Package B L 3 Except Double Cab DI 1162 DIAGNOSTI...

Page 1447: ...DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition Diagnostic Note PNP SW NSW PNP SW Status ON or OFF Shift lever position is P and N ON Except P and N OFF When the shift lever position dis played on the hand held tester dif fers from the actual position ad justment of the PNP switch or the shift cable...

Page 1448: ... according to the value s in the table below when the shift lever is moved to each position OK Shift Position Tester Connection Specified Condition P 2 6 and 4 5 Below 1 Ω Except P 10 kΩ or higher R 2 1 Below 1 Ω Except R 10 kΩ or higher N 2 9 and 4 5 Below 1 Ω Except N 10 kΩ or higher D 2 7 Below 1 Ω Except D 10 kΩ or higher 3 2 3 Below 1 Ω Except 3 10 kΩ or higher 2 2 8 Below 1 Ω Except 2 10 kΩ ...

Page 1449: ...ft lever is moved to each position OK Shift Position Tester connection Specified condition P and N E6 8 STAR NSW Body ground Below 2 V Except P and N 10 to 14 V R E4 11 R Body ground 10 to 14 V Except R Below 1 V D E4 21 D Body ground 10 to 14 V Except D Below 1 V 3 E4 19 3 Body ground 10 to 14 V Except 3 Below 1 V 2 and L E4 10 2 Body ground 10 to 14 V Except 2 and L Below 1 V HINT The voltage wi...

Page 1450: ...SMISSION A750E A750F for 2UZ FE DTC P0710 Transmission Fluid Temperature Sensor A Circuit DTC P0712 Transmission Fluid Temperature Sensor A Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor A Circuit High Input DIDWK 01 ...

Page 1451: ...n wire ATF temperature sensor No 1 ECM P0712 ATF temperature sensor No 1 resistance is less than 79 Ω for 0 5 sec or more 1 trip detection logic Short in ATF temperature sensor No 1 circuit Transmission wire ATF temperature sensor No 1 ECM P0713 ATF temperature No 1 sensor resistance is more than 156 kΩ when 15 minutes or more have elapsed after the engine start DTC is detected for 0 5 sec or more...

Page 1452: ...will run whenever these DTCs are not present See page DI 1128 Range check Fluttering Low resistance The typical enabling condition is not avail able Range check High resistance Time after engine start 15 min or more TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Fluttering TFT transmission fluid temperature sensor resistance Less than 79 Ω or More than 156 kΩ Range check L...

Page 1453: ... hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 1 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When DTC P0712 is output and h...

Page 1454: ...resistance according to the value s in the table below OK Tester Connection Specified Condition 2 OT 10 OT 79 Ω to 156 kΩ 2 OT Body ground 10 kΩ or higher 10 OT Body ground 10 kΩ or higher HINT If the resistance is out of the specified range with either the ATF temperature shown in the table below the driveability of the ve hicle may decrease ATF Temperature Specified Condition 20 C 68 F 3 to 4 kΩ...

Page 1455: ...or of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 24 THO1 E7 28 E2 79 Ω to 156 kΩ CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 24 THO1 Body ground 10 kΩ or higher E7 28 E2 Body ground NG Repair or replace the harness or connector See page IN 30 OK...

Page 1456: ...uit or a fault in the ATF temperature sensor After running the vehicle for a certain period the ATF temperature should increase If the ATF temperature is below 20 C 68 F after running the vehicle for a certain period the ECM interprets this as a fault and turns on the MIL MONITOR STRATEGY Related DTCs P0711 ATF temperature sensor Rationality check Required sensors Components ATF temperature sensor...

Page 1457: ...e OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 1 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When ...

Page 1458: ...NHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0711 is output A P0711 and other DTCs B HINT If any other codes besides P0711 are output perform troubleshooting for those DTCs first B Go to DTC chart See page DI 1156 A 2 Check transmission fluid level See page DI 1117 OK Automatic transmission f...

Page 1459: ...rious conditions thus providing smooth gear shift DTC No DTC Detection Condition Trouble Area P0717 All conditions below are detected for 5 secs or more 1 trip detection logic a Gear change is not performed b Gear position 4th or 5th c T M input shaft rpm 300 rpm or less d T M output shaft rpm 1 000 rpm or more e Park neutral position switch NSW input signal is OFF R input signal is OFF L input si...

Page 1460: ...irregularly output 2 The vehicle speed is approx 50 km h 31 mph or more MONITOR STRATEGY Related DTCs P0717 Speed sensor NT Verify pulse input R i d C t Main Speed sensor NT Required sensors Components Sub Speed sensor NO Frequency of operation Continuous Duration 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor ...

Page 1461: ...ition switch to the ON position e Push the ON button of the OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition SPD NT Input Turbine Speed display 50 r min HINT Lock up ON After warming up the engine Input Turbi...

Page 1462: ...on OK The installation bolt is tightened properly and there is no clearance between the sensor and transmission case Torque 5 4 N m 55 kgf cm 48 in lbf NG Replace speed sensor NT See page AT 8 OK 2 Inspect speed sensor NT PREPARATION Disconnect the speed sensor connector from the transmission CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Co...

Page 1463: ...ector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 35 NT E6 27 NT 560 to 680 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 35 NT Body ground 10 kΩ or higher E6 27 NT Body ground NG Repair or replace harness or connector See page IN 30 OK Replace...

Page 1464: ... the timing rotor for this sensor 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 DTC No DTC Detection Condition Trouble Area P0722 All conditions below are detected 500 times or more continu ously 1 trip detection logic a No signal from speed sensor SP2 is input to ECM while 4 pulses of N...

Page 1465: ...peed sensor SP2 The ECM will illuminate the MIL and set a DTC MONITOR STRATEGY Related DTCs P0722 Speed sensor SP2 Verify pulse input Required sensors Components Speed sensor SP2 Frequency of operation Continuous Duration 500 output shaft revolution MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever thi...

Page 1466: ...ester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition SPD SP2 Output shaft Speed min 0 km h 0 mph max 255 km h 158 mph Vehicle stopped 0 km h 0 mph HINT Equal to vehicle speed HINT SPD SP2 is always 0 while driving Open or short in the sensor or circuit SPD SP2 is always more than 0 ...

Page 1467: ...eplace speed sensor SP2 See page AT 8 OK 3 Check harness and connector ECM speed sensor SP2 PREPARATION a Connect the speed sensor connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 34 SP2 E6 26 SP2 560 to 680 Ω CHECK Measure the resistance according to the value s in the table belo...

Page 1468: ...switch remains ON during stop and go driving the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC The vehicle must stop less than 3 km h 2 mph and go 30 km h 19 mph or more ten times for two driving cycles in order to detect a malfunction MONITOR STRATEGY Related DTCs P0724 Stop light switch Range check Rationality R i d C t Main Stop light sw...

Page 1469: ...e DLC3 d Turn the ignition switch to the ON position e Push the ON button of the OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Standard Item MeasurementItem Range display Normal Condition Stop Light Switch Stop light SW Status ON or OFF Brake Pedal is depre...

Page 1470: ...e the resistance according to the value s in the table below OK Double Cab Switch position Tester Connection Specified Condition Switch pin free 1 4 Below 1 Ω Switch pin pushed in 10 kΩ or higher Except Double Cpb Switch position Tester Connection Specified Condition Switch pin free 1 2 Below 1 Ω Switch pin pushed in 10 kΩ or higher Switch pin free 3 4 10 kΩ or higher Switch pin pushed in Below 1 ...

Page 1471: ...stop lamp switch assy CHECK Measure the voltage according to the value s in the table be low when the brake pedal is depressed and released OK Condition Tester Connection Specified Condition Brake pedal is depressed E3 15 STP Body ground 10 to 14 V Brake pedal is released Below 1 V NG Repair or replace harness or connector See page IN 30 OK Replace the ECM See page SF 82 ...

Page 1472: ... The ECM commands gearshift by turning the shift solenoid valves ON OFF When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores the DTC And the ECM per forms the fail safe function and turns the other normal shift solenoid valves ON OFF In case of an open or short circuit the ECM stops sending current to the circuit ...

Page 1473: ...ission Solenoid E6 ECM GR R W 19 18 SL1 SL1 12 4 L R E1 SL1 SL1 B CPU E6 SL1 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1189 COMPONENT OPERATING RANGE Parameter Standard value Output signal duty Less than 100 WIRING DIAGRAM ...

Page 1474: ...valve SL1 is turned on off normally when the shift lever is in the D position 1 Inspect transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 12 SL1 4 SL1 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connec...

Page 1475: ...nector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 19 SL1 E6 18 SL1 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 19 SL1 Body ground 10 kΩ or higher E6 18 SL1 Body ground NG Repair or replace the harness or connector See page IN 30 O...

Page 1476: ... according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL1 See page AT 12 OK Repair or replace t...

Page 1477: ...y turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY R l t d DTC P0751 Shift solenoid valve S1 OFF malfunction Related DTCs P0751 Shift solenoid valve S1 ON malfunction Main Shift solenoid valve S1 Required sensors Components Sub Vehicle speed sensor Thro...

Page 1478: ...input speed Transfer output speed 0 9 to 1 1 OFF malfunction A ECM selected gear 1st Vehicle speed 2 to 40 km h 1 2 to 24 9 mph Throttle valve opening angle 8 or more and 7 0 or more at 2 000 rpm Conditions vary with engine speed OFF malfunction B Current ECM selected gear 5th Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec or more Actual gear when ECM selected 4th gear...

Page 1479: ...e following conditions are met Conditions A B and C 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction A Turbine speed Output speed 0 93 to 1 07 OFF malfunction B Turbine speed Output speed 0 65 to 0 79 OFF malfunction C Output record from ECM for 4th 5th upshifting Recorded ON malfunction Either of the following conditi...

Page 1480: ...anged with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 1150 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possi...

Page 1481: ...LC3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0751 is output A P0751 and other DTCs B HINT If any other codes besides P0751 are output perform troubleshooting for those DTCs first B Go to DTC ch...

Page 1482: ...Tester Connection Specified Condition 20 C 68 F Solenoid Connector S1 Solenoid Body S1 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace shift solenoid valve S1 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on each valve NG Repai...

Page 1483: ...ed Automatic transmission clutch brake or gear etc MONITOR DESCRIPTION This DTC indicates stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve S2 The ECM commands gear shifts by turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY R l t...

Page 1484: ...ing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 OFF malfunction A ECM selected gear...

Page 1485: ...th to 5th gear Less than 150 rpm Vehicle speed After transition from 4th to 5th gear Less than 100 km h 62 mph TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold OFF malfunction All of the following conditions are met Conditions A B C and D 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction A and B Turbine speed...

Page 1486: ...While driving the shift position can be forcibly changed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 1150 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others ...

Page 1487: ...LC3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0756 is output A P0756 and other DTCs B HINT If any other codes besides P0756 are output perform troubleshooting for those DTCs first B Go to DTC ch...

Page 1488: ... Tester Connection Specified Condition 20 C 68 F Solenoid Connector S2 Solenoid Body S2 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace shift solenoid valve S2 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on each valve NG Repa...

Page 1489: ...urning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same the ECM illuminates the MIL and stores the DTC MONITOR STRATEGY Related DTCs P0771 Shift solenoid valve SR Rationality check R i d C t Main Shift solenoid valve SR Required sensors Components Sub Speed sensor NT Speed sensor NO Crankshaft position sensor NE Frequency o...

Page 1490: ...r more at 2 000 rpm Conditions vary with engine speed OFF malfunction B Current ECM selected gear 5th Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec or more OFF malfunction C Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction Current ECM selected gear 2th Last ECM selected gear 1st Throttle valve opening angle During transition from 1st to 2nd gear...

Page 1491: ...e item DIAGNOSIS ENHANCED OBD II ACTIVE TEST g According to the display on the tester perform the ACTIVE TEST HINT While driving the shift position can be forcibly changed with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 1150 Item Test Details Diagnostic Note SHIFT Test Details Operate ...

Page 1492: ...put Proceed to Only P0771 is output A P0771 and other DTCs B HINT If any other codes besides P0771 are output perform troubleshooting for those DTCs first B Go to DTC chart See page DI 1156 A 2 Inspect shift solenoid valve SR operation PREPARATION Remove the shift solenoid valve SR See page AT 12 CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specifie...

Page 1493: ...Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL1 See page AT 12 OK 4 Inspect valve body See page AT 12 OK There are no foreign objects on eac...

Page 1494: ...c Shift solenoid valve SL2 remains open or closed Valve body is blocked Automatic transmission clutch brake or gear etc MONITOR DESCRIPTION This DTC indicates stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SL2 The ECM commands gear shifts by turning the shift solenoid valves ON OFF When the gear position com manded by the ECM and the actual gear position are not the same...

Page 1495: ...om Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 ON malfunction A E...

Page 1496: ...L MALFUNCTION THRESHOLDS Detection criteria Threshold Both of the following conditions are met ON lf ti A d B ON lf ti C ON malfunctions A and B or ON malfunction C ON malfunction D or E ON malfunction A Turbine speed Output speed 3 30 to 7 50 ON malfunction B Turbine speed Output speed 1 28 to 1 53 ON malfunction C Turbine speed Output speed 0 93 to 1 07 ON malfunction D Turbine speed Output spee...

Page 1497: ...nged with the hand held tester Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 1150 Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possib...

Page 1498: ...C3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0776 is output A P0776 and other DTCs B HINT If any other codes besides P0776 are output perform troubleshooting for those DTCs first B Go to DTC cha...

Page 1499: ...Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL2 See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on eac...

Page 1500: ...hift solenoid valve SL2 circuit The ECM commands gear shift by turning the shift solenoid valves ON OFF When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and stores the DTC And the ECM per forms the fail safe function and turns the other normal shift solenoid valves ON OFF In case of an open or short circuit the ECM stops...

Page 1501: ...mission Solenoid E6 ECM W B 17 16 SL2 SL2 11 3 V Y E1 SL2 SL2 B CPU E6 SL2 DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1217 COMPONENT OPERATING RANGE Parameter Standard value Output signal duty Less than 100 WIRING DIAGRAM ...

Page 1502: ...alve SL2 is turned on off normally when the shift lever is in the D position 1 Inspect transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 11 SL2 3 SL2 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connect...

Page 1503: ...onnector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 17 SL2 E6 16 SL2 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 17 SL2 Body ground 10 kΩ or higher E6 16 SL2 Body ground NG Repair or replace harness or connector See page IN 30 OK ...

Page 1504: ...according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SL2 See page AT 12 OK Repair or replace th...

Page 1505: ...FF and switching oil pressure to the valves in the valve body The ECM calculates the actual transmission gear by comparing the signals from the input speed sensor NCO and the output speed sensor SP2 The ECM can detect many mechanical problems in the shift sole noids valve body and the transmission clutches brakes and gears If the ECM detects that the actual gear position and the commanded gear pos...

Page 1506: ... advance from Max retard timing by KCS control 0 CA or more Engine Starting Transfer range HIGH 1 Transfer range HIGH 1 This condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 Conditi...

Page 1507: ...NT NO x 4th gear ratio 1 000 rpm or more Condition D Turbine speed Output speed x 5th gear ratio NT NO x 5th gear ratio 1 000 rpm or more INSPECTION PROCEDURE 1 Check other DTCs output in addition to DTC P0781 PREPARATION a Turn the ignition switch off b Connect the OBD II scan tool or hand held tester to the DLC3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item...

Page 1508: ...sition commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem See page DI 1150 Standard Item Test Details Diagnostic Note SHIFT Test Details Operate the shift solenoid valve and set each shift position by yourself Vehicle Condition Less than 50 km h 31 mph Others Press button Shift up Press button Shift down Possible to check the operation of the shift solen...

Page 1509: ...E A750F for 2UZ FE DI 1225 3 Clear the DTC and running test CHECK Clear the DTC and check DTC again after conducting the MONITOR DRIVE PATTERN FOR ECT TEST See page DI 1134 OK No DTC code NG Repair or replace valve body See page AT 12 OK END ...

Page 1510: ...en in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated 1 trip detection logic Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and sto...

Page 1511: ...present See page DI 1128 Range check Low resistance Shift solenoid valve S1 ON Range check High resistance Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve S1 resistance 8 Ω or less Range check High resistance Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Parameter Standard value Sh...

Page 1512: ... TRANSMISSION A750E A750F for 2UZ FE INSPECTION PROCEDURE HINT The shift solenoid valve S1 is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 8 Body ground 11 to 15 Ω NG Go to st...

Page 1513: ...re ECM PREPARATION a Connect the transmission wire connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 11 S1 Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 82 ...

Page 1514: ...nce according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector S1 Solenoid Body S1 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace the shift solenoid valve S1 See page AT 12 OK Repair or replace the transmission ...

Page 1515: ...en in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated 1 trip detection logic Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and sto...

Page 1516: ...t present See page DI 1128 Range check Low resistance Shift solenoid valve S2 ON Range check High resistance Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve S2 resistance 8 Ω or less Range check High resistance Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Parameter Standard value ...

Page 1517: ...SSION A750E A750F for 2UZ FE DI 1233 INSPECTION PROCEDURE HINT The shift solenoid valve S2 is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 15 Body ground 11 to 15 Ω NG Go to s...

Page 1518: ...re ECM PREPARATION a Connect the transmission wire connector b Disconnect the ECM connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 10 S2 Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 82 ...

Page 1519: ...nce according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector S2 Solenoid Body S2 11 to 15 Ω CHECK Connect the positive lead to the terminal of the solenoid con nector and the negative lead to the solenoid body OK The solenoid makes an operating sound NG Replace the shift solenoid valve S2 See page AT 12 OK Repair or replace the transmission ...

Page 1520: ...en in solenoid valve SR circuit 2 times when solenoid valve SR is not operated 1 trip detection logic Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit When there is an open or short circuit in any shift solenoid valve circuit the ECM detects the problem and illuminates the MIL and sto...

Page 1521: ... solenoid valve SR ON Battery voltage 8 V or more Ignition switch ON Starter OFF Range check High resistance Shift solenoid valve SR OFF Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve SR resistance 8 Ω or less Range check High resistance Shift solenoid valve SR resistance 100 kΩ ...

Page 1522: ...C TRANSMISSION A750E A750F for 2UZ FE INSPECTION PROCEDURE HINT The shift solenoid valve SR is turned on off normally when the shift lever is in the D position 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 7 Body ground 11 to 15 Ω NG Go to s...

Page 1523: ...ECM PREPARATION a Connect the transmission wire connector b Disconnect the connector of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 9 SR Body ground 11 to 15 Ω NG Repair or replace the harness or connector See page IN 30 OK Replace the ECM See page SF 82 ...

Page 1524: ...ording to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F Solenoid Connector SR Solenoid Body SR 11 to 15 Ω CHECK Connect the battery positive lead to the solenoid connector ter minal and the battery negative lead to the solenoid body ground OK Solenoid sounds an operation noise NG Replace the shift solenoid valve SR See page AT 12 OK Repair or replace the transmi...

Page 1525: ... of continuity in one cycle and B is the period of non continuity then Duty Ratio A A B x 100 DTC No DTC Detection Condition Trouble Area P2714 ECM detects a malfunction on SLT ON side according to the revolution difference of the turbine and the output shaft and also by the oil pressure 2 trip detection logic Shift solenoid valve SLT remains open or closed Valve body is blocked Automatic transmis...

Page 1526: ...uit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT Engine coolant temperature sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS Electric throttle control s...

Page 1527: ... Solenoid E6 G BR 14 6 SLT SLT B SLT DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1243 TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Summation of C1 clutch heat generations Turbine speed Output speed x Temporary ratio Specified value WIRING DIAGRAM ...

Page 1528: ... According to the display on tester perform the ACTIVE TEST Item Test Details Diagnostic Note LINE PRESS UP Test Details Operate the shift solenoid SLT and raise the line pressure Vehicle Condition Vehicle Stopped IDL ON HINT OFF Line pressure up When the active test of Control the Line Pres sure Up is performed the ECM commands the SLT solenoid to turn off ON No action normal operation LINE PRESS...

Page 1529: ...LC3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P2714 is output A P2714 and other DTCs B HINT If any other codes besides P2714 are output perform troubleshooting for those DTCs first B Go to DTC ch...

Page 1530: ...er Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLT See page AT 12 OK 3 Inspect valve body See page AT 12 OK There are no foreign objects on ...

Page 1531: ...a fault The ECM will turn on the MIL and store the DTC MONITOR STRATEGY Related DTCs P2716 Shift solenoid valve SLT Range check Required sensors Components Shift solenoid valve SLT Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS It Specification Item Minimum Maximum The monitor will run whenever this DTC is not present...

Page 1532: ...0F for 2UZ FE WIRING DIAGRAM INSPECTION PROCEDURE 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 14 SLT 6 SLT 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 14 SL...

Page 1533: ...nector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 13 SLT E6 12 SLT 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 13 SLT Body ground 10 kΩ or higher E6 12 SLT Body ground NG Repair or replace the harness or connector See page IN 30 O...

Page 1534: ...ccording to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLT See page AT 12 OK Repair or replace the...

Page 1535: ... ATF temperature Sensor No 2 State Detection Condition Symptom Recovery Condition AT fluid temp more than 150 C 302 F AT Oil Temp warning light re mains on AT fluid temp less than 135 C 275 F 2 AT fluid temp more than 130 C 266 F Shift point too high AT fluid temp less than 110 C 230 F Sensor is normal When the conditions a and b are satisfied a AT fluid temp more than 130 C 266 F b Engine coolant...

Page 1536: ...smission wire ATF temperature sensor No 2 ECM MONITOR DESCRIPTION The Automatic Transmission Fluid ATF temperature sensor converts ATF temperature to an electrical re sistance value Based on the resistance the ECM determines the ATF temperature and the ECM detects an open or short in the AFT temperature circuit If the resistance value of the ATF temperature is less than 25 Ω 0 046 V or more than 1...

Page 1537: ...a Threshold Range check Fluttering TFT transmission fluid temperature sensor voltage Less than 0 046 V or More than 4 915 V Range check Low voltage TFT transmission fluid temperature sensor voltage Less than 0 046 V Range check High voltage TFT transmission fluid temperature sensor voltage More than 4 915 V COMPONENT OPERATING RANGE Parameter Standard value TFT transmission fluid temperature senso...

Page 1538: ...e OBD II scan tool or the hand held tester f When you use the hand held tester Select the item DIAGNOSIS ENHANCED OBD II DATA LIST g According to the display on the tester read the DATA LIST Item MeasurementItem Range display Normal Condition AT FLUID TEMP 2 ATF Temp Sensor Value min 40 C 40 F max 215 C 419 F After Stall Test Approx 80 C 176 F Equal to ambient temperature when cold soak HINT When ...

Page 1539: ...resistance according to the value s in the table below OK Tester Connection Specified Condition 1 OT2 9 OT2 25 Ω to 156 kΩ 1 OT2 Body ground 10 kΩ or higher 9 OT2 Body ground 10 kΩ or higher HINT If the resistance is out of the specified range with either the ATF temperature shown in the table below the driveability of the ve hicle may decrease ATF Temperature Specified Condition 20 C 68 F 3 to 4 ...

Page 1540: ...or of the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 32 THO2 E7 28 E2 25 Ω to 156 kΩ CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 32 THO2 Body ground 10 kΩ or higher E7 28 E2 Body ground NG Repair or replace the harness or connector See page IN 30 OK...

Page 1541: ... condition of the lock up clutch Then the ECM compares the engagement condition of the lock up clutch with the lock up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU valve body and torque converter clutch DTC No DTC Detection Condition Trouble Area P2757 Lock up does not occur when driving in the lock up range normal driving at 80 km h 50 mph or lock up ...

Page 1542: ...bine speed of the torque converter when the ECM commands lock up Engine speed is at least 70 rpm greater than input turbine speed b There is no difference in rotation between the input side engine speed and output side input turbine speed of the torque converter when the ECM commands lock up off The difference between engine speed and input turbine speed is less than 35 rpm MONITOR STRATEGY R l t ...

Page 1543: ...is condition is applied only 4WD 1 Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO NOtf Transfer input speed Transfer output speed 0 9 to 1 1 OFF malfunction A ECM lock up command ON SLU pressure 513kpa or more Vehicle speed Less than 100 km h 62 2 mph OFF malfunction B ...

Page 1544: ...nd B OFF malfunction A Engine speed Turbine speed 70 rpm or more OFF malfunction B Turbine speed Output speed Not 3 30 to 7 50 ON malfunction 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON Vehicle speed must be under 8 km h 5 mph once before 2nd detection Difference between engine speed and turbine speed Less then 35 rpm ...

Page 1545: ...IAGNOSIS ENHANCED OBD II ACTIVE TEST g According to the display on the tester perform the ACTIVE TEST Item Test Details Diagnostic Note LOCK UP Test Details Control the shift solenoid SLU to set the automatic transmission to the lock up condition Vehicle Condition Throttle valve opening angle Less than 35 Vehicle Speed 60 km h 37 mph or more Possible to check the SLU opera tion HINT This test can ...

Page 1546: ...C3 c Turn the ignition switch to the ON position d Turn on the tester e Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P2757 is output A P2757 and other DTCs B HINT If any other codes besides P2757 are output perform troubleshooting for those DTCs first B Go to DTC cha...

Page 1547: ... the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLU See page AT 12 OK 3 Inspect valve body See page AT 12 OK There ar...

Page 1548: ...MATIC TRANSMISSION A750E A750F for 2UZ FE 4 Check torque converter clutch See page AT 39 OK The torque converter clutch operates normally NG Replace the torque converter clutch OK Repair or replace transmission See page AT 34 ...

Page 1549: ...ple if A is the period of continuity in one cycle and B is the period of non continuity then Duty Ratio A A B x 100 DTC No DTC detection condition Trouble Area P2759 Open or short is detected in shift solenoid valve SLU circuit for 1 second or more while driving 1 trip detection logic Open or short in shift solenoid valve SLU circuit Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or...

Page 1550: ...on Item Minimum Maximum The monitor will run whenever this DTC is not present See page DI 1128 Solenoid current cut status Not cut CPU commanded duty 19 or more Battery voltage 11 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Solenoid status from IC Fail Open or short COMPONENT OPERATING RANGE Parameter Standard value Output signal duty Less t...

Page 1551: ...ission wire PREPARATION Disconnect the transmission wire connector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 13 SLU 5 SLU 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 13 SLU Body ground 10 kΩ or higher 5 SLU Body ground NG Go to step 3 ...

Page 1552: ...nector CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F E6 15 SLU E6 14 SLU 5 0 to 5 6 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E6 15 SLU Body ground 10 kΩ or higher E6 14 SLU Body ground NG Repair or replace the harness or connector See page IN 30 O...

Page 1553: ... according to the value s in the table below OK Tester Connection Specified Condition 20 C 68 F 1 2 5 0 to 5 6 Ω CHECK Connect the positive lead with a 21 W bulb to terminal 2 and the negative lead to terminal 1 of the solenoid valve connec tor then check the movement of the valve OK The solenoid makes an operating sound NG Replace the shift solenoid valve SLU See page AT 12 OK Repair or replace t...

Page 1554: ... the L4 position switch L4 switch indicated that the L4 transfer case gears are engaged Transfer case shifter is in the H position Transfer case output shaft rpm is between 750 and 3 000 rpm The specified time period has elapsed If all of the above conditions are detected the ECM will conclude that there is a malfunction of the L4 switch and illuminate the MIL and store the DTC MONITOR STRATEGY Re...

Page 1555: ...R IN J58 J C L R W B W B W B 1 2 A E D B B J55 J56 J C Double Cab DIAGNOSTICS AUTOMATIC TRANSMISSION A750E A750F for 2UZ FE DI 1271 TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Both of the following conditions is met ON malfunctions A and B ON malfunction A L4 switch ON ON malfunction B Actual Transfer gear ratio Transfer input speed Transfer output speed 0 9 to 1 1 WIRING DIAGRAM ...

Page 1556: ...CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 1 Body ground Below 1 Ω NG Repair or replace the harness or connector See page IN 30 OK 2 Inspect transfer L4 position switch PREPARATION Remove the transfer position L4 switch CHECK Measure the resistance according to the value s in the table below OK Switch position Tester Connection...

Page 1557: ...isconnect the connector from the ECM CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E5 13 L4 D4 2 L4 Below 1 Ω CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition E5 13 L4 Body ground 10 kΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Replace...

Page 1558: ...FE O D Main Switch Circuit CIRCUIT DESCRIPTION The O D main switch transmission control switch is a momentary type switch When pressing the O D main switch once the O D OFF indicator light comes on and the ECM prohibits shifting into O D When pressing it once again the O D OFF indicator light goes off and the ECM allows shifting into O D Turning the IG switch OFF will reset the O D OFF indicator l...

Page 1559: ...CHECK Measure the resistance according to the value s in the table below OK Tester Connection Specified Condition 1 Body ground Below 1 Ω NG Repair or replace the harness or connector See page IN 30 OK 2 Inspect O D main switch CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition O D main switch pressed and held 1 3 Belo...

Page 1560: ...nnect the connector from the ECM CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition O D main switch pressed and held E3 12 ODMS Body ground Below 1 Ω O D main switch released 10 kΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Proceed to next circuit inspection shown on matrix chart See page...

Page 1561: ... TRANSMISSION A750E A750F for 2UZ FE DI 1277 Shift Position L Switch Circuit CIRCUIT DESCRIPTION The shift position L switch is a momentary type switch When the shift position L switch is pressed while driving with the shift lever in the 2 position the L position indicator on the combination meter comes on and the transmission is locked in 1st gear When the switch is pressed again the indicator go...

Page 1562: ... to the value s in the table below OK Tester Connection Specified Condition 10 Body ground Below 1 Ω NG Repair or replace the harness or connector See page IN 30 OK 2 Inspect center cluster integration panel shift position L switch CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition Shift position L switch pressed and h...

Page 1563: ...L switch b Disconnect the connector from the ECM CHECK Measure the resistance according to the value s in the table below OK Switch Condition Tester Connection Specified Condition Shift position L switch pressed and held E4 9 LMS Body ground Below 1 Ω Shift position L switch released 10 kΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Proceed to next circuit inspection ...

Page 1564: ...d OFF e All vacuum lines properly connected f SFI system wiring connectors fully plugged g Correct ignition timing h Transmission in neutral position i Tachometer and CO HC meter calibrated by hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 180 SE CONDS 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...

Page 1565: ... HC Problems Causes Normal High Rough idle 1 Faulty ignitions Incorrect timing Fouled shorted or improperly gapped plugs 2 Incorrect valve clearance 3 Leaky intake and exhaust valves 4 Leaky cylinders Low High Rough idle fluctuating HC reading 1 Vacuum leaks PCV hose Intake manifold Throttle body 2 Lean mixture causing misfire High High Rough idle Black smoke from exhaust 1 Restricted air filter 2...

Page 1566: ...h c for each cylinder NOTICE This measurement must be done in the shortest possible time Compression pressure 1 3 MPa 13 3 kgf cm2 189 psi or more Minimum pressure 1 0 MPa 10 2 kgf cm2 145 psi Difference between each cylinder 0 1 MPa 1 0 kgf cm2 15 psi or less e If the cylinder compression pressure in 1 or more cylin ders is low pour a small amount of engine oil into the cylin der through the spar...

Page 1567: ...IR SURGE TANK See page EM 62 5 REMOVE IGNITION COIL 6 REMOVE CYLINDER HEAD COVER See page EM 62 7 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with the timing mark 0 of the timing chain cover b Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration If not turn the cranksha...

Page 1568: ...29 to 0 39 mm 0 011 to 0 015 in 2 Record the out of specification valve clearance measurements They will be used later to determine the required replacement valve lifter b Turn the crankshaft 2 3 of a revolution 240 and check the valves indicated in the illustration 1 Using a feeler gauge measure the clearance be tween the valve lifter and camshaft Valve clearance Cold Intake 0 15 to 0 25 mm 0 006...

Page 1569: ...0 006 to 0 010 in Exhaust 0 29 to 0 39 mm 0 011 to 0 015 in 2 Record the out of specification valve clearance measurements They will be used later to determine the required replacement valve lifter 9 ADJUST VALVE CLEARANCE a Set the No 1 cylinder to the TDC compression 1 Turn the crankshaft pulley and align the notch with the timing mark 0 of the timing chain cover 2 Check that the timing marks of...

Page 1570: ...e tensioner up ward push in the plunger of the chain tensioner as shown in the illustration 3 While rotating the stopper plate of the tensioner downward insert a bar of φ 3 5 mm 0 138 in into the holes in the stopper plate and tensioner to fix the stopper plate 4 Remove the 2 bolts and chain tensioner No 1 c Remove the No 2 camshaft NOTICE As the thrust clearance of the camshaft is small the cam s...

Page 1571: ...illustration 5 Using several steps loosen and remove the 8 bear ing cap bolts uniformly in the sequence as shown in the illustration 6 Remove the 4 bearing caps and No 2 camshaft d Remove the chain tensioner No 2 1 Remove the chain tensioner No 2 bolt and then re move the chain tensioner No 2 and camshaft timing sprocket e Remove the camshaft NOTICE As the thrust clearance of the camshaft is small...

Page 1572: ...Slide the camshaft timing gear assembly and sepa rate the No 1 chain from the camshaft timing gear sprocket 3 Rotate the No 1 camshaft counterclockwise using a wrench so that the cam lobes of No 1 cylinder face upward as shown in the illustration 4 Using several steps loosen and remove the 8 bear ing cap bolts uniformly in the sequence as shown in the illustration 5 Remove the 4 bearing caps 6 Rem...

Page 1573: ...shaft thrust may crack or be damaged causing the camshaft to seize or break To avoid this the following steps should be carried out 1 While pushing down the chain tensioner No 2 in sert a pin of φ 1 0 mm 0 039 in into the hole to fix it 2 Hold the hexagonal portion of the No 4 camshaft with a wrench and remove the camshaft timing sprocket set bolt NOTICE Be careful not to damage the cylinder head ...

Page 1574: ...kept level the portion of the cylinder head which receives 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 1 Using several steps loosen and remove the 8 bear ing cap bolts uniformly in the sequence as shown in the illustration 2 Remove the 4 bearing caps 3 Hold the No 1 chain and remove the No 3 cam shaft camsh...

Page 1575: ...e thickness of a new lifter so that the valve clearance comes within the specified value T Thickness of removed lifter A Measured valve clearance N Thickness of new lifter Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 30 mm 0 012 in 3 Select a new lifter with a thickness as close as pos sible to the calculated value HINT Lifters are available in 35 sizes in increments of 0 020 mm 0 0008 in from 5 ...

Page 1576: ...ce mm in No Thickness No Thickness No Thickness Intake valve clearance Cold 0 15 to 0 25 mm 0 0059 to 0 0098 in EXAMPLE The 5 250 mm 0 2067 in lifter is installed and the measured clearance is 0 400 mm 0 0158 in Replace the 5 250 mm 0 2067 in shim with a new No 46 lifter ENGINE MECHANICAL 1GR FE VALVE CLEARANCE EM 13 ...

Page 1577: ...ce mm in No Thickness No Thickness No Thickness Exhaust valve clearance Cold 0 29 to 0 39 mm 0 0114 to 0 0154 in EXAMPLE The 5 340 mm 0 2102 in lifter is installed and the measured clearance is 0 480 mm 0 0189 in Replace the 5 340 mm 0 2102 in shim with a new No 48 lifter EM 14 ENGINE MECHANICAL 1GR FE VALVE CLEARANCE ...

Page 1578: ... avoid this the following steps should be carried out 1 Align the mark link yellow with the timing mark 2 dot mark of the camshaft timing gear assembly as shown in the illustration 2 Apply new engine oil to the thrust portions and jour nals of the camshafts 3 Temporarily put the No 1 chain on the No 2 chain of the camshaft timing gear assembly 4 Set the No 3 camshaft onto the LH cylinder head with...

Page 1579: ...in the tensioner insert a pin of φ 1 0 mm 0 039 in into the hole to fix it 2 Temporarily install the camshaft timing assembly and chain tensioner No 2 and align the mark links yellow with the timing marks 1 dot mark and 2 dot mark of the camshaft timing sprocket and camshaft timing gear assembly 3 Tighten the chain tensioner No 3 bolt Torque 19 N m 194 kgf cm 14 ft lbf m Install the No 4 camshaft ...

Page 1580: ...he bolts uniformly in the sequence as shown in the illustration Torque 9 0 N m 92 kgf cm 80 in lbf for 10 mm 0 39 in head 24 N m 245 kgf cm 18 ft lbf for 12 mm 0 47 in head 6 Hold the hexagonal portion of the No 4 camshaft with a wrench and tighten the camshaft timing sprocket set bolt Torque 100 N m 1 020 kgf cm 74 ft lbf 7 Remove the pin from the chain tensioner No 2 n Install the camshaft NOTIC...

Page 1581: ...hain of the camshaft timing gear assembly 4 Align the knock pin hole on the camshaft timing gear assembly with the knock pin of the No 1 camshaft and insert the No 1 camshaft into the camshaft tim ing gear assembly 5 Temporarily install the camshaft timing gear assem bly set bolt 6 Set the No 1 camshaft onto the RH cylinder head with the cam lobes of the No 1 cylinder facing downward as shown in t...

Page 1582: ... the No 1 camshaft clockwise using the hex agonal portion of the No 1 camshaft so that the tim ing mark of the camshaft timing gear assembly is aligned with the timing mark of the camshaft bear ing cap 11 Align the paint mark of the No 1 chain with the tim ing mark of the camshaft timing gear assembly 12 Hold the hexagonal portion of the No 1 camshaft with a wrench and tighten the camshaft timing ...

Page 1583: ...led If the camshaft is not kept level the portion of the cylinder head which receives 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 1 Set the No 2 camshaft onto the RH cylinder head with the cam lobes of No 1 cylinder facing upward as shown in the illustration 2 Install the 4 bearing caps in their proper loca...

Page 1584: ...l the chain tensioner No 1 1 While turning the stopper plate of the tensioner clockwise push in the plunger of the tensioner as shown in the illustration 2 While turning the stopper plate of the tensioner counterclockwise insert a bar of φ 3 5 mm 0 138 in into the holes on the stopper plate and tensioner to fix the stopper plate 3 Install the chain tensioner with the 2 bolts Torque 10 N m 102 kgf ...

Page 1585: ...bly and camshaft timing sprocket are aligned with the timing marks of the bearing caps as shown in the illustration 10 INSTALL CYLINDER HEAD COVER See page EM 89 11 INSTALL IGNITION COIL 12 INSTALL INTAKE AIR SURGE TANK See page EM 89 13 INSTALL AIR CLEANER See page EM 89 14 ADD ENGINE COOLANT See page CO 2 15 INSTALL V BANK COVER 16 INSPECT IGNITION TIMING See page EM 23 ...

Page 1586: ...rk Vehicle Interface Module CAN VIM Then connect the CAN VIM to the Date Link Connector 3 DLC3 2 Please refer to the hand held tester operator s manual for further details Ignition timing 7 to 24 BTDC at idle Transmission in neutral 3 Disconnect the hand held tester or OBD II scan tool from the DLC3 b When not using a hand held tester or OBD II scan tool 1 Remove the air cleaner cap 2 Connect the ...

Page 1587: ...ignition timing Ignition timing 8 to 12 BTDC at idle Transmission in neutral position 5 Remove the SST from the DLC3 6 Check the ignition timing Ignition timing 7 to 24 BTDC at idle Transmission in neutral position 7 Disconnect the timing light from the engine 8 Install the air cleaner cap ...

Page 1588: ...t 2 500 rpm for approx 90 seconds e Check the idle speed Idle speed 650 to 750 rpm Transmission in neutral position If the idle speed is not as specified check the air intake system f Disconnect the hand held tester or OBD II scan tool from the DLC3 2 When not using a hand held tester or OBD II scan tool a Using SST connect the tachometer probe to terminal TAC of the DLC3 SST 09843 18030 b Switch ...

Page 1589: ...leaner Hose Mass Air Flow Meter Connector Ventilation Hose No 2 Battery Clamp Battery Battery Tray N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf 7 5 76 66 in lbf Air Cleaner EM 26 ENGINE MECHANICAL 1GR FE TIMING CHAIN TIMING CHAIN COMPONENTS ...

Page 1590: ...A23193 Radiator Fan Shroud Fan Pulley Fan w Fluid Coupling Drive Belt 21 214 15 N m kgf cm ft lbf Specified torque ENGINE MECHANICAL 1GR FE TIMING CHAIN EM 27 ...

Page 1591: ... Wire Generator Connector Wire Harness Clamp Bracket Cooler Compressor Connector Cooler Compressor 9 0 92 80 in lbf 43 438 32 8 0 82 71 in lbf 8 0 82 71 in lbf 9 8 100 7 43 438 32 43 438 32 25 255 18 N m kgf cm ft lbf Specified torque Non reusable part EM 28 ENGINE MECHANICAL 1GR FE TIMING CHAIN ...

Page 1592: ... V Ribbed Belt Tensioner Oil Pan Oil Strainer Oil Pan No 2 Drain Plug O ring Gasket Gasket 40 408 30 10 102 7 9 0 92 80 in lbf 9 0 92 80 in lbf 10 102 7 21 214 15 21 214 15 21 214 15 36 367 27 36 367 27 54 551 40 39 398 29 9 0 92 80 in lbf N m kgf cm ft lbf Specified torque Non reusable part 37 377 27 x2 x9 x6 x2 x4 x2 x15 x5 ENGINE MECHANICAL 1GR FE TIMING CHAIN EM 29 ...

Page 1593: ...der Head Cover RH Ignition Coil Cylinder Head Cover Gasket Cylinder Head Cover Gasket Cylinder Head Cover LH 21 214 15 21 214 15 9 0 92 80 in lbf 10 102 7 10 102 7 10 102 7 9 0 92 80 in lbf 9 0 92 80 in lbf 9 0 92 80 in lbf Oil Baffle Plate 21 214 15 28 286 21 N m kgf cm ft lbf Specified torque Non reusable part x2 x4 x7 x3 x3 x7 x3 x3 Ignition Coil 9 0 92 80 in lbf 10 102 7 EM 30 ENGINE MECHANICA...

Page 1594: ...Timing Chain Idle Gear Shaft No 2 Idle Gear No 1 Idle Gear Shaft No 1 O ring Crankshaft Timing Sprocket Chain Vibration Damper No 1 23 235 17 x15 250 2 549 184 100 1 020 74 100 1 020 74 23 235 17 23 235 17 100 1 020 74 100 1 020 74 Chain Tensioner No 2 19 194 14 Chain Tensioner No 2 19 194 14 10 102 7 Chain Tensioner Slipper 60 612 44 19 194 14 N m kgf cm ft lbf Specified torque Non reusable part ...

Page 1595: ...age EM 62 12 REMOVE VVT SENSOR 13 REMOVE OIL LEVEL GAUGE GUIDE a Remove the oil level gauge b Remove the bolt and pull out the oil level gauge guide c Remove the O ring from the oil level gauge guide 14 SEPARATE VANE PUMP a Disconnect the P S oil pressure switch connector b Remove the 2 bolts and separate the vane pump NOTICE Do not hit the pulley to other parts when separating the vane pump HINT ...

Page 1596: ...e the crankshaft pulley SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05031 20 REMOVE OIL PAN NO 2 a Remove the 15 bolts and 2 nuts b Insert the blade of SST between the oil pan and oil pan No 2 cut off applied sealer and remove the oil pan No 2 SST 09032 00100 NOTICE Be careful not to damage the contact surface of the oil pan and oil pan No 2 Be careful not to damage the oil pan No 2 ...

Page 1597: ...ove the flywheel housing under cover c Remove 17 bolts and 2 nuts d Using a screwdriver remove the oil pan by prying be tween the oil pan and cylinder block in the sequence shown NOTICE Be careful not to damage the contact surfaces of the cylin der block and oil pan e Remove the O ring from the oil pump 23 REMOVE WATER INLET a Disconnect the 2 oil cooler hoses w oil cooler ...

Page 1598: ...N EM 35 b Disconnect the 2 radiator hoses c Disconnect the 5 water by pass hoses d Remove the 5 bolts and water inlet e Remove the O ring from the water outlet pipe f Remove the gasket from the water pump 24 REMOVE TIMING CHAIN COVER a Remove the 24 bolts and 2 nuts ...

Page 1599: ...R TO TDC COMPRESSION a Install the crankshaft pulley set bolt and turn the crank shaft to align the crankshaft set key with the timing line of the cylinder block b Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are aligned with the timing marks of the bearing caps as shown in the il lustration If not turn the crankshaft 1 complete revolution 360 and a...

Page 1600: ... a 10 mm hexagon wrench remove the idle gear shaft No 2 idle gear No 1 and idle gear shaft No 1 29 REMOVE CHAIN VIBRATION DAMPER NO 2 Remove the 2 chain vibration damper No 2 30 REMOVE NO 1 TIMING CHAIN 31 REMOVE CRANKSHAFT TIMING SPROCKET 32 REMOVE NO 2 TIMING CHAIN a While raising the chain tensioner No 2 insert a pin of φ 1 0 mm 0 039 in into the hole to fix it b Hold the hexagonal portion of t...

Page 1601: ...rm the same measurements by pulling at random in 3 or more places to obtain an average length If the elongation is greater than the maximum replace the chain 2 INSPECT CAMSHAFT TIMING GEAR ASSEMBLY a Put the No 1 chain on the larger gear of the camshaft tim ing gear assembly b Using a vernier caliper measure the timing gear with the chain Minimum gear diameter w chain 115 5 mm 4 547 in NOTICE The ...

Page 1602: ...or the measuring If the diameter is less than the minimum replace the No 2 chain and camshaft timing gear assembly 3 INSPECT CAMSHAFT TIMING SPROCKET a Put the No 2 chain on the camshaft timing sprocket b Using a vernier caliper measure the camshaft timing sprocket diameter with the chain Minimum gear diameter w chain 73 1 mm 2 878 in NOTICE The vernier caliper must contact the chain rollers for t...

Page 1603: ...ameter is less than the minimum replace the No 1 chain and crankshaft timing sprocket 5 INSPECT IDLE GEAR NO 1 a Put the No 1 chain on the idle gear b Using a vernier caliper measure the idle gear with the chain Minimum gear diameter w chain 61 0 mm 2 402 in NOTICE The vernier caliper must contact the chain rollers for the measuring If the diameter is less than the minimum replace the No 1 chain a...

Page 1604: ...O 1 a Check that the plunger moves smoothly when the ratchet pawl is raised with a finger b Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with a finger 8 INSPECT CHAIN TENSIONER NO 2 a Check that the plunger moves smoothly b Measure the worn depth of the chain tensioner slipper Maximum depth 1 0 mm 0 039 in If the depth is...

Page 1605: ...E TIMING CHAIN 10 INSPECT CHAIN VIBRATION DAMPER NO 1 AND NO 2 Measure the worn depth of the chain vibration damper No 1 and No 2 Maximum depth 1 0 mm 0 039 in If the depth is greater than the maximum replace the chain vibration damper No 1 or No 2 ...

Page 1606: ...the tip of the screwdriver with tape 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the timing chain cover edge SST 09226 10010 3 Apply MP grease to the oil seal lip b If the rear timing chain cover is installed 1 Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Wrap the tip of the screwdriver with tape 2 Using SST and a hammer...

Page 1607: ...NSTALL CHAIN TENSIONER NO 2 a While pushing in the tensioner insert a pin of φ 1 0 mm 0 039 in into the hole to fix it b Install the chain tensioner No 2 with the bolt Torque 19 N m 194 kgf cm 14 ft lbf 3 INSTALL NO 2 TIMING CHAIN a Align the mark links yellow with the timing marks 1 dot mark of the camshaft timing gear assembly and cam shaft timing sprocket as shown in the illustration b Align th...

Page 1608: ...AFT TIMING SPROCKET a Align the timing gear set key with the key groove of the timing sprocket b Install the timing gear onto the crankshaft with the sprock et side facing inward 6 INSTALL CHAIN TENSIONER SLIPPER 7 INSTALL CHAIN TENSIONER NO 1 a While turning the stopper plate of the tensioner clockwise push in the plunger of the tensioner as shown in the il lustration b While turning the stopper ...

Page 1609: ...ft timing sprocket and bearing caps b Using the crankshaft pulley set bolt turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block 9 INSTALL TIMING CHAIN NO 1 a Align the mark link yellow with the timing mark of the crankshaft timing sprocket b Align the mark links orange with the timing marks of the camshaft timing gear assembly and camshaft timing sprocket ...

Page 1610: ...ICE Be careful of the idle gear direction c Using a 10 mm hexagon wrench tighten the idle gear shaft No 2 Torque 60 N m 612 kgf cm 44 ft lbf d Remove the bar from the chain tensioner 12 INSTALL TIMING CHAIN COVER a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the timing chain cover cylinder head and cylinder block b Install a new O ring to the ...

Page 1611: ...acking After installing it the timing chain cover bolts and nuts must be tightened within 15 minutes Otherwise the seal packing must be re moved and reapplied Do not apply seal packing to the A as shown in the illustration e Align the key way of the oil pump drive rotor with the rect angular portion of the crankshaft timing gear and slide the timing chain cover into place f Install the timing chai...

Page 1612: ...ring d Install the water inlet with the 5 bolts Torque 9 0 N m 92 kgf cm 80 in lbf e Connect the 5 water by pass hoses f Connect the 2 radiator hoses g Connect the 2 oil cooler hoses w oil cooler 14 INSTALL OIL PAN a Install the 4 stud bolts Torque 4 0 N m 41 kgf cm 35 in lbf b Remove any old packing material FIPG and be careful not to drop any oil on the contact surfaces of the cylinder block rea...

Page 1613: ...lt A B Nut 21 N m 214 kgf cm 15 ft lbf Bolt C 10 N m 102 kgf cm 7 ft lbf HINT Each bolt length is as follows A 25 mm 0 98 in B 45 mm 1 77 in C 14 mm 0 55 in f Install the 4 housing bolts Torque 37 N m 377 kgf cm 27 ft lbf g Install the flywheel housing under cover 15 INSTALL OIL STRAINER a Install a new gasket and the oil strainer with the 2 nuts Torque 9 0 N m 92 kgf cm 80 in lbf 16 INSTALL OIL P...

Page 1614: ...que 250 N m 2 549 kgf cm 184 ft lbf 18 INSTALL IDLER PULLEY NO 1 Install the idler pulley with the bolt Torque 54 N m 551 kgf cm 40 ft lbf HINT DOUBLE is marked on the idler pulley No 1 to distinguish it from the idler pulley No 2 19 INSTALL IDLER PULLEY NO 2 Install the 2 idler pulleys with the 2 bolts Torque 39 N m 398 kgf cm 29 ft lbf 20 INSTALL V RIBBED BELT TENSIONER ASSY Tighten bolts A 1 an...

Page 1615: ... O ring c Push in the oil level gauge guide end into the guide hole of the oil pan d Install the oil level gauge guide with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf e Install the oil level gauge 26 INSTALL CYLINDER HEAD COVER See page EM 89 27 INSTALL INTAKE AIR SURGE TANK See page EM 89 28 INSTALL AIR CLEANER See page EM 89 29 INSTALL FAN W FLUID COUPLING See page EM 89 30 INSTALL DRIVE BELT S...

Page 1616: ...eaner Hose Mass Air Flow Meter Connector Ventilation Hose No 2 Battery Clamp Battery Battery Tray N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf 7 5 76 66 in lbf Air Cleaner ENGINE MECHANICAL 1GR FE CYLINDER HEAD EM 53 CYLINDER HEAD COMPONENTS ...

Page 1617: ...A23193 Radiator Fan Shroud Fan Pulley Fan w Fluid Coupling Drive Belt 21 214 15 N m kgf cm ft lbf Specified torque EM 54 ENGINE MECHANICAL 1GR FE CYLINDER HEAD ...

Page 1618: ...8 32 43 438 32 25 255 18 N m kgf cm ft lbf Specified torque Non reusable part VSV Connector Intake Air Surge Tank VSV Connector Fuel Vaper Feed Hose Surge Tank Stay No 2 Ventilation Hose No 1 Surge Tank Stay No 1 Water By pass Hose Throttle Body Connector Throttle Body Bracket Gasket 21 214 15 Oil Baffle Plate 28 286 21 9 0 92 80 in lbf 21 214 15 21 214 15 x2 x4 ENGINE MECHANICAL 1GR FE CYLINDER H...

Page 1619: ...nifold LH Front Exhaust Pipe N m kgf cm ft lbf Specified torque Non reusable part Manifold Stay Ventilation Hose Gasket 9 0 92 80 in lbf Gasket 9 0 92 80 in lbf Gasket Gasket Gasket Gasket Gasket 40 408 30 40 408 30 40 408 30 40 408 30 21 214 15 21 214 15 62 630 46 x6 x2 x6 x2 62 630 46 48 490 35 43 440 32 40 408 30 Spring EM 56 ENGINE MECHANICAL 1GR FE CYLINDER HEAD ...

Page 1620: ...er Gasket Intake Manifold Camshaft Timing Oil Control Valve Gasket Oil Filter Cap Housing Oil Filter Cap Ignition Coil Spark Plug 26 265 19 Ignition Coil 9 0 92 80 in lbf 36 367 27 36 367 27 Spark Plug 9 0 92 80 in lbf 54 551 40 39 398 29 N m kgf cm ft lbf Specified torque Non reusable part x10 9 0 92 80 in lbf Oil Level Gauge x5 10 102 7 10 102 7 ENGINE MECHANICAL 1GR FE CYLINDER HEAD EM 57 ...

Page 1621: ...Cylinder Head Cover Gasket Cylinder Head Cover Gasket 10 102 7 9 0 92 80 in lbf Cylinder Head Cover RH 10 102 7 9 0 92 80 in lbf Seal Washer Seal Washer Oil Level Gauge Guide O ring 9 0 92 80 in lbf Filter 62 632 46 62 632 46 Gasket Gasket Filter 9 0 92 80 in lbf VVT Sensor VVT Sensor 37 377 27 x15 x2 x2 x4 x6 x9 x2 x7 x7 x3 x3 x3 x3 Ventilation Valve 27 275 20 9 0 92 80 in lbf 9 0 92 80 in lbf EM...

Page 1622: ...Timing Chain Idle Gear Shaft No 2 Idle Gear No 1 Idle Gear Shaft No 1 O ring Crankshaft Timing Sprocket Chain Vibration Damper No 1 23 235 17 x15 250 2 549 184 100 1 020 74 100 1 020 74 23 235 17 23 235 17 100 1 020 74 100 1 020 74 Chain Tensioner No 2 19 194 14 Chain Tensioner No 2 19 194 14 10 102 7 Chain Tensioner Slipper 60 612 44 19 194 14 N m kgf cm ft lbf Specified torque Non reusable part ...

Page 1623: ...0 x8 x8 x8 x8 x2 See page EM 89 1st 36 367 27 2nd Turn 180 Camshaft Camshaft Camshaft Camshaft 24 245 18 9 0 92 80 in lbf 9 0 92 80 in lbf 9 0 92 80 in lbf 9 0 92 80 in lbf Camshaft Bearing Cap No 1 Camshaft Bearing Cap No 2 Camshaft Bearing Cap No 1 Camshaft Bearing Cap No 2 24 245 18 24 245 18 24 245 18 30 306 22 Camshaft Bearing Cap No 2 N m kgf cm ft lbf Specified torque Non reusable part EM 6...

Page 1624: ...etainer Lock Valve Spring Retainer Inner Compression Spring Valve Stem Oil Seal Valve Spring Seat Intake Valve Guide Bush Exhaust Valve Intake Valve Exhaust Valve Guide Bush Non reusable part ENGINE MECHANICAL 1GR FE CYLINDER HEAD EM 61 ...

Page 1625: ...age LU 3 4 REMOVE V BANK COVER Remove the 2 nuts and V bank cover 5 REMOVE AIR CLEANER a Disconnect the ventilation hose No 2 b Disconnect the vacuum hose c Disconnect the mass air flow meter connector d Remove the 2 wire harness clamps e Loosen the 2 hose clamps f Remove the 2 bolts and air cleaner 6 DISCONNECT FUEL PIPE See page SF 1 7 REMOVE FAN SHROUD 8 REMOVE RADIATOR See page CO 17 ...

Page 1626: ... turning the belt tensioner counter clockwise Remove the V ribbed belt from the belt tensioner 11 REMOVE FAN W FLUID COUPLING 12 SEPARATE VANE PUMP See page SR 47 13 REMOVE GENERATOR See page CH 7 14 SEPARATE COOLER COMPRESSOR See page AC 54 15 DISCONNECT HEATER WATER OUTLET AND INLET HOSE 16 REMOVE INTAKE AIR SURGE TANK a Disconnect the 2 water by pass hoses b Disconnect the fuel vapor feed hose ...

Page 1627: ... the ventilation hose d Disconnect the 2 VSV connectors e Disconnect the throttle body w motor connector f Separate the 3 wire harness clamps and hose clamp g Remove the 2 bolts and throttle body bracket h Remove the bolt and oil baffle plate i Remove the 4 bolts and 2 surge tank stays ...

Page 1628: ... Remove the 2 nuts oil filter cap housing and gasket c Remove the 10 bolts 3 seal washers 2 nuts cylinder head cover LH and gasket 19 REMOVE INTAKE MANIFOLD a Disconnect the 6 fuel injector connectors b Remove the 10 bolts intake manifold and 2 gaskets 20 REMOVE WATER BY PASS JOINT a Disconnect the engine coolant temperature sensor con nector b Disconnect the heater hose c Remove the 2 bolts 4 nut...

Page 1629: ... small the cam shaft must be kept level while it is being removed If the camshaft is not kept level the portion of the cylinder head which receives 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 Remove the camshafts of the RH bank 1 Rotate the camshafts counterclockwise using the wrench so that the cam lobes...

Page 1630: ... illustration Remove the 16 cylinder head bolts and plate washers NOTICE Be careful not to drop the plate washers into the cylin der head Cylinder head warpage or cracking could result from removing the bolts in the incorrect order c Lift the cylinder head from the dowels on the cylinder block and place the 2 cylinder heads on wooden blocks on a bench NOTICE Be careful not to damage the contact su...

Page 1631: ...g SST compress the inner compression spring and remove the 2 valve spring retainer locks SST 09202 70020 09202 00010 c Remove the valve inner compression spring valve spring and valve spring retainer 3 REMOVE VALVE SPRING SEAL Using compressed air and a magnetic finger remove the valve spring seat by blowing air 4 REMOVE VALVE STEM OIL SEAL Using needle nose pliers remove the valve stem oil seal 5...

Page 1632: ...ambers NOTICE Be careful not to scratch the combustion chambers c Using a valve guide bushing brush and solvent clean all the valve guide bushes d Using a soft brush and solvent thoroughly clean the cylin der head 6 CLEAN VALVE a Using a gasket scraper chip off any carbon from the valve head b Using a wire brush thoroughly clean the valve ...

Page 1633: ...a precision straight edge and feeler gauge mea sure the flatness of the contact surfaces of the cylinder block and manifolds Maximum warpage 0 10 mm 0 0039 in If warpage is greater than the maximum replace the cylinder head b Inspect cranks Using a dye penetrant check the combustion chamber intake ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head ...

Page 1634: ...UST MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge measure the flatness of the contact surface the cylinder head Maximum warpage 0 7 mm 0 028 in If warpage is greater than the maximum replace the exhaust manifold HINT Maximum warpage of each installation surface 0 3 mm 0 012 in 4 INSPECT VALVE a Inspect valve stem diameter Using a micrometer measure the diameter of the valv...

Page 1635: ... mm 4 1890 in Exhaust 105 30 mm 4 1457 in If the overall length is less than the minimum replace the valve e Inspect valve stem tip Check the surface of the valve stem tip for wear NOTICE Do not grind off more than the minimum length If the valve stem tip is worn resurface the tip with a grinder or replace the valve 5 CLEAN VALVE SEAT a Using a 45 carbide cutter resurface the valve seats b Clean t...

Page 1636: ...valve face with the width below Standard width 1 0 to 1 4 mm 0 039 to 0 055 in 7 REPAIR VALVE SEAT NOTICE Take off a cutter gradually to make the intake valve seat smooth a If the seating is too high to the valve face use 30 and 45 cutters to correct the seat b Intake side If the seating is too low to the valve face use 60 and 45 cutters to correct the seat c Exhaust side If the seating is too low...

Page 1637: ...ension of the inner compression spring at the specified installed length Installed tension 186 2 to 205 8 N 19 0 to 21 0 kgf 41 9 to 46 3 lbf at 33 3 mm 1 311 in If the installed tension is not as specified replace the inner com pression spring 9 INSPECT VALVE GUIDE BUSH OIL CLEARANCE a Using a caliper gauge measure the inside diameter of the valve guide bush Inside diameter 5 51 to 5 53 mm 0 2169...

Page 1638: ...p 10 from the lifter bore diameter measurement Standard oil clearance 0 033 to 0 059 mm 0 0013 to 0 0023 in Maximum oil clearance 0 08 mm 0 0031 in If the oil clearance is greater than the maximum replace the valve lifter If necessary replace the cylinder head 12 INSPECT CAMSHAFT OIL CLEARANCE a Clean the camshaft bearing caps camshaft bearings and camshaft journals b Install the camshaft bearing ...

Page 1639: ... the maximum replace the camshaft bearings and or camshaft If necessary replace the camshaft bearing caps and cylinder head together Reference Cylinder head journal bore diameter 40 009 to 40 017 mm 1 5752 to 1 5755 in Camshaft bearing center wall thickness Mark 2 2 004 to 2 008 mm 0 0789 to 0 0791 in Camshaft journal di ameter 35 971 to 35 985 mm 1 4165 to 1 4167 in h Remove the Plastigage comple...

Page 1640: ...ht Standard cam lobe height Intake 44 168 to 44 268 mm 1 7389 to 1 7428 in Exhaust 44 580 to 44 680 mm 1 7551 to 1 7591 in Minimum cam lobe height Intake 44 018 mm 1 7330 in Exhaust 44 430 mm 1 7492 in If the cam lobe height is less than the minimum replace the camshaft c Inspect the camshaft journals Using a micrometer measure the journal diameter No 1 journal diameter 35 971 to 35 985 mm 1 4162 ...

Page 1641: ...advances lower Each groove has 2 oil paths Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with tape 2 Prick a hole in the tape placed on the advance side path Prick a hole in the retard side path on the op posite side to that of the advance side path as shown in the illustration 3 Apply about 200 kPa 2 0 kgf cm2 of air pressure to the two broken paths ...

Page 1642: ...d angle Check the movable range and that there is no disturbance Standard Moves smoothly in a range of about 31 NOTICE Be sure to perform this check by hand instead of air pres sure f Check the lock in the most retarded position Confirm that the camshaft timing gear assembly is locked at the most retarded position g Remove the set bolt and camshaft timing gear assembly NOTICE Be sure not to remove...

Page 1643: ...9201 01055 09950 70010 09951 07100 d Using a caliper gauge measure the bush bore diameter of the cylinder head Bush bore diameter 10 295 to 10 315 mm 0 4053 to 0 4061 in If the bush bore diameter of the cylinder head is greater than 10 315 mm 0 4061 in machine the bush bore to dimensions of 10 345 to 10 365 mm 0 4073 to 0 4081 in Valve guide bush diameter STD 10 333 to 10 344 mm 0 4068 to 0 4072 i...

Page 1644: ... specified protrusion height SST 09201 10000 09201 01055 09950 70010 09951 07100 Protrusion height 9 3 to 9 7 mm 0 366 to 0 382 in h Using a sharp 5 5 mm reamer ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem Standard oil clearance Intake 0 025 to 0 060 mm 0 0010 to 0 0024 in Exhaust 0 030 to 0 065 mm 0 0012 to 0 0026 in ...

Page 1645: ...rusion Height Engine Front Engine Front EM 82 ENGINE MECHANICAL 1GR FE CYLINDER HEAD REASSEMBLY 1 INSTALL RING PIN Using a plastic faced hammer tap in the new ring pins until they reach the specified protrusion height Specified protrusion height 2 7 to 3 3 mm 0 106 to 0 130 in ...

Page 1646: ...mm 34 mm A A B C C B Protrusion Height Protrusion Height ENGINE MECHANICAL 1GR FE CYLINDER HEAD EM 83 2 INSTALL STRAIGHT PIN Using a plastic faced hammer tap in the new straight pins until they reach the specified protrusion height Specified protrusion height A 17 5 to 19 5 mm 0 689 to 0 768 in B 7 5 to 8 5 mm 0 295 to 0 335 in C 7 0 to 9 0 mm 0 276 to 0 354 in ...

Page 1647: ...r Side Exhaust Manifold Side B 12 mm 9 mm 33 3 mm A 20 mm 42 mm 13 mm B C 16 mm 27 mm 9 mm C EM 84 ENGINE MECHANICAL 1GR FE CYLINDER HEAD 3 INSTALL STUD BOLT Using the Torx socket wrench E5 and E7 install the stud bolts Torque 4 0 N m 41 kgf cm 35 in lbf for stud bolt A C 19 5 N m 199 kgf cm 14 ft lbf for stud bolt B ...

Page 1648: ...e 67 mm 9 mm 30 mm 9 mm A B A B ENGINE MECHANICAL 1GR FE CYLINDER HEAD EM 85 4 INSTALL UNION a Apply adhesive to 2 or 3 threads of the bolt end Adhesive Part No 08833 00070 THREE BOND 1324 or equiva lent b Using a deep socket wrench 12 install the unions Torque 15 N m 153 kgf cm 11 ft lbf ...

Page 1649: ...r Side SST Depth 1 5 mm EM 86 ENGINE MECHANICAL 1GR FE CYLINDER HEAD 5 INSTALL TIGHT PLUG a Apply adhesive around the tight plugs b Using SST tap in the tight plugs to the specified depth SST 09950 60010 09951 00250 09950 70010 09951 07150 Specified depth 1 5 mm 0 059 in ...

Page 1650: ...M 87 6 INSTALL STRAIGHT SCREW PLUG a Using a straight hexagon wrench 14 install a new gasket and straight screw plug Torque 80 N m 816 kgf cm 59 ft lbf 7 INSTALL VALVE STEM OIL SEAL HINT The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray a Apply a light coat of engine oil to the valve guide bush b Using SST push in a new valve stem oil seal SST 09201 41020 ...

Page 1651: ...ssion spring and valve spring retainer d Using SST compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem SST 09202 70020 09202 00010 e Using a pin punch 5 lightly tap the valve stem tip to en sure a proper fit NOTICE Be careful not to damage the valve stem tip 10 INSTALL VALVE LIFTER a Apply engine oil to the valve stem end and valve lifter and ins...

Page 1652: ...eter 2 5 to 3 mm 0 098 to 0 118 in to a new cylinder head gasket as shown in the illustration Seal packing Part No 08826 00080 or equivalent NOTICE Install the cylinder head within 3 minutes after applying seal packing After installing it the cylinder head bolts must be tightened within 15 minutes Otherwise the seal packing must be removed and reapplied 2 Place the cylinder head gasket on the cyli...

Page 1653: ...mp upper sied facing up ward NOTICE Be careful of the installation direction Place the cylinder head carefully in order not to dam age the gasket with the bottom part of the head 2 INSTALL CYLINDER HEAD a Place the RH cylinder head on the cylinder head gasket b Install the 8 cylinder head bolts HINT The cylinder head bolts are tightened in 2 successive steps steps 3 and 5 If any cylinder head bolt...

Page 1654: ...ts 2 Install the plate washer to the cylinder head bolt 3 Using several steps tighten each bolt with a 10 mm bi hexagon wrench uniformly in the sequence as shown in the illustration Torque 36 N m 367 kgf cm 27 ft lbf If any one of the cylinder head bolts does not meet the torque specification replace the cylinder head bolt NOTICE Do not drop the washers into the cylinder head 4 Mark the front side...

Page 1655: ...ing to them 5 INSTALL CAMSHAFT NOTICE As the thrust clearance of the camshaft is small the cam shaft must be kept level while it is being installed If the camshaft is not kept level the portion of the cylinder head which receives 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 Set the crankshaft position Usin...

Page 1656: ... locations 3 Apply a light coat of engine oil to the threads of the bearing cap bolts 4 Install the 16 bearing cap bolts Using several steps tighten the bolts uniformly in the sequence as shown in the illustration Torque 9 0 N m 92 kgf cm 80 in lbf for 10 mm 0 39 in head 24 N m 245 kgf cm 18 ft lbf for 12 mm 0 47 in head 5 Turn the camshafts clockwise with a wrench until the camshaft knock pin com...

Page 1657: ...ft lbf for 12 mm 0 47 in head 6 INSTALL TIMING CHAIN See page EM 44 7 INSTALL TIMING CHAIN COVER See page EM 44 8 INSTALL OIL PAN See page EM 44 9 INSTALL EXHAUST MANIFOLD a Install the RH exhaust manifold 1 Set a new gasket to the RH cylinder head with the oval shape facing forward NOTICE Be careful of the installation direction 2 Install the exhaust manifold with the 6 nuts Tighten the nuts unif...

Page 1658: ...at no foreign objects on the mesh part of the 2 filters b Install 2 new gaskets to each new plug c Insert the filters to the plugs d Apply adhesive to 2 or 3 threads of the plugs Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent e Install the plugs to each cylinder head Torque 62 N m 632 kgf cm 46 ft lbf 13 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE 14 INSTALL WATER BY PASS JOI...

Page 1659: ...illustration Seal packing Part No 08826 00080 or equivalent NOTICE Install the cylinder head cover within 3 minutes after apply ing seal packing After installing it cylinder head cover bolts and nuts must be tightened within 15 minutes Other wise the seal packing must be removed and reapplied 3 Install the seal washers to the bolts 4 Install the cylinder head cover with the 10 bolts and 2 nuts Tig...

Page 1660: ...LL IGNITER 18 INSTALL INTAKE AIR SURGE TANK a Install a new gasket to the intake air surge tank b Using the socket hexagon wrench 8 install the intake air surge tank with the 4 bolts Torque 28 N m 286 kgf cm 21 ft lbf c Install the 2 intake air surge tank nuts Torque 28 N m 286 kgf cm 21 ft lbf d Install the 2 surge tank stays with the 4 bolts Torque 21 N m 214 kgf cm 15 ft lbf e Install the oil b...

Page 1661: ...body w motor connector i Connect the 2 VSV connectors j Connect the ventilation hose k Connect the fuel vapor feed hose l Connect the 2 water by pass hoses 19 CONNECT HEATER WATER OUTLET AND INLET HOSE 20 INSTALL COOLER COMPRESSOR See page AC 58 21 INSTALL GENERATOR See page CH 15 22 INSTALL VANE PUMP See page SR 57 23 INSTALL FAN W FLUID COUPLING ...

Page 1662: ...se re move the bar d If it is hard to install the V ribbed belt perform the follow ing procedure 1 Put the V ribbed belt on every parts except the P S pump as shown in the illustration 2 While releasing the belt tension by turning the belt tensioner counterclockwise put the V ribbed belt on the P S pump 25 TIGHTEN FAN W FLUID COUPLING Tighten the 4 fluid coupling bolts Torque 21 N m 214 kgf cm 15 ...

Page 1663: ... wire harness clamps d Connect the mass air flow meter connector e Connect the vacuum hose f Connect the ventilation hose No 2 30 ADD ENGINE COOLANT 31 ADD ENGINE OIL 32 CHECK FOR LEAK 33 INSTALL V BANK COVER Install the V bank cover with the 2 nuts Torque 7 5 N m 76 kgf cm 66 in lbf ...

Page 1664: ...o 2 Hood Fuel Pipe Clamp V Bank Cover Air Cleaner Assembly Battery Tray Heater Hose Fuel Pipe Ventilation Hose No 2 Battery Battery Clamp N m kgf cm ft lbf Specified torque 7 5 76 66 in lbf ENGINE MECHANICAL 1GR FE ENGINE UNIT EM 101 ENGINE UNIT COMPONENTS ...

Page 1665: ...mbly No 1 Fan Shroud Oil Cooler Pipe for AutomaticTransmission V Belt Fan Pulley Fan w Fluid Coupling 12 120 9 N m kgf cm ft lbf Specified torque No 2 Fan Shroud 5 0 50 44 in lbf EM 102 ENGINE MECHANICAL 1GR FE ENGINE UNIT ...

Page 1666: ... 660 48 18 185 13 Engine Rear Mounting Insulator Gasket Crossmember Front Exhaust Pipe LH Torque Converter Clutch x6 48 490 35 43 440 32 48 490 35 Gasket 40 408 30 40 408 30 Manifold Stay Front Exhaust Pipe RH Gasket Spring Manifold Stay Exhaust Pipe Support Gasket 62 630 46 62 630 46 40 410 30 37 377 27 88 897 65 Stabilizer Bar Bushing Stabilizer Bar Bracket Engine Under Cover Propeller Shaft 9 8...

Page 1667: ...ft lbf Specified torque A C Compressor Connector 43 438 32 25 255 18 Generator Vane Pump 43 438 32 Vane Pump Connector Throttle Body Motor Connector VSV Connector Generator Connector Wire Harness Clamp Bracket Generator Wire EM 104 ENGINE MECHANICAL 1GR FE ENGINE UNIT ...

Page 1668: ...nector c Disconnect the PCV hose from the air cleaner case d Disconnect the 2 wire clamps from the air cleaner case e Disconnect the air cleaner case from the air cleaner hose No 1 f Remove the 2 bolts and air cleaner assembly 11 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 See page CH 7 c Remove the 4...

Page 1669: ...hose from the charcoal canister g Disconnect the EVAP hose from the charcoal canister 14 DISCONNECT A C COMPRESSOR FROM ENGINE a Disconnect the A C compressor connector b Remove the 3 bolts and disconnect the A C compressor from the engine HINT Suspend the A C compressor securely 15 DISCONNECT PS PUMP FROM ENGINE Remove the 3 bolts and disconnect the PS pump from the en gine HINT Suspend the PS pu...

Page 1670: ...d separate the engine mounting brackets from the frame brackets d Lift the engine out of the vehicle carefully NOTICE Make sure the engine is clear of all wiring and hoses e Place the engine onto a working bench 17 REMOVE DRIVE PLATE Remove the 8 bolts front spacer drive plate and rear spacer ...

Page 1671: ...s in the sequence shown in the illustration Torque 49 N m 500 kgf cm 36 ft lbf If any of the mounting bolts do not meet the torque specification replace it d Mark the mounting bolt with paint e Retighten the mounting bolts 90 in the order shown in the illustration f Check that the painted mark is now at a 90 angle to what it was in step e 2 INSTALL ENGINE ASSEMBLY IN VEHICLE a Attach the engine ch...

Page 1672: ... brake booster tube 6 CONNECT ENGINE WIRE TO CABIN a Push the engine wire through the cowl panel b Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket c Connect the 3 connectors to the ECM d Connect the 2 wire harness connectors cassette con nector e Install the ECM with the 3 screws f Install the heater to register duct g Install the lower No 2 fini...

Page 1673: ...MT 7 13 FILL WITH ENGINE COOLANT See page CO 2 14 FILL WITH ENGINE OIL See page LU 3 15 START ENGINE AND CHECK FOR LEAKS 16 INSTALL ENGINE UNDER COVERS 17 INSTALL V BANK COVER 18 INSTALL HOOD 19 PERFORM ROAD TEST Check for abnormal noise shock slippage correct shift points and smooth operation 20 RECHECK ENGINE COOLANT AND OIL LEVELS ...

Page 1674: ...ng Piston Pin Hole Snap Ring 1st 61 622 45 2nd Turn 90 See page EM 128 1st 25 250 18 2nd Turn 90 x8 Non reusable part N m kgf cm ft lbf Specified torque Piston Pin Hole Snap Ring Oil Nozzle 9 0 92 80 in lbf Knock Sensor Wire Water Outlet Pipe No 1 Water Drain Cock Water Drain Cock Knock Sensor Knock Sensor 10 102 7 10 102 7 25 255 18 25 255 18 20 204 15 20 204 15 Engine Rear Oil Seal Retainer Oil ...

Page 1675: ...oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap 5 INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator measure the thrust clearance while mov ing the connecting rod back and forth Standard thrust clearance 0 15 to 0 30 mm 0 0059 to 0 0118 in Maximum thrust clearance 0 35 mm 0 0138 in 6 INSPECT CONNECTING ROD OIL CLEARANCE a Check that the matchmarks o...

Page 1676: ...ng rod cap bolts h Using SST tighten the bolts alternately to the specified torque SST 09011 38121 Torque 25 N m 250 kgf cm 18 ft lbf i Mark the front side of each connecting cap bolt with paint j Retighten the cap bolts 90 as shown in the illustration NOTICE Do not turn the crankshaft k Remove the 2 bolts connecting rod cap and lower bear ing l Measure the Plastigage at its widest point Standard ...

Page 1677: ...to 0 0588 4 1 493 to 1 496 0 0588 to 0 0589 7 REMOVE PISTON W CONNECTING ROD a Using a ridge reamer remove all the carbon from the top of the cylinder b Push in the piston w connecting rod and upper bearing through the top of the cylinder block HINT Keep the bearings connecting rod and cap together Arrange the piston and connecting rod assemblies in the correct order 8 REMOVE CONNECTING ROD BEARIN...

Page 1678: ...2 INSPECT CRANKSHAFT THRUST CLEARANCE a Using a dial indicator measure the thrust clearance while prying the crankshaft back and forth with a screwdriver Standard thrust clearance 0 04 to 0 24 mm 0 0016 to 0 0094 in Maximum thrust clearance 0 30 mm 0 0118 in If the thrust clearance is greater than the maximum replace the pair of the thrust washers or the crankshaft HINT Thrust washer thickness is ...

Page 1679: ...the illustration c Using a screwdriver pry out the main bearing caps Re move the 4 main bearing caps and lower bearings NOTICE Pull up the main bearing cap while turning it little by little to the right and the left Be careful not to damage the joint surface of the cylin der block and the main bearing cap 14 REMOVE CRANKSHAFT THRUST WASTER SET 15 REMOVE CRANKSHAFT BEARING 16 REMOVE OIL NOZZLE Usin...

Page 1680: ...er than the maximum replace the cylinder block 2 INSPECT CYLINDER BORE Using a cylinder gauge measure the cylinder bore diameter at positions A and B in the thrust and axial directions Standard diameter 94 000 to 94 012 mm 3 7008 to 3 7013 in Maximum diameter 94 132mm 3 7060 in If the average diameter of the 4 positions is greater than the maximum replace the cylinder block 3 INSPECT PISTON Using ...

Page 1681: ... the connecting rod alignment 1 Check for misalignment Maximum misalignment 0 05 mm 0 0020 in per 100 mm 3 94 in If misalignment is greater than the maximum replace the con necting rod assembly 2 Check twist Maximum twist 0 15 mm 0 0059 in per 100 mm 3 94 in If twist is greater than the maximum replace the connecting rod assembly 6 INSPECT PISTON PIN OIL CLEARANCE a Using a caliper gauge measure t...

Page 1682: ... inside diameter Mark mm in A 22 005 to 22 008 0 8663 to 0 8665 B 22 009 to 22 011 0 8665 to 0 8666 C 22 012 to 22 014 0 8666 to 0 8667 d Subtract the piston pin diameter measurement from the piton pin hole diameter measurement Standard oil clearance 0 001 to 0 007 mm 0 00004 to 0 00028 in Maximum oil clearance 0 040 mm 0 0016 in e If the oil clearance is greater than the maximum replace the bushi...

Page 1683: ... a feeler gauge measure the end gap Standard end gap No 1 0 30 to 0 40 mm 0 0118 to 0 0157 in No 2 0 40 to 0 50 mm 0 0157 to 0 0197 in Oil Side rail 0 10 to 0 40 mm 0 0039 to 0 0157 in Maximum end gap No 1 1 0 mm 0 039 in No 2 1 1 mm 0 043 in Oil Side rail 1 0 mm 0 039 in 9 INSPECT CONNECTING ROD BOLT Using a vernier caliper measure the tension portion diameter of the bolt Standard diameter 7 2 to...

Page 1684: ...crometer measure the diameter of each crank pin Diameter 55 992 to 56 000 mm 2 2044 to 2 2047 in e Check each crank pin for taper and out of round as shownin the illustration Maximum taper and out of round 0 02 mm 0 0008 in 12 INSPECT CRANKSHAFT OIL CLEARANCE HINT Main bearings come in widths of 19 0 mm 0 748 in and 22 4 mm 0 882 in Install the 22 4 mm 0 882 in bearings in the No 1 and No 4 cylind...

Page 1685: ...k e Lay a strip of Plastigage across each journal f Examine the front marks and numbers and install the bearing caps on the cylinder block g Apply a light coat of engine oil to the threads of the bear ing cap bolts h Temporarily install the 8 main bearing cap bolts to the in side positions i Install the main bearing caps Tighten the 2 bolts for each bearing cap until the clearance between the bear...

Page 1686: ... the sequence as shown in the illustration o Check that the painted mark is now at a 90 angle to the front NOTICE Do not turn the crankshaft p Install the 8 main bearing cap bolts Using several steps uniformly tighten the bolts in the sequence as shown in the illustration Torque 25 N m 255 kgf cm 18 ft lbf q Remove the main bearing caps r Measure the Plastigage at its widest point Standard oil cle...

Page 1687: ... number There are 5 sizes of standard bearings marked 1 2 3 4 and 5 accordingly Journal bearings Cylinder block A Crankshaft 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Use Bearing 1 2 3 4 5 HINT EXAMPLE Cylinder block 11 A Crankshaft 06 B Total number 17 Use bearing 3 Item Mark mm in Cylinder block main journal bore diameter A 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 77 000 3 0315 77 001 ...

Page 1688: ... 996 2 8344 to 2 8345 71 994 to 71 995 2 8344 to 2 8344 71 993 to 71 994 2 8343 to 2 8344 71 992 to 71 993 2 8343 to 2 8343 71 991 to 71 992 2 8343 to 2 8343 71 990 to 71 991 2 8343 to 2 8343 71 989 to 71 990 2 8342 to 2 8343 71 988 to 71 989 2 8342 to 2 8342 Standard bearing center wall thickness 1 2 3 4 5 2 488 to 2 491 0 0980 to 0 0981 2 491 to 2 494 0 0981 to 0 0982 2 494 to 2 497 0 0982 to 0 ...

Page 1689: ...Align the oil holes of a new bushing and the connecting rod b Using SST and a press press in the bushing SST 09222 30010 c Using a pin hole grinder hone the bushing to obtain the standard specified clearance between the bushing and piston pin Standard oil clearance 0 005 to 0 011 mm 0 0002 to 0 0004 in HINT Check that the piston pin fits at a normal room temperature Coat the piston pin with engine...

Page 1690: ...r tap in a new oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 78010 3 Apply MP grease to the oil seal lip b If the rear oil seal retainer is installed to the cylinder block 1 Using a knife cut off the oil seal lip 2 Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screw driver tip 3 Using SST and a hammer tap in th...

Page 1691: ... 0 91 in M6 A A C C B B EM 128 ENGINE MECHANICAL 1GR FE CYLINDER BLOCK REASSEMBLY 1 INSTALL STUD BOLT a Install the stud bolts as shown in the illustration Torque Stud bolt A 11 N m 112 kgf cm 8 1 ft lbf Stud bolt B 4 5 N m 46 kgf cm 40 in lbf Stud bolt C 4 0 N m 41 kgf cm 35 in lbf ...

Page 1692: ...n A B C C C C D D D Protrusion Height 5 5 to 6 5 mm D D 10 mm 0 39 in 4 mm 0 16 in 12 mm 0 47 in 4 mm 0 16 in 12 mm 0 47 in 0 886 to 0 925 in 0 217 to 0 256 in 0 413 to 0 453 in 0 217 to 0 256 in 0 217 to 0 256 in 0 335 to 0 374 in ENGINE MECHANICAL 1GR FE CYLINDER BLOCK EM 129 2 INSTALL STRAIGHT PIN a Using a plastic faced hammer tap in the straight pin Standard protrusion Pin A 22 5 to 23 5 mm 0...

Page 1693: ... Part No 08833 00070 THREE BOND 1324 or equivalent b Using SST install the tight plugs as shown in the illustra tion SST 09950 60010 09951 00350 09950 70010 09951 07150 Standard depth 0 2 to 1 2 mm 0 008 to 0 047 in 4 INSTALL OIL JET Using a screwdriver and hammer tap in an oil jet 5 INSTALL OIL NOZZLE Using a 5 mm socket hexagon wrench install the 3 oil nozzles Torque 9 0 N m 92 kgf cm 80 in lbf ...

Page 1694: ...t 80 C 176 F b Coat the piston pin with engine oil c Align the front marks of the piston and connecting rod and push in the piston pin with a thumb 8 INSTALL PISTON PIN HOLE SNAP RING Using a screwdriver install a new snap ring on the other side of the piston pin hole HINT Be sure that the end gap of the snap ring does not overlap the pin hole cutout portion of the piston 9 INSTALL PISTON RING SET...

Page 1695: ... to them 11 INSTALL CRANKSHAFT BEARING HINT Main bearings come in widths of 19 0 mm 0 748 in and 22 4 mm 0 882 in Install the 22 4 mm 0 882 in bearings in the No 1 and No 4 cylinder block journal positions with the main bearing cap Install the 19 0 mm 0 748 in bearings in the No 2 and No 3 positions a Clean each main journal and bearing b Align the bearing claw with the claw groove of the cylinder...

Page 1696: ...per thrust washers with the oil grooves facing outward c Install the 2 lower thrust washers on the No 2 bearing cap with the grooves facing outward d Examine the front marks and numbers and install the bearing caps on the cylinder block e Apply a light coat of engine oil to the threads of the bear ing cap bolts f Temporarily install the 8 main bearing cap bolts to the in side positions g Install t...

Page 1697: ... bearing cap bolts Using several steps uniformly tighten the bolts in the sequence shown in the illustration Torque 61 N m 622 kgf cm 45 ft lbf k Mark the front side of the bearing cap bolts with paint l Retighten the bearing cap bolts 90 in the sequence as shown in the illustration m Check that the painted mark is now at a 90 angle to the front n Check that the crankshaft turns smoothly o Using s...

Page 1698: ...f the connecting rod cap and prevent oil from adhering to them Match the numbered connecting rod cap with the con necting rod d Check that the protrusion of the connecting rod cap is fac ing the correct direction e Apply a light coat of engine oil to the threads of the con necting rod cap bolts f Using SST tighten the bolts alternately to the specified torque SST 09011 38121 Torque 25 N m 250 kgf ...

Page 1699: ...nd reap plied c Install the oil seal retainer with the 5 bolts and 2 nuts Torque Bolt 10 N m 102 kgf cm 7 ft lbf Nut 9 0 N m 92 kgf cm 80 in lbf 15 INSTALL WATER DRAIN COCK a Apply adhesive to 2 or 3 threads of the drain cock ends Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b After tightening the drain cocks to the specified torque ro tate them clockwise as shown in the illustration...

Page 1700: ... EM 137 16 INSTALL KNOCK SENSOR a Install the 2 knock sensors with the 2 bolts within a 15 angle as shown in the illustration Torque 20 N m 204 kgf cm 15 ft lbf b Connect the knock sensor connectors 17 INSTALL WATER OUTLET PIPE NO 1 Install the water outlet pipe with the 3 bolts Torque 10 N m 102 kgf cm 7 ft lbf ...

Page 1701: ...haust Pipe Support Exhaust Pipe Support Heated Oxygen Sensor Bank 2 Heated Oxygen Sensor Bank 1 Front Exhaust Pipe LH Front Exhaust Pipe RH Spring N m kgf cm ft lbf Specified torque Non reusable part 32 326 24 48 490 35 43 440 32 48 490 35 44 450 33 62 630 46 62 630 46 44 450 33 62 630 46 EM 138 ENGINE MECHANICAL 1GR FE EXHAUST SYSTEM EXHAUST SYSTEM COMPONENTS ...

Page 1702: ...a Remove the 2 nuts and RH front exhaust pipe b Remove the 2 gaskets from the RH front exhaust pipe 5 REMOVE HEATED OXYGEN SENSOR BANK 2 OXYGEN SENSOR a Disconnect the heated oxygen sensor connector b Remove the heated oxygen sensor 6 REMOVE LH FRONT EXHAUST PIPE a Remove the 2 nuts exhaust pipe support and LH front ex haust pipe b Remove the 2 gaskets from the LH front exhaust pipe 7 INSTALL RH F...

Page 1703: ...bf b Connect the heated oxygen sensor connector 11 INSTALL EXHAUST CENTER PIPE a Using a vernier caliper measure the free length of the spring Minimum length 40 5 mm 1 5945 in If the free length is less than minimum replace the spring b Install the 2 exhaust pipe supports c Install the 2 bolts Torque 48 N m 490 kgf cm 35 ft lbf d Install the 2 bolts and springs Torque 43 N m 440 kgf cm 32 ft lbf 1...

Page 1704: ...e All vacuum lines properly connected f SFI system wiring connectors fully plugged g Ignition timing checked correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 180 SE CONDS 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...

Page 1705: ...Problems Causes Normal High Rough idle 1 Faulty ignitions Incorrect timing Fouled shorted or improperly gapped plugs 2 Incorrect valve clearance 3 Leaky intake and exhaust valves 4 Leaky cylinders Low High Rough idle fluctuating HC reading 1 Vacuum leaks PCV hose Intake manifold Throttle body Brake booster line 2 Lean mixture causing misfire High High Rough idle Black smoke from exhaust 1 Restrict...

Page 1706: ...ed 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 pos sible Compression pressure 1 373 kPa 14 0 kgf cm2 199 psi or more Minimum pressure 1 030 kPa 10 5 kgf cm2 149 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...

Page 1707: ...e 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 mar...

Page 1708: ...een 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 Intake 0 15 0 25 mm 0 006 0 010 in Exhaust 0 25 0 35 mm 0 010 0 014 in b Turn the crankshaft 1 revolution 360 and align the mark as above See procedure in step 8 c Check only the valves indicated as shown Me...

Page 1709: ...arance N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 30 mm 0 012 in 3 Select a new shim with thickness as close as pos sible to the calculated value HINT Shims are available in 41 increments of 0 020 mm 0 0008 in from 2 00 mm 0 0787 in to 2 80 mm 0 1102 in e Place a new adjusting shim on the valve f Place the valve lifter g Reinstall the camshafts See page EM 60 h Reinstall...

Page 1710: ...ss New shim thickness Shim No Thickness Shim No Thickness mm in Intake valve clearance Cold 0 15 0 25 mm 0 006 0 010 in EXAMPLE The 2 300 mm 0 0906 in shim is installed and the measured clearance is 0 440 mm 0 0173 in Replace the 2 300 mm 0 0906 in shim with a No 54 shim ENGINE MECHANICAL 2UZ FE VALVE CLEARANCE EM 7 ...

Page 1711: ...ss New shim thickness Shim No Thickness Shim No Thickness mm in Exhaust valve clearance Cold 0 25 0 35 mm 0 010 0 014 in EXAMPLE The 2 300 mm 0 0906 in shim is installed and the measured clearance is 0 440 mm 0 0173 in Replace the 2 300 mm 0 0906 in shim with a No 44 shim EM 8 ENGINE MECHANICAL 2UZ FE VALVE CLEARANCE ...

Page 1712: ...er Area Network Vehicle Interface Module CAN VIM Then connect the CAN VIM to the Date Link Connector 3 DLC3 2 Please refer to the hand held tester operator s manual for further details Ignition timing 5 to 15 BTDC at idle Transmission in neutral 3 Disconnect the hand held tester and CAN VIM from the DLC3 b When not using a hand held tester 1 Connect the tester probe of a timing light to the wire b...

Page 1713: ...CAL 2UZ FE IGNITION TIMING 3 Using a timing light check the ignition timing Ignition timing 5 to 15 BTDC at idle Transmission in neutral 4 Remove the SST from the DLC3 SST 09843 18040 5 Disconnect the timing light from the engine ...

Page 1714: ... the Controller Area Network Vehicle Interface Module CAN VIM Then connect the CAN VIM to the Date Link Connector 3 DLC3 2 Please refer to the hand held tester operator s manual for further details 3 Race the engine speed at 2 500 rpm for approx 90 seconds 4 Check the idle speed Idle speed 700 50 rpm Transmission in neutral If the idle speed is not as specified check the air intake system 5 Discon...

Page 1715: ...EM 12 ENGINE MECHANICAL 2UZ FE IDLE SPEED 4 Disconnect the tachometer from the DLC3 ...

Page 1716: ... Hose Fan and Fluid Coupling Assembly Fan Pulley 49 500 36 x 4 29 296 21 Throttle Body Cover MAF Meter Wire Engine Under Cover 4WD 2WD Engine Under Cover PS Pump No 2 Fan Shroud Vacuum Hose PCV Hose Clip 17 175 13 12 122 9 A C Compressor A C Suction Hose 17 175 13 x 5 29 296 21 29 296 21 ENGINE MECHANICAL 2UZ FE TIMING BELT EM 13 TIMING BELT COMPONENTS ...

Page 1717: ...e Engine Wire 7 5 76 66 in lbf 16 160 12 7 5 76 66 in lbf N m kgf cm ft lbf Specified torque Wire Grommet 39 400 29 A23303 Timing Belt LH Camshaft Timing Pulley Timing Belt Tensioner Dust Boot 245 2 500 181 16 160 12 RH Camshaft Timing Pulley 26 270 19 Fan Bracket N m kgf cm ft lbf Specified torque 8 1 83 72 in lbf 32 330 24 EM 14 ENGINE MECHANICAL 2UZ FE TIMING BELT ...

Page 1718: ... Idler Pulley Timing Belt Plate Washer Crankshaft Timing Pulley Timing Belt Cover Spacer No 2 Idler Pulley Timing Belt Guide Crankshaft Angle Sensor Plate Gasket 34 5 350 25 34 5 350 25 N m kgf cm ft lbf Specified torque Precoated part 26 265 19 39 400 29 15 5 158 11 ENGINE MECHANICAL 2UZ FE TIMING BELT EM 15 ...

Page 1719: ...CT PS PUMP Remove the 3 bolts and disconnect the PS pump from the en gine 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 ...

Page 1720: ...M 79 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 installa tion mark on the timing belt before removing each part 15 LOOSEN CRANKSH...

Page 1721: ...shaft pulley with the cen ters of the crankshaft pulley bolt and the No 2 timing belt idler pulley bolt NOTICE If the timing belt is disengaged having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley step 15 causing dam age So always set the crankshaft pulley at the correct angle d Remo...

Page 1722: ...th SST and 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 HINT Set the SST so that the claw comes in contact with the camshaft timing pulley bolt and tighten the lock nut of the SST b Disconnect the timing belt from the camshaft timing pul leys 19 REMOVE CAMSHAFT TIMING PULL...

Page 1723: ...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 pulle...

Page 1724: ...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 P...

Page 1725: ... 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 to 11 5 mm 0 413 to 0 453 in If the protrusion is not as specified replace the tensioner 4 INSPECT WATER PUMP See page CO 7 ...

Page 1726: ... bolt Torque 34 5 N m 350 kgf cm 25 ft lbf c Install the No 2 idler pulley with the bolt Torque 34 5 N m 350 kgf cm 25 ft lbf d Check that the No 1 and No 2 idler pulleys moves smoothly 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 NO...

Page 1727: ...t tensioner with the bolt and 2 nuts Torque 26 N m 265 kgf cm 19 ft lbf HINT Use a bolt of 106 mm 4 18 in in length 9 INSTALL GENERATOR See page CH 16 and CH 28 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 LH CAMSHAFT TIMING PULLEY a Align the camshaft knock pin with the knock pin groo...

Page 1728: ...lean NOTICE Only wipe the pulleys do not use any cleansing agent b Using SST turn the timing pulley Align the installation mark on the timing belt with the timing mark of the timing pulley and hang the timing belt on the timing pulley SST 09960 10010 09962 01000 09963 01000 c Using SST turn the LH camshaft timing pulley counter clockwise until there is tension between the crankshaft timing pulley ...

Page 1729: ...NG BELT TENSIONER a Temporarily install the belt tensioner with the 2 bolts b Alternately tighten the 2 bolts Torque 26 N m 270 kgf cm 19 ft lbf c Using pliers remove the 1 27 mm hexagon wrench from the belt tensioner 17 CHECK VALVE TIMING a Temporarily install the crankshaft pulley bolt b Slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC NOTICE Always turn the crankshaft pulley ...

Page 1730: ...icated in the illustration Bolt Length 106 mm 4 17 in for 12 mm head A 114 mm 4 49 in for 14 mm head B 20 INSTALL A C COMPRESSOR See page EM 83 21 INSTALL NO 2 TIMING BELT COVER Install the No 2 timing belt cover with the 2 bolts Torque 16 N m 160 kgf cm 12 ft lbf 22 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 ...

Page 1731: ...3 timing belt cover i Install the engine wire to the 2 wire clamps on the LH No 3 timing belt cover 24 INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and cover plate with the bolt Torque 39 N m 400 kgf cm 29 ft lbf 25 INSTALL PS PUMP Install the PS pump with the 3 bolts Torque 17 N m 175 kgf cm 13 ft lbf 26 INSTALL FAN PULLEY FAN FLUID COUPLING AND DRIVE BELT a Temporarily install the fa...

Page 1732: ...over 2WD A C Compressor Fan And Fluid Coupling Assembly Throttle Body Cover Engine Under Cover 49 500 36 x 4 N m kgf cm ft lbf Specified torque A T Oil Cooler Hose 4WD Vacuum Hose PCV Hose Clip 12 122 9 29 296 21 Suction Hose Intake Air Connector x 5 29 296 21 29 296 21 ENGINE MECHANICAL 2UZ FE CYLINDER HEAD EM 29 CYLINDER HEAD COMPONENTS ...

Page 1733: ...eusable part N m kgf cm ft lbf Specified torque PS Pump Oil Dipstick and Guide for A T 62 632 46 Ring Gasket 17 175 13 62 632 46 Heated Oxygen Sensor Gasket Heated Oxygen Sensor O Ring 48 489 35 48 489 35 EM 30 ENGINE MECHANICAL 2UZ FE CYLINDER HEAD ...

Page 1734: ...er Pipe Engine Wire 7 5 76 66 in lbf 7 5 76 66 in lbf N m kgf cm ft lbf Specified torque Wire Grommet 16 160 12 39 400 29 A23373 Timing Belt RH Camshaft Timing Pulley LH Camshaft Timing Pulley Timing Belt Tensioner Fan Bracket Dust Boot 16 160 12 32 330 24 26 270 19 N m kgf cm ft lbf Specified torque 8 1 83 72 in lbf ENGINE MECHANICAL 2UZ FE CYLINDER HEAD EM 31 ...

Page 1735: ...Gasket O Ring Engine Wire Heater Hose Throttle Body Cover Bracket VSV Connector for EVAP Fuel Return Hose Engine Wire EVAP Hose Heater Hose Wire Bracket Fuel Inlet Hose Gasket RH No 1 Timing Belt Rear Plate Gasket Air Switching Valve No 2 Air Tube No 3 Air Tube No 3 Gasket N m kgf cm ft lbf Specified torque Gasket 18 185 13 7 5 76 66 in lbf Gasket Gasket Air Pump Assembly 10 102 7 10 102 7 18 185 ...

Page 1736: ...Fuel Pressure Regulator Vacuum Hose RH Delivery Pipe VSV for EVAP VSV for Secondary Air Injection System VSV Wire Connector for ACIS VSV for ACIS Union Union Upper Gasket Ventilation Hose O Ring Lower Gasket 21 214 15 33 340 24 39 400 29 7 5 76 66 in lbf 7 5 76 66 in lbf 39 400 29 7 5 76 66 in lbf 39 400 29 18 185 13 7 5 76 66 in lbf 18 184 13 7 5 76 66 in lbf 21 214 15 7 5 76 66 in lbf ENGINE MEC...

Page 1737: ...ft Bearing Cap 16 160 12 O Ring LH Exhaust Camshaft Camshaft Housing Plug Semi circular Plug Strainer O Ring Gasket LH Intake Camshaft with Timing Tube RH Exhaust Camshaft Camshaft Housing Plug Engine Wire Bracket LH Cylinder Head Gasket LH Cylinder Head and Exhaust Manifold Assembly Air fuel Ratio Sensor Bank 1 Sensor 1 Connector RH Cylinder Head Gasket Engine Wire 7 5 76 66 in lbf 7 5 76 66 in l...

Page 1738: ... 5 80 66 in lbf Camshaft Driven Main Gear 78 790 58 15 150 11 A23323 Heat Insulator LH Exhaust Manifold Heat Insulator Gasket RH Cylinder Head Valve Lifter Oil Seal Spring Seat Valve Spring Spring Retainer Adjust Shim Keeper Valve Guide Bushing Valve RH Exhaust Manifold Gasket LH Cylinder Head Non reusable part N m kgf cm ft lbf Specified torque 44 450 32 44 450 32 7 5 76 66 in lbf 7 5 76 66 in lb...

Page 1739: ...DIPSTICK AND GUIDE FOR A T 9 REMOVE IGNITION COILS See page IG 5 10 REMOVE TIMING BELT REAR PLATES a Remove the 3 bolts stud bolt and RH No 1 timing belt rear plates b Disconnect the wire clamp from the LH timing belt rear plate c Remove the 3 bolts stud bolt and LH No 1 timing belt rear plates 11 DISCONNECT FUEL INLET HOSE See page SF 27 AND FUEL RETURN HOSE 12 DISCONNECT CONNECTORS FROM INTAKE M...

Page 1740: ...from the VSV for the EVAP d Disconnect the 2 vacuum hoses from the VSV for the air injection system 14 REMOVE INTAKE MANIFOLD ASSEMBLY a Disconnect the 2 water bypass hoses from the throttle body b Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe c Remove the 2 bolts holding the engine wire protector from the intake manifold and cylinder head d Remove the 2 bolts an...

Page 1741: ...connect the EVAP hose from the upper intake man ifold and remove the VSV for EVAP c Remove the bolt 2 unions 4 gaskets and front fuel pipe from the intake manifold d Remove the throttle body see page SF 44 e Remove the bolt and VSV for ACIS from the intake man ifold f Disconnect the fuel return hose from the fuel pressure regulator g Remove the 3 bolts and fuel return pipe from the intake manifold...

Page 1742: ... the 4 nuts water bypass joint and 2 gaskets 21 REMOVE ENGINE HANGERS 22 REMOVE CYLINDER HEAD COVERS Remove the 18 bolts seal washers RH and LH cylinder head covers and 2 gaskets 23 IF NECESSARY REMOVE SEMI CIRCULAR PLUGS AND CAMSHAFT HOUSING PLUGS 24 REMOVE CAMSHAFTS NOTICE Since the thrust clearance of the camshaft is small the camshaft must be kept level while it is being removed If the camshaf...

Page 1743: ...ming tube from left to right 2 to 3 times within its VVT i range 25 and use a waste cloth to collect the oil from the camshaft timing oil control valve installation hole SST 09960 10010 09962 01000 09963 00400 NOTICE Approximately 20 cc 1 2 cu in of oil will be ejected Take care not to spill it c Remove the LH camshafts 1 Bring the service bolt hole of the sub gear upward by turning the hexagon he...

Page 1744: ...n of the exhaust camshaft with a wrench 2 Secure the sub gear to the main gear with a service bolt Recommended service bolt Thread diameter 6 mm Thread pitch 1 0 mm Bolt length 16 to 20 mm 0 63 to 0 79 in HINT When removing the camshafts make sure that the torsional spring force of the sub gear has been eliminated by the above operation 3 Set the timing mark 1 dot mark of the camshaft main gear at...

Page 1745: ...move the wave washer e Remove the camshaft sub gear f Remove the camshaft gear spring NOTICE Be careful not to damage the camshaft 26 REMOVE CAMSHAFT TIMING TUBE FROM INTAKE CAMSHAFT a Mount the hexagon head portion of the intake camshaft in a vise NOTICE Be careful not to damage the camshaft The 4 bolts shown in the illustration determine back lash of the gear in the timing tube so do not remove ...

Page 1746: ...PARK PLUGS 28 REMOVE CYLINDER HEAD AND EXHAUST MAN IFOLD ASSEMBLIES a Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several steps in the sequence shown then perform the same procedure to the other side as shown Remove the 20 cylinder head bolts and plate washers NOTICE Cylinder head warpage or cracking could result from removing bolts in incorrect order Do not dr...

Page 1747: ...not to damage the contact surfaces of the cylinder head and cylinder block The cylinder head should not be tilted so as to secure the valve lifter If the cylinder head is tilted remove the valve lifter and check that the adjusting shim is set correctly 29 REMOVE RH EXHAUST MANIFOLD FROM CYLINDER HEAD a Remove the 4 bolts and heat insulator b Remove the 8 nuts exhaust manifold and gasket 30 REMOVE ...

Page 1748: ...s and shims in correct order 2 REMOVE VALVES a Using SST compress the valve spring and remove the 2 keepers SST 09202 70020 09202 00010 b Remove the spring retainer the valve spring the valve and the spring seat HINT Arrange the valves valve springs spring seats and spring re tainers incorrect order c Using needle nose pliers remove the oil seal ...

Page 1749: ...sing compressed air blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high pressure compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the cylinder block contact surface NOTICE Be careful not to scratch the surface contacting the cylin der block 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the c...

Page 1750: ... Maximum warpage 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head 7 INSPECT FOR CRACKS Using a dye penetrate check the combustion chamber intake ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head 8 INSPECT CYLINDER HEAD BOLT Using vernier calipers measure the thread outside diameter of the cylinder head bolt Standard outside...

Page 1751: ...em Valve stem diameter Intake 5 470 to 5 485 mm 0 2154 to 0 2159 in Exhaust 5 465 to 5 480 mm 0 2152 to 0 2157 in c Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance Intake 0 025 to 0 060 mm 0 0010 to 0 0024 in Exhaust 0 030 to 0 065 mm 0 0012 to 0 0026 in Maximum oil clearance Intake 0 08 mm 0 0031 in Exhaust 0 10 mm 0 0039 in I...

Page 1752: ...3 7441 in Minimum overall length Intake 94 55 mm 3 7224 in Exhaust 94 60 mm 3 7244 in If the overall length is less than minimum replace the valve e Check the surface of the valve stem tip for wear If the valve stem tip is worn resurface the tip with a grinder or replace the valve NOTICE Do not grind off more than minimum 12 INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the v...

Page 1753: ...le of the valve face with the following width 1 0 to 1 4 mm 0 039 to 0 055 in If not correct the valve seats as follows If the seating is too high on the valve face use 30 and 45 cutters to correct the seat If the seating is too low on the valve face use 60 and 45 cutters to correct the seat d Hand lap the valve and valve seat with an abrasive com pound e After hand lapping clean the valve and val...

Page 1754: ...talled tension is not as specified replace the valve spring 14 INSPECT CAMSHAFT FOR RUNOUT a Place the camshaft on V blocks b Using a dial indicator measure the circle runout at the center journal Maximum circle runout 0 03 mm 0 0012 in If the circle runout is greater than maximum replace the cam shaft 15 INSPECT CAM LOBES Using a micrometer measure the cam lobe height Standard cam lobe height Int...

Page 1755: ...ntake camshaft and check the timing tube turns smoothly If necessary replace the timing tube and intake camshaft 18 INSPECT CAMSHAFT GEAR SPRING Using vernier calipers measure the free distance between the spring ends Free distance 18 2 to 18 8 mm 0 717 to 0 740 in If the free distance is not as specified replace the gear spring 19 INSPECT CAMSHAFT BEARINGS Check the bearings for flaking and scori...

Page 1756: ...ecessary replace the bearing caps and cylinder head as a set h Completely remove the Plastigage i Remove the camshafts j Remove the camshaft timing tube from the intake cam shaft 21 INSPECT CAMSHAFT THRUST CLEARANCE a Install the camshaft timing tube to the intake camshaft see page EM 58 b Install the camshaft see page EM 58 c Using a dial indicator measure the thrust clearance while moving the ca...

Page 1757: ... e Remove the camshafts f Remove the camshaft timing tube from the intake cam shaft g Remove the drive gear from the camshaft timing tube 23 INSPECT VALVE LIFTERS AND LIFTER BORES a Using a caliper gauge measure the lifter bore diameter of the cylinder head Lifter bore diameter 31 000 to 31 016 mm 1 2205 to 1 2211 in b Using a micrometer measure the lifter diameter at the valve lifter center line ...

Page 1758: ... 55 24 INSPECT EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge measure the warapage of the surface that is in contact with the cylinder head Maximum warpage 0 10 mm 0 0394 in If warpage is greater than maximum replace the manifold ...

Page 1759: ...nd a hammer tap out the guide bushing SST 09201 01055 09950 70010 09951 07100 c Using a caliper gauge measure the bushing bore diame ter of the cylinder head d Select a new guide bushing STD or O S 0 05 If the bushing bore diameter of the cylinder head is greater than 10 306 mm 0 4057 in machine the bushing bore to the fol lowing dimension 10 335 to 10 356 mm 0 4069 to 0 4077 in If the bushing bor...

Page 1760: ...ee page EM 46 between the guide bushing and valve stem 2 REPLACE SPARK PLUG TUBE GASKETS a Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90 or more b Using a screwdriver pry out the gasket NOTICE Be careful not to damage the cylinder head cover Tape the screwdriver tip c Using SST and a hammer tap in a new gasket until its sur face is flush with the upper ed...

Page 1761: ...head spark plug tubes must be installed a Apply adhesive to the end of the spark plug tube Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b Using a wooden block and hammer tap in a new spark tube until there is 40 9 42 1 mm 1 610 1 658 in pro truding from the camshaft bearing cap installation surface of the cylinder head NOTICE Avoid tapping a new spark plug tube too far for measuring ...

Page 1762: ...lve stem SST 09202 70020 09202 00010 d Using a plastic faced hammer and the valve stem not in use tip wound with vinyl tape lightly tap the valve stem tip to assure proper fit NOTICE Be careful not to damage the valve stem tip 3 INSTALL SHIMS AND VALVE LIFTERS a Install the shim and valve lifter b Check that the valve lifter rotates smoothly by hand ...

Page 1763: ...exhaust manifold with 8 new nuts Uniformly tighten the nuts in several steps Torque 44 N m 450 kgf cm 32 ft lbf c Install the heat insulator with the 4 bolts Torque 7 5 N m 76 kgf cm 66 in lbf 2 INSTALL LH EXHAUST MANIFOLD TO CYLINDER HEAD a Place a new gasket on the cylinder head b Install the exhaust manifold with 8 new nuts Uniformly tighten the nuts in several steps Torque 44 N m 450 kgf cm 32...

Page 1764: ...f the installation direction b Place the 2 cylinder heads in the positions on the cylinder head gaskets 4 INSTALL CYLINDER HEAD BOLTS HINT The cylinder head bolts are tightened in 2 progressive steps steps c and e If any cylinder head bolt is broken or deformed replace it a Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts b Install the plate washer to ...

Page 1765: ...nto portion A the plate washer will pass through the cylinder head and cylin der block into the oil pan d Mark the front of the cylinder head bolt with paint e Retighten the cylinder head bolts by 90 in the numerical order shown f Check that the painted mark is now at a 90 angle to front 5 INSTALL SPARK PLUGS 6 ASSEMBLE EXHAUST CAMSHAFT a Install the camshaft gear spring camshaft sub gear and wave...

Page 1766: ...ign the gear teeth of the main gear and sub gear and tighten the service bolt 7 INSTALL CAMSHAFT TIMING TUBE TO INTAKE CAM SHAFT a Place a new oil seal to the timing tube NOTICE Be careful of the installation direction b Align the timing tube knock pin with the knock pin groove of the drive gear and temporarily install the drive gear with the 4 bolts c Using SST and a 5 mm hexagon wrench uniformly...

Page 1767: ...ing the camshaft to seize or break To avoid this the follow ing steps should be carried out a Set the crankshaft pulley position Turn the pulley clockwise or counterclockwise and align the timing mark of the crankshaft pulley with the centers of the crankshaft pulley bolt and idler pulley bolt NOTICE Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come i...

Page 1768: ...es and groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces Apply seal packing to the bearing cap as shown in the illustration Install a nozzle that has been cut to a 1 5 mm 0 059 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be removed and reapplied Immediately remove the no...

Page 1769: ...bolts D and E NOTICE Do not apply engine oil under the heads of the bearing cap bolts A B and C HINT Each bolt length is indicated in the illustration Bolt length 94 mm 3 70 in for A with seal washer 72 mm 2 83 in for B with seal washer 25 mm 0 98 in for C 52 mm 2 05 in for D 38 mm 1 50 in for E 12 Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration 13 Uniformly tig...

Page 1770: ...ce the intake and exhaust camshafts 3 Set the timing mark 1 dot mark of the camshaft drive and driven main gears at approx 10 angle 4 Apply seal packing to the camshaft housing plug Remove the old packing material FIPG Apply seal packing to the housing plug Seal packing Part No 08826 00080 or equivalent 5 Install the camshaft housing plug to the cylinder head as shown in the illustration 6 Install...

Page 1771: ...ent clean both sealing surfaces Apply seal packing to the bearing cap as shown in the illustration Install a nozzle that has been cut to a 1 5 mm 0 059 in opening Parts must be assembled within 5 minutes of application Otherwise the material must be removed and reapplied Immediately remove the nozzle from the tube and reinstall cap Seal packing Part No 08826 00080 or equivalent NOTICE Do not apply...

Page 1772: ...72 mm 2 83 in for B with seal washer 25 mm 0 98 in for C 52 mm 2 05 in for D 38 mm 1 50 in for E 13 Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration 14 Uniformly tighten the 22 bearing cap bolts in several steps in the sequence shown Torque 7 5 N m 76 kgf cm 66 in lbf for bolt C 16 N m 160 kgf cm 12 ft lbf for others 15 Remove the service bolt 9 CHECK AND ADJUST ...

Page 1773: ...he cylinder heads as shown in the illustration Seal packing Part No 08826 00080 or equivalent c Install the gasket to the cylinder head cover d Install the seal washer to the bolt e Install the cylinder head cover with the 9 bolts Uniformly tighten the bolts in several steps Torque 6 0 N m 60 kgf cm 53 in lbf 13 INSTALL RH CYLINDER HEAD COVER a Remove any old packing material FIPG b Apply seal pac...

Page 1774: ...e IG 6 19 INSTALL REAR WATER BYPASS JOINT a Install 2 new gaskets to the cylinder head b Install the the water bypass joint with the 4 nuts to the cyl inder heads Alternately tighten the nuts Torque 18 N m 185 kgf cm 13 ft lbf 20 INSTALL NO 2 AIR SWITCHING VALVES See page EC 27 21 INSTALL AIR PUMP ASSEMBLY See page EC 27 22 INSTALL FRONT WATER BYPASS JOINT Install 2 new gaskets and the water bypas...

Page 1775: ... lbf for union bolts 7 5 N m 80 kgf cm 66 in lbf for bolt i Install the VSV for EVAP with the bolt to the intake man ifold and connect the EVAP hose Torque 7 5 N m 76 kgf cm 66 in lbf j Install the 2 VSVs for air injection system with the 2 bolts Torque 7 5 N m 76 kgf cm 66 in lbf 25 INSTALL INTAKE MANIFOLD ASSEMBLY a Place 2 new gaskets on the intake manifold b Place the intake manifold assembly ...

Page 1776: ...7 5 N m 76 kgf cm 66 in lbf f Connect the engine wire to the engine hanger and wire bracket g Install the engine wire to the LH No 1 timing belt rear plate h Connect the wire protector to the intake manifold and cyl inder heads with the 2 bolts i Install the 2 ground cables with the 2 bolts to the RH and LH cylinder heads j Connect the 2 water bypass hoses to the throttle body k Connect the 2 wire...

Page 1777: ...8 CONNECT FUEL INLET HOSE See page SF 31 AND FUEL RETURN HOSE 29 INSTALL TIMING BELT REAR PLATES a Install the RH No 1 timing belt rear plates Install the RH No 1 timing belt rear plates to the cylinder head with the 3 bolts and stud bolt Torque 7 5 N m 76 kgf cm 66 in lbf b Install the LH No 1 timing belt rear plates 1 Connect the wire clamp to the No 1 timing belt rear plate 2 Install the LH No ...

Page 1778: ...ly Drive Belt Fan Pulley Throttle Body Cover Radiator Assembly No 2 Fan Shroud Air Cleaner Cap and Intake Air Connector Assembly Air Cleaner Case Air Filter N m kgf cm ft lbf Specified torque MAF Meter Wire Clip A T Oil Cooler Hose 12 200 15 29 296 21 Clip A C Suction Hose ENGINE MECHANICAL 2UZ FE ENGINE UNIT 2WD EM 75 ENGINE UNIT 2WD COMPONENTS ...

Page 1779: ... Connector Cassette Connector A23366 Engine Wire Clamp Engine Wire Heater Hose Ground Strap Fuel Inlet Hose Battery Negative Cable Heater Hose Fuel Return Hose Generator Wire Battery Positive Terminal Clamp Generator Connector EVAP Hose w o Hydraulic Brake Booster Brake Booster Tube EM 76 ENGINE MECHANICAL 2UZ FE ENGINE UNIT 2WD ...

Page 1780: ...member Rear Engine Mounting Bracket Transmission Control Cable 38 388 28 18 183 13 Gasket 38 388 28 Turn Pressure Tube Pressure Feed Tube RH Front Exhaust Pipe LH Front Exhaust Pipe Gasket Gasket Gasket 37 377 27 37 377 27 Retainer Bushing 29 290 21 62 632 46 62 632 46 19 190 14 62 632 46 13 130 9 72 730 53 65 663 48 74 750 54 62 632 46 ENGINE MECHANICAL 2UZ FE ENGINE UNIT 2WD EM 77 ...

Page 1781: ... Spacer Drive Plate O Ring 48 490 35 x 8 x 6 N m kgf cm ft lbf Specified torque Non reusable part Precoated part Clamp Connector Stay Stay Stay See page EM 83 1st 49 500 36 2nd Turn 90 Transmission with Torque Converter Clutch Connector Connector x 10 37 380 27 for 14 mm Head 72 730 53 for 17 mm Head EM 78 ENGINE MECHANICAL 2UZ FE ENGINE UNIT 2WD ...

Page 1782: ...ery negative cable from the left fender apron 8 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 See page CH 7 or CH 19 c Remove the 4 nuts the fan fluid coupling assembly and fan pulley 9 DISCONNECT ENGINE WIRE FROM CABIN a Remove the glove compartment door b Remove the lower No 2 panel c Remove the 3 scr...

Page 1783: ... 12 REMOVE PROPELLER SHAFT See page PR 3 13 REMOVE FRONT STABILIZER BAR See page SA 89 14 DISCONNECT POWER STEERING GEAR PIPES Disconnect the pressure feed tube turn tube and pressure tubes from the PS gear assembly See page SR 73 15 REMOVE TRANSMISSION CONTROL CABLE a Remove the 2 bolts and control cable bracket from the transmission b Remove the control cable from the control shift lever 16 DISC...

Page 1784: ...ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE a Lift the engine out of the vehicle slowly and carefully HINT Make sure the engine is clear of all wiring hoses and cables b Place the engine and transmission assembly onto the stand 22 DISCONNECT ENGINE WIRE FROM TRANSMISSION a Disconnect the 5 connectors b Disconnect the 2 wire clamps 23 REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION a Disc...

Page 1785: ...e 2 bolts and flywheel housing under cover b Turn the crankshaft pulley bolt to gain access to each bolt c Hold the crankshaft pulley bolt with a wrench and remove the 6 bolts 26 REMOVE TRANSMISSION a Remove the 10 bolts b Remove the transmission together with the torque con verter clutch from the engine 27 REMOVE DRIVE PLATE Remove the 8 bolts front spacer drive plate and rear spacer ...

Page 1786: ...rear spacer on the crankshaft c Install and uniformly tighten the 8 mounting bolts in sever al passes in the sequence shown Torque 49 N m 500 kgf cm 36 ft lbf If any one of the mounting bolts does not meet the torque speci fication replace the mounting bolt d Mark the mounting bolt with paint e Retighten the mounting bolts by 90 in the numerical or der shown f Check that the painted mark is now at...

Page 1787: ... lbf 4 INSTALL OIL COOLER PIPE FOR TRANSMISSION 5 INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION a Install a new O ring to the dipstick guide b Apply soapy water to the O ring c Connect the dipstick guide end to the dipstick tube of the oil pan d Install the dipstick guide with the bolt e Install the dipstick f Connect the 2 breather hoses to the dipstick guide 6 CONNECT ENGINE WIRE TO T...

Page 1788: ...5 N m 663 kgf cm 48 ft lbf b Install the frame crossmember with the 8 bolts and 4 nuts Torque 18 N m 183 kgf cm 13 ft lbf for bolts A 72 N m 730 kgf cm 53 ft lbf for nuts B 9 INSTALL ENGINE MOUNTING BRACKETS a Install the engine mounting brackets to the frame brack ets with the 2 nuts and 4 bolts Torque 38 N m 388 kgf cm 28 ft lbf b Remove the engine chain hoist 10 INSTALL PS PUMP Install the PS p...

Page 1789: ...MET AND CABLES a Connect the 2 PS air hoses to hose clamp on the No 3 RH timing belt cover b Connect the generator wire c Connect the generator connector d Connect the hose clamp for the PS air hose e Connect the PS air hose to the upper intake manifold f Connect the 2 heater hoses g Connect the ground strap connector h Connect the fuel inlet hose and clamps i Connect the fuel return hose and clam...

Page 1790: ...TAKE AIR CONNEC TOR ASSEMBLY a Install the air cleaner with the 3 bolt Torque 5 N m 51 kgf cm 44 in lbf b Connect the intake air connector to the throttle body c Connect the MAF meter connector d Install the A C suction hose to the intake air connector e Connect the PS air hose air inlet hose for EVAP PCV hose and MAF meter wire to the air intake connector 22 INSTALL THROTTLE BODY COVER 23 INSTALL...

Page 1791: ...ly Drive Belt Fan Pulley Throttle Body Cover Radiator Assembly No 2 Fan Shroud Air Cleaner Cap and Intake Air Connector Assembly Air Cleaner Case Air Filter N m kgf cm ft lbf Specified torque MAF Meter Wire Clip A T Oil Cooler Hose 12 200 15 29 296 21 Clip A C Suction Hose EM 88 ENGINE MECHANICAL 2UZ FE ENGINE UNIT 4WD ENGINE UNIT 4WD COMPONENTS ...

Page 1792: ... Connector Cassette Connector A23366 Engine Wire Clamp Engine Wire Heater Hose Ground Strap Fuel Inlet Hose Battery Negative Cable Heater Hose Fuel Return Hose Generator Wire Battery Positive Terminal Clamp Generator Connector EVAP Hose w o Hydraulic Brake Booster Brake Booster Tube ENGINE MECHANICAL 2UZ FE ENGINE UNIT 4WD EM 89 ...

Page 1793: ...Clamp 62 630 46 Gasket Front Exhaust Pipe RH 48 490 35 Gasket 62 630 46 Clamp Gasket 32 326 24 37 377 27 Crossmember 72 734 53 65 660 48 Engine Rear Mounting Insulator 19 5 199 14 14 5 148 11 Transmission and Transfer 88 897 65 Rear Propeller Shaft 88 897 65 40 410 30 Front Propeller Shaft 88 897 65 88 897 65 Heat Insulator 16 164 12 Front Exhaust Pipe LH 71 724 52 12 122 9 Gasket EM 90 ENGINE MEC...

Page 1794: ...ooler Pipe for Transmission Rear Spacer Stay Front Spacer x 8 Stay Stay N m kgf cm ft lbf Specified torque See page EM 95 1st 49 500 36 2nd Turn 90 17 175 13 A C Compressor Connector 38 388 28 49 500 36 38 388 28 17 175 13 ENGINE MECHANICAL 2UZ FE ENGINE UNIT 4WD EM 91 ...

Page 1795: ...take connector e Disconnect the intake air connector from the throttle body 11 DISCONNECT BATTERY CABLES a Disconnect the clamp on battery negative cable from the No 2 relay box b Disconnect the battery positive terminal cable c Disconnect the battery negative cable from the left fender apron 12 REMOVE DRIVE BELT FAN FLUID COUPLING AND FAN PULLEY a Loosen the 4 nuts holding the fluid coupling to t...

Page 1796: ...uel return hose and clamp k Disconnect the air inlet hose from the charcoal canister l Disconnect the EVAP hose from the VSV for EVAP m w o Hydraulic brake booster Disconnect the brake booster tube 15 DISCONNECT A C COMPRESSOR FROM ENGINE a Disconnect the A C compressor connector b Remove the 3 bolts and disconnect the A C compressor from the engine HINT Suspend the A C compressor securely 16 DISC...

Page 1797: ... c Lift the engine out of the vehicle slowly and carefully HINT Make sure the engine is clear of all wiring hoses and cables d Place the engine and transmission assembly onto the stand 19 REMOVE DRIVE PLATE Remove the 8 bolts front spacer drive plate and rear spacer ...

Page 1798: ...pacer drive plate and rear spacer on the crankshaft c Install and uniformly tighten the 8 mounting bolts in sever al passes in the sequence shown Torque 49 N m 500 kgf cm 36 ft lbf If any one of the mounting bolts does not meet the torque speci fication replace the mounting bolt d Mark the mounting bolt with paint e Retighten the mounting bolts by 90 in the numerical or der shown f Check that the ...

Page 1799: ...r 5 CONNECT HOSES WIRES CONNECTORS CLAMPS GROMMET AND CABLES a Connect the accelerator cable to the engine b Connect the 2 PS air hoses to hose clamp on the No 3 RH timing belt cover c Connect the generator wire d Connect the generator connector e Connect the hose clamp for the PS air hose f Connect the PS air hose to the upper intake manifold g Connect the 2 heater hoses h Connect the ground stra...

Page 1800: ...pron c Connect the clamp on battery negative cable to No 2 relay box 9 INSTALL AIR CLEANER AND INTAKE AIR CONNEC TOR PIPE ASSEMBLY a Install the air cleaner case with the 3 bolts Torque 5 N m 51 kgf cm 44 in lbf b Connect the intake air connector to the throttle body c Connect the MAF meter connector d Install the A C suction hose to the intake air connector e Connect the PS air hose air inlet hos...

Page 1801: ...e x 8 Water Pump Gasket O Ring Engine Wire Engine Wire Cover VVT Sensor 1 Engine Coolant Drain Union 36 370 27 x 5 Oil Pressure Sender Gauge Connector 7 5 76 66 in lbf N m kgf cm ft lbf Specified torque x 20 Clamp Engine Wire Protector Tape Water Bypass Pipe O Ring Gasket Engine Wire 39 400 29 Gasket x 4 30 5 310 22 15 5 160 11 7 5 76 66 in lbf 7 5 76 66 in lbf 7 5 76 66 in lbf 7 5 76 66 in lbf 28...

Page 1802: ...Ring Rear Oil Seal Retainer Upper Main Bearing Snap Ring Piston Upper Crankshaft Thrust Washer Lower Main Bearing Lower Crankshaft Thrust Washer Main Bearing Cap Non reusable part x 7 Crankshaft N m kgf cm ft lbf Specified torque Connecting Rod Bushing See page EM 118 1st 27 275 20 2nd Turn 90 See page EM 118 1st 24 5 250 18 2nd Turn 90 8 0 80 71 in lbf ENGINE MECHANICAL 2UZ FE CYLINDER BLOCK EM 9...

Page 1803: ... 70 7 REMOVE VVT SENSORS See page SF 79 8 DISCONNECT ENGINE WIRE FROM LH SIDE OF CYL INDER BLOCK a Remove the 2 bolts and engine wire cover from the LH side of the cylinder block b Remove the 2 bolts disconnect the brackets on the en gine wire from the cylinder block and engine mounting bracket 9 REMOVE OIL COOLER PIPE BRACKET FOR A T Remove the bolt and bracket 10 REMOVE ENGINE MOUNTING BRACKETS ...

Page 1804: ...e is greater than maximum replace the connecting rod assembly s If necessary replace the crank shaft Connecting rod thickness 22 880 to 22 920 mm 0 9008 to 0 9024 in 20 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Check the matchmarks on the connecting rod and see it cap to ensure correct reassembly b Remove the 2 connecting rod cap bolts c Using the 2 removed connecting rod cap bolts remo...

Page 1805: ... h Remove the 2 bolts connecting rod cap and lower bear ing See procedure b and c above i Measure the Plastigage at its widest point Standard oil clearance 0 021 to 0 047 mm 0 0008 to 0 0019 in Maximum oil clearance 0 059 mm 0 0023 in If the oil clearance is greater than maximum replace the bear ings If necessary replace the crankshaft HINT If using a standard bearing replace it with one having th...

Page 1806: ...n Mark 7 1 502 to 1 505 mm 0 0591 to 0 0593 in j Completely remove the Plastigage 21 REMOVE PISTON AND CONNECTING ROD AS SEMBLIES a Using a ridge reamer remove all the carbon from the top of the cylinder b Push the piston connecting rod assembly and upper bearing through the top of the cylinder block HINT Keep the bearings connecting rod and cap together Arrange the piston and connecting rod assem...

Page 1807: ...block d Clean each main journal and bearing e Check each main journal and bearing for peelings and scratches If the journal or bearing is damaged replace the bearings If necessary replace the crankshaft f Place the crankshaft on the cylinder block g Lay a strip of Plastigage across each journal h Install the main bearing caps See page EM 118 NOTICE Do not turn the crankshaft i Remove the main bear...

Page 1808: ...determined se lect the correct bearing by adding together the numbers im printed on the cylinder block and crankshaft then refer to the table below for the appropriate bearing number There are 5 sizes of the standard bearings For No 1 and No 5 position bearings use bearings marked 3 4 5 6 and 7 For oth ers position bearings use bearings marked 1 2 3 4 and 5 Reference Cylinder block main journal bo...

Page 1809: ...0980 in Mark 4 2 490 to 2 493 mm 0 0980 0 0981 in Mark 5 2 493 to 2 496 mm 0 0981 0 0983 in Mark 6 2 496 to 2 499 mm 0 0983 0 0984 in Mark 7 2 499 to 2 502 mm 0 0984 0 0985 in Others Mark 1 2 481 to 2 484 mm 0 0977 0 0978 in Mark 2 2 484 to 2 487 mm 0 0978 0 0979 in Mark 3 2 487 to 2 490 mm 0 0979 0 0980 in Mark 4 2 490 to 2 493 mm 0 0980 0 0981 in Mark 5 2 493 to 2 496 mm 0 0981 0 0983 in k Compl...

Page 1810: ...nge the piston rings in correct order only 27 DISCONNECT CONNECTING ROD FROM PISTON a Using a small screwdriver pry out the 2 snap rings b Gradually heat the piston to approx 60 C 140 F c Using a plastic faced hammer and brass bar lightly tap out the piston pin and pin and remove the connecting rod HINT The piston and pin are a matched set Arrange the pistons pins rings connecting rods and bearing...

Page 1811: ...oroughly clean the cylin der block 2 INSPECT CYLINDER BLOCK a Inspect for flatness Using a precision straight edge and feeler gauge mea sure the surfaces contacting the cylinder head and main bearing cap for warpage Maximum warpage 0 07 mm 0 0028 in If warpage is greater than maximum replace the cylinder block b Visually check the cylinder for vertical scratches If deep scratches are present rebor...

Page 1812: ...sitions A and B in the thrust and axial directions Standard diameter 94 010 to 94 023 mm 3 7012 to 3 7017 in Maximum diameter STD 94 223 mm 3 7096 in O S 0 50 94 723 mm 3 7292 in If the diameter is greater than maximum rebore all the 8 cylin ders and replace all the 8 pistons See page EM 115 If neces sary replace the cylinder block d Remove the cylinder ridge If the wear is less than 0 2 mm 0 008 ...

Page 1813: ...use a wire brush 4 INSPECT PISTON AND CONNECTING ROD a Inspect the piston oil clearance HINT There is 1 size of the standard piston diameter marked 2 ac cordingly The mark is stamped on the piston top 1 Using a micrometer measure the piston diameter at right angles to the piston pin center line 30 75 mm 1 2106 in from the piston head Piston diameter STD Mark 2 93 912 to 93 940 mm 3 6973 to 3 6984 ...

Page 1814: ...ace the cylinder block HINT Use a new cylinder block Use a piston with the same number mark as the cylinder diameter number marked on the cylinder block b Inspect the piston ring groove clearance Using a feeler gauge measure the clearance between the new piston ring and the wall of the ring groove Ring groove clearance No 1 0 030 to 0 080 mm 0 0012 to 0 0031 in No 2 0 020 to 0 060 mm 0 0008 to 0 0...

Page 1815: ...iston ring If the end gap is greater than maximum even with a new piston ring rebore all the 8 cylinders See page EM 115 or replace the cylinder block d Inspect the piston pin fit At 60 C 140 F you should be able to push the piston pin into the piston pin hole with your thumb e Using a rod aligner and feeler gauge check the connect ing rod alignment 1 Check for bend Maximum bend 0 05 mm 0 0020 in ...

Page 1816: ...rance 0 005 to 0 011 mm 0 0002 to 0 0004 in Maximum oil clearance 0 05 mm 0 0020 in If the oil clearance is greater than maximum replace the bush ing If necessary replace the piston and piston pin as a set g Using vernier calipers measure the tension portion of the connecting rod bolt Standard diameter 7 200 to 7 300 mm 0 2835 to 0 2874 in Minimum diameter 7 00 mm 0 2756 in If the diameter is less...

Page 1817: ...66 988 to 67 000 mm 2 6373 to 2 6378 in Crank pin diameter 51 982 to 52 000 mm 2 0465 to 2 0472 in If the diameter is not as specified check the oil clearance See page EM 100 If necessary replace the crankshaft 2 Check each main journal and crank pin for taper and out of round as shown Maximum taper and out of round 0 02 mm 0 0008 in If the taper and out of round is greater than maximum replace th...

Page 1818: ... right angles to the piston pin center line 30 75 mm 1 2106 in from the piston head c Calculate the size to be rebored for each cylinder as fol lows Size to be rebored P C H P Piston diameter C Piston clearance 0 030 to 0 071 mm 0 0012 to 0 0028 in H Allowance for honing 0 02 mm 0 0008 in or less d Bore and hone the cylinders to calculated dimensions Maximum honing 0 02 mm 0 0008 in NOTICE Excess ...

Page 1819: ... See page LU 13 4 REPLACE CRANKSHAFT REAR OIL SEAL HINT There are 2 methods a and b to replace the oil seal a If the rear oil seal retainer is removed from the cylinder block 1 Using a screwdriver and hammer tap out the oil seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 56010 3 Apply MP grease to the oil seal lip b If t...

Page 1820: ... ENGINE MECHANICAL 2UZ FE CYLINDER BLOCK EM 117 3 Apply MP grease to a new oil seal lip 4 Using SST and a hammer tap in the oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 56010 ...

Page 1821: ...n one side of the piston pin hole b Gradually heat the piston to about 60 C 140 F c Coat the piston pin with engine oil d Position the piston so that the front mark and to the out side mark on the connecting rod face in the same direc tion as shown in the illustration e Align the piston pin holes of the piston and connecting rod and push in the piston pin with your thumb f Using a screwdriver inst...

Page 1822: ...nnecting rod and connecting rod cap 4 INSTALL MAIN BEARINGS HINT Main bearings are of 19 5 mm 0 768 in and 22 5 mm 0 886 in in width Install the 22 5 mm 0 886 in bear ings in the No 1 and No 5 cylinder block journal positions with the main bearing cap Install the 19 5 mm 0 768 in bearings in the other positions Upper bearings have an oil groove and oil holes but lower bearings do not a Align the b...

Page 1823: ... main bearing cap bolts are tightened in 2 progressive steps steps b and d If any one of the main bearing cap bolts is broken or de formed replace it a Apply a light coat of engine oil to the threads and under the main bearing cap bolts b Install and uniformly tighten the 10 main bearing cap bolts in several steps in the sequence shown Torque 27 N m 275 kgf cm 20 ft lbf If any of the main bearing ...

Page 1824: ...nt mark of the piston facing forward 11 PLACE CONNECTING ROD CAP ON CONNECTING ROD a Match the numbered connecting rod cap with the con necting rod b Align the pin groove of the connecting rod cap with the pins of the connecting rod and install the connecting rod cap c Check that the outside mark of the connecting rod cap is facing in correct direction 12 INSTALL CONNECTING ROD CAP BOLTS HINT The ...

Page 1825: ...ns smoothly 13 CHECK CONNECTING ROD THRUST CLEARANCE See page EM 100 14 INSTALL REAR OIL SEAL RETAINER a Remove any old packing FIPG material and be careful not to drop any oil on the contacting surfaces of the oil seal retainer and cylinder block Using a razor blade and gasket scraper remove all the old packing FIPG materials from the gasket surfaces and sealing grooves Thoroughly clean all compo...

Page 1826: ... forward 16 INSTALL OIL PUMP See page LU 15 17 INSTALL OIL STRAINER See page LU 15 18 INSTALL NO 1 OIL PAN See page LU 15 19 INSTALL OIL PAN BAFFLE PLATE See page LU 15 20 INSTALL NO 2 OIL PAN See page LU 15 21 INSTALL WATER PUMP See page CO 8 22 INSTALL ENGINE MOUNTING BRACKETS Install the mounting bracket with the 4 bolts Install the 2 mount ing brackets Torque 36 N m 370 kgf cm 27 ft lbf 23 INS...

Page 1827: ...py water to the O ring c Push in the water bypass pipe end into the pipe hole of the water pump d Install the water bypass pipe with the bolt Torque 18 N m 185 kgf cm 13 ft lbf e Install the wire clamp to the bracket of the water bypass pipe 29 INSTALL CYLINDER HEADS See page EM 60 30 INSTALL TIMING BELT AND PULLEYS See page EM 23 31 DISCONNECT ENGINE FROM ENGINE STAND ...

Page 1828: ...RH Front Exhaust Pipe Heated Oxygen Sensor Heated Oxygen Sensor Gasket Ring 62 632 46 LH Front Exhaust Pipe Gasket Center Exhaust Pipe 48 489 35 62 632 46 No 2 Heat Insulator 44 450 33 44 450 33 5 0 51 44 in lbf 5 0 51 44 in lbf 5 0 51 44 in lbf 5 0 51 44 in lbf 7 0 71 62 in lbf C Cab No 4 Heat Insulator 4WD No 2 Heat Insulator 7 0 71 62 in lbf ENGINE MECHANICAL 2UZ FE EXHAUST SYSTEM EM 125 EXHAUS...

Page 1829: ... 3 nuts gasket and front exhaust pipe from the exhaust manifold 5 REMOVE LH FRONT EXHAUST PIPE Remove the 3 nuts gasket ring and front exhaust pipe from the exhaust manifold 6 REMOVE CENTER EXHAUST PIPE a Loosen the clamp bolt disconnect the center exhaust pipe and remove the gasket from the exhaust tailpipe b Remove the 2 rings and center exhaust pipe 7 REMOVE EXHAUST TAILPIPE a Remove the 3 ring...

Page 1830: ...XHAUST PIPE a Install a new gasket and ring to the LH front exhaust pipe b Install the LH front exhaust pipe to the exhaust manifold with 3 new nuts Torque 62 N m 632 kgf cm 46 ft lbf 5 INSTALL RH FRONT EXHAUST PIPE a Install a new gasket to the RH front exhaust pipe b Install the RH front exhaust pipe to the exhaust manifold with 3 new nuts Torque 62 N m 632 kgf cm 46 ft lbf 6 CONNECT EXHAUST CEN...

Page 1831: ...ning HC being released from the fuel tank 2 The function of each system is shown in the table below System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Three way Catalytic Converter 4 Sequential Multiport Fuel Injection PCV EVAP TWC SFI Reduces HC Reduces evaporated HC Reduces HC CO and NOx Injects a precisely timed optimum amount of fuel for reduced exha...

Page 1832: ...e Charcoal Canister Filter Fuel Tank Cap Fuel Tank Vacuum Surge Tank Air Fuel Ratio Sensor Heated Oxygen Sensor Heated Oxygen Sensor Air Fuel Ratio Sensor EC 2 EMISSION CONTROL 1GR FE PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION ...

Page 1833: ...er EVAP VSV Purge Line VENT Line Fuel Tank Air Filter ECM To Intake Manifold Pump Module M P Pressure Sensor Pump Motor Vent Valve Refueling Valve Air Inlet Line EMISSION CONTROL 1GR FE PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 DRAWING ...

Page 1834: ...e are harmful 2 Blow air into the intake manifold side and check that air does not pass through smoothly If operation is not as specified replace the ventilation valve c Remove the clean hose from the ventilation valve 4 INSTALL VENTILATION VALVE Install the ventilation valve to the LH cylinder head cover Torque 27 N m 275 kgf cm 20 ft lbf 5 VISUALLY INSPECT HOSES CONNECTIONS AND GASKETS a Check f...

Page 1835: ...anister 14 7 150 11 Non reusable part Detection Pump 14 7 150 11 O Ring Charcoal Canister Bracket N m kgf cm ft lbf Specified torque EMISSION CONTROL 1GR FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 EVAPORATIVE EMISSION EVAP CONTROL SYSTEM COMPONENTS ...

Page 1836: ...ure gauge to the fuel tank c Fill the fuel tank with fuel d Apply pressure of 4 kPa 41 gf cm2 0 58 psi to the vent port of the fuel tank HINT It is necessary to check the amount of fuel in the fuel tank When the fuel tank is full the float valve of the fill check valve is closed and no air can pass through e Remove the fuel tank cap and check that the pressure drops If the pressure does not drop r...

Page 1837: ...hat air flows from the air inlet port If the result is not as specified replace the charcoal canister as sembly 2 With the vent port closed blow 1 10 kPa 11 2 gf cm2 0 16 psi of air to the air inlet port and check that air flows from the purge port If the result is not as specified replace the charcoal canister as sembly c Check for air leakage 1 Remove the air hose between ports A and B 2 Connect...

Page 1838: ... charcoal can ister 2 Check that air flows from port A to B and then to C If the result is not as specified replace the charcoal canister as sembly 3 Connect the positive lead of the battery to termi nal 7 and the negative lead to terminal 6 4 Check that the valve is closed If the result is not as specified replace the charcoal canister as sembly 5 Install the detection pump ...

Page 1839: ... EMISSION CONTROL 1GR FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 9 8 INSPECT VSV FOR EVAP See page SF 65 9 REINSTALL CHARCOAL CANISTER ASSEMBLY ...

Page 1840: ...EC 10 EMISSION CONTROL 1GR FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM MEMO ...

Page 1841: ... EMISSION CONTROL 1GR FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 11 MEMO ...

Page 1842: ...a Check the connections for looseness or damage b Check the clamps for weakness cracks or damage 2 INSPECT TWC Check for dents or damage If any part of the protector is damaged or dented to the extent that it contacts the TWC repair or replace it 3 INSPECT HEAT INSULATOR a Check the heat insulator for damage b Check for adequate clearance between the TWC and heat insulator ...

Page 1843: ...tay Heated Oxygen Sensor Bank 1 RH Front Exhaust Pipe Exhaust Manifold RH TWC 44 450 33 44 450 33 62 630 46 21 214 15 x6 x6 21 214 15 TWC 40 408 30 40 408 30 43 440 32 48 489 35 TWC TWC 40 408 30 44 450 33 A F Sensor Bank 2 44 450 33 N m kgf cm ft lbf Specified torque Non reusable part EC 12 EMISSION CONTROL 1GR FE THREE WAY CATALYTIC CONVERTER TWC SYSTEM THREE WAY CATALYTIC CONVERTER TWC SYSTEM C...

Page 1844: ...he RH front exhaust pipe 4 REMOVE HEATED OXYGEN SENSOR BANK 2 OXYGEN SENSOR a Disconnect the heated oxygen sensor connector b Remove the heated oxygen sensor 5 REMOVE LH FRONT EXHAUST PIPE a Remove the 2 nuts exhaust pipe support and LH front ex haust pipe b Remove the 2 gaskets from the LH front exhaust pipe 6 REMOVE MANIFOLD STAY Remove the 6 bolts and 2 manifold stays 7 REMOVE A F SENSOR BANK 1...

Page 1845: ...Torque 21 N m 214 kgf cm 15 ft lbf 12 INSTALL A F SENSOR BANK 1 a Install the A F sensor Torque 44 N m 450 kgf cm 33 ft lbf b Connect the A F sensor connector 13 INSTALL EXHAUST MANIFOLD LH a Set a new gasket to the LH cylinder head with the oval shape facing backward NOTICE Be careful of the installation direction b Install the exhaust manifold with the 6 nuts Tighten the nuts uniformly in severa...

Page 1846: ...ensor Torque 44 N m 450 kgf cm 33 ft lbf b Connect the heated oxygen sensor connector 18 INSTALL RH FRONT EXHAUST PIPE a Install 2 new gaskets to the RH front exhaust pipe b Install the RH front exhaust pipe with 2 new nuts Torque 62 N m 630 kgf cm 46 ft lbf 19 INSTALL HEATED OXYGEN SENSOR BANK 1 OXY GEN SENSOR a Install the heated oxygen sensor Torque 44 N m 450 kgf cm 33 ft lbf b Connect the hea...

Page 1847: ...aining HC being released from the fuel tank 2 The function of each system is shown in these table System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Three Way Catalytic Converter 4 Sequential Multiport Fuel Injection PCV EVAP TWC SFI Reduces HC Reduces evaporated HC Reduces HC CO and NOx Injects a precisely timed optimum amount of fuel for reduced exhaus...

Page 1848: ...0680 VSV for EVAP PCV Valve Purge Line Charcoal Canister Charcoal Canister Filter Fuel Tank Cap Fuel Tank EC 2 EMISSION CONTROL 2UZ FE PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION ...

Page 1849: ...TWC TWC Air Pump Assembly VSV for Air Injection System Air Switching Valve No 2 Pressure Sensor Air Switching Valve Air Injection Control Driver EMISSION CONTROL 2UZ FE PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 ...

Page 1850: ...CM To Intake Manifold Pump Module M P Pressure Sensor Pump Motor Vent Valve Refueling Valve Air Inlet Line M P Air Switching Valve Air Switching Valve No 2 VSVs Air Pump Pressure Sensor EVAPORATIVE EMISSION EVAP CONTROL SYSTEM SECONDARY AIR INJECTION SYSTEM EC 4 EMISSION CONTROL 2UZ FE PARTS LAYOUT AND SCHEMATIC DRAWING DRAWING ...

Page 1851: ...PCV Hose PCV Valve Cover PCV Valve 27 275 20 Precoated part N m kgf cm ft lbf Specified torque EMISSION CONTROL 2UZ FE POSITIVE CRANKCASE VENTILATION PCV SYSTEM EC 5 POSITIVE CRANKCASE VENTILATION PCV SYSTEM COMPONENTS ...

Page 1852: ...ough 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 1 Apply adhesive to 2 or 3 threads Adhesive Part No 08833 00070 THREE BOND 1324 or equiva lent 2 Reinstall the PCV valve...

Page 1853: ...B03197 EMISSION CONTROL 2UZ FE POSITIVE CRANKCASE VENTILATION PCV SYSTEM EC 7 3 INSPECT HOSES CONNECTIONS AND GASKETS Visually for cracks leaks or damage 4 REINSTALL V BANK COVER ...

Page 1854: ...anister 14 7 150 11 Non reusable part Detection Pump 14 7 150 11 O Ring Charcoal Canister Bracket N m kgf cm ft lbf Specified torque EC 8 EMISSION CONTROL 2UZ FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EVAPORATIVE EMISSION EVAP CONTROL SYSTEM COMPONENTS ...

Page 1855: ...ure gauge to the fuel tank c Fill the fuel tank with fuel d Apply pressure of 4 kPa 41 gf cm2 0 58 psi to the vent port of the fuel tank HINT It is necessary to check the amount of fuel in the fuel tank When the fuel tank is full the float valve of the fill check valve is closed and no air can pass through e Remove the fuel tank cap and check that the pressure drops If the pressure does not drop r...

Page 1856: ...flows from the air inlet port If the result is not as specified replace the charcoal canister as sembly 2 With the vent port closed blow 1 10 kPa 11 2 gf cm2 0 16 psi air to the air inlet port and check that air flows from the purge port If the result is not as specified replace the charcoal canister as sembly c Check for air leakage 1 Remove the air hose between ports A and B 2 Connect the pressu...

Page 1857: ...p from the charcoal can ister 2 Check that air flows from port A to B and then C If the result is not as specified replace the charcoal canister as sembly 3 Connect the positive lead to terminal 7 and the negative lead to terminal 6 4 Check that the valve is closed If the result is not as specified replace the charcoal canister as sembly 5 Install the detection pump ...

Page 1858: ...EC 12 EMISSION CONTROL 2UZ FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM 8 INSPECT VSV FOR EVAP See page SF 65 9 REINSTALL CHARCOAL CANISTER ASSEMBLY ...

Page 1859: ... EMISSION CONTROL 2UZ FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 13 MEMO ...

Page 1860: ...EC 14 EMISSION CONTROL 2UZ FE EVAPORATIVE EMISSION EVAP CONTROL SYSTEM MEMO ...

Page 1861: ...Y 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 1862: ... Front Exhaust Pipe RH TWC Gasket Heated Oxygen Sensor Ring LH Front Exhaust Pipe 62 632 46 Gasket Gasket Heated Oxygen Sensor Gasket LH TWC 62 632 46 48 489 35 44 450 32 44 450 32 48 489 35 EMISSION CONTROL 2UZ FE THREE WAY CATALYTIC CONVERTER TWC SYSTEM EC 15 COMPONENTS ...

Page 1863: ...AUST PIPE a Remove the 3 nuts and RH front exhaust pipe b Remove the gasket from the RH front exhaust pipe 5 REMOVE LH FRONT EXHAUST PIPE a Remove the 3 nuts and LH front exhaust pipe b Remove the gasket from the LH front exhaust pipe 6 INSTALL LH FRONT EXHAUST PIPE a Install a new gasket to the LH front exhaust pipe b Install the LH front exhaust pipe with 3 new nuts Torque 62 N m 630 kgf cm 46 f...

Page 1864: ...ATED OXYGEN SENSOR BANK2 a Install the heated oxygen sensor Torque 44 N m 450 kgf cm 33 ft lbf b Connect the heated oxygen sensor connector 10 INSTALL HEATED OXYGEN SENSOR BANK1 a Install the heated oxygen sensor Torque 44 N m 450 kgf cm 33 ft lbf b Connect the heated oxygen sensor connector ...

Page 1865: ...s not as specified replace the pressure sensor 2 INSPECT VSV FOR AIR INJECTION SYSTEM a Disconnect the connector from the VSV b Disconnect the 2 vacuum hoses from the VSV c Using an ohmmeter measure the resistance between the terminals Standard Tester Connection Specified Condition 1 2 33 to 39 Ω at 20 C 68 F 1 Body ground 10 MΩ or higher 2 Body ground 10 MΩ or higher If the resistance is not as s...

Page 1866: ...erform procedures a to g to the other VSV 3 INSPECT NO 2 AIR SWITCHING VALVE a Disconnect the vacuum hose from the VSV for the air in jection system b Apply vacuum 30 kPa 306 gf cm2 4 35 psi to vacuum hose check that the vacuum does not decrease If operation is not as specified replace the No 2 air switching valve c Release the vacuum and check that the operation sound is emited from the No 2 air ...

Page 1867: ...r PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose Air Injection Control Driver N m kgf cm ft lbf Specified torque 7 5 76 66 in lbf EC 20 EMISSION CONTROL 2UZ FE SECONDARY AIR INJECTION SYSTEM COMPONENTS ...

Page 1868: ...r EVAP Fuel Return Hose N m kgf cm ft lbf Specified torque Non reusable part Gasket Gasket 16 163 12 Air Pump Assembly Intake Manifold Assembly Gasket Gasket VSV for Air Injection System 16 163 12 10 102 7 10 102 7 10 102 7 18 185 13 18 185 13 18 185 13 7 5 76 66 in lbf EMISSION CONTROL 2UZ FE SECONDARY AIR INJECTION SYSTEM EC 21 ...

Page 1869: ...B17519 Air Switching Valve Pressure Sensor Air Pump Bracket 5 0 55 48 in lbf 16 163 12 N m kgf cm ft lbf Specified torque EC 22 EMISSION CONTROL 2UZ FE SECONDARY AIR INJECTION SYSTEM ...

Page 1870: ...t the pressure sensor connector for the air in jection system d Remove the 4 bolts and air pump assembly 5 REMOVE NO 2 AIR SWITCHING VALVE a Remove the 4 nuts and 2 gaskets and disconnect the 2 No 3 air tubes from the exhaust manifolds b Remove the 4 bolts 2 gaskets and the 2 No 3 air tubes from the 2 No 2 air switching valves c Remove the 4 bolts 2 gaskets and the 2 No 2 air switch ing valves fro...

Page 1871: ...NSOR a Remove the vacuum hose from the pressure sensor and air switching valve b Remove the 2 bolts and pressure sensor from the air switching valve 2 REMOVE AIR SWITCHING VALVE a Remove the 2 bolts and air switching valve from the air pump bracket b Remove the No 1 air hose from the air switching valve and air pump ...

Page 1872: ...he air pump 2 INSPECT AIR SWITCHING VALVE a Blow air into port A and check that air is not discharged from port B b Apply positive battery between the terminals c Blow air into port A and check that air is discharged from port B If operation is not as specified replace the air switching valve 3 INSPECT NO 2 AIR SWITCHING VALVE a Blow air into port B and check that air is not discharged from port C...

Page 1873: ...o the air switching valve and air pump b Install the air switching valve with the 2 bolts to the air pump bracket Torque 16 N m 163 kgf cm 12 ft lbf 2 INSTALL PRESSURE SENSOR a Install the pressure sensor with the 2 bolts to the air switching valve Torque 5 0 N m 55 kgf cm 48 in lbf b Install the vacuum hose to the pressure sensor and air switching valve ...

Page 1874: ...kets and connect the 2 No 3 air tubes with the 4 bolts to the No 2 air switching valve Torque 10 N m 102 kgf cm 7 ft lbf d Install the 2 new gaskets and connect the 2 No 3 air tubes with the 4 nuts to the exhaust manifold Torque 10 N m 102 kgf cm 7 ft lbf 3 INSTALL AIR PUMP ASSEMBLY a Install the air pump assembly with the 4 bolts Torque 16 N m 163 kgf cm 12 ft lbf b Connect the pressure sensor co...

Page 1875: ...compartment be espe cially careful to protect the electrical system from water b Precautions when handling the oxygen sensor and A F sensor 1 Do not drop the oxygen sensor or A F sensor or hit them against another object 2 Do not allow the sensor to come into contact with water 5 IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYS TEM HAM CB ETC If the vehicle is equipped with a mobile communication syst...

Page 1876: ...r f When inspecting in rainy weather take care to prevent an intrusion of water Also when washing the engine compartment prevent water from getting on the SFI parts and wiring connectors g Parts should be replaced as an assembly h Care should be taken when pulling out and inserting wir ing connectors 1 Release the lock and pull out the connector pulling on the connectors 2 Fully insert the connect...

Page 1877: ...ery pipe and lower intake manifold as shown in the illustration NOTICE Before installing the injector apply spindle oil or gasoline where the delivery pipe or cylinder head contacts the O ring of the injector d Observe the following when disconnecting the fuel tube connector 1 Check if there is any dirt in the pipe and around the connector before disconnecting the fuel tube con nector If necessary...

Page 1878: ...and push into the connector until a click sound is heard If the connection is tight apply a small amount of fresh engine oil on the tip of the pipe 3 After finishing the connection pull the pipe and the connector to ensure it is secure 4 Check to make sure no fuel leak is present If the result is not as specified repair or replace 5 Install the fuel pipe clamp to the connector 6 Check to make sure...

Page 1879: ...e the circuit opening relay 2 Using a service wire connect terminals FP and B of the relay block NOTICE Pay careful attention to the terminal connecting position to avoid a malfunction 3 Turn the ignition switch to the ON position and check that the fuel pump operates NOTICE Do not start the engine c Check that there are no fuel leaks after performing main tenance of the fuel system d Turn the ign...

Page 1880: ...le Fuel pressure 281 to 287 kPa 2 87 to 2 93 kgf cm2 40 8 to 41 7 psi i Stop the engine j Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more If pressure is not as specified check the fuel pump pressure regulator and or injectors k After checking the fuel pressure disconnect the negative terminal cable from t...

Page 1881: ...Fuel Tank VENT Tube No 2 Fuel Tank Band Fuel Inlet Hose Clip 62 632 45 Fuel Tank Protector Fuel Tank Band Pin Fuel Return Tube 62 632 45 Fuel Tank Band Pin Fuel Inlet Pipe Fuel Main Tube Fuel Pump Gauge Retainer Fuel Pump Suction Support Clip Fuel Inlet Pipe Shield Speed Sensor Wire Charcoal Canister Assembly SFI 1GR FE FUEL PUMP SF 7 COMPONENTS ...

Page 1882: ... Fuel Suction Plate No 1 w Fuel Filter Fuel Pump Harness Fuel Pump Non reusable part Fuel Sender Gauge O Ring Spring Fuel Suction Plate No 2 E Ring Fuel Suction Filter Fuel Sub tank SF 8 SFI 1GR FE FUEL PUMP ...

Page 1883: ...ector is easily contaminated Do not use any tool in this operation Do not bend or twist the nylon tube Protect the con nector by covering it with a plastic bag When the pipe and connector are stuck push and pull the connector to release and pull the connector out carefully 3 REMOVE FUEL PUMP ASSEMBLY a Using SST loosen the fuel pump gauge retainer SST 09808 14020 09808 01410 09808 01420 09808 0143...

Page 1884: ...Disconnect the sender gauge connector from the fuel suction plate No 1 b Unlock the fuel sender gauge and slide to remove 2 REMOVE FUEL SUB TANK a Disconnect the fuel pump harness connector from the fuel suction plate No 1 b Disconnect the suction filter hose from the fuel sub tank c Disconnect the 2 tubes from the tube clamps ...

Page 1885: ...th the tip wrapped in tape discon nect the 2 snap claws from the fuel suction support NOTICE Do not damage the fuel filter assembly and fuel suction support b Remove the fuel filter assembly with fuel pump from the fuel suction support 4 REMOVE FUEL PUMP a Using a screwdriver with the tip wrapped in tape discon nect the 5 snap claws from the suction filter NOTICE Do not damage the fuel filter asse...

Page 1886: ...F 12 SFI 1GR FE FUEL PUMP 5 REMOVE FUEL SUCTION PLATE NO 2 a Using a screwdriver remove the 2 E rings from the suc tion plate No 2 b Remove the suction plate No 2 and 2 springs from the fuel suction plate No 1 ...

Page 1887: ...ON a Connect the lead wire to the fuel pump b Connect the positive lead from the battery to terminal 1 of the connector and the negative lead to terminal 2 Check that the fuel pump operates NOTICE These tests must be done quickly within 10 seconds to prevent the coil from burning out Keep the fuel pump as far away from the battery as possible Always do switching on the battery side If operation is...

Page 1888: ... 1 b Using needle nose pliers install 2 new E rings to the suction plate No 2 2 INSTALL FUEL PUMP a Apply a light coat of gasoline or spindle oil to a new O ring and install it to the fuel pump b Connect the fuel pump harness connector to the fuel pump c Install the fuel pump with the suction filter to the fuel filter 3 INSTALL FUEL FILTER Install the fuel filter to the fuel sub tank ...

Page 1889: ...ate No 2 to the fuel sub tank with the 3 snap claws engaged b Connect the 2 tubes to the tube clamps c Connect the suction filter hose to the fuel sub tank d Connect the fuel pump harness connector to the fuel suc tion plate No 1 5 INSTALL FUEL SENDER GAUGE a Install the fuel sender gauge to the fuel suction support ...

Page 1890: ...B17539 SF 16 SFI 1GR FE FUEL PUMP b Connect the sender gauge connector to the fuel suction plate No 1 ...

Page 1891: ...ew fuel pump gauge retainer with the S mark on the fuel tank while pushing down the fuel suction tube Attach the fuel pump gage retainer to the fuel tank f Rotate the fuel pump gage retainer by hand Use an SST to tighten the fule pump gage retainer by turning it one and a half times The triangle mark on the fuel pump gage retainer must be positioned between the A and MAX marks on the fuel tank SST...

Page 1892: ...onnecting part Check that the fuel tube joint is inserted securely Check that the tube joint clip is on the collar of the fuel tube joint After installing the tube joint clip check that the fuel tube joint has not been pulled off 3 CHECK FOR FUEL LEAKS 4 INSTALL FUEL TANK ASSEMBLY See page SF 36 ...

Page 1893: ...SSURE REGULATOR REMOVAL 1 PREVENT GASOLINE FROM SPILLING OUT See page SF 1 2 REMOVE V BANK COVER 3 REMOVE AIR CLEANER See page EM 62 4 DISCONNECT FUEL PIPE NO 2 5 REMOVE FUEL PRESSURE REGULATOR a Remove the 2 bolts and fuel pressure regulator b Remove the vacuum hose ...

Page 1894: ...vacuum hose b Apply a light coat of spindle oil or gasoline to a new O ring and install it to the fuel pressure regulator c Install the fuel pressure regulator with the 2 bolts Torque 9 0 N m 92 kgf cm 80 in lbf 2 CONNECT FUEL PIPE NO 2 3 INSTALL AIR CLEANER See page EM 89 4 INSTALL V BANK COVER 5 CHECK FOR FUEL LEAKS ...

Page 1895: ...INSPECT INJECTOR RESISTANCE a Disconnect the 6 injector connectors b Using an ohmmeter measure the resistance between the terminals Resistance 11 6 to 12 4 Ω at 20 C 68 F If the resistance is not as specified replace the injector c Reconnect the 6 injector connectors 5 INSTALL INTAKE AIR SURGE TANK See page EM 89 6 INSTALL AIR CLEANER See page EM 89 7 INSTALL V BANK COVER ...

Page 1896: ...G 01 A23082 7 5 76 66 in lbf V bank Cover N m kgf cm ft lbf Specified torque Ventilation Hose No 2 Mass Air Flow Meter Connector Vacuum Hose 8 0 82 71 in lbf Air Cleaner SF 22 SFI 1GR FE INJECTOR COMPONENTS ...

Page 1897: ...e Clamp No 2 Fuel Pipe No 1 Throttle Motor Connector Gasket Water By pass Hose No 4 Water By pass Hose No 5 Ventilation Hose No 1 Throttle Body Bracket 15 153 11 21 214 16 21 214 16 21 214 16 Intake Air Surge Tank Surge Tank Stay No 1 Fuel Vapor Feed Hose VSV Connector Surge Tank Stay No 2 VSV Connector Engine Wire Heater Water Inlet Hose Heater Water Outlet Hose 28 286 21 SFI 1GR FE INJECTOR SF 2...

Page 1898: ...Keep the plug free from foreign objects To protect the fuel pipe cover it with a plastic bag af ter checking When the fuel pipe and fuel delivery pipe are stuck pinch the nylon tube with fingers and turn it carefully to free and then disconnect the fuel pipe 7 DISCONNECT FUEL PIPE NO 2 a Remove the fuel pipe clamp b Pinch the tube connector and then pull out the fuel pipe NOTICE Check if there is ...

Page 1899: ...Remove the 6 bolts and fuel delivery pipe together with the 6 fuel injectors NOTICE Be careful not to drop the injectors when removing the fuel delivery pipe 9 REMOVE FUEL INJECTOR a Remove the 6 fuel injectors from the fuel delivery pipe b Remove the O ring and injector vibration insulator from each fuel injector ...

Page 1900: ...ON Connect the fuel tube connector quick type after observ ing the precautions c Remove the pressure regulator from the delivery pipe d Install the O ring to the fuel inlet of the pressure regulator e Connect the SST hose to the fuel inlet of the pressure regulator with another SST union and the 2 bolts SST 09268 41047 95336 08070 09268 41091 Torque 9 0 N m 92 kgf cm 80 in lbf f Connect the fuel r...

Page 1901: ... 3 times SST 09842 30080 Volume 76 to 91 cm3 4 6 to 5 5 cu in per 15 seconds Difference between each injector 15 cm3 0 9 cu in or less If the injection volume is not as specified replace the injector 2 INSPECT LEAKAGE Under the above conditions disconnect the tester probes of the SST wire from the battery and check the fuel leakage from the injector SST 09842 30080 Fuel drop 1 drop or less per 12 ...

Page 1902: ...ts which are used to hold the fuel delivery pipe to the intake manifold c Check that the fuel injectors rotate smoothly HINT If the fuel injectors do not rotate smoothly the probable cause is incorrect installation of O rings Replace the O ring of the in jector that does not rotate smoothly d Position the fuel injector connector facing out from the fuel delivery pipe e Tighten the 6 bolts which ar...

Page 1903: ...ny damage or foreign objects on the connected part of the fuel pipe After connecting check if the pipe and connector are securely connected by pulling them b Install the fuel pipe clamp 5 INSTALL INTAKE AIR SURGE TANK See page EM 62 6 INSTALL AIR CLEANER See page EM 89 7 INSTALL V BANK COVER 8 ADD ENGINE COOLANT 9 CHECK FOR FUEL LEAKS ...

Page 1904: ...SATION DAMPER FUEL PRESSURE PULSATION DAMPER REMOVAL 1 PREVENT GASOLINE FROM SPILLING OUT See page SF 1 2 REMOVE V BANK COVER 3 REMOVE FUEL PRESSURE PULSATION DAMPER a Remove the clip b Pull out the fuel pressure pulsation damper from the fuel delivery pipe ...

Page 1905: ...TALL FUEL PRESSURE PULSATION DAMPER a Apply a light coat of spindle oil or gasoline to a new O ring and install it to the fuel pressure pulsation damper b Install the fuel pressure pulsation damper to the fuel deliv ery pipe c Install the clip 2 INSTALL V BANK COVER 3 CHECK FOR FUEL LEAKS ...

Page 1906: ...ank Protector Fuel Tank Band Pin Fuel Return Tube 62 632 45 Fuel Tank Band Pin Fuel Inlet Pipe Fuel Main Tube Fuel Pump Gauge Retainer Fuel Pump Suction Support Clip Fuel Inlet Pipe Shield Speed Sensor Wire Charcoal Canister Assembly SF 32 SFI 1GR FE FUEL TANK AND LINE FUEL TANK AND LINE COMPONENTS CAUTION Always use new gaskets when replacing the fuel tank or component parts Apply the proper torq...

Page 1907: ...R ASSEMBLY a Remove the 4 bolts and charcoal canister assembly b Disconnect the pump module connector vent hose and purge line hose from the charcoal canister 5 DISCONNECT SPEED SENSOR WIRE Remove the nut and disconnect the speed sensor wire from the fuel tank 6 DISCONNECT FUEL MAIN TUBE AND RETURN TUBE See page SF 1 7 REMOVE FUEL TANK ASSEMBLY a Set up a transmission jack under the fuel tank b Re...

Page 1908: ...F 34 SFI 1GR FE FUEL TANK AND LINE c Remove the 2 bolts and disconnect the 2 fuel tank bands from the fuel tank d Operate the transmission jack and remove the fuel tank 8 REMOVE FUEL PUMP ASSEMBLY See page SF 9 ...

Page 1909: ... a Check the fuel lines for cracks or leakage and all connec tions for deformation b Check the fuel tank vapor vent system hoses and connec tions 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 illustra tion If a problem is found re...

Page 1910: ...orque 62 N m 632 kgf cm 45 ft lbf d Install the fuel pipe bracket to the body with the 2 nuts Torque 20 N m 204 kgf cm 15 ft lbf 3 CONNECT FUEL PUMP CONNECTOR 4 CONNECT FUEL MAIN TUBE AND RETURN TUBE See page SF 1 5 CONNECT SPEED SENSOR WIRE Connect the speed sensor wire to the fuel tank with the nut 6 INSTALL CHARCOAL CANISTER ASSEMBLY a Connect the pump module connector vent hose and purge line ...

Page 1911: ...B17586 SFI 1GR FE FUEL TANK AND LINE SF 37 7 INSTALL FUEL INLET PIPE SHIELD a Install the fuel inlet pipe shield with the 4 bolts b Install the fuel tank cap 8 CHECK FOR FUEL LEAKS 9 INSTALL SPARE TIRE ...

Page 1912: ... 21 to 2 69 kΩ at 20 C 68 F 0 49 to 0 67 kΩ at 60 C 140 F 3 INSPECT MASS AIR FLOW METER a If using a hand held tester 1 Connect the hand held tester to the DLC3 2 Turn the ignition switch to the ON position 3 Enter the following menus DIAGNOSIS EN HANCED OBD II DATA LIST MAF 4 Blow air into the MAF meter and check that the air flow value of the CURRENT DATA changes If operation is not as specified...

Page 1913: ...he throttle valve opening angle THROTTLE POS of the CURRENT DATA Standard percentage of the valve opening angle 60 or more If operation is not as specified check the accelerator pedal position sensor see page DI 299 the wiring and the ECM If not using a hand held tester measure the voltage between the terminals VTA1 E2 VTA2 E2 of the ECM connector see page DI 34 3 INSPECT AIR ASSIST SYSTEM a Start...

Page 1914: ...reusable part N m kgf cm ft lbf Specified torque Ventilation Hose No 2 Water By pass Hose No 5 Throttle Motor Connector Throttle Body Gasket Mass Air Flow Meter Connector Vacuum Hose Throttle Body Air Cleaner 8 0 82 71 in lbf 11 112 9 SF 40 SFI 1GR FE THROTTLE BODY COMPONENTS ...

Page 1915: ...AL 1 DRAIN ENGINE COOLANT 2 REMOVE V BANK COVER 3 REMOVE AIR CLEANER See page EM 62 4 DISCONNECT WATER BY PASS HOSE NO 5 5 DISCONNECT WATER BY PASS HOSE NO 4 6 REMOVE THROTTLE BODY a Disconnect the throttle motor connector b Remove the 4 bolts throttle body and gasket ...

Page 1916: ...new gasket and the throttle body w motor with the 4 bolts Torque 11 N m 112 kgf cm 9 ft lbf b Connect the throttle motor connector 2 CONNECT WATER BY PASS HOSE NO 4 3 CONNECT WATER BY PASS HOSE NO 5 4 INSTALL AIR CLEANER See page EM 89 5 INSTALL V BANK COVER 6 ADD ENGINE COOLANT 7 CHECK FOR ENGINE COOLANT LEAKS ...

Page 1917: ... hand held tester to the DLC3 b Turn the ignition switch to the ON position c Start the engine and warm it up d Connect the hand held tester and select the VVT from the ACTIVE TEST menu e Check the engine speed when the OCV is operated by the hand held tester Standard VVT system is OFF OCV is OFF Normal engine speed VVT system is ON OCV is ON Rough idle or engine stalled ...

Page 1918: ...7 5 76 66 in lbf V bank Cover N m kgf cm ft lbf Specified torque Ventilation Hose No 2 Mass Air Flow Meter Connector Vacuum Hose 8 0 82 71 in lbf Air Cleaner SF 44 SFI 1GR FE CAMSHAFTTIMING OIL CONTROL VALVE COMPONENTS ...

Page 1919: ...se No 5 Ventilation Hose No 1 Throttle Body Bracket 15 153 11 21 214 16 21 214 16 21 214 16 Intake Air Surge Tank Surge Tank Stay No 1 Fuel Vapor Feed Hose VSV Connector Surge Tank Stay No 2 VSV Connector Engine Wire Heater Water Inlet Hose Heater Water Outlet Hose 28 286 21 Camshaft Timing Oil Control Valve Camshaft Timing Oil Control Valve 9 0 92 80 in lbf 9 0 92 80 in lbf SFI 1GR FE CAMSHAFTTIM...

Page 1920: ...E V BANK COVER 2 REMOVE AIR CLEANER See page EM 62 3 REMOVE INTAKE AIR SURGE TANK See page EM 62 4 REMOVE FUEL DELIVERY PIPE 5 REMOVE CAMSHAFT TIMNG OIL CONTROL VALVE a Disconnect the 2 oil control valve connectors b Remove the 2 bolts and 2 camshaft timing oil control valves ...

Page 1921: ...en the ter minals Resistance 6 9 to 7 9 Ω at 20 C 68 F 2 INSPECT VALVE MOVEMENT Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check the movement of the valve NOTICE Confirm that the valve does not catch HINT Bad returning of the valve by catching foreign objects causes subtle pressure leak in the advanced direction DTCs could be detected ...

Page 1922: ...VE a Install the 2 camshaft timing oil control valves to each cylinder head and tighten the 2 bolts Torque 9 0 N m 92 kgf cm 80 in lbf b Connect the 2 oil control valve connectors 2 INSTALL FUEL DELIVERY PIPE 3 INSTALL INTAKE AIR SURGE TANK See page EM 89 4 INSTALL AIR CLEANER See page EM 89 5 INSTALL V BANK COVER ...

Page 1923: ...Connect the hand held tester to the DLC3 c Perform the ACTIVE TEST then check that the actuator rod operates d Start the engine e Check that the VSV for ACIS is ON under the following conditions Depressing the accelerator pedal to 60 accelerator opening angle Racing the engine above 4 700 rpm f Check that the VSV for ACIS is OFF under the following conditions The engine idling Release the accelera...

Page 1924: ...ge needle points to 0 kPa 0 mmHg 0 in Hg The actuator rod is returned f Remove the vacuum gauge and connect the vacuum hose to the actuator g Reinstall the V bank cover 3 INSPECT INTAKE AIR SURGE TANK Inspect the diaphragm 1 Check that the lever moves when a vacuum of 26 6 kPa 200 mmHg 7 9 in Hg is applied with the MI TYVAC hand held vacuum pump on 2 Check that the vacuum of 26 6 kPa 200 mmHg 7 9 ...

Page 1925: ... Air E F SFI 1GR FE ACOUSTIC CONTROL INDUCTION SYSTEM ACIS SF 51 c Inspect VSV operation 1 Check that air flows from port E to the filter 2 Apply battery voltage across the terminals 3 Check that air flows from port E to port F ...

Page 1926: ...EFI MAIN RELAY a Using an ohmmeter check for continuity between each terminal Specified condition Terminal No Specified condition 1 2 Continuity 3 5 No continuity b Using an ohmmeter check for continuity between termi nals 3 and 5 when the battery voltage is applied across terminals 1 and 2 Specified condition Continuity 3 INSTALL EFI MAIN RELAY ...

Page 1927: ... INSPECT A F SENSOR HEATER RELAY a Using an ohmmeter check for continuity between each terminal Specified condition Terminal No Specified condition 1 2 Continuity 3 5 No continuity b Using an ohmmeter check for continuity between termi nals 3 and 5 when the battery voltage is applied across terminals 1 and 2 Specified condition Continuity 3 INSTALL A F SENSOR HEATER RELAY ...

Page 1928: ...NSPECT CIRCUIT OPENING RELAY a Using an ohmmeter check for continuity between each terminal Specified condition Terminal No Specified condition 1 2 Continuity 3 5 No continuity b Using an ohmmeter check for continuity between termi nals 3 and 5 when the battery voltage is applied across terminals 1 and 2 Specified condition Continuity 3 INSTALL CIRCUIT OPENING RELAY ...

Page 1929: ... an ohmmeter check for continuity between each terminal Specified condition Terminal No Specified condition 1 2 3 4 Continuity 3 5 No continuity b Using an ohmmeter check for continuity between termi nals 3 and 5 when the battery voltage is applied across terminals 1 and 2 Specified condition Continuity 3 INSTALL ACC CUT RELAY ...

Page 1930: ...UEL PUMP RELAY a Using an ohmmeter check for continuity between each terminal Specified condition Terminal No Specified condition 1 2 3 4 Continuity 3 5 No continuity b Using an ohmmeter check for continuity between termi nals 3 and 5 when the battery voltage is applied across terminals 1 and 2 Specified condition Continuity 3 INSTALL FUEL PUMP RELAY ...

Page 1931: ...Ohmmeter SF1Z6 01 SFI 1GR FE FUEL PUMP RESISTOR SF 57 FUEL PUMP RESISTOR INSPECTION INSPECT FUEL PUMP RESISTOR Using an ohmmeter measure the resistance between termi nals Resistance 0 70 to 0 76 Ω at 20 C 68 F ...

Page 1932: ...istance between the terminals Resistance 26 to 30 Ω at 20 C 68 F If the resistance is not as specified replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no continuity be tween each terminal and the body If there is continuity replace the VSV c Inspect VSV operation 1 Check that air does not flow from the ports 2 Apply battery voltage across the terminals 3 Check th...

Page 1933: ... from the water by pass joint 4 INSPECT ENGINE COOLANT TEMPERATURE SEN SOR RESISTANCE Using an ohmmeter measure the resistance between termi nals Resistance 2 32 to 2 59 kΩ at 20 C 68 F 0 310 to 0 326 kΩ at 80 C 176 F NOTICE When inspecting the water temperature sensor in water prevent water flow into the terminals After inspection wipe the water off from the sensor 5 INSTALL ENGINE COOLANT TEMPER...

Page 1934: ...MOVE CYLINDER HEAD See page EM 62 2 DISCONNECT HEATER WATER INLET HOSE 3 REMOVE WATER OUTLET PIPE NO 1 a Remove the 4 wire harness clamps b Remove the 3 bolts and water outlet pipe 4 REMOVE KNOCK SENSOR a Disconnect the 2 knock sensor connectors b Remove the 2 bolts and 2 knock sensors ...

Page 1935: ...r SFI 1GR FE KNOCK SENSOR SF 61 INSPECTION 1 INSPECT KNOCK SENSOR Using an ohmmeter measure the resistance between termi nals Resistance 120 to 280 kΩ at 20 C 68 F HINT If the resistance is not as specified replace the sensor ...

Page 1936: ...cen ter of the sensor comes within the range of 15 from the bolt center as shown in the illustration Torque 20 N m 204 kgf cm 15 ft lbf b Connect the 2 knock sensor connectors 2 INSTALL WATER OUTLET PIPE NO 1 a Install the water outlet pipe with the 3 bolts Torque 9 0 N m 92 kgf cm 80 in lbf b Install the 4 wire harness clamps 3 CONNECT HEATER WATER INLET HOSE 4 INSTALL CYLINDER HEAD See page EM 8...

Page 1937: ...e A1A E1 IG switch ON 3 3V A1A E1 IG switch ON 3 0V A2A E1 IG switch ON 3 3V A2A E1 IG switch ON 3 0V NOTICE Connect test leads from the back side of the ECM connec tor HINT The voltage between terminals of the ECM is kept constant re gardless of the voltage of the A F sensor b Connect the hand held tester to the DLC3 c Select DATA MONITOR A FS B1 S1 A FS B2 S1 and O2S B1 S2 to display the monitor...

Page 1938: ... SENSOR INSPECTION INSPECT HEATED OXYGEN SENSOR BANK1 BANK2 OXYGEN SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance Terminal No Resistance 1 HT 2 B 5 to 10 Ω at 20 C 68 F 1 HT 4 E1 No Continuity If the resistance is not as specified replace the sensor ...

Page 1939: ...of the CURRENT DATA indicates the standard value Accelerator pedal released 1 2 to 2 0 V Accelerator pedal depressed 3 4 to 5 3 V If not using a hand held tester measure the voltage between terminals VPA EPA VPA2 EPA2 of the ECM connector see page DI 34 2 REMOVE ACCELERATOR PEDAL ROD a Disconnect the accelerator pedal connector b Remove the 2 nuts and the accelerator pedal assy 3 INSTALL ACCELERAT...

Page 1940: ...SF1ZF 01 A23205 ECM ECM Connector Lower No 2 Finish Panel Glove Compartment Door Heater to Register Duct SF 66 SFI 1GR FE ENGINE CONTROL MODULE ECM ENGINE CONTROL MODULE ECM COMPONENTS ...

Page 1941: ...SF1ZG 01 SFI 1GR FE ENGINE CONTROL MODULE ECM SF 67 INSPECTION INSPECT ECM See page DI 1 ...

Page 1942: ...FF RPM a Increase the engine speed to at least 3 500 rpm b Use a sound scope to check for injector operating noise c Check that the injector operation noise stops momentarily and then resumes when the accelerator pedal is released Fuel cut off rpm 2 500 rpm Fuel return rpm 1 200 rpm ...

Page 1943: ...to protect the electrical system from water b Observe the following when handling the air fuel ratio sensors and oxygen sensor 1 Do not drop the sensor or hit it against another ob ject 2 The sensor should be free from any contact with wa ter 5 IF VEHICLE IS EQUIPPED WITH MOBILE RA DIO SYSTEM HAM CB ETC If the vehicle is equipped with a mobile communication system refer to the precaution in the IN...

Page 1944: ...aken when pulling out and inserting wir ing connectors 1 Release the lock and pull out the connector pulling on the connectors 2 Fully insert the connector and check that it is locked i Use SST for inspection or test of the injector or its wiring connector SST 09842 30070 8 FUEL SYSTEM a When disconnecting the high fuel pressure line a large amount of gasoline will spill out Observe the following ...

Page 1945: ...all the injector to the delivery pipe and intake manifold as shown in the illustration Before installing the injector apply spindle oil or gasoline on the place where the delivery pipe or the intake man ifold touches the O ring of the injector e Observe the following when disconnecting the fuel tube connector quick type 1 Check if there is any dirt in the pipe and around the connector before disco...

Page 1946: ...e oil on the tip of the pipe 3 After finishing the connection pull the pipe and the connector to ensure it is secure 4 Check to make sure no fuel leak is present If the result is not specified repair or replace 5 Install the fuel pipe clamp to the connector 6 Check to make sure no fuel leak is present If the result is not specified repair or replace g Observe the following when disconnecting the f...

Page 1947: ... is any damage or foreign objects in the connected part of the pipe 2 Match the axis of the connector with the axis of the pipe and push into the connector until a click sound is heard If the connection is tight apply a small amount of fresh engine oil on the tip of the pipe 3 After finishing the connection pull the pipe and the connector to ensure it is secure 4 Check to make sure no fuel leak is...

Page 1948: ...held tester main switch ON NOTICE Do not start the engine 3 Enter the following menus DIAGNOSIS EN HANCED OBDII ACTIVE TEST FUEL PUMP SPD 4 Please refer to the hand held tester operator s manual for further details 5 Pinch the fuel return hose The pressure in the high pressure line will rise to approx 392 kPa 4 kgf cm2 57 psi In this state check to see that there are no leaks from any part of the ...

Page 1949: ... Check that the pulsation damper screw rises up when the fuel pump operates If operation is not as specified check the fusible link fuses EFI main relay fuel pump ECM and wiring connections f Turn the ignition switch OFF g Disconnect the hand held tester and CAN VIM from the DLC3 2 CHECK FUEL PRESSURE a Check the battery positive voltage is above 12 V b Disconnect the negative terminal cable from ...

Page 1950: ...2 7 3 1 kgf cm2 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 cm2 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 preve...

Page 1951: ...Fuel Tank VENT Tube No 2 Fuel Tank Band Fuel Inlet Hose Clip 62 632 45 Fuel Tank Protector Fuel Tank Band Pin Fuel Return Tube 62 632 45 Fuel Tank Band Pin Fuel Inlet Pipe Fuel Main Tube Fuel Pump Gauge Retainer Fuel Pump Suction Support Clip Fuel Inlet Pipe Shield Speed Sensor Wire Charcoal Canister Assembly SFI 2UZ FE FUEL PUMP SF 9 COMPONENTS ...

Page 1952: ... Fuel Suction Plate No 1 w Fuel Filter Fuel Pump Harness Fuel Pump Non reusable part Fuel Sender Gauge O Ring Spring Fuel Suction Plate No 2 E Ring Fuel Suction Filter Fuel Sub tank SF 10 SFI 2UZ FE FUEL PUMP ...

Page 1953: ...omes contaminated easily Do not use any tool in this operation Do not bend or twist the nylon tube Protect the con nector by covering it with a vinyl or plastic bag When the pipe and connector are stuck push and pull the connector to release and pull the connector out carefully 3 REMOVE FUEL PUMP ASSEMBLY a Using SST loosen the fuel pump gage retainer SST 09808 14020 09808 01410 09808 01420 09808 ...

Page 1954: ...Disconnect the sender gage connector from the fuel suc tion plate No 1 b Unlock the fuel sender gage and slide the remove 2 REMOVE FUEL SUB TANK a Disconnect the fuel pump harness connector from the fuel suction plate No 1 b Disconnect the suction filter hose from the fuel sub tank c Disconnect the 2 tubes from the tube clamps ...

Page 1955: ...th the tip wrapped in tape discon nect the 2 snap claws from the fuel suction support NOTICE Do not damage the fuel filter assembly or fuel suction sup port b Remove the fuel filter assembly with fuel pump from the fuel suction support 4 REMOVE FUEL PUMP a Using a screwdriver with the tip wrapped in tape discon nect the 5 snap claws from the suction filter NOTICE Do not damage the fuel filter asse...

Page 1956: ...F 14 SFI 2UZ FE FUEL PUMP 5 REMOVE FUEL SUCTION PLATE NO 2 a Using a screwdriver remove the 2 E rings from the suc tion plate No 2 b Remove the suction plate No 2 and 2 springs from the fuel suction plate No 1 ...

Page 1957: ...ON a Connect the lead wire to the fuel pump b Connect the positive lead from the battery to terminal 1 of the connector and the negative lead to terminal 2 Check that the fuel pump operates NOTICE These tests must be done quickly within 10 seconds to prevent the coil from burning out Keep the fuel pump as far away from the battery as possible Always do switching at the battery side If operation is...

Page 1958: ...Using a needle nose pliers install the 2 new E rings to the suction plate No 2 2 INSTALL FUEL PUMP a Apply a light coat of gasoline or spindle oil to a new O ring and install it to the fuel pump b Connect the fuel pump harness connector to the fuel pump c Install the fuel pump with the suction filter to the fuel fuel filter 3 INSTALL FUEL FILTER Install the fuel filter to the fuel sub tank ...

Page 1959: ...late No 2 to the fuel sub tank with the 3 snap claws engaged b Connect the 2 tubes to the tube clamps c Connect the suction filter hose to the fuel sub tank d Connect the fuel pump harness connector to the fuel suc tion plate No 1 5 INSTALL FUEL SENDER GAGE a Install the fuel sender gage to the fuel suction support ...

Page 1960: ...B17539 SF 18 SFI 2UZ FE FUEL PUMP b Connect the sender gage connector to the fuel suction plate No 1 ...

Page 1961: ...n the triangle mark on new fuel pump gage retainer with the S mark on the fuel tank while pushing down the fuel suction tube attach the fuel pump gage retainer f Rotate the fuel pump gage retainer by hand then tighten it one complete turn and half using SST Triangle mark on the fuel pump gage retainer must be positioned between A and MAX indications on the fuel tank SST 09808 14020 09808 01410 098...

Page 1962: ...connecting part Check that the fuel tube joint is inserted securely Check that the tube joint clip is on the collar of the fuel tube joint After installing the tube join clip check that the fuel tube joint has not been pulled off 3 CHECK FOR FUEL LEAKS 4 INSTALL FUEL TANK ASSEMBLY See page SF 37 ...

Page 1963: ...17758 Vacuum Hose Fuel Pressure Regulator N m kgf cm ft lbf Non reusable part Specified torque O Ring Fuel Return Hose 7 5 80 66 in lbf SFI 2UZ FE FUEL PRESSURE REGULATOR SF 21 FUEL PRESSURE REGULATOR COMPONENTS ...

Page 1964: ...MOVE FUEL PRESSURE REGULATOR a Disconnect the vacuum hose from intake air resonator b Disconnect the fuel return hose from the pressure regula tor 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 ...

Page 1965: ...asoline 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 76 kgf cm 66 in lbf d Connect the vacuum hose to intake air resonator e Connect the fuel return hose to the pressure regulator 2 CHECK FOR FUEL LEAKS See page SF 1 ...

Page 1966: ...TOR 3 INSPECT INJECTOR RESISTANCE a Disconnect the 8 injector connectors b Using an ohmmeter measure the resistance between the terminals Resistance 13 4 to 14 2 Ω 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 1967: ...SF0OS 15 B17459 Throttle Body Cover PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose SFI 2UZ FE INJECTOR SF 25 COMPONENTS ...

Page 1968: ...tion Damper Gasket O Ring Injector Connector PCV Hose Vacuum Hose N m kgf cm ft lbf Non reusable part Specified torque For use with SST Gasket Fuel Return Pipe O Ring Fuel Return Hose Throttle Body Cover Bracket VSV Connector for EVAP EVAP Hose 21 214 15 21 214 15 LH Delivery Pipe 39 400 29 39 400 29 7 5 76 66 in lbf 7 5 76 66 in lbf 33 340 24 39 400 29 18 184 13 SF 26 SFI 2UZ FE INJECTOR ...

Page 1969: ...V HOSE FROM PCV VALVE 6 DISCONNECT VSV FOR EVAP a Disconnect the VSV connector for EVAP b Disconnect the EVAP hose c Remove the 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 t...

Page 1970: ... 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 and 8 insulators f Remove the O ring and grommet from each injector ...

Page 1971: ...268 41047 09268 41091 Torque 7 5 N m 76 kgf cm 66 in lbf f Connect the fuel return hose to the fuel outlet of the pres sure regulator g Install the O ring to the injector h Connect SST adaptor 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 i...

Page 1972: ...ss If the injection volume is not as specified replace the injector 2 INSPECT LEAKAGE a Under the above conditions disconnect the tester probes of SST wire from the battery and check fuel leakage from the injector SST 09842 30070 Fuel drop 1 drop or less per 12 minutes b Turn the ignition switch off c Disconnect the negative terminal cable from the bat tery d Remove the SST and fuel tube connector...

Page 1973: ... outward e Place the 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 39 N m 400 kgf cm 29 ft lbf for union bolts 7 5 N m 76 kgf cm 66 in lbf for bolt i Install the bolt holding the clamp on the fuel return pip...

Page 1974: ...r and engine wire bracket c Install the engine wire protector with the 2 bolts 3 CONNECT PCV HOSE TO PCV VALVE 4 CONNECT VSV FOR EVAP TO UPPER INTAKE MAN IFOLD a Install the 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 FUEL PRESSURE...

Page 1975: ...ank Protector Fuel Tank Band Pin Fuel Return Tube 62 632 45 Fuel Tank Band Pin Fuel Inlet Pipe Fuel Main Tube Fuel Pump Gauge Retainer Fuel Pump Suction Support Clip Fuel Inlet Pipe Shield Speed Sensor Wire Charcoal Canister Assembly SFI 2UZ FE FUEL TANK AND LINE SF 33 FUEL TANK AND LINE COMPONENTS CAUTION Always use new gaskets when replacing the fuel tank or component parts Apply the proper torq...

Page 1976: ...R ASSEMBLY a Remove the 4 bolts and charcoal canister assembly b Disconnect the pump module connector vent hose and purge line hose from the charcoal canister 5 DISCONNECT SPEED SENSOR WIRE Remove the nut and disconnect the speed sensor wire from the fuel tank 6 DISCONNECT FUEL MAIN TUBE AND RETURN TUBE See page SF 1 7 REMOVE FUEL TANK ASSEMBLY a Set up a transmission jack under the fuel tank b Re...

Page 1977: ...I 2UZ FE FUEL TANK AND LINE SF 35 c Remove the 2 bolts and disconnect the 2 fuel tank bands from the fuel tank d Operate the transmission jack and remove the fuel tank 8 REMOVE FUEL PUMP ASSEMBLY See page SF 11 ...

Page 1978: ... a Check the fuel lines for cracks or leakage and all connec tions for deformation b Check the fuel tank vapor vent system hoses and connec tions 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 illustra tion If a problem is found re...

Page 1979: ...orque 62 N m 632 kgf cm 45 ft lbf d Install the fuel pipe bracket to the body with the 2 nuts Torque 20 N m 204 kgf cm 15 ft lbf 3 CONNECT FUEL PUMP CONNECTOR 4 CONNECT FUEL MAIN TUBE AND RETURN TUBE See page SF 1 5 CONNECT SPEED SENSOR WIRE Connect the speed sensor wire to the fuel tank with the nut 6 INSTALL CHARCOAL CANISTER ASSEMBLY a Connect the pump module connector vent hose and purge line ...

Page 1980: ...B17586 SF 38 SFI 2UZ FE FUEL TANK AND LINE 7 INSTALL FUEL INLET PIPE SHIELD a Install the fuel inlet pipe shield with the 4 bolts b Install the fuel tank cap 8 CHECK FOR FUEL LEAKS 9 INSTALL SPARE TIRE ...

Page 1981: ...SF0P1 12 B17463 MAF Meter Connector MAF Meter SFI 2UZ FE MASS AIR FLOW MAF METER SF 39 MASS AIR FLOW MAF METER COMPONENTS ...

Page 1982: ...20 C 4 F 2 19 to 2 67 kΩ at 20 C 68 F 0 50 to 0 68 kΩ at 60 C 140 F 3 INSPECT MASS AIR FLOW METER a If using a hand held tester 1 Connect the hand held tester to the DLC3 2 Turn the ignition switch to the ON position 3 Blow air into the MAF meter and check that the air flow value of the CURRENT DATA changes If operation is not as specified check the MAF meter see page DI 531 and DI 534 as well as ...

Page 1983: ... 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 showns 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 page DI 794 wiring and ECM If not using a hand held teste...

Page 1984: ...otor resistance be tween terminals M and M Motor resistance 0 3 to 100 Ω at 20 C 68 F If the resistance is not as specified replace the throttle body as sembly see page SF 44 c Reconnect the throttle control motor connector 4 INSPECT THROTTLE POSITION SENSOR See page DI 548 If necessary replace the throttle body assembly see page SF 44 5 REINSTALL THROTTLE BODY COVER ...

Page 1985: ...ose Throttle Control Connector Intake Air Connector 14 143 10 N m kgf cm ft lbf Specified torque PCV Hose Vacuum Hose MAF Meter Wire Suction Hose Throttle Body Assembly Water Bypass Hose Water Bypass Hose SFI 2UZ FE THROTTLE BODY SF 43 COMPONENTS ...

Page 1986: ...TLE BODY COVER 2 DRAIN ENGINE COOLANT 3 REMOVE INTAKE AIR CONNECTOR 4 REMOVE THROTTLE BODY a Disconnect the throttle control connector b Disconnect the 2 water bypass hoses from the throttle body c Remove the nut and 3 bolts and remove the throttle body from the intake manifold ...

Page 1987: ... body with the nut and 3 bolts Torque 14 N m 143 kgf cm 10 ft lbf b Connect the 2 water bypass hoses to the throttle body c Connect the throttle control connector 2 INSTALL INTAKE AIR CONNECTOR 3 FILL WITH ENGINE COOLANT See page CO 2 4 START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 5 INSTALL THROTTLE BODY COVER ...

Page 1988: ...cover b Remove the intake air connector c Disconnect the oil control valve connector d Using an ohmmeter measure the resistance between the terminals Resistance 6 9 to 7 9 Ω at 20 C 68 F If the resistance is not as specified replace the valve e Reconnect the oil control valve connector f Reinstall the intake air connector g Reinstall the throttle body cover ...

Page 1989: ...ctor Suction Hose MAF Meter Wire PCV Hose Vacuum Hose Camshaft Oil Control Valve Bank 2 N m kgf cm ft lbf Non reusable part O Ring Specified torque O Ring Camshaft Oil Control Valve Bank 1 7 5 76 66 in lbf SFI 2UZ FE CAMSHAFTTIMING OIL CONTROL VALVE SF 47 COMPONENTS ...

Page 1990: ...REMOVE CAMSHAFT TIMING OIL CONTROL VALVE a Disconnect the 2 camshaft oil control valve connectors b Remove the bolt camshaft oil control valve and O ring Torque 7 5 N m 76 kgf cm 66 in lbf c Remove the O ring from the each camshaft oil control valve HINT At the time of installation please refer to the following items Use a new O rings ...

Page 1991: ...ection Valve moves in direction SFI 2UZ FE CAMSHAFTTIMING OIL CONTROL VALVE SF 49 INSPECTION INSPECT OIL CONTROL VALVE OPERATION Connect the positive lead to terminal 1 of the connector and the negative lead to terminal 2 then check the movement of the valve If operation is not as specified replace the oil control valve ...

Page 1992: ...SF1XL 02 SF 50 SFI 2UZ FE CAMSHAFTTIMING OIL CONTROL VALVE INSTALLATION Installation is in the reverse order of removal See page SF 48 ...

Page 1993: ... SYSTEM ACIS ON VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE OPERATION a Start the engine b While the engine idling check that the actuator rod moves c Disconnect the VSV connector and check that the actua tor rod is returned If the operation is not as specified inspect the intake air control valve VSV and ECM ...

Page 1994: ...SF1XM 01 B17459 Throttle Body Cover PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose SF 52 SFI 2UZ FE ACOUSTIC CONTROL INDUCTION SYSTEM ACIS COMPONENTS ...

Page 1995: ...ble part 18 185 13 VSV Connector for EVAP Injector Connector Fuel Return Hose VSV Connector Engine Wire Engine Wire Throttle Body Connector 18 185 13 Injector Connector VSV Connector 18 185 13 Engine Wire SFI 2UZ FE ACOUSTIC CONTROL INDUCTION SYSTEM ACIS SF 53 ...

Page 1996: ...1 VSV for ACIS VSV Wire Connector Vacuum Hose Vacuum Hose 7 5 80 66 in lbf N m kgf cm ft lbf Specified torque 7 5 80 66 in lbf Intake Manifold Assembly SF 54 SFI 2UZ FE ACOUSTIC CONTROL INDUCTION SYSTEM ACIS ...

Page 1997: ... CONTROL INDUCTION SYSTEM ACIS SF 55 REMOVAL 1 REMOVE THROTTLE BODY COVER 2 REMOVE INTAKE MANIFOLD ASSEMBLY See page EM 36 3 REMOVE VSV FOR ACIS a Remove the 2 vacuum hoses from the VSV b Remove the bolt and VSV from the intake manifold ...

Page 1998: ...t the actuator rod does not return If the operation is not as specified replace the intake manifold 2 INSPECT VSV a Using an ohmmeter check that there is continuity be tween each terminal Resistance 33 to 39 Ω at 20 C 68 F If there is no continuity replace the VSV b Using an ohmmeter check that there is no continuity be tween each terminal and the body If there is continuity replace the VSV c Chec...

Page 1999: ...EM ACIS SF 57 INSTALLATION 1 INSTALL VSV FOR ACIS a Install the VSV to the intake manifold with the bolt Torque 7 5 N m 76 kgf cm 66 in lbf b Connect the 2 vacuum hoses to the VSV 2 INSTALL INTAKE MANIFOLD ASSEMBLY See page EM 60 3 INSTALL THROTTLE BODY COVER ...

Page 2000: ...n ohmmeter check that there is continuity be tween 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 be tween terminals 3 and 5 If there is no continu...

Page 2001: ...Y a Using an ohmmeter check that there is continuity be tween 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 A F SENSOR HEATER RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Using an ohmmeter check that there is continuity be tween terminals 3 and 5 If...

Page 2002: ... an ohmmeter check that there is continuity be tween 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 be tween terminals 3 and 5 If t...

Page 2003: ...mmeter check that there is continuity be tween 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 be tween terminals 3 and 4 If there is c...

Page 2004: ...SF138 05 B17500 Fuel Pump Resistor 8 0 82 71 in lbf N m kgf cm ft lbf Specified torque SF 62 SFI 2UZ FE FUEL PUMP RESISTOR FUEL PUMP RESISTOR COMPONENTS ...

Page 2005: ...OVE FUEL PUMP RESISTOR 2 INSPECT FUEL PUMP RESISTOR Using an ohmmeter measure the resistance between the ter minals Resistance 0 70 to 0 76 Ω at 20 C 68 F If the resistance is not as specified replace the resistor 3 REINSTALL FUEL PUMP RESISTOR Torque 8 0 N m 82 kgf cm 71 in lbf ...

Page 2006: ...SF0Y7 10 B17502 VSV for EVAP EVAP Hose EVAP Hose N m kgf cm ft lbf Specified torque 18 184 13 SF 64 SFI 2UZ FE VSV FOR EVAPORATIVE EMISSION EVAP VSV FOR EVAPORATIVE EMISSION EVAP COMPONENTS ...

Page 2007: ...tween the terminals Resistance 30 to 34 Ω 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 be tween each terminal and the body If there is continuity replace the VSV c Inspect the VSV operation 1 Check that air dose not flow from port 2 Apply battery positive voltage across the terminals 3 Check that air flows f...

Page 2008: ...ket ECT Sensor Connector ECT Sensor N m kgf cm ft lbf Specified torque Non reusable part Vacuum Hose Throttle Body Cover MAF Meter Wire Suction Hose 20 204 15 SF 66 SFI 2UZ FE ENGINE COOLANT TEMPERATURE ECT SENSOR ENGINE COOLANT TEMPERATURE ECT SENSOR COMPONENTS ...

Page 2009: ...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 ter minals 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 Torque 19 6 N m 200 kgf cm 14 ft lbf b Connect the ECT sensor connector 8 R...

Page 2010: ...SF0PR 16 B17459 Throttle Body Cover PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose SF 68 SFI 2UZ FE KNOCK SENSOR KNOCK SENSOR COMPONENTS ...

Page 2011: ...bf Specified torque Non reusable part Knock Sensor 2 VSV Connector for EVAP Fuel Inlet Hose Knock Sensor 1 Fuel Return Hose Intake Manifold Assembly Engine Wire Air Pump Assembly 18 185 13 18 185 13 16 163 12 16 163 12 20 204 15 20 204 15 SFI 2UZ FE KNOCK SENSOR SF 69 ...

Page 2012: ...re the resistance between ter minals Resistance 120 to 280 kΩ at 20 C 68 F HINT If the resistance is not as specified replace the sensor 5 REMOVE KNOCK SENSOR a Disconnect the 2 knock sensor connectors b Remove the 2 nuts and 2 knock sensors 6 INSTALL KNOCK SENSOR a Install the 2 knock sensors with the 2 nuts as shown in the illustration Torque 20 N m 204 kgf cm 15 ft lbf b Connect the 2 knock sen...

Page 2013: ...orque Air fuel Ratio Sensor Engine Under Cover Bank 2 Sensor 1 44 450 32 Bank 1 Sensor 1 Air fuel Ratio Sensor Connector Air fuel Ratio Sensor 44 450 32 Air fuel Ratio Sen sor Connector SFI 2UZ FE AIR FUELRATIO A F SENSOR SF 71 AIR FUEL RATIO A F SENSOR COMPONENTS ...

Page 2014: ... sensor connector 2 INSPECT OPERATION OF AIR FUEL RATIO SENSOR See page DI 507 3 INSPECT AIR FUEL RATIO COMPENSATION SYS TEM a Measure the voltage between the terminals of the ECM connectors Standard Tester Connection Condition Specified Condition B2 22 A1A B1 1 E1 Ignition switch ON 3 3 V B2 30 A1A B1 1 E1 Ignition switch ON 2 9 V B2 23 A2A B1 1 E1 Ignition switch ON 3 3 V B2 31 A2A B1 1 E1 Ignit...

Page 2015: ...ep the engine speed at 2 500 rpm and confirm that the display of the A FS B1 S1 is as shown in the illustration HINT The illustration may slightly differ from the display on the hand held tester The waveform of the A F sensor is displayed only on the hannd heldtester g Confirm that the display of the O2S B1 S2 changes be tween 0 and 1 V with the engine speed at 2 500 rpm OK The voltage output osci...

Page 2016: ...que Heated Oxygen Sensor Connector Heated Oxygen Sensor Engine Under Cover Bank 2 Sensor 1 44 450 32 Bank 1 Sensor 1 Heated Oxygen Sensor Connector Heated Oxygen Sensor 44 450 32 SF 74 SFI 2UZ FE HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR COMPONENTS ...

Page 2017: ...nnect the oxygen sensor connector b Using an ohmmeter measure the resistance between ter minals B and HT Resistance 11 to 16 Ω at 20 C 68 F If the resistance is not as specified replace the sensor Torque 44 N m 450 kgf cm 32 ft lbf c Reconnect the oxygen sensor connector 2 INSPECT OPERATION OF HEATED OXYGEN SEN SOR See page DI 512 ...

Page 2018: ...SF1XX 01 B17459 Throttle Body Cover PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose SF 76 SFI 2UZ FE VVT SENSOR VVT SENSOR COMPONENTS ...

Page 2019: ...ctor Fuel Return Hose Engine Wire Injector Connector VSV Connector for EVAP VVT Sensor 2 N m kgf cm ft lbf Specified torque Non reusable part Gasket VVT Sensor 1 VSV Connector for ACIS VVT Sensor Connector VVT Sensor Connector 18 185 13 18 185 13 7 5 76 66 in lbf SFI 2UZ FE VVT SENSOR SF 77 ...

Page 2020: ...Y COVER 2 REMOVE INTAKE MANIFOLD ASSEMBLY See page EM 36 3 INSPECT VVT SENSOR RESISTANCE a Disconnect the VVT sensor connector b Using an ohmmeter measure the resistance between the terminals Resistance Cold 835 to 1 400 Ω Hot 1 060 to 1 645 Ω If the resistance is not as specified replace the sensor c Reconnect the VVT sensor connector d Connect the VVT sensor connector 4 REINSTALL INTAKE MANIFOLD...

Page 2021: ...EM 36 3 REMOVE VVT SENSOR a Disconnect the VVT sensor connector b Remove the bolt and VVT sensor 4 INSTALL VVT SENSOR a Attach a new VVT sensor to the cylinder head b Install the VVT sensor with the bolt Torque 6 5 N m 65 kgf cm 58 in lbf 5 REINSTALL INTAKE MANIFOLD ASSEMBLY See page EM 60 6 REINSTALL THROTTLE BODY COVER ...

Page 2022: ... Assembly N m kgf cm ft lbf Specified torque Accelerator Pedal Position Sensor Accelerator Pedal Position Sensor Connector 5 0 51 44 in lbf SF 80 SFI 2UZ FE ACCELERATOR PEDAL POSITION SENSOR ACCELERATOR PEDAL POSITION SENSOR COMPONENTS ...

Page 2023: ... SF 81 INSPECTION INSPECT ACCELERATOR PEDAL POSITION SENSOR See page DI 794 If necessary replace the accelerator pedal assembly NOTICE Be care not to give a shock to the accelerator pedal assembly Be care not to disassemble the accelerator pedal assembly ...

Page 2024: ...ECM Connector ECM and Bracket Assembly Glove Compartment Door Lower No 2 Finish Panel ECM Bracket ECM Bracket ECM Heater to Register Duct SF 82 SFI 2UZ FE ENGINE CONTROL MODULE ECM ENGINE CONTROL MODULE ECM COMPONENTS ...

Page 2025: ...nish panel 3 REMOVE HEATER TO REGISTER DUCT 4 REMOVE ECM a Disconnect the 5 connectors b Remove the 2 bolts and ECM 5 INSPECT ECM See page DI 453 6 REINSTALL ECM a Install the ECM with the 2 bolts b Connect the 5 connectors 7 INSTALL HEATER TO REGISTER DUCT 8 INSTALL GLOVE COMPARTMENT a Install the lower No 2 finish panel with 3 screws b Install the glove compartment door with the 2 screws 9 CONNE...

Page 2026: ... Then connect the CAN VIM to the Date Link Connector 3 DLC3 b Please refer to the hand held tester operator s manual for further details 3 INSPECT FUEL CUTOFF RPM OPERATION a Increase the engine speed to at least 2 500 rpm b Check for injector operating noise c Check that when the throttle lever is released injector op eration noise stops momentarily and then resumes HINT The vehicle should be sto...

Page 2027: ...amine non nitrite and non borate coolant with long life hybrid organic acid technology 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 arou...

Page 2028: ...gh qual ity ethylene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid or ganic acid technology New Toyota vehicles are filled with Toyota Super Long Life Coolant color is pink premixed ethylene glycol con centration is approximately 50 and freezing tempera ture is 35 C 31 F When replacing the coolant Toyo ta Super long Life Coolant is recommended Observe...

Page 2029: ...d torque Air Cleaner Hose Engine Under Cover x 5 Battery Tray V Bank Cover 9 8 100 87 in lbf Battery Battery Clamp Ventilation Hose Mass Air Flow Meter Connector Vacuum Hose Air Cleaner Case COOLING 1GR FE WATER PUMP CO 3 WATER PUMP COMPONENTS ...

Page 2030: ...embly No 1 Fan Shroud Oil Cooler Pipe for AutomaticTransmission V Belt Fan Pulley Fan w Fluid Coupling 21 214 15 N m kgf cm ft lbf Specified torque No 1 Fan Shroud 12 120 9 5 0 50 44 in lbf CO 4 COOLING 1GR FE WATER PUMP ...

Page 2031: ...que Non reusable part Water Pump Gasket Idler Pulley No 1 Idler Pulley No 2 Washer V Ribbed Belt Tensioner Water By pass Hose No 3 O ring O ring Water By pass Hose No 1 Oil Cooler Hose Water Inlet 9 0 92 80 in lbf 54 551 40 36 367 27 COOLING 1GR FE WATER PUMP CO 5 ...

Page 2032: ...ND GENERATOR V BELT See page EM 62 6 REMOVE FAN W FLUID COUPLING a Disconnect the radiator reserve tank hose b Remove the 4 fan shroud bolts c Remove the 4 fluid coupling nuts and then remove the fan w fluid coupling and fan shroud together d Remove the fan pulley 7 DISCONNECT VENTILATION HOSE NO 2 8 REMOVE AIR CLEANER 9 REMOVE WATER INLET a Disconnect the 2 oil cooler hoses w oil cooler b Disconn...

Page 2033: ...ve the O ring from the water outlet pipe f Remove the gasket from the water pump 10 REMOVE IDLER PULLEY NO 2 a Remove the 2 bolts and 2 idler pulleys 11 REMOVE GENERATOR See page CH 7 12 SEPARATE COOLER COMPRESSOR See page EM 105 13 REMOVE V RIBBED BELT TENSIONER Seepage EM 32 14 REMOVE WATER PUMP a Remove the 17 bolts water pump and gasket ...

Page 2034: ... hole for coolant leak age 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 Check that the fluid coupling is not damaged and that no silicon oil leaks If necessary replace the fluid coupling ...

Page 2035: ...INSTALL WATER INLET a Install a new O ring to the water outlet pipe b Install a new gasket to the water pump c Apply soapy water to the O ring d Install the water inlet with the 5 bolts Torque 9 0 N m 92 kgf cm 80 in lbf e Connect the 5 water by pass hoses f Connect the 2 radiator hoses g Connect the 2 oil cooler hoses w oil cooler 7 INSTALL AIR CLEANER 8 CONNECT VENTILATION HOSE NO 2 9 INSTALL FA...

Page 2036: ...ANT See page CO 2 13 CHECK FOR ENGINE COOLANT LEAKS 14 INSTALL ENGINE UNDER COVER a Install the engine under cover with the 4 bolts Torque 29 N m 296 kgf cm 21 ft lbf 15 INSTALL V BANK COVER a Install the V bank cover with the 2 nuts Torque 9 8 N m 100 kgf cm 87 in lbf 16 RECHECK ENGINE COOLANT LEVEL 17 FILL WITH ENGINE COOLANT 18 START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 19 RECHECK ENGINE C...

Page 2037: ...ed cooling efficiency would be harmed If the engine should tend to overheat do not remove the thermostat 1 DRAIN ENGINE COOLANT See page CO 2 2 REMOVE V BANK COVER 3 DISCONNECT RADIATOR OUTLET NO 2 HOSE CLAMP OR CLIP 4 REMOVE WATER INLET W THERMOSTAT a Remove the 3 nuts water inlet w thermostat and gasket ...

Page 2038: ... the valve opening temperature of the thermostat Valve opening temperature 80 to 84 C 176 to 183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 8 mm 0 31 in 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 temperature below 40 C 104...

Page 2039: ...ter inlet w thermostat b Install the water inlet w thermostat with the 3 nuts Torque 9 0 N m 92 kgf cm 80 in lbf 2 CONNECT RADIATOR OUTLET NO 2 HOSE CLAMP OR CLIP 3 ADD ENGINE COOLANT See page CO 2 4 CHECK FOR ENGINE COOLANT LEAKS 5 INSTALL V BANK COVER Install the V bank cover with the 2 nuts Torque 9 8 N m 100 kgf cm 87 in lbf ...

Page 2040: ...e steam cleaner and the core is too close there is a possibility of damaging the fin so keep the following injection distance Injection Pressure Injection Distance 2 942 to 4 903 kpa 30 to 50 kg cm2 427 to711 psi 300 mm 11 811 in 4 903 to 7 845 kpa 50 to 80 kg cm2 711 to 1 138 psi 500 mm 19 685 in If the fins are bent straighten them with a screwdriver or pliers Never apply water directly onto the...

Page 2041: ...TICE Push the pump at a constant speed If air is not coming from the vacuum valve replace the radiator cap b Pump the radiator cap tester and measure the relief valve opening pressure Pump speed 1 push within 1 second NOTICE This pump speed is for the first pump only in order to close the vacuum valve After this the pump speed can be re duced Opening pressure Standard 93 to 123 kPa 0 95 to 1 25 kg...

Page 2042: ...t lbf Specified torque No 1 Fan Shroud Oil Cooler Pipe for AutomaticTransmission V Belt Fan Pulley Fan w Fluid Coupling 21 214 15 Radiator Assembly 5 0 50 44 in lbf 12 120 9 No 2 Fan Shroud CO 16 COOLING 1GR FE RADIATOR COMPONENTS ...

Page 2043: ...RADIATOR 4 DISCONNECT UPPER RADIATOR HOSE FROM RA DIATOR 5 DISCONNECT LOWER RADIATOR HOSE FROM RA DIATOR 6 DISCONNECT A T OIL COOLER HOSES FROM RA DIATOR 7 REMOVE NO 2 FAN SHROUD Remove the 2 clips and No 2 fan shroud 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 ...

Page 2044: ...port holes b Install the 4 bolts Torque 12 N m 120 N m 9 ft lbf 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 RADIA TOR 8 FILL WITH ENGINE COOLANT 9 START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 10 RECHECK ENG...

Page 2045: ...nt 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 filler hole and the coolant should be ...

Page 2046: ...al ity ethylene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid or ganic acid technology New Toyota vehicles are filled with Toyota Super Long Life Coolant color is pink premixed ethylene glycol con centration is approximately 50 and freezing tempera ture is 35 C 31 F When replacing the coolant Toyo ta Super long Life Coolant is recommended Observe the ...

Page 2047: ...with Fluid Coupling A C Compressor A C Compressor Connector Engine Under Cover 4WD x 5 Radiator Assembly N m kgf cm ft lbf Specified torque 12 120 9 49 500 36 A T Oil Cooler Hose Clip Clip Engine Under Cover 2WD Vacuum Hose PCV Hose Suction Hose MAF Meter Wire COOLING 2UZ FE WATER PUMP CO 3 WATER PUMP COMPONENTS ...

Page 2048: ...Position Sensor Connector Engine Wire Oil Cooler Pipe Timing Belt Fan Bracket Drive Belt Timing Pulley Timing Belt Tensioner Dust Boot N m kgf cm ft lbf Specified torque Cover Plate 16 160 12 39 400 29 32 330 24 Water Bypass Hose Grommet 245 2 500 181 16 160 12 CO 4 COOLING 2UZ FE WATER PUMP ...

Page 2049: ...Guide Crankshaft Angle Sensor Plate No 2 Idler Pulley Timing Belt Cover Spacer Gasket N m kgf cm ft lbf Specified torque Non reusable part Water Inlet Housing Assembly Water Pump O Ring Gasket O Ring 18 185 13 21 215 15 Wire Clamp PS Vane Pump 100 A Type Generator 34 5 350 25 39 400 29 15 5 158 11 39 400 29 COOLING 2UZ FE WATER PUMP CO 5 ...

Page 2050: ...t 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 fr...

Page 2051: ... smoothly and quietly If necessary replace the water pump 2 INSPECT FLUID COUPLING a Remove the 4 nuts and fan from the fluid coupling b Check that the fluid coupling is not damaged and that no silicon oil leaks If necessary replace the fluid coupling c Reinstall the fan to the fluid coupling with the 4 nuts Torque 5 4 N m 55 kgf cm 47 in lbf 3 INSPECT FAN PULLEY BRACKET Check the turning smoothne...

Page 2052: ...ntact surfaces of the water in let housing and water pump Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket sur faces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the sealing groove of water inlet housing as shown in the illustration S...

Page 2053: ...13 ft lbf HINT Each bolt length is indicated in the illustration Bolt length 76 mm 3 00 in for A 22 mm 0 87 in for B g Connect the water bypass hose to the water inlet housing 3 INSTALL NO 2 IDLER PULLEY See page EM 23 4 INSTALL TIMING BELT See page EM 23 5 FILL WITH ENGINE COOLANT 6 START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 7 RECHECK ENGINE COOLANT LEVEL ...

Page 2054: ...CO0IU 08 D12717 Water Inlet Thermostat Gasket 19 195 14 N m kgf cm ft lbf Specified torque Non reusable part CO 10 COOLING 2UZ FE THERMOSTAT THERMOSTAT COMPONENTS ...

Page 2055: ...wering of cooling efficiency Do not remove the thermo stat even if the engine tends to overheat 1 DRAIN ENGINE COOLANT 2 DISCONNECT WATER INLET FROM WATER INLET HOUSING Remove the 3 nuts and disconnect the water inlet from the wa ter inlet housing 3 REMOVE THERMOSTAT a Remove the thermostat b Remove the gasket from the thermostat ...

Page 2056: ...er b Check the valve opening temperature Valve opening temperature 80 to 84 C 176 to 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 in 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 ...

Page 2057: ... 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 pre scribed position 2 INSTALL WATER INLET Install the water inlet with the 3 nuts Torque 19 N m 195 kgf cm 14 ft lbf 3 FILL WITH ENGINE COOLANT 4 START ENGINE AND CHECK FOR COOLANT LEAKS 5 RECHECK ENGINE COOLANT LEVEL ...

Page 2058: ...e steam cleaner and the core is too close there is a possibility of damaging the fin so keep the following injection distance Injection Pressure Injection Distance 2 942 to 4 903 kPa 30 to 80 kgf cm2 427 to 711 psi 300 mm 11 81 in 4 903 to 7 845 kPa 50 to 80 kgf cm2 711 to 1 138 psi 500 mm 19 69 in If the fins are bent straighten them with a screwdriver or pliers Never apply water directly onto th...

Page 2059: ...OTICE Push the pump at a constant speed If air is not coming from the vacuum valve replace the radiator cap b Pump the radiator cap tester and measure the relief valve opening pressure Pump speed 1 push within 1 second NOTICE This pump speed is for the first pump only in order to close the vacuum valve After this the pump speed can be re duced Opening pressure Standard 74 to 103 kPa 0 75 to 1 05 k...

Page 2060: ...A T Oil Cooler Hose Engine Under Cover 4WD Upper Radiator Hose Lower Radiator Hose x 5 N m kgf cm ft lbf Specified torque 12 120 9 No 1 Fan Shroud No 2 Fan Shroud Engine Under Cover 2WD Clip Clip CO 16 COOLING 2UZ FE RADIATOR COMPONENTS ...

Page 2061: ...RADIATOR 4 DISCONNECT UPPER RADIATOR HOSE FROM RA DIATOR 5 DISCONNECT LOWER RADIATOR HOSE FROM RA DIATOR 6 DISCONNECT A T OIL COOLER HOSES FROM RA DIATOR 7 REMOVE NO 2 FAN SHROUD Remove the 2 clips and No 2 fan shroud 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 ...

Page 2062: ...port holes b Install the 4 bolts Torque 12 N m 120 N m 9 ft lbf 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 RADIA TOR 8 FILL WITH ENGINE COOLANT 9 START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 10 RECHECK ENG...

Page 2063: ...s or more after the engine has stopped If the engine is too hot a false level will be read The oil level should be between the low and full level marks of the dipstick If it is below the low level mark check for leakage and add oil up to the full level mark NOTICE Do not fill with engine oil over the full level mark 3 REMOVE OIL PRESSURE SWITCH ASSY a Disconnect the oil pressure switch connector b...

Page 2064: ...c Using a 24 mm deep socket wrench install the oil pres sure switch Torque 15 N m 152 kgf cm 11 ft lbf HINT Do not start the engine for 1 hour after installation d Connect the oil pressure switch connector 8 START ENGINE AND CHECK FOR LEAKS ...

Page 2065: ...order to preserve the environment used oil and used oil filters must be disposed of at designated dis posal sites 1 DRAIN ENGINE OIL a Remove the engine under cover seal No 3 b Remove the oil pan drain plug and drain the engine oil c Clean the oil pan drain plug and install it and a new gas ket Torque 40 N m 408 kgf cm 30 ft lbf 2 REMOVE OIL FILTER When using a container a Remove the drain pipe ca...

Page 2066: ...t of a new oil filter with clean engine oil c Tighten the oil filter by hand until the rubber gasket con tacts the seat of the filter bracket d Using SST give it an additional 3 4 turn to set the filter SST 09228 07501 4 ADD ENGINE OIL a Fill with new engine oil Capacity Drain and refill w Oil filter change 4 5 liters 4 8 US qts 4 0 lmp qts w o Oil filter change 4 2 liters 4 4 US qts 3 7 lmp qts D...

Page 2067: ...uum Hose Air Cleaner Hose Mass Air Flow Meter Connector Ventilation Hose No 2 Battery Clamp Battery Battery Tray N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf 7 5 76 66 in lbf LUBRICATION 1GR FE OIL PUMP LU 5 OIL PUMP COMPONENTS ...

Page 2068: ...A23193 Radiator Fan Shroud Fan Pulley Fan w Fluid Coupling Drive Belt 21 214 15 N m kgf cm ft lbf Specified torque LU 6 LUBRICATION 1GR FE OIL PUMP ...

Page 2069: ...rator Wire Generator Connector Wire Harness Clamp Bracket Cooler Compressor Connector Cooler Compressor 9 0 92 80 in lbf 43 438 32 8 0 82 71 in lbf 8 0 82 71 in lbf 9 8 100 7 43 438 32 43 438 32 25 255 18 N m kgf cm ft lbf Specified torque Non reusable part LUBRICATION 1GR FE OIL PUMP LU 7 ...

Page 2070: ... Washer V ribbed Belt Tensioner Oil Pan Oil Strainer Oil Pan No 2 Drain Plug O ring Gasket Gasket 40 408 30 10 102 7 9 0 92 80 in lbf 9 0 92 80 in lbf 10 102 7 21 214 15 21 214 15 21 214 15 36 367 27 36 367 27 54 551 40 39 398 29 9 0 92 80 in lbf N m kgf cm ft lbf Specified torque Non reusable part 37 377 27 x2 x9 x6 x2 x4 x2 x15 LU 8 LUBRICATION 1GR FE OIL PUMP ...

Page 2071: ...Cylinder Head Cover RH Ignition Coil Cylinder Head Cover Gasket Cylinder Head Cover Gasket Cylinder Head Cover LH 21 214 15 21 214 15 10 102 7 9 0 92 80 in lbf 10 102 7 9 0 92 80 in lbf 9 0 92 80 in lbf 10 102 7 9 0 92 80 in lbf 9 0 92 80 in lbf 10 102 7 Oil Baffle Plate 21 214 15 28 286 21 N m kgf cm ft lbf Specified torque Non reusable part x2 x4 x7 x3 x3 x7 x3 x3 Ignition Coil LUBRICATION 1GR F...

Page 2072: ...ing Chain Idle Gear Shaft No 2 Idle Gear No 1 Idle Gear Shaft No 1 O ring Crankshaft Timing Sprocket Chain Vibration Damper No 1 23 235 17 x15 250 2 549 184 100 1 020 74 100 1 020 74 23 235 17 23 235 17 100 1 020 74 100 1 020 74 Chain Tensioner No 2 19 194 14 Chain Tensioner No 2 19 194 14 10 102 7 Chain Tensioner Slipper 60 612 44 19 194 14 N m kgf cm ft lbf Specified torque Non reusable part x9 ...

Page 2073: ...ef Valve Plug Relief Valve Spring Relief Valve Driven Rotor Drive Rotor Oil Pump Cover O ring 49 500 36 9 0 92 80 in lbf 9 0 92 80 in lbf 9 0 92 80 in lbf N m kgf cm ft lbf Specified torque Non reusable part x7 x2 LUBRICATION 1GR FE OIL PUMP LU 11 ...

Page 2074: ...VAL 1 REMOVE TIMING CHAIN COVER See page EM 32 2 REMOVE OIL PUMP COVER a Remove the 3 bolts and oil pipe b Remove the 2 O rings c Remove the 7 bolts oil pump cover drive rotor and driven rotor 3 REMOVE OIL PUMP RELIEF VALVE Remove the plug spring and relief valve ...

Page 2075: ... 0 16 mm 0 0063 in If the clearance is greater than the maximum replace the rotors as a set c Inspect rotor side clearance Using a feeler gauge and precision straight edge mea sure the clearance between the rotors and the precision straight edge Standard clearance 0 03 to 0 09 mm 0 0012 to 0 0035 in Maximum side clearance 0 09 mm 0 0035 in If the clearance is greater than the maximum replace the d...

Page 2076: ...L SEAL a Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the oil pump assembly Wrap the tip of the screwdriver with tape b Using SST and a hammer tap in a new oil seal until its sur face is flush with the timing chain cover edge SST 09226 10010 c Apply MP grease to the oil seal lip ...

Page 2077: ...36 ft lbf 2 INSTALL OIL PUMP COVER a Apply new engine oil to the drive and driven rotors b Place the drive and driven rotors into the timing chain cov er with the marks facing upward c Install the oil pump cover with the 7 bolts Torque 9 0 N m 92 kgf cm 80 in lbf d Install a new O ring to the oil pump cover e Install a new O ring to the oil pipe f Install the oil pipe with the 3 bolts Torque 9 0 N...

Page 2078: ...Union Bolt Plate Washer Oil Cooler Oil Filter Bracket Oil Cooler Hose Oil Cooler Hose 68 693 50 O ring O ring 19 194 14 N m kgf cm ft lbf Specified torque Non reusable part x3 x2 LU 16 LUBRICATION 1GR FE OIL COOLER OIL COOLER COMPONENTS ...

Page 2079: ...MOVE V BANK COVER 4 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 5 REMOVE OIL FILTER BRACKET a Disconnect the lower radiator hose b Remove the 2 nuts 3 bolts oil filter bracket and O ring ...

Page 2080: ...LU0QH 01 A23127 LU 18 LUBRICATION 1GR FE OIL COOLER INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging If necessary replace the oil cooler ...

Page 2081: ... 2 INSTALL OIL COOLER a Clean the contact surface of the oil filter bracket with the cooler mounting b Place a new O ring on the oil cooler c Apply a light coat of engine oil to the threads of the union bolt d Install the oil cooler and plate washer with the union bolt Torque 68 N m 693 kgf cm 50 ft lbf e Connect the 2 oil cooler hoses to the oil cooler 3 INSTALL OIL FILTER 4 ADD ENGINE COOLANT 5 ...

Page 2082: ...marks on the dip stick 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 At idle 29 kPa 0 3 kgf cm2 4 2 psi or more At 3 000 rpm 294 588 kPa 3 0 6 ...

Page 2083: ... 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 desig nated disposal sites 1 w Oil filter change REMOVE ENGINE UNDER COVER 2 DRAIN ENGINE ...

Page 2084: ... drain plug with a new gasket Torque 39 N m 400 kgf cm 29 ft lbf b Fill with fresh engine oil Capacity Drain and refill w Oil filter change w o Oil filter change 6 2 liters 6 6 Us qts 5 5 Imp qts 5 7 liters 6 0 Us qts 5 0 Imp qts Dry fill 7 1 liters 7 5 Us qts 6 2 Imp qts c Reinstall the oil filler cap HINT Install the oil filler cap facing the direction as shown in the il lustration 5 START ENGIN...

Page 2085: ...on Sensor Connector Engine Wire Drive Belt Idler Pulley Timing Belt Fan Bracket N m kgf cm ft lbf Specified torque Oil Cooler Pipe Timing Belt Tensioner Dust Boot Cover Plate 32 330 24 16 160 12 Water Bypass Hose Grommet 245 2 500 181 39 400 29 16 160 12 LU 4 LUBRICATION 2UZ FE OIL PUMP OIL PUMP COMPONENTS ...

Page 2086: ...Belt Guide Crankshaft Angle Sensor Plate No 1 Idler Pulley Crankshaft Timing Pulley Plate Washer No 2 Idler Pulley Timing Belt Cover Spacer Gasket Precoated part N m kgf cm ft lbf Specified torque 39 400 29 Generator Wire 34 5 350 25 34 5 350 25 39 400 29 15 5 158 11 LUBRICATION 2UZ FE OIL PUMP LU 5 ...

Page 2087: ...ng Gasket No 1 Oil Pan No 2 Oil Pan Oil Pan Baffle Plate Clamp Drain Plug x 24 N m kgf cm ft lbf Specified torque Non reusable part Gasket 30 5 310 22 O Ring 15 5 160 11 18 185 13 Vinyl Tape Wire Clamp Oil Pressure Switch Connector 15 5 160 11 Gasket 39 400 29 x 8 7 5 76 66 in lbf 28 290 21 7 5 76 66 in lbf 28 290 21 7 5 76 66 in lbf 7 5 76 66 in lbf 7 5 76 66 in lbf LU 6 LUBRICATION 2UZ FE OIL PU...

Page 2088: ...tor Drive Rotor Oil Pump Body Compression Spring Oil Pump Body Cover Non reusable part Relief Valve Crankshaft Front Oil Seal Plug 49 500 36 10 105 8 x 10 N m kgf cm ft lbf Specified torque LUBRICATION 2UZ FE OIL PUMP LU 7 ...

Page 2089: ...ION SENSOR See page IG 11 8 REMOVE OIL DIPSTICK AND GUIDE a Remove the bolt holding the oil dipstick to the LH cylinder head b Pull out the dipstick guide together with the dipstick from the No 1 oil pan c Remove the O ring from the dipstick guide 9 REMOVE OIL FILTER OIL COOLER AND FILTER BRACKET ASSEMBLY a Disconnect the oil pressure switch connector b Take out the vinyl tape and disconnect the w...

Page 2090: ... NOTICE Be careful not to damage the No 2 oil pan contact sur face of the No 1 oil pan Be careful not to damage the No 2 oil pan flange 11 REMOVE OIL PAN BAFFLE PLATE Remove the 7 bolts 2 nuts and baffle plate 12 REMOVE NO 1 OIL PAN a Remove the 18 bolts and 2 nuts b Using a screwdriver remove the No 1 oil pan by prying between the oil pan and cylinder block in the sequence shown NOTICE Be careful...

Page 2091: ... REMOVE OIL PUMP a Remove the 8 bolts HINT Use a 6 mm hexagon wrench for the hexagon head bolt b Using a screwdriver remove the oil pump by prying the portions between the oil pump and cylinder block NOTICE Be careful not to damage the contact surface of the cylin der block and oil pump c Remove the O ring from the cylinder block ...

Page 2092: ...611 LUBRICATION 2UZ FE OIL PUMP LU 11 DISASSEMBLY 1 REMOVE RELIEF VALVE Remove the plug compression spring and relief valve 2 REMOVE DRIVE AND DRIVEN ROTORS Remove the 10 screws pump body cover the drive and driven rotors ...

Page 2093: ... If the tip clearance is greater than maximum replace the rotors as a set c Inspect the rotors for the side clearance Using a feeler gauge and precision straight edge mea sure the clearance between the rotors and precision straight edge Side clearance 0 030 to 0 090 mm 0 0012 to 0 0035 in Maximum body clearance 0 09 mm 0 0035 in If the side clearance is greater than maximum replace the ro tors as ...

Page 2094: ...ap in a new oil seal until its surface is flush with the oil pump body edge SST 09316 60011 09316 00011 3 Apply MP grease to the oil seal lip b If the oil pump is installed to the cylinder block 1 Using a knife cut off the oil seal lip 2 Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screw driver tip 3 Apply MP grease to a new oil seal lip 4 Using ...

Page 2095: ...drive and driven rotors into pump body with the marks facing the pump body cover side b Install the pump body cover with the 10 screws Torque 10 N m 105 kgf cm 7 ft lbf 2 INSTALL RELIEF VALVE a Insert the relief valve and compression spring into the oil pump body hole b Install the plug Torque 49 N m 500 kgf cm 36 ft lbf ...

Page 2096: ...p as shown in the illustra tion Seal packing Part No 08826 00080 or equivalent NOTICE Avoid applying an excessive amount to the surface Be par ticularly careful near oil passage Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening Parts must be assembled within 3 minutes of ap plication Otherwise the material must be removed and reapplied Immediately remove nozzle from the tube and ...

Page 2097: ...g FIPG material and be careful not to drop any oil on the contact surfaces of the No 1 oil pan cylinder block oil pump and rear oil seal retainer Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket sur faces and sealing groove Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply ...

Page 2098: ... nuts in several passes Torque 7 5 N m 76 kgf cm 66 in lbf for 10 mm head 28 N m 290 kgf cm 21 ft lbf for 12 mm head 4 INSTALL OIL PAN BAFFLE PLATE Install the baffle plate with the 7 bolts and 2 nuts Torque 7 5 N m 76 kgf cm 66 in lbf 5 INSTALL NO 2 OIL PAN a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the No 1 and No 2 oil pans Using a razor...

Page 2099: ...the oil filter bracket b Install the oil filter oil cooler and filter bracket assembly with the 2 bolts and nut Torque 18 N m 185 kgf cm 13 ft lbf c Connect the oil cooler hose to the oil cooler d Install the clamp Turn the clamp clockwise and install the clamp to the oil filter bracket e Install the wire to the clamp with a vinyl tape f Connect the oil pressure switch connector 8 INSTALL OIL DIPS...

Page 2100: ...19 10 INSTALL NO 1 IDLER PULLEY See page EM 23 11 INSTALL NO 2 IDLER PULLEY See page EM 23 12 INSTALL TIMING BELT See page EM 23 13 DISCONNECT ENGINE FROM ENGINE STAND 14 INSTALL ENGINE TO VEHICLE 2WD See page EM 83 4WD See page EM 95 ...

Page 2101: ...8W 10 B07331 Oil Cooler Hose O Ring Oil Cooler Plate Washer Union Bolt Oil Filter N m kgf cm ft lbf Specified torque Non reusable part 68 6 700 51 LU 20 LUBRICATION 2UZ FE OIL COOLER OIL COOLER COMPONENTS ...

Page 2102: ...OLER LU 21 REMOVAL 1 DRAIN ENGINE COOLANT 2 REMOVE OIL FILTER See page LU 2 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 ...

Page 2103: ...LU08Y 08 B07334 LU 22 LUBRICATION 2UZ FE OIL COOLER INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging If necessary replace the oil cooler ...

Page 2104: ... 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 N m 700 kgf cm 51 ft lbf e Connect the 2 oil cooler hoses to the oil cooler 2 INSTALL OIL FILTER See page LU 2 3 FILL WITH ENGINE COOLANT 4 START ENGINE AND CHECK FOR ENGINE OIL LEAKS 5 CHECK ENGINE OIL LEVEL ...

Page 2105: ... Thrust Washer Crankshaft See page EM 118 1st 24 5 250 18 2nd Turn 90 Upper Main Bearing Lower Crankshaft Thrust Washer Main Bearing Cap See page EM 118 1st 27 275 20 2nd Turn 90 N m kgf cm ft lbf Specified torque Non reusable part Oil Nozzle 9 0 92 80 in lbf LU 24 LUBRICATION 2UZ FE OIL NOZZLE OIL NOZZLE COMPONENTS ...

Page 2106: ...LU0ID 07 B17484 LUBRICATION 2UZ FE OIL NOZZLE LU 25 REMOVAL 1 REMOVE CRANKSHAFT See page EM 100 2 REMOVE OIL NOZZLE WITH RELIEF VALVE Using a 5 mm hexagon wrench remove the bolt and oil nozzle ...

Page 2107: ...LU0IE 05 B17485 LU 26 LUBRICATION 2UZ FE OIL NOZZLE INSPECTION INSPECT RELIEF VALVE OIL NOZZLE Push the valve with a wooden stick to check if it is stuck If stuck replace the relief valve ...

Page 2108: ...RICATION 2UZ FE OIL NOZZLE LU 27 INSTALLATION 1 INSTALL OIL NOZZLE WITH RELIEF VALVE Using a 5 mm hexagon wrench install the oil nozzle with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf 2 INSTALL CRANKSHAFT See page EM 118 ...

Page 2109: ...Repair wiring between the VVT sensor and ECM Replace the VVT sensor NG OK IGNITION 1GR FE IGNITION SYSTEM IG 1 IGNITION SYSTEM ON VEHICLE INSPECTION NOTICE Cold and Hot in this section mean 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 1 INSPECT IGNITION COIL AND SPARK TEST a Confirm DTCs NOTICE If a DTC is present perform tr...

Page 2110: ...m 7 ft lbf 2 INSPECT SPARK PLUGS a Clean the spark plugs Air pressure Below 588 kPa 6 kg cm2 85 psi Duration 20 seconds or less b Check the spark plug for any damage to its thread and in sulator If there is damage replace the spark plug Recommended spark plug NGK made LFR6C 11 DENSO made K20HR U11 c Adjust electrode gap Electrode gap 1 0 to 1 1 mm 0 039 to 0 043 in Maximum electrode gap 1 46 mm 0 ...

Page 2111: ...hanges between the Hi range and Lo range as shown in the table below HINT For the terminal arrangement of the ECM see page DI 34 Sensor position Terminal No Voltage Hi Voltage Lo Bank 1 VV1 VV1 3 75 to 4 5 V 0 5 to 1 25 V Bank 2 VV2 VV2 3 75 to 4 5 V 0 5 to 1 25 V 4 INSPECT CRANKSHAFT POSITION SENSOR a Using an ohmmeter measure the resistance between the terminals RESISTANCE 1630 to 2740 Ω at cold...

Page 2112: ...5 76 66 in lbf V bank Cover N m kgf cm ft lbf Specified torque Ventilation Hose No 2 Mass Air Flow Meter Connector Vacuum Hose 8 0 82 71 in lbf Air Cleaner Assy IG 4 IGNITION 1GR FE IGNITION COIL IGNITION COIL COMPONENTS ...

Page 2113: ...et 21 214 16 21 214 16 21 214 16 Intake Air Surge Tank Surge Tank Stay No 1 Fuel Vapor Feed Hose VSV Connector Surge Tank Stay No 2 VSV Connector 28 286 21 9 0 92 80 in lbf Oil Baffle Plate N m kgf cm ft lbf Specified torque Non reusable part Ignition Coil 10 102 7 IGNITION 1GR FE IGNITION COIL IG 5 ...

Page 2114: ...1GR FE IGNITION COIL REMOVAL 1 REMOVE V BANK COVER 2 REMOVE AIR CLEANER See page EM 62 3 REMOVE INTAKE AIR SURGE TANK See page EM 62 4 REMOVE IGNITION COIL a Disconnect the ignition coil connector b Remove the bolt and ignition coil ...

Page 2115: ...STALLATION 1 INSTALL IGNITION COIL a Install the ignition coil with the bolt Torque 10 N m 102 kgf cm 7 ft lbf b Connect the ignition coil connector 2 INSTALL INTAKE AIR SURGE TANK See page EM 89 3 INSTALL AIR CLEANER See page EM 89 4 INSTALL V BANK COVER ...

Page 2116: ... 7 3 SEPARATE COOLER COMPRESSOR a Remove the bolt and separate the suction hose sub assy b Disconnect the cooler compressor assy connector c Remove the 4 bolts and separate the cooler compressor from the V ribbed belt tensioner 4 REMOVE CRANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove the bolt and crankshaft position sensor ...

Page 2117: ...FT POSITION SENSOR Using an ohmmeter measure the resistance between the terminals RESISTANCE 1 630 to 2 740 Ω at cold 2 065 to 3 225 Ω at hot NOTICE Cold and Hot mean 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 ...

Page 2118: ...t position sensor with the bolt Torque 10 N m 102 kgf cm 7 ft lbf c Connect the crankshaft position sensor connector 2 INSTALL COOLER COMPRESSOR a Install the cooler compressor assy with the 4 bolts Torque 25 N m 255 kgf cm 18 ft lbf b Connect the cooler compressor assy connector c Install the suction hose sub assy with the bolt Torque 8 0 N m 82 kgf cm 71 in lbf 3 INSTALL GENERATOR See page CH 15...

Page 2119: ...E V BANK COVER 3 REMOVE AIR CLEANER See page EM 62 4 REMOVE VVT SENSOR a RH bank side VVT sensor 1 Disconnect the VVT sensor connector 2 Remove the bolt and VVT sensor b LH bank side VVT sensor 1 Disconnect the water by pass hose No 4 and No 5 2 Disconnect the VVT sensor connector 3 Remove the bolt and VVT sensor ...

Page 2120: ...r with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf 3 Connect the VVT sensor connector 4 Connect the water by pass hose No 4 and No 5 b RH bank side VVT sensor 1 Apply a light coat of engine oil to an O ring of the VVT sensor 2 Install the VVT sensor with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf 3 Connect the VVT sensor connector 2 INSTALL AIR CLEANER See page EM 89 3 INSTALL V BANK COVER 4 ADD ...

Page 2121: ...SPARK TEST Check that the spark occurs 1 Remove the ignition coils with igniter see page IG 5 2 Remove the spark plugs 3 Install the spark plugs to each ignition coil with ig niter and connect the ignition coil with igniter con nector 4 Disconnect the 8 injector connectors 5 Ground the spark plug 6 Check that spark occurs while engine is being cranked NOTICE To prevent gasoline from being injected...

Page 2122: ...OK Replace the ignition coil with igniter NO OK 985 1 600 Ω 1 265 1 890 Ω BAD CHECK POWER SUPPLY TO IGNITION COIL WITH 1 Turn ignition switch to ON 2 Check that there is battery voltage at ignition coil positive terminal IGNITER CHECK TDC NG SENSOR See page IG 12 B03198 16 mm Plug Wrench IG 2 IGNITION 2UZ FE IGNITION SYSTEM If the spark does not occur do the test as follows 7 Using a 16 mm plug wr...

Page 2123: ...e are traces of oil remove it with gasoline before using the spark plug cleaner d Check the spark plug for thread damage and insulator damage If abnormal replace the spark plug Recommended spark plug DENSO made SK20R11 NGK made IFR6A11 e Adjust the spark plug electrode gap Electrode gap 1 0 to 1 1 mm 0 039 to 0 043 in f Using a 16 mm plug wrench install the spark plugs Torque 17 5 N m 180 kgf cm 1...

Page 2124: ...IG08Q 06 B07248 Ignition Coil with Igniter Connector Ignition Coil with Igniter N m kgf cm ft lbf Specified torque 7 5 76 66 in lbf IG 4 IGNITION 2UZ FE IGNITION COIL IGNITION COIL COMPONENTS ...

Page 2125: ... 2UZ FE IGNITION COIL IG 5 REMOVAL 1 DISCONNECT IGNITION COIL WITH IGNITER CON NECTORS 2 REMOVE IGNITION COILS WITH IGNITER Remove the bolt and pull out the ignition coil with igniter Re move the 8 ignition coils with igniter ...

Page 2126: ...NITION COIL INSTALLATION 1 INSTALL IGNITION COILS WITH IGNITER Install the ignition coil with igniter with the bolt Install the 8 ignition coils with igniter Torque 7 5 N m 76 kgf cm 66 in lbf 2 CONNECT IGNITION COIL WITH IGNITER CONNEC TORS ...

Page 2127: ...6 Drive Belt Camshaft Position Sensor Connector Grommet Engine Wire Camshaft Position Sensor Oil Cooler Pipe LH No 3 Timing Belt Cover IGNITION 2UZ FE CAMSHAFT POSITION SENSOR IG 7 CAMSHAFT POSITION SENSOR COMPONENTS ...

Page 2128: ...CAMSHAFT POSITION SENSOR REMOVAL 1 DRAIN ENGINE COOLANT 2 REMOVE DRIVE BELT See page CH 7 and CH 19 3 REMOVE LH NO 3 TIMING BELT COVER See page EM 16 4 REMOVE CAMSHAFT POSITION SENSOR Remove the bolt stud bolt and camshaft position sensor ...

Page 2129: ...SOR 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 See page EM 23 3 INSTALL DRIVE BELT See page CH 16 and CH 28 4 FILL ENGINE COOLANT See page CO 2 5 CHECK ENGINE COOLANT FOR LEAKS 6 CHECK IGNITION TIMING See page EM 9 ...

Page 2130: ... torque Crankshaft Position Sensor Engine Under Cover 2WD Crankshaft Position Sensor Connector Engine Under Cover 4WD x 5 6 5 65 58 in lbf 29 296 21 29 296 21 IG 10 IGNITION 2UZ FE CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR COMPONENTS ...

Page 2131: ...ITION 2UZ FE CRANKSHAFT POSITION SENSOR IG 11 REMOVAL 1 REMOVE ENGINE UNDER COVER 2 REMOVE CRANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove the bolt and crankshaft position sensor ...

Page 2132: ...era ture 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 Using an ohmmeter measure the resistance between the ter minals Resistance Cold 1 630 to 2 740 Ω Hot 2 065 to 3 225 Ω If the resistance is not as specified replace the crankshaft posi tion sensor ...

Page 2133: ...T POSITION SENSOR IG 13 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 2134: ...1 STARTING 1GR FE STARTING SYSTEM ST 1 STARTING SYSTEM ON VEHICLE INSPECTION NOTICE Before changing the starter check these items again Connector connection Accessory installation e g engine immobilizer system ...

Page 2135: ...ST0PM 01 B17655 N m kgf cm ft lbf Specified torque Starter 37 377 27 Engine Under Cover 9 8 100 87 in lbf ST 2 STARTING 1GR FE STARTER 1 6 kW STARTER 1 6 kW COMPONENTS ...

Page 2136: ...air Service Starter Kit Starter Commutator End Frame Cover Planetary Gear Starter Center Bearing Clutch Sub assy Starter Armature Assy Plate Washer Starter Armature Plate Starter Drive Lever Set Pin Starter Drive Housing Assy 7 5 76 66 in lbf 10 102 7 4 6 0 61 53 in lbf Snap Ring STARTING 1GR FE STARTER 1 6 kW ST 3 ...

Page 2137: ... REMOVE ENGINE UNDER COVER 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3 REMOVE STARTER ASSEMBLY a Disconnect the terminal 50 connector from the starter b Remove the nut and disconnect the wire harness from ter minal 30 c Remove the 2 bolts and the starter ...

Page 2138: ...nger 2 REMOVE STARTER YOKE ASSY a Remove the 2 through bolts and pull out the starter yoke assy together with the commutator end frame assy 3 REMOVE STARTER COMMUTATOR END FRAME ASSY a Remove the commutator end frame assy from the starter yoke assy 4 REMOVE STARTER ARMATURE PLATE a Remove the starter armature plate from the starter yoke assy 5 REMOVE STARTER COMMUTATOR END FRAME COVER a Using a sc...

Page 2139: ...ARY GEAR a Remove the 3 planetary gears 8 REMOVE STARTER CENTER BEARING CLUTCH SUB ASSY a Remove the starter center bearing clutch and drive lever set pin together from the starter drive housing b Remove the drive lever set pin from the starter center bearing clutch ...

Page 2140: ... is dirty or burnt correct it with sandpaper No 400 or on a lathe 3 INSPECT COMMUTATOR LENGTH a Using vernier calipers measure the commutator length Standard length 3 1 mm 0 122 in Maximum length 3 8 mm 0 150 in If the length is greater than maximum replace the armature 4 INSPECT STARTER COMMUTATOR END FRAME ASSY a Using vernier calipers measure the brush holder length Standard length 9 0 mm 0 354...

Page 2141: ... the plunger 1 Push in the plunger and check that it returns quickly to its original position If necessary replace the repair service starter kit 7 INSPECT MAGNET STATER SWITCH a Check the pull in coil for open circuit 1 Using an ohmmeter check that there is continuity between terminal 50 and C If there is no continuity replace the repair service starter kit b Check whether or not the hold in coil...

Page 2142: ...ry gears 3 INSTALL STARTER ARMATURE ASSY a Apply grease to the plate washer and armature shaft b Install the armature shaft to the starter commutator end frame assy c Using snap ring pliers install the plate washer and new snap ring d Using vernier calipers measure the snap ring Maximum length 5 0 mm 0 197 in If the length is greater than maximum replace the new snap ring 4 INSTALL STARTER COMMUTA...

Page 2143: ...n the key of the starter yoke assy with the keyway of starter drive housing b Install the starter yoke assy with the 2 through bolts Torque 6 0 N m 61 kgf cm 53 in lbf 8 INSTALL REPAIR SERVICE STARTER KIT a Apply grease to the plunger and hook b Hang the plunger hook of the repair service starter kit to the drive lever c Install the plunger and return spring d Install the repair service starter ki...

Page 2144: ...A23149 STARTING 1GR FE STARTER 1 6 kW ST 11 e Connect the lead wire to the terminal with the nut Torque 10 N m 102 kgf cm 7 4 ft lbf ...

Page 2145: ... gear protrudes b Do holding test 1 Disconnect the negative lead from the terminal C with the above condition a is being sustained Check that the pinion gear remains protruded c Inspect clutch pinion gear return 1 Disconnect the negative lead from the switch body Check that the clutch pinion gear returns in ward d Perform the operation test without load 1 Connect the field coil lead wire to termin...

Page 2146: ...l the starter with the 2 bolts Torque 37 N m 377 kgf cm 27 ft lbf a Connect the wire harness to the terminal 30 and install the nut Torque 9 8 N m 100 kgf cm 7 ft lbf b Connect the terminal 50 to the starter 2 INSTALL ENGINE UNDER COVER ASSY REAR 3 CONNECT CABLE TO NEGATIVE BATTERY TER MINAL ...

Page 2147: ...ST0PT 01 B17656 N m kgf cm ft lbf Specified torque Starter 37 377 27 Engine Under Cover 9 8 100 87 in lbf ST 14 STARTING 1GR FE STARTER 2 0 kW STARTER 2 0 kW COMPONENTS ...

Page 2148: ...Assy Magnet Starter Switch Assy Starter Magnet Switch Return Spring Steel Ball x 4 Brush Spring O ring Starter Idle Gear Pinion Starter Idle Gear Clutch Roller Starter Drive Housing Assy O ring Commutator End Frame Starter Idle Gear Retainer 9 3 95 82 in lbf 3 8 39 34 in lbf 5 9 60 52 in lbf 9 3 95 82 in lbf STARTING 1GR FE STARTER 2 0 kW ST 15 ...

Page 2149: ...1 REMOVE ENGINE UNDER COVER 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3 REMOVE STARTER ASSEMBLY a Disconnect the terminal 50 connector from the starter b Remove the nut and disconnect the wire harness from ter minal 30 c Remove the 2 bolts and the starter ...

Page 2150: ...g from the starter yoke 2 REMOVE MAGNET STARTER SWITCH ASSY a Remove the 2 screws and magnet starter switch b Remove these parts from the starter drive housing 1 Starter magnet switch return spring 2 Starter idle gear pinion 3 Starter idle gear clutch roller 4 Starter idle gear retainer 5 Starter clutch c Using a magnetic finger remove the steel ball from the clutch shaft hole 3 REMOVE STARTER BRU...

Page 2151: ...4 ST 18 STARTING 1GR FE STARTER 2 0 kW c Using a screwdriver hold the spring back and disconnect the 4 brushes from the brush holder d Remove the brush holder from the armature 4 REMOVE STARTER ARMATURE ASSY ...

Page 2152: ...s dirty or burnt correct it with sandpaper No 400 or on a lathe 3 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial indicator measure the circle runout Maximum circle runout 0 05 mm 0 0020 in If the circle runout is greater than maximum correct it on a lathe 4 INSPECT COMMUTATOR DIAMETER Using vernier calipers measure the commutator diameter Standard diameter 35 0 ...

Page 2153: ... holder insulation 1 Using an ohmmeter check that there is no continu ity between the positive and negative brush holders If there is continuity repair or replace the brush holder b Check the brush spring load 1 Take a pull scale reading at the instant the brush spring separates from the brush Standard spring load 21 5 to 27 5 N 2 2 to 2 8 kgf 4 8 to 6 2 lbf Minimum spring load 12 7 N 1 3 kgf 2 9 ...

Page 2154: ...9 Ω at 20 C 68 F If the resistance is not as specified replace the field frame 11 INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise and check that it turns freely Check that it locks by rotating the pinion gear counterclockwise If necessary replace the clutch assembly 12 INSPECT MAGNET STATER SWITCH a Check the pull in coil for open circuit 1 Using an ohmmeter check that there is continu...

Page 2155: ...f the field frame e Install the end frame with the 2 screws Torque 3 8 N m 39 kgf cm 34 in lbf 2 INSTALL MAGNET STARTER SWITCH ASSY a Apply grease to the steel ball and install it to the clutch shaft hole b Apply grease to the these parts 2 5 and install them to the starter drive housing 1 Starter magnet switch return spring 2 Starter idle gear pinion 3 Starter idle gear clutch roller 4 Starter id...

Page 2156: ...to the groove of the starter yoke b Align the key of the starter yoke with the groove of the magnet starter switch c Install the starter yoke and armature with the 2 through bolts Torque 9 3 N m 95 kgf cm 82 in lbf d Connect the lead wire to the C terminal with the nut Torque 5 9 N m 60 kgf cm 52 in lbf ...

Page 2157: ...r protrudes b Do holding test 1 Disconnect the negative lead from the terminal C with the above condition a is being sustained Check that the pinion gear remains protruded c Inspect clutch pinion gear return 1 Disconnect the negative lead from the switch body Check that the clutch pinion gear returns in ward d Perform the operation test without load 1 Connect the field coil lead wire to terminal C...

Page 2158: ...l the starter with the 2 bolts Torque 37 N m 377 kgf cm 27 ft lbf a Connect the wire harness to the terminal 30 and install the nut Torque 9 8 N m 100 kgf cm 7 ft lbf b Connect the terminal 50 to the starter 2 INSTALL ENGINE UNDER COVER ASSY REAR 3 CONNECT CABLE TO NEGATIVE BATTERY TER MINAL ...

Page 2159: ...NUITY a Using an ohmmeter check that there is continuity be tween 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 be tween terminals 3 and 5...

Page 2160: ...re 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 c Check that there is continuity between terminals 3 and 4 If there is no continuity replace the relay 3 INSPECT ACC CUT RELAY OPERATION a Apply battery positive voltage across terminals 1 and 2 b Using an ohmmeter check that there is no continuity be tween t...

Page 2161: ...4 STARTING 2UZ FE STARTING SYSTEM ST 1 STARTING SYSTEM ON VEHICLE INSPECTION NOTICE Before changing the starter check these items again Connector connection Accessory installation e g engine immobilizer system ...

Page 2162: ...ST0GK 03 B17459 Non reusable part Throttle Body Cover PS Air Hose Intake Air Connector Suction Hose MAF Meter Wire PCV Hose Vacuum Hose ST 2 STARTING 2UZ FE STARTER STARTER COMPONENTS ...

Page 2163: ...ntake Manifold Assembly Engine Wire and Clamp Gasket Non reusable part Engine Wire Protector Fuel Return Hose Engine Wire N m kgf cm ft lbf Specified torque Gasket Air Switching Valve No 2 Gasket Gasket 10 102 7 10 102 7 10 102 7 10 102 7 39 400 29 STARTING 2UZ FE STARTER ST 3 ...

Page 2164: ...tch Assembly Wave Washer Terminal Nut O Ring Terminal Insulator Terminal Bolt Terminal C Kit Part Lead Terminal Plunger Gasket End Cover Terminal Insulator Terminal Bolt Contact Plate Terminal Insulator Wave Washer O Ring Terminal Nut Terminal 30 Kit Part Non reusable part Packing Dust Protector Dust Protector 1 4 kW Type Field Frame Field Coil O Ring 17 170 13 17 170 13 N m kgf cm ft lbf Specifie...

Page 2165: ... Insulator Magnetic Switch Assembly Wave Washer Terminal Nut O Ring Terminal Insulator Terminal Bolt Terminal C Kit Part Lead Terminal Plunger Gasket End Cover Terminal Insulator Terminal Bolt Contact Plate Terminal Insulator Wave Washer O Ring Terminal Nut Terminal 30 Kit Part Non reusable part Packing Dust Protector Dust Protector O Ring 2 0 kW Type N m kgf cm ft lbf Specified torque 17 170 13 1...

Page 2166: ...Y FROM INTAKE MANIFOLD See pege SF 44 5 REMOVE INTAKE MANIFOLD ASSEMBLY See page EM 36 6 REMOVE AIR PUMP ASSEMBLY See page EC 23 7 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 prot...

Page 2167: ...magnetic switch assembly NOTICE 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 a 1 4 kW type Remove the 2 bolts Torque 5 9 N m 60 kgf cm ...

Page 2168: ...SH 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 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 ...

Page 2169: ...e 4 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial indicator 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 Using vernier calipers measure the commutator diameter Standard diameter 1 4 kW type 30 0 mm 1 181 in 2 0 kW type 35 0 mm 1 378 in Minimum diameter ...

Page 2170: ... 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 to 1 9 Ω at 20 C 68 F If the resistance is not as specified replace the field frame 10 INSPECT BRUSH LENGTH Using vernier calipers measure the brush length Standard...

Page 2171: ...e 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 th...

Page 2172: ... 50 Continuity ST 12 STARTING 2UZ FE STARTER 17 DO HOLD IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity between ter minal 50 and the switch body If there is no continuity replace the magnetic switch ...

Page 2173: ...ST 09286 46011 b Using a press press in a new bearing 2 REPLACE FRONT BEARING a Using SST remove the bearing SST 09286 46011 b Using SST and a press press in a new bearing NOTICE Be careful of the bearing installation direction SST 09820 00031 3 REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS a Remove magnetic switch end cover Remove the 3 bolts end cover gasket and plunger ...

Page 2174: ...ve the terminal nut wave washer terminal in sulator outside O ring terminal bolt contact plate terminal insulator inside and insulation pa per 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 term...

Page 2175: ...y install a new wave washer 7 Temporarily install a new terminal nut NOTICE 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 kg...

Page 2176: ... may cause cracks on the in side 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 2177: ...G 2UZ FE STARTER ST 17 REASSEMBLY Reassembly is in the reverse order of disassembly See page ST 7 HINT At the time of assembly use high temperature grease to lubricate the bearing and gears when assembling the starter ...

Page 2178: ...inion 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 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 Chec...

Page 2179: ... m 100 kgf cm 84 in lbf c Connect the starter connector d Connect the starter to the cylinder block 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 AIR PUMP ASSEMBLY See page EC 27 3 INSTALL INTAKE MANIFOLD ASSEMBLY See page EM 60 4 CONNECT THROTTLE BODY ASSEMBLY TO INTAKE MANIFOLD See page SF 45 5 INSTALL INTAKE AIR CONNE...

Page 2180: ...uity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay b Inspect the relay operation 1 Apply battery voltage across terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 If there is no ...

Page 2181: ...re 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 c Check that there is continuity between terminals 3 and 4 If there is no continuity replace the relay 3 INSPECT ACC CUT RELAY OPERATION a Apply battery positive voltage across terminals 1 and 2 b Using an ohmmeter check that there is no continuity be tween t...

Page 2182: ...enance Free Battery If under the lower level add distilled water 2 CHECK BATTERY SPECIFIC GRAVITY Except Maintenance Free Battery a Check the specific gravity of each cell Standard specific gravity 1 25 to 1 29 at 20 C 68 F HINT If the specific gravity is less than specification charge the bat tery 3 CHECK BATTERY VOLTAGE a After having driven the vehicle and in the case that 20 minutes have not p...

Page 2183: ...ced b Check that it fits properly in the ribbed grooves HINT Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley 6 VISUALLY CHECK GENERATOR WIRING a Check that the wiring is in good condition 7 LISTEN FOR ABNORMAL NOISES FROM GENERA TOR a Check that there is no abnormal noise from the generator while the engine is running 8 INSPECT CHARGE WAR...

Page 2184: ...the engine running from idle to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperage 10 A or less Standard voltage 13 2 to 14 8 V HINT If the voltmeter reading is more than standard voltage re place the voltage regulator If the voltmeter reading is less than the standard voltage check the voltage regulator and generator as follows 10 INSPECT CHARGING CIRCUIT WITH LOAD a With ...

Page 2185: ...CH0N6 01 B17628 N m kgf cm ft lbf Specified torque Engine Under Cover x 5 Battery Tray V Bank Cover 9 8 100 87 in lbf Battery Tray Battery Clamp CH 4 CHARGING 1GR FE GENERATOR GENERATOR COMPONENTS ...

Page 2186: ...ft lbf Specified torque A C Compressor Connector 43 438 32 25 255 18 Generator Drive Belt Generator Connector Wire Harness Clamp Bracket Generator Wire 9 8 100 87 in lbf 8 0 82 71 in lbf 8 0 82 71 in lbf CHARGING 1GR FE GENERATOR CH 5 ...

Page 2187: ... Retainer Plate Generator Rotor Assy Generator Rotor Bearing Generator Bearing Cover Washer Generator Coil Assy Terminal Insulator Generator Plate Seal Generator Brush Holder Assy Generator Plate Seal Generator Rear End Cover 110 1 122 81 x4 x4 2 6 27 23 in lbf 4 6 47 41 in lbf 1 8 18 16 in lbf 5 8 59 51 in lbf CH 6 CHARGING 1GR FE GENERATOR ...

Page 2188: ... GENERATOR V BELT See page EM 62 4 REMOVE BATTERY 5 REMOVE GENERATOR a Disconnect the wire harness 1 Remove the bolt and wire harness stay 2 Disconnect the connector from the generator 3 Remove the terminal cap and nut 4 Disconnect the wire harness from the terminal B b Remove the 2 bolts and wire harness clamp bracket from the generator assy c Remove the 2 bolts and generator ...

Page 2189: ... Check that SST is secured to the rotor shaft b Mount SST 2 in a vise c Insert SST A and B into SST C and attach the pulley nut to SST C d To loosen the pulley nut turn SST A in the direction shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half turn e Remove the generator from SST C f Turn SST B and remove SST A and B g Remove the pu...

Page 2190: ...HOLDER ASSY a Remove the plate seal b Remove the 2 nuts and brush holder c Remove the plate seal 5 REMOVE GENERATOR COIL ASSY a Remove the 4 bolts b Using SST remove the coil SST 09950 40011 09951 04020 09952 04010 09953 04020 09954 04010 09955 04071 09957 04010 09958 04011 6 REMOVE GENERATOR ROTOR ASSY a Remove the washer and rotor ...

Page 2191: ...ontinuity replace the rotor c Check that the slip rings are not rough or scored If rough or scored replace the rotor d Using vernier calipers measure the slip ring diameter Standard diameter 14 2 to 14 4 mm 0 559 to 0 567 in Minimum diameter 14 0 mm 0 551 in If the diameter is less than the minimum replace the rotor 2 INSPECT BRUSHES Using vernier caliper measure the exposed brush length Standard ...

Page 2192: ...OTOR BEARING SST 09820 00021 NOTICE Be careful not to damage the fan a Remove the bearing cover Inside 3 INSTALL GENERATOR ROTOR BEARING a Place the rotor on the pulley b Install the bearing cover Inside c Using SST and a press press in a new bearing SST 09820 00031 d Using SST push in the bearing cover outside SST 09285 76010 4 INSPECT GENERATOR DRIVE END FRAME BEARING a Check the bearing is not ...

Page 2193: ...and retainer plate b Using SST tap out the bearing SST 09950 60010 09951 00250 09950 70010 09951 07100 6 INSTALL GENERATOR DRIVE END FRAME BEARING a Using SST and a press press in a new bearing SST 09950 60010 09951 00470 09950 70010 09951 07100 b Install the retainer plate with the 4 screws Torque 2 6 N m 27 kgf cm 23 in lbf ...

Page 2194: ...e 5 8 N m 59 kgf cm 51 in lbf 3 INSTALL GENERATOR BRUSH HOLDER ASSY a Install the plate seal Inside b Place the brush holder with the pin facing upward NOTICE Be careful of the brush holder installing direction c Install the 2 screws Torque 1 8 N m 18 kgf cm 16 in lbf d Align the pins of the brush holder with the holes of the plate seal outside and install the plate seal outside 4 INSTALL TERMINAL...

Page 2195: ...nd tighten SST B clockwise with the specified torque Torque 39 N m 400 kgf cm 29 ft lbf NOTICE Check that SST is secured to the rotor shaft c Mount SST C in a vise d Insert SST A and B into SST C and attach the pulley nut to SST C e Tighten the pulley nut by turning SST A in the direction shown in the illustration Torque 111 N m 1 125 kgf cm 81 ft lbf f Remove the generator from SST C g Turn SST B...

Page 2196: ...rness to the terminal B and install the nut Torque 9 8 N m 100 kgf cm 7 ft lbf 2 Connect the connector to the generator assy 3 Install the wire harness stay with the bolt Torque 8 0 N m 82 kgf cm 71 in lbf 2 INSTALL BATTERY 3 INSTALL FAN AND GENERATOR V BELT See page EM 89 4 INSTALL ENGINE UNDER COVER SUB ASSY NO 1 Install the engine under cover sub assy No 1 with the 4 bolts Torque 29 N m 296 kgf...

Page 2197: ...ace the battery or add distilled wa ter 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 to 1 29 at 20 C 68 F If the specific gravity is less than specification charge the bat tery 3 Maintenance...

Page 2198: ...LT HINT A belt tensioner is used so checking the belt tension is not nec essary a Visually check the drive belt for excessive wear frayed cords etc If necessary replace the drive belt HINT Cracks on the rib side of a drive belt are considered ac ceptable If the drive belt has chunks missing from the ribs it should be replaced The drive belt tension can be released by turning the belt tensioner cou...

Page 2199: ...n turn it off b Switch off all accessories c Turn the ignition switch ON and check that the charge warning light is lit d Start the engine and check that the light goes off If the light does not go off as specified troubleshoot the charge light circuit 9 INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT If a battery generator tester is available connect the tester to the charging circuit as per manufactu...

Page 2200: ...INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the heater blower switch at HI b Check the reading on the ammeter Standard amperage 30 A or more If the ammeter reading is less than the standard amperage re pair the generator HINT If the battery is fully charged the indication will sometimes be less than standard amperage 11 REINS...

Page 2201: ...ed torque 39 400 29 Engine Under Cover 2WD Engine Under Cover 4WD x 5 Drive Belt Wire Clamp Generator PS Vane Pump 39 400 29 Intake Air Connector Terminal Cap Throttle Body Cover 39 400 29 39 400 29 CHARGING 2UZ FE GENERATOR Standard Spec CH 5 GENERATOR Standard Spec COMPONENTS ...

Page 2202: ...otor Assembly Rectifier End Frame Terminal Insulator Rectifier Holder Rectifier Brush Holder Rubber Insulator Non reusable part Rear End Cover N m kgf cm ft lbf Specified torque Brush Holder Cover Voltage Regulator 110 5 1 125 81 CH 6 CHARGING 2UZ FE GENERATOR Standard Spec ...

Page 2203: ...OR 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 6 REMOVE PS VANE PUMP FROM ENGINE See page SR 61 7 REMOVE GENERATOR a Disconnect the generator connector b Remove the terminal cap and nut and disconnect the generator wire c Disconnect the wire clamp from the cord clip o...

Page 2204: ...der 2 REMOVE BRUSH HOLDER a Remove the 2 screws and brush holder b Remove the seal plate from the rectifier end frame 3 REMOVE VOLTAGE REGULATOR AND RECTIFIER HOLDER a Remove the 3 screws and voltage regulator b Remove the 4 screws and rectifier holder c Remove the 4 rubber insulators 4 REMOVE PULLEY a Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 09820 63...

Page 2205: ...ST A in the direction shown in the illustration NOTICE 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 5 REMOVE RECTIFIER END FRAME a Remove the 4 nuts b Using SST remove the rectifier end frame SST 09286 46011 c Remove the generator washer from th...

Page 2206: ...anged there is continuity in one way but no continuity in another way If the continuity is not as specified replace the regulator 2 INSPECT ROTOR FOR OPEN CIRCUIT a Check the rotor for open circuit Using an ohmmeter check that there is continuity be tween the slip rings Standard resistance 2 1 to 2 5 Ω at 20 C 68 F If there is no continuity replace the rotor b Check the rotor for ground Using an o...

Page 2207: ...onnect one tester probe to the positive terminal and the other to each rectifier terminal 2 Reverse the polarity of the tester probes and repeat step a 3 Check that one shows continuity and the other shows no continuity If continuity is not as specified replace the rectifier holder b Check the negative rectifire 1 Using an ohmmeter connect one tester probe to each negative terminal and the other t...

Page 2208: ...H 12 CHARGING 2UZ FE GENERATOR Standard Spec 6 INSPECT BEARING Check that the bearing is not rough or worn If necessary replace the drive end frame assembly front bear ing or rotor assembly rear bearing ...

Page 2209: ...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 4 nuts Torque 4 5 N m 46 kgf cm 39 in lbf 4 INSTALL PULLEY a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 09820 63011 Torque 39 N m 400 kgf cm 29 ft lbf...

Page 2210: ...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 a Install the 4 rubber insulators on the lead wires NOTICE Be careful of the rubber insulators installation direction b Install the rectifier while pushing it with the 4 screws Torque 1 9...

Page 2211: ...me NOTICE Be careful of the brush holder installation direction c Install the 5 screws Torque 1 96 N m 20 kgf cm 17 in lbf 7 INSTALL REAR END COVER a Place the brush holder cover on the brush holder b 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 c Install the terminal insulator with the nut Torque 4 1 N m...

Page 2212: ...Install the terminal cap e Install the wire clamp to the cord clip on the generator 2 INSTALL PS VANE PUMP See page SR 69 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 CONNECT INTAKE AIR CONNECTOR TO THROTTLE BODY 5 PERFORM ON VEHICLE INSPECTION See page CH 1 6 INSTALL THROTTLE BODY COVER 7 ...

Page 2213: ...400 29 Engine Under Cover 2WD Engine Under Cover 4WD x 5 Drive Belt Wire Clamp Generator PS Vane Pump 39 400 29 Terminal Cap Intake Air Connector Throttle Body Cover 15 5 158 11 39 400 29 39 400 29 CHARGING 2UZ FE GENERATOR Towing Package Spec CH 17 GENERATOR Towing Package Spec COMPONENTS ...

Page 2214: ...Drive End Frame Stator Rotor Bearing Cover Generator Washer Bearing Cover Rectifier End Frame Terminal Insulator Brush Holder Non reusable part Rear End Cover N m kgf cm ft lbf Specified torque 110 5 1 125 81 Seal Plate CH 18 CHARGING 2UZ FE GENERATOR Towing Package Spec ...

Page 2215: ...ATOR 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 6 REMOVE PS VANE PUMP FROM ENGINE See page SR 61 7 REMOVE GENERATOR a Disconnect the generator connector b Remove the terminal cap and nut and disconnect the generator wire c Disconnect the wire clamp from the cord clip...

Page 2216: ...der c Remove the front seal plate from the coil assembly 3 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 e To loosen the pulley nut turn SST A in the direction s...

Page 2217: ...B and remove SST A and B h Remove the pulley nut and pulley 4 REMOVE COIL ASSEMBLY a Remove the 4 bolts b Using SST remove the coil assembly SST 09950 40011 09951 04020 09952 04010 09953 04020 09954 04010 09955 04071 09957 04010 09958 04011 c Remove the generator washer 5 REMOVE ROTOR FROM DRIVE END FRAME ...

Page 2218: ... ring and rotor If there is continuity replace the rotor c Check that the slip rings are not rough or scored If rough or scored replace the rotor d Using vernier calipers measure the slip ring diameter Standard diameter 14 2 to 14 4 mm 0 559 to 0 567 in Minimum diameter 14 0 mm 0 551 in If the diameter is less than minimum replace the rotor 2 INSPECT BRUSHES Using vernier caliper measure the expos...

Page 2219: ...9950 60010 09951 00250 09950 70010 09951 07100 c Using SST and a press press in a new bearing SST 09950 60010 09951 00470 09950 70010 09951 07100 d Install the bearing retainer with the 4 screws Torque 2 6 N m 27 kgf cm 23 in lbf 2 REPLACE REAR BEARING a Using SST remove the bearing cover outside and bear ing SST 09820 00021 NOTICE Be careful not to damage the fan b Remove the bearing cover inside...

Page 2220: ...B12272 SST B12273 SST CH 24 CHARGING 2UZ FE GENERATOR Towing Package Spec d Using SST and a press press in a new bearing SST 09820 00031 e Using SST push in the bearing cover outside SST 09285 76010 ...

Page 2221: ...Y a Place the generator washer on the rotor b Using SST and a press slowly press in the coil assembly SST 09285 76010 c Install the coil assembly with the 4 bolts Torque 5 8 N m 59 kgf cm 51 in lbf 3 INSTALL PULLEY a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 09820 63011 Torque...

Page 2222: ...orque 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 4 INSTALL BRUSH HOLDER a Place the front seal plate on the coil assembly b Place the brush holder on the coil assembly with the pin facing upward NOTICE Be careful of the holder installation direction c Install the ...

Page 2223: ...er with the holes of the rear seal plate and install the rear seal plate 5 INSTALL REAR END COVER a Install the terminal insulator NOTICE Be careful of the terminal insulator installation direction b Install the end cover with the 3 nuts Torque 4 6 N m 47 kgf cm 41 in lbf 6 CHECK THAT ROTOR ROTATES SMOOTHLY ...

Page 2224: ...nstall the terminal cap e Install the wire clamp to the cord clip on the generator 2 INSTALL PS VANE PUMP See page SR 69 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 CONNECT INTAKE AIR CONNECTOR TO THROTTLE BODY 5 PERFORM ON VEHICLE INSPECTION See page CH 1 6 INSTALL THROTTLE BODY COVER 7 I...

Page 2225: ... dirty or damaged 2 Input shaft bearing Worn dirty or damaged 3 Clutch disc Damaged torsion rubber CL 17 CL 15 Clutch slips 1 Clutch pedal Freeplay out of adjustment 2 Clutch disc Oily 3 Clutch disc Worn out 4 Diaphragm spring Damaged 5 Pressure plate Distortion 6 Flywheel Distortion CL 2 CL 18 CL 17 CL 17 CL 17 Clutch does not disengage 1 Clutch pedal Freeplay out of adjustment 2 Clutch line Air ...

Page 2226: ...ns to be felt Pedal freeplay 5 0 to 15 0 mm 0 197 to 0 591 in b Gently push on the pedal until the resistance begins to in crease a little Push rod play at pedal top 1 0 to 5 0 mm 0 039 to 0 197 in 4 IF NECESSARY ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY a Remove the lower finish panel and disconnect the air duct b Loosen the lock nut and turn the push rod until correct freeplay and push rod play ar...

Page 2227: ... end position Standard distance 25 mm 0 98 in or more From pedal stroke end position to release point If the distance is not as specified perform the following opera tions Check pedal height Check push rod play and pedal freeplay Bleed clutch line Check clutch cover and disc 6 CHECK CLUTCH START SYSTEM a Check that the engine does not start when the clutch ped al is released b Check that the engin...

Page 2228: ...h from the clutch pedal bracket c Measure the resistance between the terminals when the switch is ON and when it is OFF Standard Switch position Condition ON pushed Below 1 Ω OFF free 10 kΩ or higher If the result is not as specified replace the switch d Install the clutch start switch to the clutch pedal bracket with the nut e Connect the connector ...

Page 2229: ...usable part Specified torque Clutch Line Master Cylinder Body Slotted Spring Pin Reservoir Tank Grommet 14 143 10 14 143 10 Spring Snap Ring Boot Clip Clevis Pin Wave Washer Gasket 15 155 11 Lithum soap base glycol grease CLUTCH CLUTCH MASTER CYLINDER CL 5 CLUTCH MASTER CYLINDER COMPONENTS ...

Page 2230: ...nted surface If brake fluid spill onto a painted surface wash it off immediately 3 DISCONNECT CLUTCH LINE FROM MASTER CYL INDER Using SST disconnect the clutch line Use a container to catch the fluid SST 09023 00101 4 REMOVE CLIP AND CLEVIS PIN a Using needle nose pliers remove the clip b Remove the clevis pin and wave washer 5 REMOVE 2 MOUNTING NUTS AND PULL OUT MAS TER CYLINDER 6 REMOVE GASKET ...

Page 2231: ...rive out the slotted spring pin b Remove the reservoir and grommet 2 REMOVE CLEVIS AND BOOT a Loosen the lock nut to remove the clevis and remove the lock nut b Remove the boot 3 REMOVE PUSH ROD a While pushing the push rod remove the snap ring using snap ring pliers b Remove the push rod and washer 4 REMOVE PISTON WITH SPRING ...

Page 2232: ... 2 INSERT PISTON WITH SPRING INTO CYLINDER 3 INSTALL PUSH ROD AND BOOT a Install the washer to the push rod b Push the push rod into the piston and install the snap ring using snap ring pliers c Install the boot 4 TEMPORARILY INSTALL LOCK NUT AND CLEVIS 5 INSTALL RESERVOIR a Install the reservoir and a new grommet b Using a pin punch and hammer drive in the slotted spring pin ...

Page 2233: ...UNTING NUTS Torque 14 N m 143 kgf cm 10 ft lbf 3 CONNECT CLUTCH LINE TO MASTER CYLINDER Using SST connect the clutch line SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 4 INSTALL CLEVIS PIN WAVE WASHER AND CLIP 5 FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM 6 ADJUST CLUTCH PEDAL See page CL 2 7 CHECK FOR LEAKS ...

Page 2234: ...Boot Piston Spring N m kgf cm ft lbf Specified torque Lithum soap base glycol grease Clutch Line Clutch Housing Cover Clutch Accumulator 12 120 9 15 155 11 15 155 11 12 120 9 11 110 8 12 120 9 12 120 9 CL 10 CLUTCH CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER COMPONENTS ...

Page 2235: ...to a painted surface wash it off immediately 3 REMOVE CLUTCH HOUSING COVER Remove the 3 bolts and clutch housing cover 4 REMOVE CLUTCH ACCUMULATOR a Remove the bolt and clamp b Using SST disconnect the clutch lines from the clutch ac cumulator and clutch release cylinder Use a container to catch the fluid SST 09023 00101 c Remove the 3 bolts and clutch accumulator 5 REMOVE CLUTCH RELEASE CYLINDER ...

Page 2236: ...od b Remove the boot from the push rod 2 REMOVE PISTON AND SPRING Using compressed air remove the piston with the spring from the cylinder NOTICE Blowing off the air may cause the piston to jump out When removing the piston hold it by hand using a waste Take care not to splash brake fluid when air blowing 3 REMOVE BLEEDER PLUG ...

Page 2237: ...STALL BLEEDER PLUG Torque 11 N m 110 kgf cm 8 ft lbf 2 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 3 INSTALL PISTON AND SPRING INTO CYLINDER 4 INSTALL BOOT AND PUSH ROD a Install the push rod to the boot b Install the boot with the push rod to the cylinder ...

Page 2238: ...ulator with the 3 bolts Torque 12 N m 120 kgf cm 9 ft lbf b Using SST connect the clutch lines to the clutch release cylinder and clutch accumulator SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf c Install the clamp with the bolt Torque 12 N m 120 kgf cm 9 ft lbf 3 INSTALL CLUTCH HOUSING COVER Install the clutch housing cover with the 3 bolts Torque 12 N m 120 kgf cm 9 ft lbf 4 FILL CLUTCH RES...

Page 2239: ...ch Release Bearing Clutch Release Fork Clutch Cover N m kgf cm ft lbf Specified torque Boot 19 195 14 Clip Clutch spline grease Release hub grease Flywheel 47 479 35 Release Fork Support CLUTCH CLUTCH UNIT CL 15 CLUTCH UNIT COMPONENTS ...

Page 2240: ...l and clutch cover b Loosen each set bolt one turn at a time until spring tension is released c Remove the set bolts and pull off the clutch cover with the clutch disc NOTICE Do not drop the clutch disc 3 REMOVE BOOT CLUTCH RELEASE BEARING AND CLUTCH RELEASE FORK FROM TRANSMISSION a Remove the boot and release bearing together with the fork b Remove the clip from the release bearing ...

Page 2241: ...SPECT FLYWHEEL RUNOUT Using a dial indicator with a roller instrument check the flywheel runout Maximum runout 0 1 mm 0 004 in If necessary replace the flywheel 4 INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers measure the diaphragm spring for depth and width of wear Maximum Depth A 0 5 mm 0 020 in Width B 6 0 mm 0 236 in If necessary replace the clutch cover 5 INSPECT CLUTCH RELEASE BEARING Turn...

Page 2242: ... up and down right and left and tighten the bolts 2 CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with a roller instrument check the dia phragm spring tip alignment Maximum non alignment 0 5 mm 0 020 in If alignment is not as specified adjust the diaphragm spring tip alignment using SST SST 09333 00013 3 APPLY RELEASE HUB GREASE Apply release hub grease to the release fork and clutch...

Page 2243: ... CLUTCH CLUTCH UNIT CL 19 6 INSTALL TRANSMISSION TO ENGINE See page MT 3 ...

Page 2244: ...per remove all the old packing FIPG material from the gas ket surfaces Thoroughly clean all components to remove any loose material Clean both sealing surfaces with a non residue solvent Apply FIPG in a continuous line width approximately 1 mm 0 04 in along the sealing surface Parts must be assembled within 10 minutes of FIPG application Otherwise the packing materi al must be removed and reapplie...

Page 2245: ... See page Noise 1 Oil Level low 2 Oil Wrong 3 Gear Worn or damaged 4 Bearing Worn or damaged MT 7 MT 7 MT 10 MT 10 Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn or damaged 4 O ring Worn or damaged MT 7 MT 10 MT 10 MT 10 Hard to shift or will not shift 1 Synchronizer ring Worn or damaged 2 Shift key spring Damaged MT 34 MT 52 MT 34 MT 52 Jumps out of gear 1 Locking ball spring D...

Page 2246: ... Gasket Gasket Gasket 88 897 65 40 410 30 12 120 9 12 120 9 12 120 9 12 120 9 72 730 53 37 380 27 39 400 29 72 734 53 18 180 13 65 660 48 N m kgf cm ft lbf Specified torque Non reusable part No 1 Engine Under Cover Stabilizer Bar Stabilizer Bar Bracket Bushing 37 377 27 62 630 46 62 630 46 Manifold Stay 40 408 30 40 408 30 43 440 32 48 490 35 9 8 100 7 9 8 100 7 2 0 kW Starter 1 6 kW x5 x4 Apply M...

Page 2247: ...a Remove the drain plug and gasket and drain the trans mission oil b Install a new gasket and the drain plug Torque 37 N m 380 kgf cm 27 ft lbf 4 REMOVE LH AND RH FRONT EXHAUST PIPE See page EM 126 5 REMOVE PROPELLER SHAFT See page PR 3 HINT Cover the transmission extension housing with a cloth to pre vent any oil from leaking 6 DISCONNECT VEHICLE SPEED SENSOR BACK UP LIGHT SWITCH CONNECTOR 7 REMO...

Page 2248: ...er 10 REMOVE STARTER a Disconnect the connector b Remove the nut and disconnect the terminal c Remove the 2 bolts and starter 11 JACK UP TRANSMISSION Using a transmission jack support the transmission 12 REMOVE CROSSMEMBER a Remove the 4 set bolts of the engine rear mounting on the crossmember b Remove the 4 nuts washers bolts and crossmember 13 REMOVE STABILIZER BAR BRACKET Remove the 2 bolts nut...

Page 2249: ...bolts from the en gine b Separate the wire harness from the clamps of the trans mission c Pull out the transmission down and toward the rear NOTICE Be careful not to damage the PS tube 15 REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine rear mounting 16 REMOVE TRANSMISSION COVER Remove the 5 bolts and transmission cover ...

Page 2250: ... a Install the wire harness to the clamps of the transmission b Install the transmission to the engine with the 9 bolts Torque Bolt A 72 N m 730 kgf cm 53 ft lbf Bolt B 37 N m 380 kgf cm 27 ft lbf 4 INSTALL CROSSMEMBER a Install the crossmember with the 4 bolts washers and nuts Torque 72 N m 734 kgf cm 53 ft lbf b Install the 4 set bolts for the engine rear mounting Torque 18 N m 180 kgf cm 13 ft ...

Page 2251: ... ft lbf c Install the clamp with the bolt Torque 12 N m 120 kgf cm 9 ft lbf 8 INSTALL CLUTCH HOUSING COVER Install the clutch housing cover with the 3 bolts Torque 12 N m 120 kgf cm 9 ft lbf a Install the clutch accumulator with the 3 bolts Torque 12 N m 120 kgf cm 9 ft lbf b Install the clutch housing cover with the 3 bolts Torque 12 N m 120 kgf cm 9 ft lbf 9 CONNECT VEHICLE SPEED SENSOR BACK UP ...

Page 2252: ... Install a new gasket and the filler plug Torque 37 N m 380 kgf cm 27 ft lbf 14 INSTALL TRANSMISSION SHIFT LEVER a Apply MP grease to the tip of the shift lever b While pressing down on the shift lever cap rotate it clock wise to install c Install the dust cover d Install the transmission shift lever boot e Install the shift lever boot retainer with the 4 bolts f Install the transmission shift lev...

Page 2253: ...Ring Oil Receiver Pipe Reverse Idler Gear Shaft Needle Roller Bearing Reverse Idler Gear Oil Seal 39 397 29 N m kgf cm ft lbf Specified torque Non reusable part 21 214 15 x4 Snap Ring Oil Receiver Pipe 44 449 32 47 480 35 Counter Gear Shaft MT 10 MANUAL TRANSMISSION RA60 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION ASSEMBLY COMPONENTS ...

Page 2254: ... Gear Shaft Bolt Filler Plug Drain Plug Middle Case Counter Gear Rear Bearing Rear Case Front Case x8 x3 28 286 21 37 377 27 N m kgf cm ft lbf Specified torque Non reusable part Gasket Gasket Gasket 37 377 27 40 408 30 40 408 30 8 5 87 75 in lbf x2 Plug 24 5 250 18 x10 40 408 30 Bearing Lock Plate 11 115 8 Transmission Oil Separator Seal Bearing Outer Race Bearing Outer Race Oil Receiver Pipe Oil ...

Page 2255: ... Remove the bolt and speedometer sensor b Remove the clip from the speedometer sensor c Remove the driven gear from the speedometer sensor d Remove the O ring from the speedometer sensor e Check the teeth of the speedometer driven gear If the driven gear is damaged replace it 3 REMOVE EXTENSION HOUSING DEFLECTOR Using a plastic hammer remove the deflector 4 REMOVE DRAIN PLUG 5 REMOVE FILLER PLUG 6...

Page 2256: ...ove the 4 bolts from the control retainer b Using a plastic hammer remove the control retainer 9 REMOVE EXTENSION HOUSING a Remove the bolt from the shift lever housing b Remove the 8 bolts and clamp c Using a plastic hammer carefully tap out the extension housing HINT Place the brass bar against the rib portion of the case d Remove the shift lever housing ...

Page 2257: ...eedometer drive gear ball and oil receiver pipe 11 REMOVE OUTPUT SHAFT ADJUST NUT a Using a chisel and hammer unstake the nut b Shift to fifth gear and then hold the input shaft with SST SST 09556 16030 c Using a belt and wooden block fasten the transmission to the work bench d Using SST remove the nut from the output shaft SST 09922 10010 e Remove the belt and wooden block from the transmis sion ...

Page 2258: ...er roller bearing No 2 and spacer 12 REMOVE REAR CASE a Remove the plug spring and lock ball pin b Remove the 10 bolts and 3 clamps c Using a plastic hammer carefully tap out the rear case HINT Place the brass bar against the rib portion of the case 13 REMOVE TRANSMISSION OIL SEPARATOR Remove the 2 bolts and transmission oil separator ...

Page 2259: ...R SHAFT BOLT Remove the reverse idler gear shaft bolt and gasket 15 REMOVE MIDDLE CASE a Remove the oil receiver pipe from the middle case b Remove the 11 bolts from the middle case c Using a plastic hammer carefully tap out the middle case HINT Place the brass bar against the rib portion of the case 16 REMOVE SHIFT SELECT LEVER SHAFT ...

Page 2260: ...edle roller bearing and reverse idler gear 19 INSPECT REVERSE IDLER GEAR RADIAL CLEAR ANCE Using a dial indicator measure the radial clearance Standard clearance 0 015 to 0 050 mm 0 0006 to 0 0020 in Maximum clearance 0 050 mm 0 0020 in If the clearance exceeds the maximum replace the needle roll er bearing 20 REMOVE OUTPUT SHAFT INPUT SHAFT COUNTER GEAR SHAFT AND CONTROL SUB ASSEMBLY a Remove the...

Page 2261: ...t and control sub assembly as a unit NOTICE Do not strike the front case with excessive force If the out put shaft input shaft counter gear shaft and control sub assembly are subjected to a strong impact the balls or springs may fly out of the clutch hubs e Separate the output shaft input shaft counter gear shaft and control sub assembly 21 DISASSEMBLE EXTENSION HOUSING a Using SST remove the oil ...

Page 2262: ...parator seal from the rear case b Remove the oil receiver pipe from the rear case c Remove the bolt and bearing lock plate from the rear case d Using SST remove the counter gear rear bearing SST 09308 55010 09520 00031 e Using SST remove the 2 bearing outer races SST 09308 55010 09520 00031 23 DISASSEMBLE FRONT CASE a Using snap ring pliers remove the 2 snap rings ...

Page 2263: ...D13929 D13928 MT 20 MANUAL TRANSMISSION RA60 MANUAL TRANSMISSION ASSEMBLY b Using a screwdriver remove the oil seal HINT Tape the screwdriver tip before use c Remove the oil receiver pipe ...

Page 2264: ...g snap ring pliers install the 2 snap rings c Using SST and a hammer tap in a new oil seal to the clutch housing until dimension A falls within the specified range SST 09388 40010 Dimension A 60 0 to 60 8 mm 2 362 to 2 394 in d Apply gear oil to the lip of the oil seal 2 REASSEMBLE REAR CASE a Using SST and a press press in 2 new bearing outer races SST 09950 60020 09951 00790 09951 00850 09950 70...

Page 2265: ...o the rear case HINT Make sure that the protruding part on the transmission oil sepa rator seal is fitted into the notch on the rear case 3 REASSEMBLE EXTENSION HOUSING a Using SST and a hammer tap in a new oil seal to the ex tension housing until dimension A falls within the speci fied range SST 09950 60020 09951 00640 09950 70010 09951 07100 Dimension A 0 5 to 0 5 mm 0 0197 to 0 0197 in b Apply ...

Page 2266: ...hile expanding the 2 snap rings with snap ring pliers install the output shaft input shaft counter gear shaft and control sub assembly HINT Make sure that the snap rings are securely fitted into the grooves on the front bearings of the input shaft and counter gear shaft d Remove the device binding the output shaft input shaft counter gear shaft and control sub assembly e Install the 4 bolts to the...

Page 2267: ...aft and the claw to the gap on the control shaft assembly to install the shift select lever shaft 7 INSTALL MIDDLE CASE a Apply FIPG to the middle case as shown in the illustration FIPG Part No 08826 00090 THREE BOND 1281 or equiva lent b Install the middle case to the front case with the 11 bolts Torque 40 N m 408 kgf cm 30 ft lbf Bolt length Bolt A 40 mm 1 57 in Bolt B 80 mm 3 15 in c Install th...

Page 2268: ...ALL TRANSMISSION OIL SEPARATOR Install the transmission oil separator with the 2 bolts Torque 8 5 N m 87 kgf cm 75 in lbf 10 INSTALL REAR CASE a Apply FIPG to the rear case as shown in the illustration FIPG Part No 08826 00090 THREE BOND 1281 or equiva lent b Install the rear case to the middle case with the 10 bolts and 3 clamps Torque 40 N m 408 kgf cm 30 ft lbf c Install the lock ball pin sprin...

Page 2269: ...ng torque and note it down f Using SST tighten the nut Torque Reference 220 N m 2 240 kgf cm 162 ft lbf SST 09922 10010 g Shift to fifth gear measure the starting torque and note it down h Make sure that the difference between the values mea sured at steps e and g is within the specified range Preload at starting 0 45 to 1 35 N m 4 59 to 13 77 kgf cm 3 98 to 11 95 in lbf If the result is not as sp...

Page 2270: ... a snap ring expander install the snap ring 13 INSTALL EXTENSION HOUSING a Apply FIPG to the extension housing as shown in the il lustration FIPG Part No 08826 00090 THREE BOND 1281 or equiva lent b Install the extension housing and shift lever housing to the rear case with the 8 bolts and clamp Torque 29 N m 296 kgf cm 21 ft lbf c Install the bolt to the shift lever housing Torque 33 N m 340 kgf ...

Page 2271: ...the 4 bolts Torque 20 N m 204 kgf cm 15 ft lbf 15 INSTALL PLUG Install the plug to the clutch housing Torque 39 N m 397 kgf cm 29 ft lbf 16 INSTALL SPEEDOMETER DRIVEN GEAR a Install a new O ring to the speedometer shaft sleeve b Install the speedometer driven gear to the speedometer sensor with the clip NOTICE Make sure to install the clip in the direction shown in the illustration c Install the s...

Page 2272: ...77 kgf cm 27 ft lbf 19 INSTALL FILLER PLUG Install a new gasket and the filler plug Torque 37 N m 377 kgf cm 27 ft lbf 20 INSTALL RELEASE FORK SUPPORT Install the release fork support to the clutch housing Torque 47 N m 480 kgf cm 35 ft lbf 21 INSTALL BACK UP LAMP SWITCH Using SST install the back up lamp switch SST 09817 16011 Torque 44 N m 449 kgf cm 32 ft lbf ...

Page 2273: ...g Key Hub Sleeve Spacer Synchronizer Ring Set No 3 3rd Gear 3rd Gear Thrust Washer Pin 6th Gear Snap Ring Ring Snap Ring Needle Roller Bearing Snap Ring Needle Roller Bearing Synchronizer Ring No 3 Ball Spring Synchromesh Shifting Key Clutch Hub No 3 Hub Sleeve Apply gear oil Outer Middle Inner MT 30 MANUAL TRANSMISSION RA60 INPUT SHAFT INPUT SHAFT COMPONENTS ...

Page 2274: ...193 2 INSPECT EACH GEAR RADIAL CLEARANCE Using a dial indicator measure the clearance between the gear and the shaft with the needle roller bearing installed Standard gear radial clearance Gear Radial Clearance mm in 3rd and 4th 0 015 to 0 067 0 00059 to 0 00264 6th 0 015 to 0 065 0 00059 to 0 00256 If necessary replace the gear needle roller bearing or shaft 3 REMOVE 6TH GEAR a Using 2 screwdrive...

Page 2275: ...der remove the snap ring b Remove the 3rd gear thrust washer and pin c Remove the 3rd gear synchronizer ring set No 3 needle roller bearing and spacer 5 REMOVE 4TH GEAR a Using a snap ring expander remove the snap ring b Using SST and a press remove the clutch hub No 2 hub sleeve synchronizer ring and 4th gear SST 09950 00020 c Remove the needle roller bearing ...

Page 2276: ...ng 2 screwdrivers and a hammer remove the snap ring b Using SST and a press remove the input shaft bearing SST 09950 00020 7 REMOVE CLUTCH HUB NO 2 AND NO 3 Remove the clutch hub 3 synchromesh shifting keys 3 balls and 3 springs from the hub sleeve HINT Be careful not to scatter the balls or springs Use the same procedures to remove the clutch hub No 2 and No 3 ...

Page 2277: ... the synchro nizer ring set No 3 b Coat the 3rd gear cone with gear oil Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone Check that the ring locks 2 INSPECT SYNCHRONIZER RING NO 3 a Using a feeler gauge measure the clearance between the synchronizer ring No 3 and the 4th gear Standard clearance 0 70 to 1 50 mm ...

Page 2278: ...ng it against the 6th gear cone Check that the ring locks 4 INSPECT HUB SLEEVE a Using a vernier caliper measure the width of the groove of the hub sleeve A and thickness of both the gear shift forks No 2 and No 3 B as shown in the illustration Width of the groove of the hub sleeve A 10 5 to 10 6 mm 0 4134 to 0 4173 in Thickness of the gear shift fork B 9 76 to 10 24 mm 0 3843 to 0 4031 in b Calcu...

Page 2279: ...7 to 32 980 1 2979 to 1 2984 Minimum Part Outside diameter mm in A 34 002 1 3387 B 44 985 1 7711 C 44 985 1 7711 D 41 985 1 6530 E 32 967 1 2979 If the diameter is less than the minimum replace the input shaft 6 INSPECT 3RD GEAR Using a cylinder gauge measure the inside diameter of the gear Standard inside diameter 51 015 to 51 040 mm 2 0085 to 2 0094 in Maximum inside diameter 51 040 mm 2 0094 in...

Page 2280: ... 2 0085 to 2 0094 in Maximum inside diameter 51 040 mm 2 0094 in If the inside diameter exceeds the maximum replace the 6th gear 9 INSPECT 3RD GEAR THRUST WASHER Using a micrometer measure the thrust washer thickness Standard thickness 7 12 to 7 18 mm 0 2803 to 0 2827 in Minimum thickness 7 12 mm 0 2803 in If the thickness is less than the minimum replace the 3rd gear thrust washer ...

Page 2281: ...bearing is installed in the direction shown in the illustration b Select a snap ring that allows for the minimum amount of axial play Standard clearance 0 1 mm 0 0039 in or less Mark Thickness mm in A 2 65 to 2 70 0 1043 to 0 1063 B 2 70 to 2 75 0 1063 to 0 1083 C 2 75 to 2 80 0 1083 to 0 1102 D 2 80 to 2 85 0 1102 to 0 1122 E 2 85 to 2 90 0 1122 to 0 1142 F 2 90 to 2 95 0 1142 to 0 1161 c Using a...

Page 2282: ...e pushing down the balls NOTICE Be careful not to scatter the balls HINT Make sure that the clutch hub No 2 is installed in the direction shown in the illustration 3 ASSEMBLE CLUTCH HUB NO 3 a Apply gear oil to the clutch hub sleeve and clutch hub b Install the clutch hub sleeve to the clutch hub No 3 c Install the 3 shifting keys to the clutch hub d Install the 3 shifting key springs to the clutc...

Page 2283: ...he input shaft SST 09308 14010 HINT Make sure that the protruding part on the synchronizer ring is fitted into the notch or the clutch hub e Make sure that the gear and synchronizer ring move smoothly f Select a snap ring that allows for the minimum amount of axial play Standard clearance 0 1 mm 0 0039 in or less Mark Thickness mm in A 1 77 to 1 82 0 0697 to 0 0717 B 1 82 to 1 87 0 0717 to 0 0736 ...

Page 2284: ...stall the spacer to the input shaft 5 INSTALL 3RD GEAR a Apply gear oil to the needle roller bearing and 3rd gear ta per cone b Install the synchronizer ring set No 3 to the clutch hub No 2 c Install the needle roller bearing and 3rd gear to the input shaft d Install the pin and 3rd gear thrust washer to the input shaft ...

Page 2285: ... 0835 B 2 12 to 2 17 0 0835 to 0 0854 C 2 17 to 2 22 0 0854 to 0 0874 D 2 22 to 2 27 0 0874 to 0 0894 E 2 27 to 2 32 0 0894 to 0 0913 F 2 32 to 2 37 0 0913 to 0 0933 f Using a snap ring expander install the snap ring 6 INSTALL 6TH GEAR a Apply gear oil to the needle roller bearing and 6th gear ta per cone b Install the ring needle roller bearing and 6th gear to the input shaft c Install the synchr...

Page 2286: ...ve smoothly f Select a snap ring that allow for the minimum amount of axial play Standard clearance 0 1 mm 0 0039 in or less Mark Thickness mm in A 2 10 to 2 15 0 0827 to 0 0846 B 2 15 to 2 20 0 0846 to 0 0866 C 2 20 to 2 25 0 0866 to 0 0886 D 2 25 to 2 30 0 0886 to 0 0906 E 2 30 to 2 35 0 0906 to 0 0925 F 2 35 to 2 40 0 0925 to 0 0945 G 2 40 to 2 45 0 0945 to 0 0965 g Using a brass bar and hammer...

Page 2287: ...MT0HY 01 D14074 Needle Roller Bearing Synchronizer Ring Output Shaft Output Shaft Bearing Non reusable part Apply gear oil MT 44 MANUAL TRANSMISSION RA60 OUTPUT SHAFT OUTPUT SHAFT COMPONENTS ...

Page 2288: ...078 SST MANUAL TRANSMISSION RA60 OUTPUT SHAFT MT 45 DISASSEMBLY 1 REMOVE SYNCHRONIZER RING 2 REMOVE NEEDLE ROLLER BEARING 3 REMOVE OUTPUT SHAFT BEARING Using SST and a press remove the output shaft bearing SST 09950 00020 ...

Page 2289: ...ace the output shaft 2 INSPECT SYNCHRONIZER RING a Using a feeler gauge measure the clearance between the synchronizer ring and the gear spline Standard clearance 0 70 to 1 50 mm 0 0276 to 0 0591 in Minimum clearance 0 70 mm 0 0276 in If the clearance is less than the minimum replace the synchro nizer ring b Coat the output shaft and synchronizer ring cone with gear oil Check the braking effect of...

Page 2290: ...g SST and a press install a new output shaft bearing to the output shaft SST 09710 20010 09710 06060 09950 60010 09951 00650 b Apply grease to the output shaft bearing 2 INSTALL NEEDLE ROLLER BEARING 3 INSTALL SYNCHRONIZER RING a Apply gear oil to the synchronizer ring b Install the synchronizer ring to the output shaft ...

Page 2291: ...ne 1st Gear Ball Spring Synchromesh Shifting Key Clutch Hub Sleeve 2nd Gear Counter Shaft Non reusable part Needle Roller Bearing Synchronizer Ring Set No 1 Needle Roller Bearing Snap Ring Synchronizer Ring Set No 1 Needle Roller Bearing Inner Race Snap Ring Inner Middle Outer Inner Middle Outer Clutch Hub No 1 Apply gear oil Ball MT 48 MANUAL TRANSMISSION RA60 COUNTER GEAR COUNTER GEAR COMPONENTS...

Page 2292: ...EACH GEAR RADIAL CLEARANCE Using a dial indicator measure the clearance between the gear and the shaft with the needle roller bearing installed Standard gear radial clearance Gear Radial Clearance mm in 1st and 2nd 0 015 to 0 067 0 00059 to 0 00264 Reverse 0 015 to 0 065 0 00059 to 0 00256 If necessary replace the gear needle roller bearing or shaft 3 REMOVE NEEDLE ROLLER BEARING INNER RACE a Usin...

Page 2293: ...g reverse gear bearing inner race needle roller bearing and reverse gear SST 09950 00020 c Remove the ball from the counter shaft 5 REMOVE HUB SLEEVE Remove the hub sleeve 2 shifting keys key spring and reverse synchronizer ring from the reverse gear spline 6 REMOVE 1ST GEAR a Using SST and a press remove the reverse gear spline and 1st gear SST 09950 00020 b Remove the needle roller bearing ...

Page 2294: ...AR a Using a snap ring expander remove the snap ring b Using SST and a press remove the clutch hub No 1 and 2nd gear SST 09950 00020 c Remove the needle roller bearing d Remove the synchronizer ring set No 1 from the 2nd gear 8 DISASSEMBLE CLUTCH HUB NO 1 Remove the hub sleeve 3 synchromesh shifting keys 3 balls and 3 springs from the clutch hub No 1 HINT Be careful not to scatter the balls or spr...

Page 2295: ...less than the minimum replace the synchro nizer ring set No 1 b Coat the 1st gear cone with gear oil Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it against the 1st gear cone Check that the ring locks 2 INSPECT SYNCHRONIZER RING SET NO 2 a Using a feeler gauge measure the clearance between the synchronizer ring set No 1 and the 2nd gea...

Page 2296: ...brak ing effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it against the reverse gear cone Check that the ring locks 4 INSPECT HUB SLEEVE a Using a vernier caliper measure the width of the groove of the hub sleeve A and thickness of both the gear shift forks No 1 and No 4 B as shown in the illustration Width of the groove of the hub sleeve A No 1 11 95 to 1...

Page 2297: ...nal surface Standard Part Outside diameter mm in A 34 002 to 34 015 1 3387 to 1 3392 B 36 985 to 37 000 1 4561 to 1 4567 C 47 985 to 48 000 1 8892 to 1 8898 D 53 985 to 54 000 2 1254 to 2 1260 E 34 002 to 34 015 1 3387 to 1 3392 Minimum Part Outside diameter mm in A 34 002 1 3387 B 36 985 1 4561 C 47 985 1 8892 D 53 985 2 1254 E 34 002 1 3387 If the diameter is less than the minimum replace the co...

Page 2298: ...3628 to 2 3638 in Maximum inside diameter 60 040 mm 2 3638 in If the inside diameter exceeds the maximum replace the 2nd gear 8 INSPECT REVERSE GEAR Using a cylinder gauge measure the inside diameter of the gear Standard inside diameter 51 015 to 51 040 mm 2 0085 to 2 0094 in Maximum inside diameter 51 040 mm 2 0094 in If the inside diameter exceeds the maximum replace the re verse gear ...

Page 2299: ...b e Place the balls on the holes on the shifting keys and install the hub sleeve while pushing down the balls NOTICE Be careful not to scatter the balls 2 INSTALL 2ND GEAR a Apply gear oil to the needle roller bearing and 2nd gear taper cone b Install the needle roller bearing 2nd gear and synchroniz er ring set No 1 to the counter shaft c Using SST and a press install the clutch hub No 1 SST 0930...

Page 2300: ...98 to 0 0917 B 2 33 to 2 38 0 917 to 0 0937 C 2 38 to 2 43 0 0937 to 0 0957 D 2 43 to 2 48 0 0957 to 0 0976 E 2 48 to 2 53 0 0976 to 0 0996 F 2 53 to 2 58 0 0996 to 0 1016 G 2 58 to 2 63 0 1016 to 0 1035 f Using a snap ring expander install the snap ring 3 INSTALL 1ST GEAR a Apply gear oil to the needle roller bearing and 1st gear ta per cone b Install the needle roller bearing synchronizer ring s...

Page 2301: ...VERSE GEAR a Install the key spring and 2 shifting keys to the reverse gear HINT Face the grooves on the shifting keys towards the reverse gear Face the claws on the key spring towards the reverse gear Make sure that the key spring is positioned as shown in the illustration b Install the hub sleeve to the reverse gear 5 INSTALL REVERSE GEAR a Apply gear oil to the needle roller bearing and reverse...

Page 2302: ...6041 HINT Make sure that the bearing is installed in the direction shown in the illustration b Select a snap ring that allows for the minimum amount of axial play Standard clearance 0 1 mm 0 0039 in or less Mark Thickness mm in A 2 35 to 2 40 0 0925 to 0 0945 B 2 40 to 2 45 0 0945 to 0 0965 C 2 45 to 2 50 0 0965 to 0 0984 D 2 50 to 2 55 0 0984 to 0 1004 E 2 55 to 2 60 0 1004 to 0 1024 F 2 60 to 2 ...

Page 2303: ...andard clearance 0 1 mm 0 0039 in or less Mark Thickness mm in A 2 35 to 2 40 0 0925 to 0 0945 B 2 40 to 2 45 0 0945 to 0 0965 C 2 45 to 2 50 0 0965 to 0 0984 D 2 50 to 2 55 0 0984 to 0 1004 E 2 55 to 2 60 0 1004 to 0 1024 F 2 60 to 2 65 0 1024 to 0 1043 G 2 65 to 2 70 0 1043 to 0 1063 H 2 70 to 2 75 0 1063 to 0 1083 J 2 75 to 2 80 0 1083 to 0 1102 K 2 80 to 2 85 0 1102 to 0 1122 L 2 85 to 2 90 0 ...

Page 2304: ...n No 1 Interlock Pin No 2 Interlock Pin No 3 Slotted Pin Spring Ball Slotted Pin Slotted Pin Shift Select Lever Shaft Lock Ball Pin Shift Select Lever Shift Select Lever Cam Spring E ring Shift Arm Pivot Shift Arm 19 5 200 14 19 5 200 14 33 340 25 N m kgf cm ft lbf Specified torque Non reusable part Interlock Bracket E ring MANUAL TRANSMISSION RA60 CONTROL SHAFT ASSEMBLY MT 61 CONTROL SHAFT ASSEMB...

Page 2305: ...HIFT FORK SHAFT NO 3 Remove the shift fork shaft No 3 ball spring interlock pin No 2 and interlock pin No 3 3 REMOVE SHIFT FORK SHAFT NO 2 Remove the shift fork shaft No 2 ball spring interlock pin No 2 and interlock pin No 3 4 REMOVE SHIFT HEAD NO 1 a Using a pin punch 5 mm 0 20 in and hammer tap out the slotted pin b Remove the shift fork shaft No 1 ball spring shift head No 1 and interlock pin ...

Page 2306: ... mm 0 20 in and hammer tap out the slotted pin b Remove the shift head No 2 and shift fork No 1 6 REMOVE SHIFT FORK NO 4 a Using a pin punch 5 mm 0 20 in and hammer tap out the slotted pin b Remove the shift fork No 4 7 REMOVE SHIFT FORK SHAFT NO 4 Remove the shift fork shaft No 4 ball and spring 8 REMOVE SHIFT ARM a Using a screwdriver remove the E ring ...

Page 2307: ...EMBLY b Remove the shift arm pivot and shift arm 9 REMOVE SHIFT SELECT LEVER a Remove the bolt from the shift select lever b Using a screwdriver remove the E ring c Remove the shift select lever cam shift select lever lock ball pin and spring from the shift select shaft ...

Page 2308: ...l the shift select lever shaft to the shift select le ver and shift select lever cam d Install a new E ring to the shift select lever shaft e Install the bolt to the shift select lever Torque 33 N m 340 kgf cm 25 ft lbf 2 INSTALL SHIFT ARM a Install the shift arm and shift arm pivot to the interlock bracket b Install a new E ring to the shift arm pivot 3 INSTALL SHIFT FORK SHAFT NO 4 a Install the...

Page 2309: ... a Apply MP grease to the interlock pin No 1 and install it to the interlock bracket b Install the spring and ball to the interlock bracket c Install the shift fork shaft No 1 to the interlock bracket HINT Make sure that the shift fork shaft No 4 is in the neutral position 7 INSTALL SHIFT HEAD NO 1 a Install the shift head No 1 to the shift fork shaft No 1 b Using a pin punch 5 mm 0 20 in and hamm...

Page 2310: ...ll them to the interlock bracket b Install the spring and ball to the interlock bracket c Install the shift fork shaft No 1 to the interlock bracket HINT Make sure that the shift fork shaft No 1 No 2 and No 4 are in the neutral position 10 INSTALL SHIFT FORK NO 2 AND NO 3 Install the shift fork No 2 and No 3 with 2 new bolts Torque 19 5 N m 200 kgf cm 14 ft lbf ...

Page 2311: ...TOMATIC TRANSMISSION A750E A750F AUTOMATIC TRANSMISSION SYSTEM AT 1 AUTOMATIC TRANSMISSION SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the precautions in the IN section ...

Page 2312: ...B3 Brake No 1 B1 Brake No 2 B2 One way Clutch No 3 F3 Brake No 4 B4 Shift Solenoid Valve SLT Shift Solenoid Valve SL1 Shift Solenoid Valve S1 Shift Solenoid Valve S2 Shift Solenoid Valve SR Shift Solenoid Valve SL2 Shift Solenoid Valve SLU AT 2 AUTOMATIC TRANSMISSION A750E A750F AUTOMATIC TRANSMISSION SYSTEM OPERATION ...

Page 2313: ... 3rd 1st 1st S1 C1 C2 B1 B2 B3 B4 F3 F1 F2 Operates Gear Position Shift Lever Position 2nd 2nd 2nd 3rd 3rd R N D D O D OFF 3 2 L P S2 SR SL2 C3 SLU F1 F2 F3 Operates only when driving AUTOMATIC TRANSMISSION A750E A750F AUTOMATIC TRANSMISSION SYSTEM AT 3 ...

Page 2314: ... Remove the refill plug and overflow plug b Fill the transmission through the refill hole until fluid be gins to trickle out of the overflow tube c Reinstall the overflow plug 3 TRANSMISSION FILL a Fill the transmission with the correct amount of fluid as listed in the table below b Reinstall the refill plug to avoid fluid splash Repair Fill Amount Transmission hose and pipe removal 0 6 L 0 63 US ...

Page 2315: ...ls using SST SST 09843 18040 2 Move the shift lever back and forth between N and D at 1 5 seconds interval for six seconds 3 The A T OIL TEMP indicator comes on for two se conds when the combination meter starts to detect the fluid temperature 4 The A T OIL TEMP indicator comes on again when the fluid temperature reaches 46 C 115 F and blinks when it exceeds 56 C 130 F 5 Allow the engine to idle u...

Page 2316: ...e c Remove the refill plug d Add 0 4 liters 0 42 US qts 0 35 lmp qts of fluid e Allow the engine to idle and wait for 10 seconds f Proceed to step 6 8 COMPLETE a Install the overflow plug with a new gasket Torque 20 N m 205 kgf cm 15 ft lbf b Stop the engine c Install the refill plug with a new gasket Torque 39 N m 400 kgf cm 29 ft lbf ...

Page 2317: ...new gasket and the drain plug Torque 20 N m 204 kgf cm 15 ft lbf 2 REMOVE PROPELLER SHAFT See page PR 3 3 REMOVE REAR OIL SEAL NOTICE Clean the extension housing before removing the oil seal Using SST remove the oil seal SST 09308 10010 4 INSTALL OIL SEAL a Using SST and a hammer carefully drive a new oil seal in until it stops SST 09325 40010 b Coat the lip of the oil seal with MP grease 5 INSTAL...

Page 2318: ... NT AND SP2 CON NECTOR 2 REMOVE SPEED SENSOR NT AND SP2 a Remove the 2 bolts speed sensors NT and SP2 b Remove the 2 O rings from the speed sensors NT and SP2 3 INSTALL SPEED SENSOR NT AND SP2 a Coat 2 new O rings with ATF and install them to the speed sensors NT and SP2 b Install the speed sensors NT and SP2 with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf 4 CONNECT SPEED SENSOR NT AND SP2 CON...

Page 2319: ...en sors c Disconnect the transmission wire connector d Remove the bolt and the transmission wire harness 5 INSTALL ATF TEMPERATURE SENSOR a Install the transmission wire harness b Install the bolt Torque 5 4 N m 55 kgf cm 48 in lbf c Connect the transmission wire connector d Connect the 7 solenoid valve connectors e Install the 2 ATF temperature sensors and clamps to the valve body with the 2 bolt...

Page 2320: ...INSTALL OIL PAN HINT Remove any packing material and be careful not to spill oil on the contacting surfaces of the transmission case and the oil pan Using a new gasket install the oil pan with the 20 bolts Torque 4 4 N m 45 kgf cm 39 in lbf 8 FILL TRANSMISSION See page AT 4 ...

Page 2321: ...lock washer and remove the nut b Remove the bolt and park neutral position switch 3 INSTALL PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch with the bolt Torque 13 N m 130 kgf cm 10 ft lbf b Install a new lock washer and the nut Torque 6 9 N m 70 kgf cm 61 in lbf c Bend the claws on the lock washer to stake the nut d Adjust the park neutral position switch See page DI 952 o...

Page 2322: ...lts b Remove the oil pan gasket 3 EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel par ticles Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission Steel magnetic bearing gear and clutch plate wear Brass non magnetic bushing wear 4 REMOVE OIL STRAINER Remove the 4 bolts the oil ...

Page 2323: ...nd SLU e Remove the shift solenoid valves SL1 and SLT f Remove the O ring from the solenoid valve S2 8 INSTALL SOLENOID VALVE a Install a new O ring to the shift solenoid valve S2 b Install the shift solenoid valves SL1 and SLT c Install the shift solenoid valves SL2 and SLU d Install the 4 straight pins and the 2 solenoid lock plates with the 2 bolts Torque 6 4 N m 65 kgf cm 57 in lbf e Install t...

Page 2324: ...perly check the wire harness color prior to installation Torque A 11 N m 112 kgf cm 8 ft lbf B 10 N m 100 kgf cm 7 ft lbf Bolt length Bolt A 36 mm 1 42 in Bolt B 12 mm 0 47 in Sensor wire harness Wire harness Color for linear control Orange for oil temp warning lamp Blue 11 INSTALL OIL STRAINER a Install a new O ring b Install the oil strainer with the 4 bolts Torque 10 N m 100 kgf cm 7 ft lbf 12 ...

Page 2325: ...racket 3 REMOVE PARKING LOCK ROD 4 REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 5 REMOVE PARKING LOCK PAWL AND SHAFT 6 INSTALL PARKING LOCK PAWL AND SHAFT 7 INSTALL SPRING TO PARKING LOCK PAWL SHAFT 8 INSTALL PARKING LOCK PAWL BRACKET Install the parking lock pawl bracket with the 3 bolts HINT Push the lock rod fully forward Check that the parking lock pawl operates smoothly Torque 7 4 N m 75 kgf cm...

Page 2326: ...il Cooler 11 115 8 4 9 50 43 in lbf 5 0 50 48 in lbf Clip Clip Clip Grommet Grommet Condenser Mounting Insulator 11 115 8 Hose Hose Grommet Condenser Mounting Insulator AT 16 AUTOMATIC TRANSMISSION A750E A750F AIR COOLED OIL COOLER Towing Package Spec AIR COOLED OIL COOLER Towing Package Spec COMPONENTS ...

Page 2327: ...3 bolts and oil cooler Torque 11 N m 115 kgf cm 8 ft lbf b Remove the bolt transmission oil cooler bracket and grommet Torque 4 9 N m 50 kgf cm 43 in lbf c Remove the 2 grommets and condenser mounting insula tors 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 N m 50 kgf cm 48 in lbf c Loosen the 2 clips and...

Page 2328: ... 18 AUTOMATIC TRANSMISSION A750E A750F AIR COOLED OIL COOLER Towing Package Spec INSTALLATION Installation is in the reverse order of removal See page AT 17 HINT After installation check fluid level See page AT 4 ...

Page 2329: ...st Torx Screw 35 360 26 35 360 26 8 0 82 71 in lbf 26 260 19 26 260 19 8 8 90 78 in lbf 50 500 35 8 8 90 78 in lbf Hood Lock Release Lever 8 0 82 71 in lbf No 2 lntermediate Shaft Assembly Brake Pedal Return Spring Column Upper Cover N m kgf cm ft lbf Specified torque Steering Wheel Lower No 3 Cover Steering Wheel Lower No 2 Cover 35 360 26 Sliding Yoke Double Cab AUTOMATIC TRANSMISSION A750E A750...

Page 2330: ...column Column Lower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel No 2 Universal Joint Assembly No 2 Intermediate Shaft Assembly No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Hood Lock Release Lever Transmission Control Cable Assembly Sliding Yoke 35 360 26 Torx Screw Torx Screw AT 20 AUTOMATIC...

Page 2331: ...steering column Column Lower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel No 2 Universal Joint Assembly No 2 Intermediate Shaft Assembly No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Hood Lock Release Lever Transmission Control Cable Assembly Sliding Yoke 35 360 26 Torx Screw AUTOMATIC TRANSMI...

Page 2332: ...g Shift Lever Steering Column Assembly 10 5 110 8 2 2 23 19 in lbf 2 9 29 25 in lbf 12 120 9 Parking Lock Cable Housing 18 180 13 Parking Lock Cable No 2 Parking Lock Cable No 1 MP grease Non reusable part AT 22 AUTOMATIC TRANSMISSION A750E A750F COLUMN SHIFT ASSEMBLY ...

Page 2333: ...emove 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 4 REMOVE SHIFT LEVER HOUSING Using a torx socket wrench remove the 3 torx screws and shift lever housing ...

Page 2334: ...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 N m 29 kgf cm 25 in lbf d Wire the cable No 1 and No 2 as shown in the illustra tion e Temporarily install the cable housing to steering column assembly with 2 new bolts NOTICE Be careful not to bend or twist the cable abnormally f After installation conf...

Page 2335: ...al 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 N m 110 kgf cm 8 ft lbf 6 CONFIRM SHIFT LOCK SYSTEM OPERATION a Only when the brake pedal is engaged and the ignition key is not in the LOCK position the shift lever can be shifted f...

Page 2336: ...g Insulator Gasket Crossmember Front Exhaust Pipe LH Torque Converter Clutch x6 48 490 35 43 440 32 48 490 35 Gasket 40 408 30 40 408 30 Manifold Stay Front Exhaust Pipe RH Gasket Spring Manifold Stay Exhaust Pipe Support Gasket 62 630 46 62 630 46 40 410 30 37 377 27 88 897 65 Stabilizer Bar Bushing Stabilizer Bar Bracket No 1 Engine Under Cover Propeller Shaft 9 8 100 7 37 377 27 AT 26 AUTOMATIC...

Page 2337: ... JACK UP VEHICLE 3 REMOVE NO 1 ENGINE UNDER COVER 4 DRAIN AUTOMATIC TRANSMISSION FLUID a Remove the drain plug and gasket and drain the ATF b Install a new gasket and the drain plug Torque 20 N m 204 kgf cm 15 ft lbf 5 REMOVE RH AND LH FRONT EXHAUST PIPE See page EM 138 6 REMOVE PROPELLER SHAFT See page PR 3 7 DISCONNECT SPEED SENSOR NT AND SP2 CON NECTORS 8 DISCONNECT TRANSMISSION WIRE CONNECTOR ...

Page 2338: ...N m 148 kgf cm 11 ft lbf b Remove the 2 bolts and shift control cable bracket from the transmission Torque 19 5 N m 199 kgf cm 14 ft lbf 11 DISCONNECT OIL COOLER PIPE a Remove the bolt and clamp Torque 12 N m 122 kgf cm 9 ft lbf b Disconnect the 2 oil cooler pipes SST 09023 12701 Torque 34 N m 346 kgf cm 25 ft lbf 12 DISCONNECT STABILIZER BAR a Remove the 2 bolts nuts and stabilizer bar with the b...

Page 2339: ...nkshaft to gain access and remove the 6 bolts while holding the crankshaft pulley set bolt with a wrench Torque 48 N m 490 kgf cm 35 ft lbf HINT At the time of installation refer to the following First install the green colored bolt and then the remaining 5 bolts 15 JACK UP TRANSMISSION SLIGHTLY Securely support the transmission on a transmission jack Lift the transmission slightly from the crossm...

Page 2340: ...NSULATOR Remove the 4 bolts and engine rear mounting insulator from the transmission Torque 65 N m 660 kgf cm 48 ft lbf 18 REMOVE TRANSMISSION a Separate the wire harness from the transmission b Lower the rear end of the transmission c Remove the 9 bolts and transmission Torque 17 mm head 71 N m 724 kgf cm 52 ft lbf 14 mm head 37 N m 377 kgf cm 27 ft lbf ...

Page 2341: ...he converter fitting part of the drive plate c Using vernier calipers and a straight edge measure di mension B shown in the illustration and check that B is greater than A measured in step b Standard distance A 1 mm 0 04 in or more 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR See page AT 39 3 TRANSMISSION INSTALLATION a Installation is in the reverse order of removal See page AT 27 b Adjust ...

Page 2342: ...ngine Under Cover 40 410 30 88 897 65 18 185 13 Crossmember 72 734 53 65 660 48 Engine Rear Mounting Insulator 14 5 148 11 19 5 199 14 Shift Control Cable 37 377 27 Gasket Front Exhaust Pipe LH Rear End Plate 18 185 13 Gasket 62 630 46 62 630 46 48 490 35 32 326 24 Clamp Gasket Propeller Shaft 12 122 9 Gasket Double Cab 88 897 65 AT 32 AUTOMATIC TRANSMISSION A750E A750F AUTOMATIC TRANSMISSION UNIT...

Page 2343: ... 46 Gasket Front Exhaust Pipe RH 48 490 35 Gasket 62 630 46 Clamp Gasket 32 326 24 37 377 27 Crossmember 72 734 53 65 660 48 Engine Rear Mounting Insulator 19 5 199 14 14 5 148 11 Transmission and Transfer 88 897 65 Rear Propeller Shaft 88 897 65 40 410 30 Front Propeller Shaft 88 897 65 88 897 65 Heat Insulator 16 164 12 Front Exhaust Pipe LH 71 724 52 12 122 9 Gasket AUTOMATIC TRANSMISSION A750E...

Page 2344: ...ve the drain plug and gasket and drain the ATF b Install a new gasket and the drain plug Torque 20 N m 204 kgf cm 15 ft lbf 4 REMOVE RH AND LH FRONT EXHAUST PIPE See page EM 125 5 A750E REMOVE PROPELLER SHAFT See page PR 3 6 A750F REMOVE HEAT INSULATOR Remove the 2 bolts and heat insulator Torque 16 N m 164 kgf cm 12 ft lbf 7 A750F REMOVE FRONT AND REAR PROPELLER SHAFT See page PR 10 8 DISCONNECT ...

Page 2345: ...IFT CONTROL CABLE FROM TRANS MISSION a Remove the nut and disconnect the shift control cable Torque 14 5 N m 148 kgf cm 11 ft lbf b Remove the 2 bolts and shift control cable bracket from the transmission Torque 19 5 N m 199 kgf cm 14 ft lbf 12 DISCONNECT OIL COOLER PIPE a Remove the 3 bolts and clamps Torque 12 N m 122 kgf cm 9 ft lbf b Disconnect the 2 oil cooler pipes SST 09023 12701 Torque 34 ...

Page 2346: ...he crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley set bolt with a wrench Torque 48 N m 490 kgf cm 35 ft lbf HINT At the time of installation refer to the following First install the green colored bolt and then the remaining 5 bolts 15 JACK UP TRANSMISSION SLIGHTLY Securely support the transmission on a transmission jack Lift the transmission slightly from the ...

Page 2347: ... bolts and engine rear mounting insulator Torque 65 N m 660 kgf cm 48 ft lbf 18 REMOVE TRANSMISSION a A750E Separate the wire harness from the transmission b A750F Separate the wire harness from the transmission and transfer c Lower the rear end of the transmission d Remove the 10 bolts and transmission Torque 17 mm head 71 N m 724 kgf cm 52 ft lbf 14 mm head 37 N m 377 kgf cm 27 ft lbf ...

Page 2348: ... converter fitting part of the drive plate c Using vernier calipers and a straight edge measure the dimension B shown in the illustration and check that B is greater than A measured in step b Standard distance A 1 mm 0 04 in or more 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR See page AT 39 3 TRANSMISSION INSTALLATION a Installation is in the reverse order of removal See page AT 34 b Adjust...

Page 2349: ... if it rotates smoothly when turned clockwise and locks when turned counterclockwise If necessary clean the converter clutch and retest the one way clutch Replace the converter clutch if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR a Set up a dial indicator and measure the drive plate runout Maximum runout 0 20 mm 0 0079 in b Check for damage to the ring gear ...

Page 2350: ...move all the old packing FIPG material from gasket surfaces Thoroughly clean all components to remove any loose material Clean both sealing surfaces with a non residue solvent Apply FIPG in approx a 1 mm 0 04 in wide bead along the sealing surface Parts must be assembled within 10 minutes of FIPG application Otherwise the packing materi al must be removed and reapplied ...

Page 2351: ...trol system 9 4WD control ECU 10 Transfer assembly TR 39 BE 86 TR 7 BE 86 TR 39 SA 59 TR 39 TR 6 Shift from 4WD 4HI to 4WD 4LO impossible 1 4LO switch 2 Vehicle speed sensor 3 L4 position switch 4 Park neutral position switch 5 4LO indicator switch 6 Actuator assembly 7 Wire harness 8 4WD control ECU TR 39 BE 86 TR 7 DI 993 BE 86 TR 39 TR 39 Shift from 4WD 4HI to 2WD impossible 1 4WD fuse 2 Wire h...

Page 2352: ...haft Transfer 4WD Position Switch Connector Rear Propeller Shaft Engine Rear Mounting Gasket 88 897 65 62 630 46 Gasket LH Front Exhaust Pipe 62 630 46 Gasket 65 664 48 N m kgf cm ft lbf Specified torque Non reusable part 72 740 53 RH Front Exhaust Pipe Heat Insulator Clamp Clamp 48 489 35 48 489 35 74 750 54 18 185 13 16 163 12 TRANSFER TRANSFER UNIT TR 3 TRANSFER UNIT COMPONENTS ...

Page 2353: ...CROSSMEMBER a Remove the 2 bolts and heat insulator b Support the rear side of the transmission with a transmis sion jack c Remove the 4 bolts d Remove the 4 bolts nuts and crossmember 6 REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine rear mounting from the transfer adaptor 7 DISCONNECT TRANSFER DETECTION SWITCHES AND MOTOR ACTUATOR CONNECTORS See page TR 3 8 REMOVE TRANSFER a Support th...

Page 2354: ...adaptor with the 4 bolts Torque 65 N m 664 kgf cm 48 ft lbf 5 INSTALL CROSSMEMBER a Install the crossmember with the 4 bolts and nuts Torque 72 N m 740 kgf cm 53 ft lbf b Install the 4 bolts Torque 18 N m 185 kgf cm 13 ft lbf c Remove the transmission jacks d Install the heat insulator with the 2 bolts Torque 16 N m 163 kgf cm 12 ft lbf 6 INSTALL FRONT AND REAR PROPELLER SHAFTS See page PR 15 7 IN...

Page 2355: ...ehicle Speed Sensor Drive Gear Extension Housing Ball 12 122 9 37 377 27 Transfer L4 Position Switch 37 377 27 Rear Companion Flange 118 1 203 87 Gasket O Ring Rear Output Shaft Assembly Race Actuator Assembly Snap Ring Gasket Plug 37 377 27 28 285 21 Gasket Plug 37 377 27 Needle Roller Bearing Thrust Bearing Ball 19 190 14 Ball Shift Fork Shaft Stopper Snap Ring Straight Pin 19 190 14 Front Drive...

Page 2356: ...ANGE a Using a chisel and hammer loosen the staked part of the front companion flange lock nut b Using SST hold the front companion flange and remove the front companion flange lock nut SST 09330 00021 c Using SST remove the front companion flange SST 09950 40011 09951 04020 09952 04010 09953 04030 09954 04010 09955 04051 09957 04010 09958 04011 6 REMOVE REAR COMPANION FLANGE Remove the rear compa...

Page 2357: ...ammer tap on the front case and rear case and separate them 10 REMOVE SHIFT FORK SHAFT a Using a hexagon wrench 6 mm remove the 2 straight screw plugs springs and balls from the front drive and high and low shift forks b Using 2 screwdrivers and a hammer tap out the 2 snap rings from the shift fork shaft c Remove the bolt and shift fork shaft stopper ...

Page 2358: ...e Pull out the shift fork shaft f Using a magnetic finger remove the 2 straight pins from the front drive and high and low shift forks 11 REMOVE REAR OUTPUT SHAFT ASSEMBLY DRIVEN SPROCKET ASSEMBLY CHAIN AND FRONT DRIVE AND HIGH AND LOW SHIFT FORKS a Using 2 screwdrivers and a hammer tap out the snap ring from the shift fork shaft of the actuator assembly HINT Remove only the snap ring on the front...

Page 2359: ...rive and high and low shift forks from the rear output shaft assembly 12 REMOVE ACTUATOR ASSEMBLY a Using 2 screwdrivers and a hammer remove the snap ring b Remove the 3 bolts and actuator assembly c Remove the O ring transfer 4WD position switch trans fer L4 position switch and 2 gaskets from the actuator as sembly 13 REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET Remove the 3 bolts and separator ...

Page 2360: ... INPUT SHAFT ASSEMBLY a Using a snap ring expander remove the snap ring b Pull out the planetary gear assembly with the input shaft assembly 17 REMOVE LOW GEAR SPLINE PIECE a Using a screwdriver remove the snap ring b Remove the low gear spline piece 18 REMOVE NEEDLE ROLLER BEARING FROM INPUT SHAFT ASSEMBLY ...

Page 2361: ...R AND THRUST WASHER a Using a snap ring expander remove the snap ring b Remove the input gear stopper ball and thrust washer 20 REMOVE INPUT SHAFT ASSEMBLY THRUST BEAR ING AND RACE 21 REMOVE PLANETARY RING GEAR a Using a screwdriver remove the snap ring b Remove the head screw plug spring and pin ...

Page 2362: ...Q07290 TRANSFER TRANSFER ASSEMBLY TR 13 c Remove the planetary ring gear ...

Page 2363: ... 14 TRANSFER TRANSFER ASSEMBLY INSPECTION INSPECT SWITCH Measure the resistance between the terminals as shown Standard Switch Condition Specified Condition Pushed Below 1 Ω Free 10 k Ω or higher If the result is not as specified replace the switch ...

Page 2364: ...ing c Apply sealant to the head screw plug threads Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent d Install the head screw plug Torque 19 N m 190 kgf cm 14 ft lbf e Using a screwdriver install the snap ring NOTICE Make sure the end gap of the snap ring is not aligned with the upper side of the case 2 INSTALL INPUT SHAFT ASSEMBLY THRUST BEAR ING AND RACE 3 INSTALL THRUST WASH...

Page 2365: ...o 2 45 0 0945 to 0 0965 H 2 45 to 2 50 0 0965 to 0 0984 J 2 50 to 2 55 0 0984 to 0 1004 K 2 55 to 2 60 0 1004 to 0 1024 L 2 60 to 2 65 0 1024 to 0 1043 M 2 65 to 2 70 0 1043 to 0 1063 N 2 70 to 2 75 0 1063 to 0 1083 P 2 75 to 2 80 0 1083 to 0 1102 Q 2 80 to 2 85 0 1102 to 0 1122 R 2 85 to 2 90 0 1122 to 0 1142 S 2 90 to 2 95 0 1142 to 0 1161 T 2 95 to 3 00 0 1161 to 0 1181 U 3 00 to 3 05 0 1181 to...

Page 2366: ... carrier 6 INSTALL PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY a Install the planetary gear assembly with the input shaft assembly HINT If necessary heat the front case to about 50 to 80 C 122 to 176 F b Using a snap ring expander install the snap ring HINT Check that the planetary gear and input shaft assembly turn slightly 7 INSTALL OIL PUMP DRIVE GEAR 8 INSTALL OIL PUMP BODY ASSEMBLY Inst...

Page 2367: ...er drive in the snap ring to the shift fork shaft of the actuator assembly HINT Install only the snap ring on the rear side of the shift fork shaft 11 INSTALL REAR OUTPUT SHAFT ASSEMBLY DRIVEN SPROCKET ASSEMBLY CHAIN AND FRONT DRIVE AND HIGH AND LOW SHIFT FORKS a Install the driven sprocket assembly chain and front drive and high and low shift forks to the rear output shaft as sembly NOTICE Make s...

Page 2368: ...actuator assembly HINT Check that the rear output shaft assembly and driven sprocket assembly turn slightly 12 INSTALL SHIFT FORK SHAFT a Using a magnetic finger install the 2 straight pins to the front drive and high and low shift forks b To push into the shift fork shaft shift the front drive and high and low shift forks to the positions as shown in the illustration c Push into the shift fork sh...

Page 2369: ...hexagon wrench 6 mm install the 2 straight screw plugs to the front drive and high and low shift forks Torque 19 N m 190 kgf cm 14 ft lbf 13 REASSEMBLE FRONT AND REAR CASE HINT Remove any FIPG material and be careful not to drop oil on the contacting surface of the rear case a Apply FIPG to the rear case as shown in the illustration FIPG Part No 08826 00090 THREE BOND 1281 or equivalent b Install ...

Page 2370: ...alent c Install the extension housing with the 5 bolts Torque 12 N m 122 kgf cm 9 ft lbf 16 INSTALL FRONT COMPANION FLANGE a Install the front companion flange to the input shaft b Using SST hold the front companion flange and install a new front companion flange lock nut SST 09330 00021 Torque 118 N m 1 203 kgf cm 87 ft lbf c Stake the front companion flange lock nut 17 INSTALL REAR COMPANION FLA...

Page 2371: ...he bolt threads Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Install the front bearing retainer with the 5 bolts Torque 11 5 N m 117 kgf cm 8 ft lbf 20 INSTALL PROTECTOR Install the protector with the 4 bolts Torque 18 N m 184 kgf cm 13 ft lbf Torque 37 N m 380 kgf cm 27 ft lbf 21 INSTALL SPEEDOMETER DRIVEN GEAR HOLE COV ER a Install a new O ring to the speedometer drive...

Page 2372: ...TR00F 09 Q07499 Front Bearing Non reusable part Driven Sprocket Rear Bearing TRANSFER DRIVEN SPROCKET TR 23 DRIVEN SPROCKET COMPONENTS ...

Page 2373: ...MENT 1 REMOVE FRONT BEARING Using a press remove the front bearing 2 REMOVE REAR BEARING Using SST a press and steel bar remove the rear bearing SST 09555 55010 3 INSTALL REAR BEARING Using a press install a new rear bearing 4 INSTALL FRONT BEARING Using a press install a new front bearing ...

Page 2374: ...Hub Rear Output Shaft Ball Snap Ring Needle Roller Bearing Shifting Key Front Drive Clutch Sleeve Drive Sprocket Synchronizer Center Ring Shifting Key Spring Synchronizer Inner Ring Synchronizer Outer Ring Spacer Bearing TRANSFER REAR OUTPUT SHAFT TR 25 REAR OUTPUT SHAFT COMPONENTS ...

Page 2375: ... AND LOW CLUTCH SLEEVE AS SEMBLY a Remove the clutch sleeve b Using a snap ring expander remove the snap ring c Using a press remove the clutch hub 3 REMOVE BEARING SPACER DRIVE SPROCKET SYNCHRONIZER OUTER CENTER AND INNER RINGS AND FRONT DRIVE CLUTCH SLEEVE AS SEMBLY a Using SST and a press remove the bearing SST 09555 55010 b Remove the spacer and ball c Remove the drive sprocket needle roller b...

Page 2376: ...nce 0 010 to 0 055 mm 0 0004 to 0 0022 in Maximum clearance 0 055 mm 0 0022 in If the clearance exceeds the maximum replace the drive sprocket rear output shaft or needle roller bearing 3 INSPECT FRONT DRIVE SHIFT FORK AND CLUTCH SLEEVE CLEARANCE Using a feeler gauge measure the clearance between the front drive shift fork and clutch sleeve Maximum clearance 1 0 mm 0 039 in If the clearance exceed...

Page 2377: ...2 springs NOTICE Install the key springs so that their end gaps are not in line 2 INSTALL SYNCHRONIZER OUTER CENTER AND IN NER RINGS DRIVE SPROCKET SPACER AND BEAR ING a Apply gear oil to the rear output shaft and needle roller bearing b Install the synchronizer outer ring to the rear output shaft NOTICE Align the slots of the synchronizer outer ring with the shift ing keys c Install the synchroni...

Page 2378: ... the synchronizer center ring f Install the spacer and align it with the ball g Using SST and a press install a new bearing with the spacer groove facing the drive sprocket SST 09316 60011 09316 00011 09316 00071 3 INSPECT DRIVE SPROCKET THRUST CLEARANCE Using a feeler gauge measure the drive sprocket thrust clear ance Standard clearance 0 10 to 0 25 mm 0 0039 to 0 0098 in 4 INSERT HIGH AND LOW CL...

Page 2379: ... axial play and install it to the shaft Mark Thickness mm in K 2 00 to 2 05 0 0787 to 0 0807 L 2 05 to 2 10 0 0807 to 0 0827 A 2 10 to 2 15 0 0827 to 0 0846 B 2 15 to 2 20 0 0846 to 0 0866 C 2 20 to 2 25 0 0866 to 0 0886 D 2 25 to 2 30 0 0886 to 0 0906 E 2 30 to 2 35 0 0906 to 0 0925 F 2 35 to 2 40 0 0925 to 0 0945 G 2 40 to 2 45 0 0945 to 0 0965 H 2 45 to 2 50 0 0965 to 0 0984 J 2 50 to 2 55 0 09...

Page 2380: ...TR00L 07 F08802 Oil Seal Ring Input Shaft TRANSFER INPUT SHAFT TR 31 INPUT SHAFT COMPONENTS ...

Page 2381: ... 47 59 mm 1 8736 in If the outer diameter is less than the minimum replace the input shaft b Using a dial indicator measure the inside diameter of the input shaft bushing Maximum inside diameter 39 14 mm 1 5409 in If the inside diameter exceeds the maximum replace the input shaft 3 INSTALL OIL SEAL RING Install the 2 oil seal rings HINT Apply gear oil to the oil seal ring Engage securely to elimin...

Page 2382: ...TR00N 09 Q07455 Snap Ring Outer Bearing Non reusable part Planetary Gear Assembly Inner Bearing TRANSFER PLANETARY GEAR TR 33 PLANETARY GEAR COMPONENTS ...

Page 2383: ...EAR RADIAL CLEARANCE Using a dial indicator measure the planetary pinion gear radial clearance Standard clearance 0 009 to 0 038 mm 0 0004 to 0 0015 in Maximum clearance 0 038 mm 0 0015 in If the clearance exceeds the maximum replace the planetary gear assembly 3 IF NECESSARY REPLACE PLANETARY GEAR OUT ER BEARING a Using a snap ring expander remove the snap ring b Using SST and a press remove the ...

Page 2384: ...30 to 0 0650 5 1 65 to 1 70 0 0650 to 0 0669 e Using a snap ring expander install a snap ring 4 IF NECESSARY REPLACE PLANETARY GEAR INNER BEARING a Using SST remove the bearing SST 09612 65014 09612 01030 09612 01050 NOTICE Engage the claws of the SST securely so that there is no clearance between the inner bearing and planetary gear b Using SST and a press install a new bearing SST 09950 60010 09...

Page 2385: ...ont Bearing Retainer Front Case Rear Companion Flange x 5 Extension Housing Front Companion Flange Non reusable part x 5 Oil Seal Oil Seal Oil Seal Oil Seal Rear Case Oil Seal TR 36 TRANSFER OIL SEAL OIL SEAL COMPONENTS ...

Page 2386: ... in a new oil seal until its surface is flush with the case upper surface SST 09316 60011 09316 00011 c Coat the lip of the oil seal with MP grease 3 IF NECESSARY REPLACE EXTENSION HOUSING OIL SEAL a Using a screwdriver and hammer drive out the oil seal b Using SST and a hammer drive in a new oil seal until its surface is flush with the housing upper surface SST 09554 22010 c Coat the lip of the o...

Page 2387: ...ch 4HI and 4LO Indicator Light Combination Meter A D D Actuator Actuator Assembly Vehicle Speed Sensor Transfer 4WD Position Switch Transfer L4 Position Switch TR 38 TRANSFER TOUCH SELECT 2 4 AND HIGH LOW SYSTEM TOUCH SELECT 2 4 AND HIGH LOW SYSTEM LOCATION ...

Page 2388: ...itching is not completed after 3 seconds of shift op eration the 4HI indicator light will flash 2 INSPECT 4HI 4LO SHIFT a Turn the ignition switch to the ON position b Shift the transmission shift lever in the N position c Turn the 2WD 4HI switch ON d Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the 4LO switch is in the ON position e Check that the 4LO indic...

Page 2389: ...connection Specified condition OFF 1 4 10 kΩ or higher ON 1 4 Below 1 Ω If the result is not as specified replace the center integration panel assembly See page BO 111 4 INSPECT ACTUATOR RESISTANCE a Using an ohmmeter measure the resistance between ter minals 1 and 2 Standard resistance 0 3 to 100 Ω b Using an ohmmeter measure the resistance between ter minals 1 or 2 and body ground Standard resis...

Page 2390: ...er main relay NOTICE Be careful not to touch the neighboring terminals or metal lic parts of the relay housing when connecting b 4HI 2WD shift Connect lines via a relay as shown in the illustration then check that the actuator fork shaft moves from the 4HI to 2WD position c 4HI 4LO shift Connect lines via a relay as shown in the illustration then check that the actuator fork shaft moves from the 4...

Page 2391: ...ng sound dis connect the connector and measure the resistance be tween each terminal HINT When shifting the actuator fork shaft connect the connectors Standard Shift position Tester connection Specified condition 2WD 3 4 3 5 3 6 4 5 4 6 5 6 10 kΩ or higher 10 kΩ or higher 10 kΩ or higher Below 1 Ω 10 kΩ or higher 10 kΩ or higher 4HI 3 4 3 5 3 6 4 5 4 6 5 6 10 kΩ or higher 10 kΩ or higher 10 kΩ or ...

Page 2392: ...ND Ignition switch ON touch select 2 4 switch ON Touch select high low switch OFF ON 10 to 14 1 5 or less F21 23 TL3 F20 6 GND Ignition switch ON touch select 2 4 switch ON 4HI touch select high low switch OFF 4LO touch select high low switch ON 10 to 14 0 88 or less F21 25 TL1 F20 6 GND Ignition switch ON 4HI touch select 2 4 switch ON 2WD touch select 2 4 switch OFF 10 to 14 0 88 or less F20 13 ...

Page 2393: ...3 5 F20 19 IND1 F20 6 GND Ignition switch ON Touch select 2 4 switch ON 1 5 to 3 5 F21 24 TL2 F20 6 GND Ignition switch ON 2WD touch select 2 4 switch OFF 4HI touch select 2 4 switch ON 10 to 14 0 88 or less F20 21 DL2 F20 6 GND Ignition switch ON A D D LOCK FREE 10 to 14 0 5 or less F20 6 GND Body ground Ignition switch OFF Below 1 ...

Page 2394: ...bearing Worn 2 Sleeve yoke spline Worn 3 Spider bearing Worn or stuck PR 5 PR 5 Vibration 1 Transmission extension housing rear bushing Runout 2 Sleeve yoke spline Stuck 3 Propeller shaft Runout 4 Propeller shaft Imbalance PR 5 PR 5 4WD Symptom Suspected Area See page Noise 1 Center support bearing Worn 2 Sleeve yoke spline Worn 3 Spider bearing Worn or stuck PR 12 PR 12 Vibration 1 Transmission e...

Page 2395: ...cer Center Yoke Spider Sleeve Yoke Spider Bearing Snap Ring Spider Propeller Shaft Flange Yoke Spider 40 410 30 88 897 65 See page PR 6 Dust Cover Apply MP grease Spider Bearing Snap Ring Spider Bearing Snap Ring 88 897 65 Double Cab PR 2 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY 2WD PROPELLER SHAFT ASSEMBLY 2WD COMPONENTS ...

Page 2396: ...atchmarks on the differential and propeller shaft flanges b Except Double Cab model Remove the 4 bolts washers and nuts c Double Cab model Remove the 4 nuts and washers d Remove the 2 mounting bolts and center support bearing from the frame crossmember e Pull out the propeller shaft yoke from the transmission f Insert SST in the transmission to prevent oil leakage SST 09325 40010 ...

Page 2397: ... Place matchmarks on the yoke and propeller shaft b Disassemble the center yoke See SPIDER BEARING REPLACEMENT on page PR 17 2 REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE SHAFT a Using a hammer and chisel loosen the staked part of the nut b Clamp the yoke in a vise and remove the spacer and nut c Place matchmarks on the yoke and shaft d Using a brass bar and hammer remove the center yoke dust...

Page 2398: ... in If shaft runout is greater than the maximum replace it 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 the flange while holding the shaft tightly Maximum bearing axial play 0 05 mm 0 0020 in If the spider bearing axial play exceeds the maximum replace the spider bearing See page PR 17 3...

Page 2399: ...rection shown 2 INSTALL CENTER YOKE ON INTERMEDIATE SHAFT a Coat the splines of the intermediate shaft with MP grease b Install the spacer and dust cover c Place the center yoke on the shaft and align the match marks HINT If replacing either the center yoke or intermediate shaft reas semble them so that the front side yoke of the intermediate shaft and the center yoke are facing the same direction...

Page 2400: ...0882 Matchmarks PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY 2WD PR 7 3 CONNECT PROPELLER SHAFT AND INTERMEDIATE SHAFT Assemble the center yoke aligning matchmarks See SPIDER BEARING REPLACEMENT on page PR 17 ...

Page 2401: ...the matchmarks on the flanges and connect the flanges with the 4 bolts washers and nuts e Torque the 4 bolts Torque 88 N m 897 kgf cm 65 ft lbf f Double Cab model Align the matchmarks on the flanges and connect the flanges with the 4 washers and nuts g Torque the 4 nuts Torque 88 N m 897 kgf cm 65 ft lbf 2 ADJUST CENTER SUPPORT BEARING HINT With the vehicle unloaded adjust the center support beari...

Page 2402: ...eller Shaft 88 897 65 Flange Yoke Snap Ring Spider Bearing Spider Spacer Center Support Bearing Intermediate Shaft See page PR 13 74 754 54 Rear Propeller Shaft Sleeve Yoke Snap Ring Spider Bearing Spider Flange Yoke Grease Fitting Grease Fitting Grease Fitting Spacer Companion Flange Apply MP grease 88 897 65 40 410 30 88 897 65 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY 4WD PR 9 PROPELLER SHAFT AS...

Page 2403: ...ks on the transfer and propeller shaft flanges e Remove the 4 nuts and washers f Remove the propeller shaft from the transfer flange 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 pro peller shaft from the transfer flange c Use a rope to suspend the front edge of the propeller shaft d Remove the 2 moun...

Page 2404: ...ks on the flanges b Remove the 4 nuts bolts and washers 2 Rear propeller shaft REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE SHAFT a Using a hammer and chisel loosen the staked part of the nut b Using SST to hold the flange remove the nut and spacer SST 09330 00021 c Place matchmarks on the flange and shaft d Using SST remove the flange from the intermediate shaft SST 09950 30012 09951 03010 09...

Page 2405: ...check the spider bearing axial play by turning the yoke of the flange while holding the shaft tightly Maximum bearing axial play Front propeller shaft 0 05 mm 0 0020 in Rear propeller shaft 0 mm 0 in If the spider bearing axial play exceeds the maximum replace it See page PR 17 3 Rear propeller shaft INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely If the beari...

Page 2406: ...ustration below 1 Rear propeller shaft INSTALL CENTER SUPPORT BEARING ON INTER MEDIATE SHAFT HINT Install the center support bearing in the direction shown 2 Rear propeller shaft INSTALL FLANGE ON INTERMEDIATE SHAFT a Coat the splines of the intermediate shaft with MP grease b Install the spacer c Place the flange on the shaft and align the matchmarks HINT If replacing either the center flange or ...

Page 2407: ...gf cm 60 ft lbf 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 the 4 bolts washers and nuts HINT If replacing either the center flange or intermediate shaft reas sembly it so that the front side flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are fa...

Page 2408: ...anges with the 4 nuts and washers d Torque the 4 nuts Torque 88 N m 897 kgf cm 65 ft lbf 2 INSTALL REAR PROPELLER SHAFT a Align the matchmarks on the propeller shaft and differen tial flanges and connect the flanges with the 4 bolts washers and nuts b Torque the 4 bolts Torque 88 N m 897 kgf cm 65 ft lbf c Temporarily install the center support bearing with the 2 mounting bolts HINT Make sure the ...

Page 2409: ...With the vehicle unloaded adjust the center support bearing to keep the angles as shown Under the same conditions check the center line in the axial direction Adjust the bearing if necessary The center bearing center line and center bearing hous ing center line must be adjusted to within 0 1 0 mm of each other in the vehicle s longitudinal direction with the vehicle unloaded Torque the 2 bolts Tor...

Page 2410: ...es 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 using the same pro cedure c Install the 2 removed bearing outer races to the ...

Page 2411: ... 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 to the yoke d Using SST install the bearing to the spider SST 09332 25010 e Using SST adjust both bearings so that the snap ring grooves are at maximum and are equal in width ...

Page 2412: ...0 0969 to 0 0976 2 28 to 2 30 2 30 to 2 32 2 32 to 2 34 2 34 to 2 36 0 0992to 0 1000 0 0984 to 0 0992 0 0976 to 0 0984 0 0890 to 0 0898 0 0882 to 0 0890 0 0874 to 0 0882 0 0866 to 0 0874 0 0937 to 0 0945 0 0858 to 0 0866 0 0953 to 0 0961 0 0945 to 0 0953 0 0929 to 0 0937 D E 2 54 to 2 56 0 1000to 0 1008 2 56 to 2 58 0 1008to 0 1016 PROPELLER SHAFT SPIDER BEARING PR 19 5 INSTALL SNAP RINGS a Instal...

Page 2413: ...n 1 384 0 0545 b Using a hammer tap the yoke until there is no clearance between the bearing outer race and snap ring 6 CHECK SPIDER BEARING a Check that the spider bearing moves smoothly b Check the spider bearing axial play Maximum bearing axial play 4WD rear propeller shaft 0 mm 0 in 2WD and 4WD front propeller shaft 0 05 mm 0 0020 in HINT Install new spider bearings on the flange side using th...

Page 2414: ...of the grease fittings from the rear No 1 No 2 No 3 No 4 No 5 Sleeve Yoke No 2 No 3 No 4 and No 5 Sleeve Yoke No 1 PROPELLER SHAFT SPIDER BEARING PR 21 When replacing the rear propeller shaft spider on 4WD vehicles be sure that the grease fitting assembly holes are facing in the direction shown in the illustration below ...

Page 2415: ... Shock absorber Worn 4 Suspension parts Worn SA 3 SA 5 SA 65 SA 150 Noise in front differential 1 Oil level Low or wrong grade 2 Excessive backlash between pinion and ring gear 3 Ring pinion or side gear Worn or chipped 4 Pinion shaft bearing Worn 5 Side bearing Worn 6 Differential bearing Loose or worn SA 36 SA 38 SA 38 SA 38 SA 38 SA 38 Oil leak from front differential 1 Oil level Too high or wr...

Page 2416: ...s there steering off center Adjust front tie rods NO YES Is the lead pull stronger than before YES NOTICE Do not exceed 1 of cross camber Do not exceed adjustment range Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 35mph Please confirm safety and set the steering wheel to its straight position Drive the vehicle in a straight line for 10...

Page 2417: ... 210 2 1 30 2 P265 65R17 200 2 0 29 220 2 2 32 D cab Type Cold tire inflation pressure Tire size Front kPa kgf cm2 psi Rear kPa kgf cm2 psi P245 70R16 220 2 2 32 240 2 4 35 P265 70R16 1 200 2 0 29 1 220 2 2 32 2 220 2 2 32 1 230 2 3 33 2 P265 65R17 200 2 0 29 220 2 2 32 1 Vehicle without off road package 2 Vehicle with off road package b Using a dial indicator check the tire runout Tire runout 3 0...

Page 2418: ...heck and adjust the On the car balance Imbalance after adjustment 14 0 g 0 031 lb or less 4 CHECK FRONT SUSPENSION FOR LOOSENESS 5 CHECK STEERING LINKAGE FOR LOOSENESS 6 CHECK BALL JOINT FOR LOOSENESS 7 CHECK SHOCK ABSORBER WORKS PROPERLY Check if oil leaks Check the mounting bushings for wear Bounce front and rear of the vehicle ...

Page 2419: ...ehicle height is not the specified value try to adjust it by pushing down on or lifting the body 2 INSTALL CAMBER CASTER KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES TER Follow the specific instructions of the equipment manufacturer 3 INSPECT CAMBER CASTER AND STEERING AXIS INCLINATION See page SS 59 If the steering axis inclination is not within the specified value after the camber an...

Page 2420: ...r the particular model 2 Mark the selected standard value on the adjustment chart Example Camber 0 16 0 26 Caster 1 17 1 28 3 Measure the present wheel alignment value with the vehicle in non loaded condition 4 Mark the measured present value on the adjust ment chart Example Camber 0 50 0 83 Caster 1 18 1 30 5 As shown in the example chart read the distance from the measured value to the standard ...

Page 2421: ...ear Cam Graduation Direction Arm Shorter Direction Arm Longer Direction Arm Longer Direction Arm Shorter SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT SA 7 d Torque the front and or rear adjusting cam set bolts Torque 130 N m 1 325 kgf cm 96 ft lbf ...

Page 2422: ...the lengths of the right and left rack ends are the same Rack end length difference 1 5 mm 0 059 in or less e Tighten the tie rod end lock nuts Torque 55 N m 560 kgf cm 41 ft lbf 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 See page SS 59 Turn the steering wheel fully and measure the turning angle Wheel turning angle I...

Page 2423: ... m 41 kgf cm 35 in lbf and push the valve core 2 or 3 times to remove any dirt attached to the valve core If there is still air leakage replace the grommet the washer and the nut all together d When installing the tire pressure monitor valve check whether the rim grommet washer and nut are clean Use a manufacturer specified cap e When putting air into the tire first install the tire pressure valve...

Page 2424: ...SA2D8 01 F16842 N m kgf cm ft lbf Specified torque Tire Pressure Monitor Receiver 7 5 76 66 in lbf SA 10 SUSPENSION AND AXLE TIRE PRESSURE MONITOR RECEIVER TIRE PRESSURE MONITOR RECEIVER COMPONENTS ...

Page 2425: ...sconnect the connector b Remove the nut c Remove the EA RIB LH d Remove the tire pressure monitor receiver from the EA RIB LH 4 INSTALL TIRE PRESSURE MONITOR RECEIVER a Install the tire pressure monitor receiver to the EA RIB LH b Connect the connector c Install the EA RIB LH to the body d Install the nut Torque 7 5 N m 76 kgf cm 66 in lbf 5 INSTALL ROOF HEADLINING See page BO 130 or BO 138 6 CONN...

Page 2426: ...16843 N m kgf cm ft lbf Specified torque Tire Pressure Monitor Valve Grommet Washer Nut 4 0 41 35 in lbf Valve Core Cap SA 12 SUSPENSION AND AXLE TIRE PRESSURE MONITOR VALVE TIRE PRESSURE MONITOR VALVE COMPONENTS ...

Page 2427: ...sposing of the tire pressure monitor valve sub assy remove the battery and dispose of it correctly DISPOSE OF TIRE PRESSURE MONITOR VALVE a Insert the tip of a screwdriver into the clearance and pry off the cover Remove the back cover b The battery and base board covered with silicone resin are exposed While taking out the battery cut off the 2 ter minals which connect the battery and base board ...

Page 2428: ... tire remover NOTICE Be careful not to damage the tire pressure monitor valve because of interference between the sensor and tire bead d Remove the bead on the upper side e Take out the sensor from the tire and remove the bead on the lower side f Remove the inner grommet from the tire pressure monitor valve sub assy HINT Check that there are no cracks or damage to the grommet If any damage is foun...

Page 2429: ...as mud dirt or sand attached to the grommet Replace the grommet with a new one if any of the defects men tioned above are found Check that there is no oil water or lubricant around the rim hole tire pressure monitor valve washer and nut Failing to do so may result in improper installa tion c After the tire is inflated the valve nut may be loose Re tighten the nut to the specified torque and then c...

Page 2430: ...SA 16 SUSPENSION AND AXLE TIRE PRESSURE MONITOR VALVE 9 INSPECT TIRE PRESSURE WARNING SYSTEM See page DI 1287 SST 09843 18040 ...

Page 2431: ...SA2D5 01 F16844 Tire Pressure Monitor ECU SUSPENSION AND AXLE TIRE PRESSURE MONITOR ECU SA 17 TIRE PRESSURE MONITOR ECU COMPONENTS ...

Page 2432: ...TOR ECU a Disconnect the connector b Remove the nut and tire pressure monitor ECU 5 INSTALL TIRE PRESSURE MONITOR ECU a Install the tire pressure monitor ECU with the nut b Connect the connector 6 INSTALL GLOVE COMPARTMENT See page BO 120 7 INSTALL INTEGRATION CONTROL PANEL See page BO 120 8 CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 9 REGISTRATION OF TRANSMITTED ID See page DI 1290 10 INSPECT TI...

Page 2433: ...100 65 662 48 123 1 250 90 28 285 21 Steering Knuckle with Axle Hub Disc 4WD Cotter Pin 235 2 400 173 Lock Cap Grease Cap Grease Cap 2WD 4WD Oil Seal ABS Speed Sensor Rotor Spacer w o ABS Dust Cover Steering Knuckle 18 185 13 Oil Seal Bearing Snap Ring Axle Hub w ABS Bearing Spacer w ABS 4WD 274 2 800 203 Lock Nut 2WD SUSPENSION AND AXLE FRONT AXLE HUB SA 19 FRONT AXLE HUB COMPONENTS ...

Page 2434: ...lace the bearing d Inspect the axle hub deviation 1 Using a dial indicator check the deviation at the sur face of the axle hub Maximum 0 05 mm 0 0020 in If the deviation exceeds the maximum replace the bearing e Install the front disc f Install the front disc brake caliper 1 Install the brake caliper and 2 bolts Torque 123 N m 1 250 kgf cm 90 ft lbf 4 4WD DISCONNECT DRIVE SHAFT a Remove the cotter...

Page 2435: ...OWER BALL JOINT DUST COVER PROTECTOR Remove the 4 bolts and disconnect the lower ball joint with low er ball joint dust cover protector 9 REMOVE STEERING KNUCKLE a Remove the cotter pin and loosen the nut b Using SST disconnect the steering knuckle SST 09950 40011 09951 04010 09952 04010 09553 04020 09554 04010 09955 04031 09958 04011 c Remove the nut and steering knuckle NOTICE 4WD Be careful not...

Page 2436: ... SPACER a Using a chisel and hammer loosen the staked part of the lock nut NOTICE Be careful not to damage the bushing b Using SST remove the lock nut SST 09318 12010 c Remove the ABS speed sensor rotor spacer NOTICE Take care not to scratch the serration of the speed sensor rotor 4 REMOVE AXLE HUB FROM STEERING KNUCKLE a Remove the 4 bolts and shift the dust cover towards the hub side outside b U...

Page 2437: ...sor 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 ...

Page 2438: ... AXLE HUB TO STEERING KNUCKLE a Install the dust cover to the steering knuckle with the 4 bolts Torque 18 N m 185 kgf cm 13 ft lbf 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...

Page 2439: ...LE FRONT AXLE HUB SA 25 8 4WD INSTALL NEW OIL SEAL INSIDE a Using SST and a plastic hammer install a new oil seal in side SST 09527 17011 HINT Lightly strike the SST on its circumference evenly b Coat MP grease to the oil seal lip ...

Page 2440: ...K ABSORBER See page SA 68 4 INSTALL BRAKE CALIPER a Install the disc brake caliper and 2 bolts Torque 123 N m 1 250 kgf cm 90 ft lbf b Install the brake line clamp to the steering knuckle with the bolt Torque 28 N m 285 kgf cm 21 ft lbf 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 the 2 bolts Torque 8 0 N m...

Page 2441: ...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 N m 1 250 kgf cm 90 ft lbf b Install the brake line ...

Page 2442: ...Boot Clamp Dust Seal Outboard Joint Shaft Cotter Pin Cotter Pin Grease Cap Lock Cap Lock Nut 235 2 400 173 140 1 450 103 Non reusable part N m kgf cm ft lbf Specified torque Shock Absorber with Coil Spring 135 1 400 100 LH side 64 650 47 SA 28 SUSPENSION AND AXLE FRONT DRIVE SHAFT FRONT DRIVE SHAFT COMPONENTS ...

Page 2443: ...he lock nut 5 DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT a Remove the cotter pin and nut b Using 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 N...

Page 2444: ...and hammer remove the RH drive shaft NOTICE Be careful not to damage the dust cover and oil seal b LH drive shaft Using SST remove the LH 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 in board joint shaft ...

Page 2445: ...iers pinch the claws to compress the large in board 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 ex...

Page 2446: ...FT Align the matchmarks placed before disassembly and using a snap ring expander put in the inboard joint shaft while expand ing 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 i...

Page 2447: ... INSTALL OTHER BOOT CLAMPS TO BOTH BOOTS a Secure the clamp onto the boot b Place 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 in 10 CHECK DRIVE SHAFT See page SA 31 ...

Page 2448: ...oved by hand 2 LH drive shaft INSTALL LH SHOCK ABSORBER See page SA 68 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 u...

Page 2449: ...pacer N m kgf cm ft lbf Specified torque Differential Oil Seal Oil Slinger Bearing 74 750 54 Companion Flange 74 750 54 See page SA 48 SUSPENSION AND AXLE FRONT DIFFERENTIAL REAR OIL SEAL SA 35 FRONT DIFFERENTIAL REAR OIL SEAL COMPONENTS ...

Page 2450: ...he flange remove the nut SST 09330 00021 c Using SST remove the companion flange SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03030 09956 03020 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 ...

Page 2451: ...T 09554 22010 Oil seal drive in depth 4 5 0 3 mm 0 177 0 012 in 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 N m 1 100 kgf cm 80 ft lbf 10 ADJUST DRIVE PINION PRELOAD See page SA 48 11 STAKE DRIVE PINION NUT 12 INSTALL FRONT PROPELLER SHAFT Se...

Page 2452: ...ing Cushion Front RH Mounting Cushion N m kgf cm ft lbf Specified torque Non reusable part 87 890 64 157 1 600 116 137 1 400 101 Snap Ring 13 130 9 Tube with Wire Harness Assembly Breather Hose 108 1 100 80 108 1 100 80 157 1 600 116 137 1 400 101 74 750 54 74 750 54 SA 38 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER FRONT DIFFERENTIAL CARRIER COMPONENTS ...

Page 2453: ...ng Washer Drive Pinion Front Bearing Differential Carrier Oil Seal Drain Plug 65 660 48 Gasket Filler Plug 39 400 29 Ring Gear 69 700 51 x10 Side Bearing Retainer Side Bearing x10 x5 Plate Washer 97 985 71 Lock Plate Bearing Differential Case Bearing Side Bearing Straight Pin Plate Washer Thrust Washer Side Gear Pinion Shaft Pinion Gear Thrust Washer Non reusable part Precoated part N m kgf cm ft ...

Page 2454: ...nnect the breather hose vacuum hose and actuator connector b Remove the bolt and tube with wire harness assembly 5 REMOVE FRONT DIFFERENTIAL CARRIER a Support the front differential with a jack b Using a hexagon 12 mm wrench remove the rear mounting nut c Remove the 2 front mounting bolts d Lower the jack and remove the front differential carrier 6 REMOVE DIFFERENTIAL MOUNTING CUSHIONS a Remove th...

Page 2455: ...e points on the circumference of the ring gear If the backlash is not within the specified value adjust the side bearing preload or repair as necessary 3 MEASURE DRIVE PINION PRELOAD Using a torque wrench measure the preload using the back lash between the drive pinion and ring gear Preload at starting 0 6 1 0 N m 6 10 kgf cm 5 2 8 7 in lbf 4 CHECK TOTAL PRELOAD Using a torque wrench measure the t...

Page 2456: ...lastic hammer tap on the clutch case to remove it 8 REMOVE SIDE OIL SEAL Using SST remove the side oil seal SST 09308 00010 9 REMOVE INTERMEDIATE SHAFT NO 1 a Using SST remove the intermediate shaft No 1 SST 09350 20015 09369 20040 09950 40011 09951 04010 09952 04010 09953 04020 09954 04010 09955 04011 09957 04010 09958 04011 b Remove the snap ring 10 REMOVE COMPANION FLANGE a Using a chisel and h...

Page 2457: ...0 b Remove the bearing spacer 13 REMOVE SIDE BEARING RETAINER Remove the 10 bolts and tap out the retainer with a plastic ham mer 14 REMOVE DIFFERENTIAL CASE ASSEMBLY 15 REMOVE DRIVE PINION FROM DIFFERENTIAL CAR RIER 16 REMOVE DRIVE PINION FRONT BEARING Using SST and a press remove the bearing and washer from the drive pinion SST 09950 00020 HINT If the drive pinion or ring gear is damaged replace...

Page 2458: ...50 70010 09951 07150 b Using SST and a press remove the plate washer and out er race from the differential carrier SST 09950 60010 09951 00650 09950 70010 09951 07150 19 REMOVE RING GEAR a Place matchmarks on the ring gear and differential case b Using a screwdriver and hammer unstake the 5 lock plates c Remove the 10 bolts and 5 lock plates d Using a plastic hammer tap on the ring gear to separat...

Page 2459: ...IFFERENTIAL CASE ASSEMBLY a Using a pin punch and hammer remove the straight pin b Remove the pinion shaft 2 pinion gears pinion gear thrust washers side gears and side gear thrust washers from the differential case 22 REMOVE BEARINGS Using a brass bar and hammer remove the 2 bearings ...

Page 2460: ...t deflector SST 09636 20010 2 REPLACE INTERMEDIATE SHAFT NO 2 IF NEC ESSARY a Remove the clutch hub 1 Using a snap ring expander remove the snap ring 2 Remove the clutch hub from the intermediate shaft No 2 b Remove the oil seal Using SST remove the oil seal from the tube SST 09308 00010 c Remove the intermediate shaft No 2 from the tube 1 Using needle nose pliers remove the snap ring 2 Remove the...

Page 2461: ...37010 2 Using a snap ring expander install a new snap ring f Install the intermediate shaft No 2 to the tube 1 Install the shaft into the tube 2 Using needle nose pliers install a new snap ring g Install a new oil seal 1 Using SST and a plastic hammer install a new oil seal SST 09223 15020 Oil seal drive in depth 5 5 0 3 mm 0 217 0 012 in 2 Coat the oil seal lip with MP grease h Install the clutch...

Page 2462: ...e gear backlash while holding one pinion gear toward the differential case Backlash 0 0 20 mm 0 0 0079 in If the backlash is not within the specified value replace the side gear thrust washer with an appropriate thickness HINT Refer to the following table to select thrust washers which will ensure that the backlash is within the specified value Washer thickness Thickness mm in Thickness mm in 0 96...

Page 2463: ...olts Torque 97 N m 985 kgf cm 71 ft lbf g Using a chisel and hammer stake the 5 lock plates HINT Stake the claws of the lock plates to fix the bolts For the claw contacting the protruding portion of the bolt stake only the half of it along the tightening direction 5 INSTALL SIDE BEARINGS Using SST and a press install the bearings into the differential case SST 09226 10010 6 INSTALL SIDE BEARING OU...

Page 2464: ...on HINT First fit a washer with the same thickness as the washer which was removed then after checking the tooth contact pattern re place the washer with one of a different thickness if necessary b Using SST and a press install the front bearing onto the drive pinion SST 09506 30012 9 TEMPORARILY ADJUST DRIVE PINION PRELOAD a Install the drive pinion rear bearing and oil slinger HINT After adjusti...

Page 2465: ...New bearing 1 2 1 9 N m 12 19 kgf cm 10 4 16 5 in lbf Reused bearing 0 6 1 0 N m 6 10 kgf cm 5 2 8 7 in lbf 10 INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL CARRIER 11 ADJUST RING GEAR BACKLASH a Install the side bearing retainer with the 10 bolts Torque 69 N m 700 kgf cm 51 ft lbf b Using SST and a dial indicator measure the ring gear backlash SST 09564 32011 Backlash 0 13 0 18 mm 0 0051 0 0071 in If...

Page 2466: ... 0878 2 48 2 50 0 0976 0 0984 2 75 2 77 0 1083 0 1091 2 24 2 26 0 0882 0 0890 2 51 2 53 0 0988 0 0996 2 78 2 80 0 1094 0 1102 12 MEASURE TOTAL PRELOAD Using a torque wrench measure the preload with the teeth of the drive pinion and ring gear in contact Total preload at starting Drive pinion preload plus 0 4 0 6 N m 4 6 kgf cm 3 5 5 2 in lbf 13 INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINI...

Page 2467: ...760 0 0768 2 17 2 19 0 0854 0 0862 1 72 1 74 0 0677 0 0685 1 96 1 98 0 0772 0 0780 2 20 2 22 0 0866 0 0874 1 75 1 77 0 0689 0 0697 1 99 2 01 0 0783 0 0791 2 23 2 25 0 0878 0 0886 1 78 1 80 0 0701 0 0709 2 02 2 04 0 0795 0 0803 2 26 2 28 0 0890 0 0898 1 81 1 83 0 0713 0 0720 2 05 2 07 0 0807 0 0815 2 29 2 31 0 0902 0 0909 1 84 1 86 0 0724 0 0732 2 08 2 10 0 0819 0 0827 2 32 2 34 0 0913 0 0921 1 87 ...

Page 2468: ...ld the flange torque the nut SST 09330 00021 Torque 108 N m 1 100 kgf cm 80 ft lbf 19 ADJUST DRIVE PINION PRELOAD Using a torque wrench measure the preload of the drive pinion using the backlash between the drive pinion and the ring gear Preload at starting New bearing 1 2 1 9 N m 12 19 kgf cm 10 4 16 5 in lbf Reused bearing 0 6 1 0 N m 6 10 kgf cm 5 2 8 7 in lbf If the preload is greater than the...

Page 2469: ...ring retainer with the 10 bolts Torque 69 N m 700 kgf cm 51 ft lbf 22 CHECK TOTAL PRELOAD See step 12 23 RECHECK RING GEAR BACKLASH See page SA 41 24 RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION See step 13 25 CHECK COMPANION FLANGE RUNOUT See page SA 41 26 STAKE DRIVE PINION NUT 27 INSTALL SIDE OIL SEAL a Using SST and a plastic hammer install a new oil seal un til its surface is flus...

Page 2470: ...ine or alcohol c Apply FIPG to the differential as shown in the illustration FIPG Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the differential tube within 10 minutes after applying FIPG d Install the differential tube to the differential e Clean the threads of the 2 long torx bolts and retainer bolt holes with toluene or trichlorethylene f Apply adhesive to 2 or 3 threads of the...

Page 2471: ...57 c Apply FIPG to the clutch case as shown in the illustration FIPG Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the actuator within 10 minutes after applying FIPG d Install the A D D actuator with the 4 bolts Torque 21 N m 210 kgf cm 15 ft lbf ...

Page 2472: ...the front differential b Install the 2 front mounting bolts Torque 137 N m 1 400 kgf cm 101 ft lbf c Using a hexagon 12 mm wrench install the rear mounting nut Torque 87 N m 890 kgf cm 64 ft lbf d Remove the jack 3 INSTALL TUBE WITH WIRE HARNESS ASSEMBLY a Install the tube with wire harness assembly with the bolt Torque 13 N m 130 kgf cm 9 ft lbf b Connect the actuator connector vacuum hose and br...

Page 2473: ...and 4LO Switch 4WD and Center Diff Lock Indicator Light Combination Meter Transfer 4WD Position Switch Transfer L4 Position Switch A D D Actuator Actuator Connector SUSPENSION AND AXLE A D D CONTROL SYSTEM SA 59 A D D CONTROL SYSTEM LOCATION ...

Page 2474: ...e actuator operation by sound A D D status and conti nuity between terminals 3 and 4 Battery voltage applied terminal 3 4 terminals continuity A D D status 2 6 Continuity Connected 2 6 No continuity Disconnected If the operation is not as specified replace the actuator assem bly 3 INSPECT LIMIT SWITCH CONTINUITY a Connect the actuator connector b Push the 2WD 4HI switch and check that the 4WD indi...

Page 2475: ...4 No continuity 3 5 No continuity 4 5 No continuity k Connect the actuator connector 4 INSPECT TRANSFER 4WD POSITION SWITCH See page TR 14 5 REMOVE A D D ACTUATOR See page SA 41 6 INSPECT CLUTCH HUB AND CLUTCH SLEEVE a Check the clutch hub and clutch sleeve for wear and dam age If necessary replace them b Check that clutch sleeve slides smoothly on the clutch hub 7 MEASURE SLEEVE FORK AND CLUTCH S...

Page 2476: ...pring N m kgf cm ft lbf Specified torque Non reusable part 64 650 47 Retainer Cushion Suspension Support Retainer Coil Spring Shock Absorber 25 250 18 135 1 400 100 SA 62 SUSPENSION AND AXLE FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER COMPONENTS ...

Page 2477: ...a Remove the shock absorber lower side set nut and wash er 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 ...

Page 2478: ...27 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 neces sary Do not use an impact wrench It will damage the SST Do not place yourself over the top of the shock ab sorber b Remove the suspension support center nut c Remove the 2 retainers cushion suspension support and coil spring ...

Page 2479: ...SPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds If there is any abnormality replace the shock absorber with a new one NOTICE When discarding the shock absorber see DISPOSAL on page SA 66 ...

Page 2480: ...ISPOSAL 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 illustra tion to discharge the gas inside CAUTION The discharged gas is harmless but be careful of chips which may fly out when drilling ...

Page 2481: ... coil spring to the shock absorber HINT Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber 2 INSTALL SUSPENSION SUPPORT a Install the 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 illustra tion d Remove the SST SST 09727 30021 09727 0001...

Page 2482: ...stall the upper side of the 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 the shock absorber to the lower suspension arm with the bolt washer and nut Torque 135 N m 1 400 kgf cm 100 ft lbf 2 INSTALL FRONT WHEEL Torque 110 N m 1 150 kgf cm 83 ft lbf ...

Page 2483: ...l Line Clamp Rear Fender Apron Seal ABS Speed Sensor Wire Harness w ABS Bushing Bushing Cotter Pin 105 1 100 77 64 650 47 98 1 000 72 135 1 400 100 Shock Absorber with Coil Spring 8 0 82 71 in lbf 5 5 56 49 in lbf SUSPENSION AND AXLE FRONT UPPER SUSPENSION ARM SA 69 FRONT UPPER SUSPENSION ARM COMPONENTS ...

Page 2484: ...T UPPER BALL JOINT a Remove the cotter pin and loosen the nut b Using SST disconnect the upper ball joint SST 09950 40011 09951 04010 09952 04010 09953 04020 09954 04010 09955 04031 09958 04011 c Support the steering knuckle securely d Remove the nut 4 REMOVE 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...

Page 2485: ...A 71 REPLACEMENT 1 REMOVE BUSHING a Using a chisel and hammer pry up the flange of the bush ing b Using SST and a press remove the bushing SST 09613 26010 09631 20060 09950 00020 2 INSTALL NEW BUSHING Using SST a press and steel plate install a new bushing SST 09631 12090 09710 30021 09710 03051 ...

Page 2486: ...orque 5 5 N m 56 kgf cm 49 in lbf 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 N m 1 100 kgf cm 77 ft lbf 5 w ABS CONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS Torque 8 0 N m 82 kgf cm 71 in lbf 6...

Page 2487: ... Power Steering Gear Cotter Pin Cotter Pin 31 315 23 23 235 17 135 1 400 100 130 1 325 96 Cam Cam Plate Cam No 2 Bushing No 1 Bushing Lower Suspension Arm Stabilizer Bar Link 140 1 450 103 Cotter Pin 69 700 51 Retainer Retainer Bushing Stabilizer Bar Stabilizer Bar Bracket Bushing 37 375 27 130 1 325 96 19 190 14 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM SA 73 FRONT LOWER SUSPENSION ARM COMPO...

Page 2488: ...EAR 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 the 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 wash er NOTICE Do not remove the bo...

Page 2489: ...in 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 suspen sion arm while slightly shifting the power steering gear rearward NOTICE Do not damage the power steering gear tubes ...

Page 2490: ...ushing SST 09502 12010 09631 12090 HINT Before installing the bushing set it in the correct direction as shown in the illustration d Using SST a press and steel plate install a new No 2 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 w...

Page 2491: ...ar See page SA 89 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 in Torque 23 N m 235 kgf cm 17 ft lbf 3 Install the stabilizer bar See page SA 91 d Install the front wheel Torque 110 N m 1 150 kgf cm 83 ft lbf ...

Page 2492: ... If the holes for the cotter pin are not aligned tighten the nut fur ther up to 60 3 CONNECT SHOCK ABSORBER TO LOWER SUSPEN SION ARM Torque 135 N m 1 400 kgf cm 100 ft lbf 4 CONNECT STABILIZER BAR LINK TO LOWER SUS PENSION ARM Torque 69 N m 700 kgf cm 51 ft lbf 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 ...

Page 2493: ...0 47 Brake Caliper Cotter Pin 105 1 100 77 Shock Absorber 123 1 250 90 28 285 21 Steering Knuckle with Axle Hub Disc 4WD Cotter Pin 235 2 400 173 Lock Cap Grease Cap 8 0 82 71 in lbf ABS Speed Sensor w ABS 80 820 59 135 1 400 100 SUSPENSION AND AXLE FRONT UPPER BALL JOINT SA 79 FRONT UPPER BALL JOINT COMPONENTS ...

Page 2494: ...ERING KNUCKLE WITH AXLE HUB See page SA 20 2 REMOVE UPPER BALL JOINT a Remove the wire and boot b Using a snap ring expander remove the snap ring c Using SST and a deep socket wrench remove the upper ball joint SST 09950 40011 09951 04010 09952 04010 09953 04020 09954 04010 09955 04031 09957 04010 09958 04011 ...

Page 2495: ... 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 N m 7 45 kgf cm 6 39 in lbf ...

Page 2496: ... 1 INSTALL UPPER BALL JOINT a Using SST and a socket wrench install a new ball joint SST 09309 37010 b Using a snap ring expander install a new snap ring c Install a new boot and fix it with a new wire HINT Use the grease supplied in the kit 2 INSTALL STEERING KNUCKLE WITH AXLE HUB See page SA 26 ...

Page 2497: ...LE INSPECTION INSPECT LOWER BALL JOINT EXCESSIVE PLAY ON VE HICLE a Remove the front wheel and install the hub nuts to the disc b Using a dial indicator check the lower ball joint for exces sive play when you push the hub nuts up and down with a force of 294 N 30 kgf 66 lbf Maximum 0 5 mm 0 020 in ...

Page 2498: ...pecified torque Non reusable part Tie Rod End Cotter Pin Lower Suspension Arm Lower Ball Joint Cotter Pin 91 930 67 65 662 48 159 1 620 117 Lower Ball Joint Dust Cover Protector SA 84 SUSPENSION AND AXLE FRONT LOWER BALL JOINT COMPONENTS ...

Page 2499: ...om the lower ball joint SST 09610 20012 4 REMOVE LOWER BALL JOINT WITH LOWER BALL JOINT DUST COVER PROTECTOR 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 Remove the lower ball joint dust cover protector e While lifting the upper suspension arm and steer...

Page 2500: ... 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 N m 1 25 kgf cm 1 22 in lbf ...

Page 2501: ...er ball joint to the lower suspension arm and a new cotter pin Torque 159 N m 1 620 kgf cm 117 ft lbf 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 N m 930 kgf cm 67 ft lbf If the holes for the cotter pin are not aligned tighten the nut further up to ...

Page 2502: ...m ft lbf Retainer Stabilizer Bar Link Specified torque Stabilizer Bar Bracket Bushing Non reusable part 19 190 14 37 375 27 25 260 19 69 700 51 69 700 51 19 190 14 Bushing SA 88 SUSPENSION AND AXLE FRONT STABILIZER BAR FRONT STABILIZER BAR COMPONENTS ...

Page 2503: ...her 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 cush ions and brackets b Remove the 2 brackets and cushions from the stabilizer bar 3 REMOVE STABILIZER BAR LINKS a Hold the stabilizer bar link and remove the nut b Remove the stabilizer bar link 2 retainers and bushings from the stabilizer bar c Use the same p...

Page 2504: ...SPECT 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 N m 0 5 20 kgf cm 0 4 17 in lbf ...

Page 2505: ... 14 ft lbf c Use the same procedures described above to the other side 2 INSTALL STABILIZER BAR a Install the 2 bushings with their cutouts facing to the rear ward to the stabilizer bar b Install the stabilizer bar and 2 brackets with the nut and bolts Torque 37 N m 375 kgf cm 27 ft lbf 3 CONNECT STABILIZER BAR LINKS TO LOWER SUS PENSION ARM Torque 69 N m 700 kgf cm 51 ft lbf HINT If the ball join...

Page 2506: ...rake Line Pin w ABS 8 0 82 71 in lbf 15 155 11 69 700 51 Non reusable part w ABS ABS Speed Sensor Rotor Hub Bolt Oil Deflector Snap Ring Bearing Retainer Bearing Bearing Case Backing Plate Oil Seal Serration Bolt Gasket Rear Axle Shaft x6 Bearing Retainer Rear Axle Shaft Assembly SA 92 SUSPENSION AND AXLE REAR AXLE SHAFT REAR AXLE SHAFT COMPONENTS ...

Page 2507: ...aximum 0 1 mm 0 004 in 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 See page BR 48 6 DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE a Using SST disconnect the brake line from the wheel cylin der SST 09023 00101 b Remove the clip and pin and disconnect the parking b...

Page 2508: ...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 SST on the backing plate with the 4 nuts SST 09521 25011 09521 25022 b Using a press remove the rear axle shaft and bearing re tainer from the backing plate c Remove the SST SST 09521 25011 09521 25022 4 INSPECT AXLE S...

Page 2509: ...earing 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 11 REPLACE BEARING CASE a Remove the outer side oil seal See step 5 b Remove the beari...

Page 2510: ...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 a snap ring expander install a...

Page 2511: ...R04284 SST SUSPENSION AND AXLE REAR AXLE SHAFT SA 97 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 ...

Page 2512: ... clip b Using SST connect the brake line to the wheel cylinder SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 4 INSTALL REAR BRAKE ASSEMBLY See page BR 52 5 w ABS INSTALL ABS SPEED SENSOR Torque 8 0 N m 82 kgf cm 71 ft lbf 6 CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION See page SA 93 7 INSTALL NEW GASKET AND BRAKE DRUM 8 INSTALL REAR WHEEL Torque 110 N m 1 150 kgf cm 83 ft lbf 9 BLEED BRAKE...

Page 2513: ... BOLT Using 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 N m 1 150 kgf cm 83 ft lbf ...

Page 2514: ...pacer Oil Seal Companion Flange N m kgf cm ft lbf Specified torque w o LSD See page SA 112 w LSD See page SA 133 Non reusable part 74 750 56 Propeller Shaft SA 100 SUSPENSION AND AXLE REAR DIFFERENTIAL FRONT OIL SEAL REAR DIFFERENTIAL FRONT OIL SEAL COMPONENTS ...

Page 2515: ... the nut b Using SST to hold the flange remove the nut SST 09330 00021 c Using SST remove the companion flange SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03030 09956 03050 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 Remo...

Page 2516: ...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 the 2 SST with vinyl tape 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 N m 1 50...

Page 2517: ...Capacity Standard type 2WD Standard Cab and Access Cab Double Cab 3 80 liters 4 02 US qts 3 34 lmp qts 4 00 liters 4 23 US qts 3 52 lmp qts Double Cab 4WD Standard Cab and Access Cab Double Cab 4 00 liters 4 23 US qts 3 52 lm qts 3 50 liters 3 70 US qts 3 08 lmp qts 4 00 liters 4 23 US qts 3 52 lmp qts LSD type 2WD Standard Cab and Access Cab Double Cab 3 15 liters 3 33 US qts 2 77 lmp qts 3 35 li...

Page 2518: ... Gasket Drain Plug x10 Axle Shaft and Brake Assembly Brake Drum Axle Shaft and Brake Assembly Specified torque Brake Line Gasket Gasket 49 500 39 15 155 11 49 500 39 69 700 51 74 750 56 73 740 54 Non reusable part Propeller Shaft SA 104 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER REAR DIFFERENTIAL CARRIER COMPONENTS ...

Page 2519: ...ar Bearing Adjusting Washer Bearing Spacer Front Bearing Dust Deflector Companion Flange Bearing Cap Thrust Washer Plate Washer Side Bearing Side Bearing Plate Washer Differential Carrier Washer Oil Seal x12 125 1 270 92 113 1 150 83 113 1 150 83 See page SA 112 Non reusable part Precoated part SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER SA 105 ...

Page 2520: ...R OIL 2 REMOVE REAR AXLE SHAFTS See page SA 93 3 DISCONNECT REAR PROPELLER SHAFT 2WD See page PR 3 4WD See page PR 10 4 REMOVE DIFFERENTIAL CARRIER ASSEMBLY a Remove the 10 nuts washers and differential carrier as sembly NOTICE Be careful not to damage the installation surface b Remove the gasket ...

Page 2521: ...CK RING GEAR BACKLASH Using a dial indicator while holding the companion flange mea sure the ring gear backlash Backlash 0 13 0 18 mm 0 0051 0 0071 in HINT Measure at 3 or more positions around the circumference of the ring gear If the backlash is not within the specified value adjust the side bearing preload or repair as necessary 4 CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION See page ...

Page 2522: ...d with the teeth of the drive pinion and ring gear in contact Total preload at starting Drive pinion preload plus 0 4 0 6 N m 4 6 kgf cm 3 5 5 2 in lbf If necessary disassemble and inspect the differential 8 REMOVE COMPANION FLANGE a Using a chisel and hammer unstake the staked part of the nut b Using SST to hold the flange remove the nut SST 09330 00021 c Using SST remove the companion flange SST...

Page 2523: ...r b Remove the 4 bolts and bearing cap c Using SST and a plastic hammer remove the 2 side bear ing plate washers SST 09504 22012 HINT Measure the plate washer thickness and note it down d Remove the differential case with the bearing outer races from the carrier HINT Tag the bearing outer races to show the location for reassem bling 12 REMOVE DRIVE PINION FROM DIFFERENTIAL CAR RIER Remove the driv...

Page 2524: ... it from the differential case 16 CHECK DIFFERENTIAL CASE RUNOUT a Install the differential case in the differential carrier See page SA 112 b Using a dial indicator measure the differential case run out Maximum case runout 0 04 mm 0 0016 in c Remove the differential case 17 REMOVE SIDE BEARINGS Using SST remove the 2 side bearings from the differential case SST 09950 40011 09951 04010 09952 04010...

Page 2525: ...NSION AND AXLE REAR DIFFERENTIAL CARRIER SA 111 REPLACEMENT REPLACE COMPANION FLANGE DUST DEFLECTOR a Using SST a socket wrench and a press remove the dust deflector SST 09950 00020 b Using SST a press and steel plate install a new dust de flector SST 09523 36010 ...

Page 2526: ... side gear thrust washer with an appropriate thickness HINT Refer to the following table to select thrust washers which will ensure that the backlash is within the specified value Washer thickness Thickness mm in Thickness mm in 1 50 0 0590 1 75 0 0689 1 55 0 0610 1 80 0 0709 1 60 0 0630 1 85 0 0728 1 65 0 0650 1 90 0 0748 1 70 0 0669 d Using a pin punch and hammer install the straight pin through...

Page 2527: ...0 THREE BOND 1360K or equiv alent Torque 125 N m 1 270 kgf cm 92 ft lbf 4 INSPECT RING GEAR RUNOUT a Install the differential case into the carrier and install the plate washers to where there is no play in the bearing See step 8 b Install the bearing cap See step 11 c Using a dial indicator measure the runout of the ring gear d Remove the bearing caps and differential case Maximum runout 0 05 mm ...

Page 2528: ...r tooth contact pattern assemble the spacer washers and oil seal b Using SST install the companion flange SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03030 09956 03050 c Coat the threads of the nut with hypoid gear oil d Adjust the drive pinion preload by tightening the compan ion flange nut HINT Using SST to hold the flange torque the nut SST 09330 00021 NOTICE As there is no spacer...

Page 2529: ...rential case in the carrier 9 ADJUST RING GEAR BACKLASH a Install the plate washer on the ring gear back side HINT Make sure that the ring gear has backlash b Tap on the ring gear with a plastic hammer so that the washer fits to the bearing c Using a dial indicator while holding the companion flange measure the ring gear backlash Backlash reference 0 13 0 18 mm 0 0051 0 0071 in d Select a plate wa...

Page 2530: ...djust it by ei ther increasing or decreasing the thickness of the washers on both sides by an equal amount HINT There should be no clearance between the plate washer and the case Make sure that there is a ring gear backlash 10 ADJUST SIDE BEARING PRELOAD a Remove the ring gear teeth side plate washer and using a micrometer measure the thickness b Using the backlash as a reference install a new was...

Page 2531: ... 42 3 42 0 1346 80 2 80 0 1102 12 3 12 0 1228 44 3 44 0 1354 82 2 82 0 1110 14 3 14 0 1236 46 3 46 0 1362 84 2 84 0 1118 16 3 16 0 1244 48 3 48 0 1370 86 2 86 0 1126 18 3 18 0 1252 88 2 88 0 1134 20 3 20 0 1260 11 INSTALL BEARING CAP a Align the matchmarks on the cap and carrier b Install and torque the 4 bolts Torque 113 N m 1 150 kgf cm 83 ft lbf 12 MEASURE TOTAL PRELOAD Using a torque wrench me...

Page 2532: ...rk mm in Thickness Mark mm in 87 1 87 0 0736 01 2 01 0 0791 15 2 15 0 0846 88 1 88 0 0740 02 2 02 0 0795 16 2 16 0 0850 89 1 89 0 0744 03 2 03 0 0799 17 2 17 0 0854 90 1 90 0 0748 04 2 04 0 0803 18 2 18 0 0858 91 1 91 0 0752 05 2 05 0 0807 19 2 19 0 0862 92 1 92 0 0756 06 2 06 0 0811 20 2 20 0 0866 93 1 93 0 0760 07 2 07 0 0815 21 2 21 0 0870 94 1 94 0 0764 08 2 08 0 0819 22 2 22 0 0874 95 1 95 0 ...

Page 2533: ...earing then remove the companion flange SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03030 09956 03050 17 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 18 INSTALL COMPANION FLANGE a Place the c...

Page 2534: ...the specified preload is reached Torque 451 N m 4 600 kgf cm 333 ft lbf or less If the maximum torque is exceeded while retightening the nut replace the bearing spacer and repeat the preload procedure Do not loosen the pinion nut to reduce the preload 20 CHECK TOTAL PRELOAD Using a torque wrench measure the total preload with the teeth of the drive pinion and ring gear in contact Total preload at ...

Page 2535: ...ket b Install the differential carrier assembly with the 10 washers and nuts NOTICE Be careful not to damage the installation surface Torque 73 N m 740 kgf cm 54 ft lbf 2 CONNECT REAR PROPELLER SHAFT 2WD See page PR 8 4WD See page PR 15 3 INSTALL REAR AXLE SHAFTS See page SA 98 4 FILL DIFFERENTIAL WITH HYPOID GEAR OIL See page SA 101 ...

Page 2536: ...et Filler Plug 49 500 36 O Ring O Ring Brake Line 15 155 11 Parking Brake Cable Brake Drum Rear Axle Shaft LH and Brake Assembly Rear Axle Shaft RH and Brake Assembly 74 750 56 ABS Speed Sensor 73 740 54 Brake Drum 49 500 36 69 700 51 8 0 82 71 in lbf SA 122 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD REAR DIFFERENTIAL CARRIER w LSD COMPONENTS ...

Page 2537: ...ctor Oil Seal Bearing Differential Carrier Washer Bearing Spacer Bearing Cap 113 1 150 83 Drive Pinion Rear Bearing Adjusting Washer Plate Washer Side Bearing Ring Gear Differential Case Side Bearing Plate Washer x12 125 1 270 92 See page SA 133 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD SA 123 ...

Page 2538: ...e side gear thrust washer and the differential case RH Differential Case Adjusting Shim Clutch Plate Side Gear Thrust Washer Pinion Gear Thrust Washer Pinion Gear Spider Compression Spring Side Gear Spring Retainer LH Differential Case x8 Side Gear Thrust Washer Adjusting Shim Clutch Plate 47 480 35 SA 124 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD ...

Page 2539: ...GEAR OIL 2 REMOVE REAR AXLE SHAFTS See page SA 93 3 DISCONNECT REAR PROPELLER SHAFT 2WD See page PR 3 4WD See page PR 10 4 REMOVE DIFFERENTIAL CARRIER ASSEMBLY a Remove the 10 nuts washers and differential carrier as sembly NOTICE Be careful not to damage the installation surface b Remove the gasket ...

Page 2540: ... CHECK RING GEAR BACKLASH Using a dial indicator while holding the companion flange mea sure the ring gear backlash Backlash 0 13 0 18 mm 0 0051 0 0071 in HINT Measure at 3 or more positions around the circumference of the ring gear If the backlash is not within the specification adjust the side bearing preload or repair if necessary 4 CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION See pag...

Page 2541: ...ake the nut b Using SST to hold the flange remove the nut SST 09330 00021 c Using SST remove the companion flange SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03030 09956 03030 8 REMOVE FRONT OIL SEAL Using SST remove the oil seal from the differential carrier SST 09308 10010 9 REMOVE FRONT BEARING AND BEARING SPACER a Using SST remove the bearing from the drive pinion SST 09556 22010...

Page 2542: ...rom the carrier HINT Tag the disassembled parts to show the location for reassem bling 11 REMOVE DRIVE PINION FROM DIFFERENTIAL CAR RIER Remove the drive pinion with the rear bearing 12 REMOVE DRIVE PINION REAR BEARING Using SST and a press remove the bearing from the drive pin ion SST 09950 00020 HINT If the drive pinion or ring gear is damaged replace them as a set 13 REMOVE FRONT AND REAR BEARI...

Page 2543: ... mm 0 0016 in c Remove the differential case 16 REMOVE SIDE BEARINGS Using SST remove the 2 side bearings from the differential case SST 09950 40011 09951 04010 09952 04010 09953 04020 09954 04010 09955 04061 09957 04010 09958 04011 09950 60010 09951 00480 HINT Fix the claws of SST to the notch in the differential case 17 DISASSEMBLE DIFFERENTIAL CASE a Place matchmarks on the LH and RH cases b Re...

Page 2544: ...e b Remove these parts from the RH case 1 Remove the spring LH retainer 2 Remove the compression spring 3 Remove the spider with the pinion gear 4 Remove the spring RH retainer 5 Remove the side gear 6 Remove the 5 side gear thrust washers 7 Remove the 4 clutch plates HINT Face the rough side of the thrust washer marked by to the differential case ...

Page 2545: ... bare metal is showing Thickness For reference 1 77 2 49 mm 0 0697 0 0980 in If necessary replace the thrust washers HINT If replacing the thrust washer also replace the clutch plate that contacts with it 3 INSPECT CLUTCH PLATE FOR WEAR OR DAMAGE Using a micrometer measure the contact surface of the clutch plate and check that there is no abnormal wear Thickness For reference 1 57 1 63 mm 0 0618 0...

Page 2546: ...USPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD REPLACEMENT REPLACE COMPANION FLANGE DUST DEFLECTOR a Using SST a socket wrench and a press remove the dust deflector SST 09950 00020 b Using SST a press and steel plate install a new dust de flector SST 09523 36010 ...

Page 2547: ...fferential case dimension A1 as shown in the illustration b Install the thrust washers face their fine side to the side gear and clutch plates on the side gear HINT Install the new thrust washer Mark N instead of the thrust washers Mark A M to the differential case side c Using SST to press down the thrust washers and clutch plates with about pressure of 10 kgf 22 lbf measure di mension B1 as show...

Page 2548: ...ter assembling A shim SA 134 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD HINT Three or two adjusting shims can be used together if the total of their thickness meets one of the above combinations even if the combination does not exist in the above table ...

Page 2549: ...n b Install the thrust washers face their fine side to the side gear and clutch plates on the side gear HINT Install the new thrust washer Mark N instead of the thrust washers Mark A M to the differential case side c Using SST to press down the thrust washers and clutch plates with about pressure of 10 kgf 22 lbf measure di mension B2 as shown in the illustration SST 09649 17010 d Referring to the...

Page 2550: ...F16255 Reassemble another type shim or check the backlash after assembling A shim Less SA 136 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD ...

Page 2551: ... spider knock pins and install the LH retainer d Install the pinion gear and spider to the differential LH case HINT Install the spider to the LH case tightly and do not move the spring retainer e Using a dial indicator check the side gear backlash while holding the side gear and spider Backlash 0 05 0 20 mm 0 0019 0 0079 in HINT Measure at all 4 locations Measure the backlash at the LH case and a...

Page 2552: ...ss install the 2 side bearings into the differ ential case SST 09950 60010 09951 00480 09951 00640 09950 70010 09951 07150 7 INSTALL RING GEAR ON DIFFERENTIAL CASE a Clean the contact surfaces of the differential case and ring gear b Heat the ring gear to about 100 C 212 F in boiling wa ter c Carefully take the ring gear out of the boiling water d After the moisture on the ring gear has completely...

Page 2553: ... bearing outer race to the carrier SST 09950 60020 09951 00710 09950 70010 09951 07150 b Using SST and a press install a new adjusting washer and a new rear bearing outer race to the carrier SST 09950 60020 09951 00910 09950 70010 09951 07150 HINT First fit a washer with the same thickness as the washer which was removed then after checking the tooth contact pattern re place the washer with a diff...

Page 2554: ... a little at a time and be careful not to overtighten it e Using a torque wrench measure the preload of the drive pinion using the backlash between the drive pinion and ring gear Preload at starting New bearing 1 3 1 9 N m 13 19 kgf cm 11 4 16 7 in lbf Reused bearing 0 6 0 9 N m 6 1 9 2 kgf cm 5 3 8 0 in lbf 12 INSTALL DIFFERENTIAL CASE IN CARRIER a Place the 2 bearing outer races on their respect...

Page 2555: ...washer for back side ring gear using the backlash as a reference e Select a ring gear teeth side plate washer so that there is no clearance between the outer race and case f Remove the 2 plate washers and differential case g Install the plate washer into the ring gear back side of the carrier h Place the other plate washer onto the differential case to gether with the outer race and install the di...

Page 2556: ...lash Backlash 0 13 0 18 mm 0 0051 0 0071 in If the backlash is not within the specified value adjust it by ei ther increasing or decreasing the thickness of washers on both sides by an equal amount HINT The backlash will change by about 0 02 mm 0 0008 in corre sponding to 0 03 mm 0 0012 in change in the plate washer Washer thickness Thickness Mark mm in Thickness Mark mm in Thickness Mark mm in 58...

Page 2557: ...he cap and carrier b Install and torque the 4 bolts Torque 113 N m 1 150 kgf cm 83 ft lbf 16 MEASURE TOTAL PRELOAD Using a torque wrench measure the total preload with the teeth of the drive pinion and ring gear in contact Total preload at starting Drive pinion preload plus 0 4 0 6 N m 4 6 kgf cm 3 5 5 2 in lbf 17 INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION a Coat 3 or 4 teeth at thre...

Page 2558: ...0 0870 94 1 94 0 0764 08 2 08 0 0819 22 2 22 0 0874 95 1 95 0 0768 09 2 09 0 0823 23 2 23 0 0878 96 1 96 0 0772 10 2 10 0 0827 24 2 24 0 0882 97 1 97 0 0776 11 2 11 0 0831 25 2 25 0 0886 98 1 98 0 0780 12 2 12 0 0835 26 2 26 0 0890 99 1 99 0 0783 13 2 13 0 0839 27 2 27 0 0894 00 2 00 0 0787 14 2 14 0 0843 28 2 28 0 0898 18 REMOVE COMPANION FLANGE See page SA 126 19 REMOVE FRONT BEARING See page SA...

Page 2559: ... 1 9 N m 13 19 kgf cm 11 4 16 7 in lbf Reused bearing 0 6 0 9 N m 6 1 9 2 kgf cm 5 3 8 0 in lbf If the preload is greater than the specified value replace the bearing spacer If the preload is less than the specified value retighten the nut with a force of 13 N m 130 kgf cm 9 ft lbf until the specified preload is reached Torque 451 N m 4 600 kgf cm 333 ft lbf or less If the maximum torque is exceed...

Page 2560: ... 146 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER w LSD 26 RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION See step 17 27 CHECK COMPANION FLANGE RUNOUT See page SA 126 28 STAKE DRIVE PINION NUT ...

Page 2561: ...gasket b Install the differential carrier assembly with the 10 washers and nuts NOTICE Be careful not to damage the installation surface Torque 73 N m 740 kgf cm 54 ft lbf 2 CONNECT REAR PROPELLER SHAFT 2WD See page PR 8 4WD See page PR 15 3 INSTALL REAR AXLE SHAFTS See page SA 98 4 FILL DIFFERENTIAL WITH HYPOID GEAR OIL See page SA 101 ...

Page 2562: ...4447 N m kgf cm ft lbf Specified torque Non reusable part Shock Absorber Retainer Cushion Bushing 87 890 64 20 200 15 Retainer Cushion SA 148 SUSPENSION AND AXLE REAR SHOCK ABSORBER REAR SHOCK ABSORBER COMPONENTS ...

Page 2563: ...s 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 ab sorber ...

Page 2564: ...PECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds If there is any abnormality replace the shock absorber with a new one NOTICE When disposing of the shock absorber see DISPOSAL on page SA 151 ...

Page 2565: ...BER SA 151 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 illustra tion to discharge the gas inside CAUTION The discharged gas is harmless but be careful of chips which may fly out when drilling ...

Page 2566: ...2 SST SA 152 SUSPENSION AND AXLE REAR SHOCK ABSORBER REPLACEMENT REPLACE BUSHING a Using SST 19 mm deep socket wrench and a press re move the bushing SST 09632 36010 b Using SST and a press install a new bushing SST 09630 24014 09620 24041 09632 36010 ...

Page 2567: ...ners and cushion to the shock absorber b Install the shock absorber cushion and retainer with the nut Torque 20 N m 200 kgf cm 15 ft lbf c Install the lower side of the shock absorber with the bolt and nut Torque 87 N m 890 kgf cm 64 ft lbf 2 INSTALL REAR WHEEL Torque 110 N m 1 150 kgf cm 83 ft lbf 3 REMOVE SAFETY STANDS ...

Page 2568: ...per Spacer Rivet Bushing Bushing 170 1 735 125 Shackle Bushing U Bolt Leaf Spring 133 1 350 98 Non reusable part Spacer Standard cab 4WD 2UZ FE engine Caster Wedge Standard cab 4WD 2UZ FE engine Rivet Caster Wedge 2WD Off road Package SA 154 SUSPENSION AND AXLE REAR LEAF SPRING REAR LEAF SPRING COMPONENTS ...

Page 2569: ...tands b Lower the axle housing until the leaf spring tension is free and keep it at this position 2 REMOVE REAR WHEEL 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 ...

Page 2570: ...ner 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...

Page 2571: ...all a new rivet into the holes of the leaf spring and clip Then rivet with a press d Install the 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 N m 450 kgf cm 33 ft lbf e Bend the spring clips Using a hammer bend the spring clips into the position ...

Page 2572: ...kgf cm 125 ft lbf 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 N m 1 350 kgf cm 98 ft lbf 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 N m 1 150 kgf cm 83 ft lbf 4 REMOVE SAFETY STANDS ...

Page 2573: ... 51 69 704 51 29 296 21 29 296 21 Bushing Bushing Bracket Bracket Stabilizer Bar Stabilizer Bar Link Stabilizer Bar Link 69 704 51 SUSPENSION AND AXLE REAR STABILIZER BAR Sport Suspension Package SA 159 REAR STABILIZER BAR Sport Suspension Package COMPONENTS ...

Page 2574: ... the 2 nuts and stabilizer bar link Torque 69 N m 704 kgf cm 51 ft lbf HINT If the ball joint stud turns together with the nut use a hexagon wrench to hold the stud b Use the same procedure described above to the other side 4 REMOVE STABILIZER BAR FROM REAR AXLE HOUSING a Remove the 4 bolts and stabilizer bar with the bushings and brackets Torque 29 N m 296 kgf cm 21 ft lbf b Remove the 2 brackets...

Page 2575: ...PENSION AND AXLE REAR STABILIZER BAR Sport Suspension Package SA 161 INSPECTION INSPECT STABILIZER BAR LINK Rotate the ball joint stud in all directions If it does not move smoothly and freely replace the stabilizer link ...

Page 2576: ...SA2BF 01 SA 162 SUSPENSION AND AXLE REAR STABILIZER BAR Sport Suspension Package INSTALLATION Installation is in the reverse order of removal See page SA 160 ...

Page 2577: ...he performance of the brake system and result in a driving hazard Replace the parts with parts having the same part number or equivalent It is very important to keep parts and the area clean when repairing the brake system If the vehicle is equipped with a mobile communication system refer to the precautions in the IN section ...

Page 2578: ...ment DI 1455 BR 4 BR 41 BR 51 BR 22 BR 28 BR 34 BR 38 Brake drag 1 Brake pedal freeplay Minimum 2 Parking brake lever travel Out of adjustment 3 Parking brake pedal travel Out of adjustment 4 Parking brake wire Sticking 5 Rear brake shoe clearance Out of adjustment 6 Pad or lining Cracked or distorted 7 Piston Stuck 8 Piston Frozen 9 Anchor or return spring Faulty 10 Booster push rod Out of adjust...

Page 2579: ...cored 9 Booster push rod Out of adjustment 10 Vacuum leak in booster system DI 1455 BR 4 BR 39 BR 47 BR 39 BR 47 BR 52 BR 39 BR 47 BR 39 BR 47 BR 44 BR 34 BR 38 BR 31 BR 35 Noise from brakes 1 Pad or lining Cracked or distorted 2 Installation bolt Loose 3 Disc Scored 4 Pad or lining Dirty 5 Pad or lining Glazed 6 Anchor or return spring Faulty 7 Anti squeal shim Damaged 8 Shoe hold down spring Dam...

Page 2580: ...cylinder HINT If the master cylinder was disassembled or if the reservoir be comes empty bleed the air from the master cylinder 1 Disconnect the brake lines from the master cylinder SST 09023 00101 2 Slowly depress the brake pedal and hold it 3 Block off the outlet plug with your finger and release the brake pedal 4 Repeat 2 and 3 3 or 4 times c Bleed brake line 1 Connect the vinyl tube to the cal...

Page 2581: ...n the engine If the brake fluid attaches to any painted surfaces wash it off immediately a Fill 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 b Bleed brake line 1 Connect the vinyl tube to the brake caliper bleeder plug 2 Depress the brake pedal several times then loosen the bleeder plug with ...

Page 2582: ...ing out tighten the master cylinder 3rd chamber bleeder plug then release the brake pedal 6 Repeat 4 and 5 until all the air in the fluid has been bled out 7 Tighten the master cylinder 3rd chamber bleeder plug Torque 11 N m 110 kgf cm 8 ft lbf 8 Tighten the brake caliper bleeder plug or wheel cyl inder bleeder plug Torque 11 N m 110 kgf cm 8 ft lbf 9 Stop the engine d Bleed brake line 1 Connect t...

Page 2583: ...the accumulator is released reaction force becomes light and stroke becomes longer 3 Repeat 1 and 2 5 times 4 Make sure that the interval between pump start and pump stop is 8 to 14 seconds If it takes 14 seconds or more repeat 3 c Bleed front brake line 1 Turn the ignition switch to the ON position and wait until the pump motor has stopped HINT Pump operating sound can be heard 2 Connect the viny...

Page 2584: ...t lbf 5 Repeat the above procedures for each wheel to bleed the air out of the brake line e Hydraulic brake booster disassembly Bleed hydraulic brake booster NOTICE When disassembling the hydraulic brake booster bleed the air from the hydraulic brake booster by following the procedures below 1 Connect the hand held tester to the DLC3 2 Turn the ignition switch to the ON position HINT Pump operatin...

Page 2585: ...heel to bleed the air out of the brake line 10 Turn the ignition switch off 11 Turn the ignition switch on again 12 Clear DTCs see page DI 1397 or DI 1497 f Check fluid level in reservoir 1 Turn the ignition switch off and depress the brake pedal more than 20 times HINT When pressure in the accumulator is released reaction force becomes light and stroke becomes longer 2 Add brake fluid up to the M...

Page 2586: ...ht switch to lock the nut in the position where the stop light goes off e After installation push in the brake pedal 5 to 15 mm 0 20 to 0 59 in and check that the stop light lights up f After adjusting the stop light switch check the pedal height and the pedal free play 3 CHECK PEDAL FREE PLAY W O VSC a Stop the engine and depress the brake pedal several times until there is no more vacuum left in...

Page 2587: ... lock nut e Adjust the pedal height by turning the pedal push rod f Tighten the clevis lock nut Torque 25 5 N m 260 kgf cm 19 ft lbf g Install the stop light switch and turn it until it lightly con tacts the pedal stopper h Connect the connector to the stop light switch i Push in the brake pedal 5 to 15 mm 0 20 to 0 59 in turn the stop light switch to lock the nut in the position where the stop li...

Page 2588: ...he clevis and pin It is 1 to 3 mm 0 04 to 0 12 in at the pedal 8 CHECK PEDAL RESERVE DISTANCE w VSC Release the parking brake With the engine running depress the pedal and measure the pedal reserve distance as shown in the illustration Pedal reserve distance from asphalt sheet at 490 N 50 kgf 110 2 lbf More than 95 mm 3 74 in If the reserve distance is incorrect troubleshoot the brake sys tem ...

Page 2589: ... Pedal Collar 34 350 25 Return Spring Cushion Plate Pedal Pad Brake Pedal Clip Brake Pedal Lever Collar Pin 34 350 25 E Ring Brake Pedal Link Cowl Side Trim Front Door Scuff Plate Specified torque N m kgf cm ft lbf Non reusable part Lithium soap base glycol grease Bushing Bushing Cushion Collar Bushing 13 130 9 13 130 9 Manual Transmission BRAKE BRAKE PEDAL BR 13 COMPONENTS ...

Page 2590: ...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 on page BR 52 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 n...

Page 2591: ... Finish Panel Hood Lock Release Lever Parking Brake Wire 5 4 55 48 in lbf Clip 13 130 9 Pedal Pad Parking Brake Pedal Assembly 13 130 9 Cowl Side Trim Front Door Scuff Plate Specified torque N m kgf cm ft lbf BRAKE PARKING BRAKE PEDAL BR 15 COMPONENTS ...

Page 2592: ...D 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 N m 130 kgf cm 9 ft lbf ...

Page 2593: ...R10C 04 BRAKE PARKING BRAKE PEDAL BR 17 INSTALLATION Installation is in the reverse order of removal See page BR 16 HINT After installation check and adjust the parking brake pedal travel see page BR 14 ...

Page 2594: ...SSARY 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 on page BR 52 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 bell crank st...

Page 2595: ...Reservoir 1 8 18 16 in lbf Reservoir Set Screw Grommet Grommet Cylinder Body No 2 Piston and Spring No 1 Piston and Spring Snap Ring Gasket Piston Stopper Bolt 10 100 7 N m kgf cm ft lbf Specified torque Non reusable part Lithium soap base glycol grease Wire Harness Bracket w o VSC BRAKE BRAKE MASTER CYLINDER Standard Cab Access Cab BR 19 BRAKE MASTER CYLINDER Standard Cab Access Cab COMPONENTS ...

Page 2596: ... fluid remain on a painted surface Wash it off immediately 3 DISCONNECT BRAKE LINES Using SST disconnect the 5 brake lines from the master cylin der and 3 way SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 4 REMOVE MASTER CYLINDER a Remove the 2 nuts wire harness bracket 3 way and check valve bracket Torque 13 N m 130 kgf cm 9 ft lbf b Pull out the master cylinder from the brake booster ...

Page 2597: ... 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 them straight out not at an angle NOTICE If pulled out and installed at an angle there is a possi bility that the cylinder bore could be damaged At the time of reassembly be careful not to...

Page 2598: ...rd Cab Access Cab 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 ...

Page 2599: ...ASTER CYLINDER Standard Cab Access Cab BR 23 REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 21 NOTICE Apply lithium soap base glycol grease to the rubber parts indicated by the arrows See page BR 19 ...

Page 2600: ...Before installation adjust length of the brake booster push rod see page BR 34 After installation fill the brake reservoir with brake fluid and bleed the brake system see page BR 4 Check for leaks check and adjust the brake pedal see page BR 10 Check brake pedal height see page BR 10 Check the brake actuator with the hand held tester see page BR 62 ...

Page 2601: ...inder No 1 Piston Lithium soap base glycol grease Cap Strainer Grommet Reservoir Tank Stopper Pin 15 155 11 Grommet O ring 15 155 11 15 155 11 15 155 11 15 155 11 11 110 8 Bleeder Plug Cap Front Brake Tube No 1 Master Cylinder Body Bleeder Plug Brake Tube 3 Way 25 255 11 25 255 11 BRAKE BRAKE MASTER CYLINDER Double Cab BR 25 BRAKE MASTER CYLINDER Double Cab COMPONENTS ...

Page 2602: ... OUT FLUID WITH SYRINGE NOTICE Do not let brake fluid remain on a painted surface Wash it off immediately 3 DISCONNECT BRAKE LINES a Using SST disconnect the 5 brake lines from the master cylinder and 3 way SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf b Remove the front brake tube No 1 from the master cylin der and 3 way 4 REMOVE BRAKE MASTER CYLINDER Remove the 2 nuts 3 way and brake master...

Page 2603: ...ing SST remove the brake tube from the brake master cylinder SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf d Remove the 2 nuts 2 bolts and brake master cylinder sub assy Torque 25 N m 255 kgf cm 18 ft lbf NOTICE Pay due attention so as not to drop the No 1 piston from the plunger master cylinder If the No 1 piston is dropped it cannot be reused e Remove the master cylinder body and master cyl...

Page 2604: ... Double Cab 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 ...

Page 2605: ...RAKE MASTER CYLINDER Double Cab BR 29 REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 27 NOTICE Apply lithium soap base glycol grease to the rubber parts indicated by the arrows See page BR 25 ...

Page 2606: ...r of removal See page BR 26 HINT After installation fill the brake reservoir with brake fluid and bleed the brake system see page BR 4 Check for leaks check and adjust the brake pedal see page BR 10 Check brake pedal height see page BR 10 Check the brake actuator with the hand held tester see page BR 67 ...

Page 2607: ...ake 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...

Page 2608: ... Switch Connector Brake Booster 25 260 19 Gasket Stopper Ring Clevis Pin 13 130 9 Brake Booster Bracket Stopper Ring 13 130 9 Gasket Clevis Clip Specified torque N m kgf cm ft lbf Non reusable part Pedal Return Spring 13 130 9 13 130 9 Wire Harness Bracket w o VSC BR 32 BRAKE BRAKE BOOSTER ASSEMBLY Standard Cab Access Cab COMPONENTS ...

Page 2609: ...KE BOOSTER 3 REMOVE SCUFF PLATE LH COWL SIDE TRIM LH LOWER FINISH PANEL AND NO 2 HEATER TO REG ISTER DUCT See page BO 111 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 ...

Page 2610: ...e brake booster 2 INSTALL NO 2 HEATER TO REGISTER DUCT LOWER FINISH PANEL COWL SIDE TRIM LH AND SCUFF PLATE See page BO 120 3 ADJUST LENGTH OF BOOSTER PUSH ROD 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 p...

Page 2611: ...airtight If not replace the brake booster b Operating check 1 Depress the brake pedal several times with the igni tion switch OFF and check that there is no change in the pedal reserve distance 2 Depress the brake pedal and start the engine HINT If the pedal goes down slightly the operation is normal If not replace the brake booster c Start the engine and stop it after 1 or 2 minutes Depress the b...

Page 2612: ...oster Gasket Vacuum Hose Clip Brake Vacuum Check Valve Master Cylinder 15 155 11 12 5 128 9 Clip Push Rod Pin w o VSC 3 way Gasket 25 260 19 Stopper Ring Brake Booster Bracket 13 130 9 Front Brake Tube No 1 13 130 9 Clevis BR 36 BRAKE BRAKE BOOSTER ASSEMBLY Double Cab COMPONENTS ...

Page 2613: ...INDER See page BR 26 2 DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3 REMOVE SCUFF PLATE LH COWL SIDE TRIM LH LOWER FINISH PANEL AND NO 2 HEATER TO REG ISTER DUCT See page BO 111 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 b...

Page 2614: ... 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 See page BO 120 NOTICE Do not adjust the brake booster push rod Do not change the combination of the diameter converting unit and brake 3 INSTALL MASTER CYLINDER See page BR ...

Page 2615: ...BR10J 05 F07750 Clip Inner Pad Anti rattle Spring Outer Pad Anti squeal Shim Pin Inner Anti squeal Shim Disc brake grease BRAKE FRONT BRAKE PAD BR 39 FRONT BRAKE PAD COMPONENTS ...

Page 2616: ...ogether 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 pads 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 so...

Page 2617: ... 90 Piston Seal Piston Boot Set Ring Clip Inner Pad Outer Pad Anti squeal Shim Anti rattle Spring Inner Anti squeal Shim Pin Specified torque N m kgf cm ft lbf Lithium soap base glycol grease Disc brake grease BRAKE FRONT BRAKE CALIPER BR 41 FRONT BRAKE CALIPER COMPONENTS ...

Page 2618: ... a container to catch brake fluid SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 3 REMOVE CALIPER Remove the 2 mounting bolts and caliper Torque 123 N m 1 250 kgf cm 90 ft lbf 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 ha...

Page 2619: ...boot set rings and boots 2 REMOVE PISTONS FROM CYLINDER a Prepare a wooden plate to hold the pistons b Place the plate between the pistons and insert a pad at one side c Use compressed air to remove the pistons alternately from the cylinder CAUTION Do not place your fingers in front of the pistons when using compressed air 3 REMOVE PISTON SEALS Using a screwdriver remove the 4 piston seals from th...

Page 2620: ...at a position 10 mm 0 39 in from the outside edge Maximum disc runout 0 07 mm 0 0028 in If the runout is greater than the maximum replace the disc or grind it on an On Car brake lathe HINT Before measuring the runout confirm that the front hub bearing play is within specifications see page SA 20 4 IF NECESSARY ADJUST DISC RUNOUT a Remove the hub nuts and disc Reinstall the disc 1 6 of a turn round...

Page 2621: ...ONT BRAKE CALIPER BR 45 REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 43 NOTICE Apply lithium soap base glycol grease and disc brake grease to the parts indicated by the arrows See page BR 41 ...

Page 2622: ...E FRONT BRAKE CALIPER INSTALLATION Installation is in the reverse order of removal See page BR 42 HINT After installation fill the brake reservoir with brake fluid and bleed the brake system See page BR 4 Check for leaks ...

Page 2623: ...rank Tension Spring Pin Bellcrank Bracket C washer Pin 13 130 9 Parking Brake Cable No 1 Front Shoe Shoe Hold down Spring Anchor Spring Adjusting Lever Spring Automatic Adjusting Lever 10 100 7 11 110 8 Bleeder Plug 10 100 7 Piston Boot Adjuster Cup Spring Wheel Cylinder Adjuster Return Spring Rear Shoe Parking Brake Lever C washer Cup E Ring Gasket Drum BRAKE REAR DRUM BRAKE BR 47 REAR DRUM BRAKE...

Page 2624: ...removed easily do the following steps b Remove the adjusting hole plug from the backing plate c Insert a screwdriver through the hole in the backing plate and hold the automatic adjusting lever away from the ad justing bolt d Using another screwdriver reduce the brake shoe adjust ment by turning the adjusting bolt 4 REMOVE REAR SHOE a Using SST disconnect the return spring from the rear shoe SST 0...

Page 2625: ...e adjusting lever spring b Remove the adjuster 7 REMOVE AUTOMATIC ADJUSTING LEVER AND PARKING BRAKE LEVER a Remove the E ring b Remove the automatic adjusting lever c Remove the C washer d Remove the parking brake lever 8 REMOVE AND DISASSEMBLE PARKING BRAKE BELLCRANK a Remove the clip and pin and disconnect the parking brake cable b Remove the 2 tension springs c Remove the 2 bolts and bellcrank ...

Page 2626: ...brake line Use a container to catch brake fluid SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf b Remove the 2 bolts and the wheel cylinder Torque 10 N m 100 kgf cm 7 ft lbf 10 DISASSEMBLE WHEEL CYLINDER a Remove the 2 boots 2 pistons and spring b Remove the 2 piston cups from each piston ...

Page 2627: ... MEASURE BRAKE SHOE LINING THICKNESS Using a ruler measure the shoe lining thickness Standard thickness 6 0 mm 0 236 in Minimum thickness 1 0 mm 0 039 in If the shoe lining is less than the minimum or shows signs of uneven wear replace the brake shoes HINT If any of the brake shoes have to be replaced replace all of the brake shoes in order to maintain even braking 4 INSPECT BRAKE LINING AND DRUM ...

Page 2628: ...nsion C will be 0 4 to 0 8 mm 0 016 to 0 031 in c Lock the adjusting bolt with the lock nut d Connect the parking brake cable to the parking brake bell crank and install the pin and clip e Install the 2 tension springs 2 CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM a Move the parking brake lever of the front shoe back and forth Check that the adjuster turns If the adjuster does not turn check ...

Page 2629: ...he brake drum inside diameter and diameter of the brake shoes Check that the difference between the diameters is the correct shoe clearance Shoe clearance 0 5 mm 0 020 in If it is incorrect check the parking brake system 4 FILL BRAKE RESERVOIR WITH BRAKE FLUID 5 BLEED BRAKE SYSTEM See page BR 4 6 CHECK FOR LEAKS ...

Page 2630: ...05 lb 2UZ FE engine 1 050 kg 2 315 lb 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 PRES SURE 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 ho...

Page 2631: ...e valve body Low pressure Lower the body High pressure Raise the body e Torque the nuts Torque 13 N m 130 kgf cm 9 ft lbf f Adjust the length of 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 in In this situation do not...

Page 2632: ...3 Load Sensing Spring Assembly Plate Washer Shackle No 1 Shackle No 2 18 185 13 13 130 9 Cushion Retainer Collar Bushing x 2 Shackle Bracket 29 300 22 Specified torque N m kgf cm ft lbf Lithium soap base glycol grease Plate Washer 29 300 22 29 300 22 w o VSC F18915 w VSC Specified torque N m kgf cm ft lbf 29 296 21 Blend Proportioning Valve Assembly BR 56 BRAKE LOAD SENSING PROPORTIONING AND BY PA...

Page 2633: ... 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 3 w BLEND PROPORTIONING VALVE REMOVE BLEND PROPORTIONING VALVE AS SEMBLY a Disconnect the 4 brake lines b Remove the 3 bolts and blend valve Torque 29 ...

Page 2634: ...e valve body 2 DISCONNECT SPRING FROM VALVE Using pliers remove the clip and remove the spring from the valve 3 REMOVE SHACKLES NO 1 AND NO 2 a Remove the nut washer and bolt and remove the load sensing spring and 2 plate washers b Loosen the 2 nuts and plate washer plate and remove shackle No 1 from shackle No 2 4 DISASSEMBLE LOAD SENSING SPRING a Remove the 4 bushings and 2 collars b Remove the ...

Page 2635: ...R09V 10 Z03645 Wear Limit 0 7 mm BRAKE LOAD SENSING PROPORTIONING AND BY PASS VALVE LSP BV BR 59 INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING CON TACT SURFACE FOR WEAR Wear limit 0 7 mm 0 028 in ...

Page 2636: ...asher and shackle No 1 to shackle No 2 then install the upper nut Torque 13 N m 130 kgf cm 9 ft lbf 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 N m 185 kgf cm 13 ft lbf 4 INSTALL LOAD SENSING SPRING TO VALVE BODY Install the load sensing spring to the load sensing valve with the clip...

Page 2637: ...2 in Torque 13 N m 130 kgf cm 9 ft lbf b Install the shackle bracket and 2 bolts Torque 29 N m 300 kgf cm 22 ft lbf c Connect the 2 bushings collar and shackle No 2 to the shackle bracket Torque 13 N m 130 kgf cm 9 ft lbf d Install the cushion retainer and nut 4 SET REAR AXLE LOAD See page BR 54 5 SET VALVE BODY a When pulling down the load sensing spring check that the valve piston moves down smo...

Page 2638: ...lay OFF 3 INSPECT RIGHT FRONT WHEEL SOLENOID a Depress the brake pedal and hold it for about 15 seconds and then check that the brake pedal does not go down fur ther If the brake pedal goes down replace the ABS actuator be cause the sealing condition of the reduction solenoid valve is abnormal b Select the ABS MOT RELAY on the hand held tester display then operate the ABS actuator motor c Check th...

Page 2639: ...ause reduction solenoid valve operation is abnormal j Check that the brake pedal returns when the motor relay is turned ON by the hand held tester NOTICE Do not keep the motor relay ON for more than 5 seconds continuously When operating it continuously set the inter val of more than 20 seconds If the brake pedal does not return replace the ABS actuator be cause motor operation is in failure k Turn...

Page 2640: ...orque 15 2 155 11 2 Actuator Bracket 15 2 155 11 2 15 2 155 11 2 15 2 155 11 2 15 2 155 11 2 To Rear Brake To Right Front Brake To Left Front Brake From Master Cylinder rear port From Master Cylinder front port Connector 11 2 114 8 5 4 55 48 in lbf w o VSC BR 64 BRAKE ABS ACTUATOR COMPONENTS ...

Page 2641: ...orque 15 2 N m 155 kgf cm 11 2 ft lbf HINT When disconnecting the brake line use tags or make a memo to identify the place to reconnect see page BR 64 At the time of installation connect each brake line to the correct position see page BR 64 4 REMOVE ABS ACTUATOR ASSEMBLY Remove the 3 nuts and ABS actuator assembly Torque 11 2 N m 114 kgf cm 8 ft lbf 5 REMOVE ABS ACTUATOR a Remove the 2 nuts and A...

Page 2642: ...BRAKE ABS ACTUATOR INSTALLATION Installation is in the reverse order of removal See page BR 65 HINT After installation fill the brake reservoir with brake fluid and bleed the brake system See page BR 4 Check for leaks ...

Page 2643: ...k fluid pressure At 245 N 25 kgf 55 lbf Front brake pressure Rear brake pressure 2 050 to 3650 kPa 20 9 to 37 2 kgf cm2 297 to 529 psi 0 kPa 0 kgf cm2 0 psi At 343 N 35 kgf 77 lbf Front brake pressure Rear brake pressure 3 270 to 4870 kPa 33 3 to 50 kgf cm2 474 to 711 psi 0 kPa 0 kgf cm2 0 psi e When booster operates 1 Turn the ignition switch on and wait until the pump motor has stopped HINT Pump...

Page 2644: ... to 1 079 psi 2 INSPECT HYDRAULIC BRAKE BOOSTER OPERA TION a Inspect the battery voltage Battery voltage 10 to 14 V b Turn the ignition switch off and depress the brake pedal more than 20 times HINT When pressure in the accumulator power supply system is re leased reaction force becomes light and stroke becomes long er c Check that the brake pedal becomes light to depress If the pedal does not bec...

Page 2645: ...luid Reservoir Accumulator SREC STR SREA SMCF SRLH SRRH SFLH SFRH SRLR SRRR SFLR SFRR RL w c RR w c FL w c FR w c Brake Pedal Master Cylinder Solenoid BRAKE HYDRAULIC BRAKE BOOSTER w VSC BR 69 3 INSPECTION PROCEDURE ...

Page 2646: ... hand held tester 2 Turn the SRCF SA1 on by the hand held tester then depress the brake pedal with stable force and check that the pedal cannot be depressed If the pedal can be depressed replace the hydraulic brake booster HINT To protect the solenoids the hand held tester turns off auto matically 2 seconds after every solenoid has been turned on NOTICE When operating it continuously set the inter...

Page 2647: ...front wheels rotate replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheels fast the fail safe function is ac tivated and judgement cannot be made properly So rotate the wheels as slowly as p...

Page 2648: ...e right front wheel by rotating it by hand If the right front wheel stops replace the hydraulic brake boost er NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated and judgement canno...

Page 2649: ...the left front wheel by rotating it by hand If the left front wheel stops replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated and judgement cannot...

Page 2650: ...noids are on check the right front wheel by rotating it by hand If the right front wheel stops replace the hydraulic brake boost er NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vate...

Page 2651: ...lenoids are on check the left front wheel by rotating it by hand If the left front wheel stops replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated...

Page 2652: ...e pedal when the solenoid is on and check that the rear wheels do not rotate by hand If the rear wheels rotate replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheels fast the fail safe funct...

Page 2653: ...ulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheels fast the fail safe function is ac tivated and judgement cannot be made properly So rotate the wheels as slowly as possible 4 When the solenoids are off ...

Page 2654: ...e right rear wheel by rotating it by hand If the right rear wheel stops replace the hydraulic brake boost er NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated and judgement cannot ...

Page 2655: ...the left rear wheel by rotating it by hand If the left rear wheel stops replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated and judgement cannot b...

Page 2656: ...ids are on check the right rear wheel by rotating it by hand If the right rear wheel stops replace the hydraulic brake boost er NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated an...

Page 2657: ...olenoids are on check the left rear wheel by rotating it by hand If the left rear wheel stops replace the hydraulic brake booster NOTICE When operating it continuously set the interval of more than 20 seconds HINT To protect the solenoids the hand held tester turns off automatically 2 seconds after every solenoid has been turned on When rotating the wheel fast the fail safe function is acti vated ...

Page 2658: ...ket Fluid Level Warning Switch Connector Actuator Connector Clevis Pin Clip 15 2 155 11 2 15 2 155 11 2 N m kgf cm ft lbf Specified torque Non reusable part To Right Rear Brake To Right Front Brake To Left Front Brake To Left Rear Brake Actuator Connector 15 2 155 11 2 15 2 155 11 2 14 2 145 10 14 2 145 10 w VSC BR 82 BRAKE HYDRAULIC BRAKE BOOSTER w VSC COMPONENTS ...

Page 2659: ...ctuator Tube No 1 15 2 155 11 2 Plug 2 9 30 26 in lbf 2 9 30 26 in lbf Clip 7 8 80 69 in lbf Pin Bush Collar Collar Bush 7 8 80 69 in lbf Pin Brake Actuator Bracket 7 8 80 69 in lbf Brake Booster Pump Bracket 7 8 80 69 in lbf Bush Clevis 25 5 260 19 Clevis Lock Nut Boot C Ring Piston 31 9 325 24 31 9 325 24 Gasket Master Cylinder Solenoid Master Cylinder Body Pump Motor Assembly O Ring Accumulator...

Page 2660: ...OUT FLUID WITH SYRINGE NOTICE Do not let brake fluid remain on a painted surface Wash it off immediately 2 REMOVE FRONT DOOR SCUFF PLATE COWL SIDE TRIM BOARD SIDE PANEL LOWER FINISH PANEL AND NO 2 HEATER TO REGISTER DUCT See page BO 111 3 DISCONNECT 3 CONNECTORS Disconnect the 2 actuator connectors and fluid level warning switch connector 4 DISCONNECT BRAKE LINES Using SST disconnect the 4 brake l...

Page 2661: ...E BOOSTER w VSC BR 85 5 REMOVE CLIP AND CLEVIS PIN 6 REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY a Remove the 4 booster installation nuts Torque 14 2 N m 145 kgf cm 10 ft lbf b Remove the hydraulic brake booster assembly and gas ket ...

Page 2662: ...r from the brake actuator bracket No 1 2 REMOVE MASTER CYLINDER RESERVOIR AS SEMBLY a Remove the screw from the master cylinder reservoir as sembly Torque 1 7 N m 17 kgf cm 15 in lbf b Using a pin punch and hammer remove the pin from the master cylinder reservoir assembly c Pull out the master cylinder reservoir assembly from the hydraulic brake booster assembly d Remove the 3 grommets from the ma...

Page 2663: ...ve the 2 plugs from the hydrau lic brake booster assembly b Remove the 2 screws and pull the wire harness from the hydraulic brake booster assembly Torque 2 9 N m 30 kgf cm 26 in lbf c Using a screwdriver remove the clip from the hydraulic brake booster assembly d Using a hexagon wrench 4 mm loosen the 2 pins and brake booster w accumulator pump assembly from the hydraulic brake booster assembly T...

Page 2664: ...cylinder solenoid and the gasket from the master cylinder body NOTICE Do not let water dust and or other objects attach to the surface and or attaching surface of the master cylinder so lenoid master cylinder and body gasket 9 REMOVE CLEVIS a Loosen the clevis lock nut Torque 25 5 N m 260 kgf cm 19 ft lbf b Remove the clevis and clevis lock nut from the hydraulic brake booster assembly 10 REMOVE B...

Page 2665: ...mulator pump assembly in a vise between a cloth b Using a socket wrench 17 mm remove the brake boost er accumulator assembly from the pump motor assembly Torque 57 4 N m 585 kgf cm 42 ft lbf c Remove the brake accumulator pipe compression spring and O ring from the brake booster accumulator assembly and the pump motor assembly ...

Page 2666: ...OSTER w VSC INSPECTION INSPECT HYDRAULIC BRAKE BOOSTER PUMP MOTOR ASSEMBLY OPERATION a Connect the positive lead from the battery to the red cable of the pump motor and the negative lead to the black cable b Check pump motor operation OK Normal operating sound is heard ...

Page 2667: ...rake accumulator as sembly shown in the illustration on the left using a saw and discharge the gas remaining inside CAUTION Cover with a piece of cloth when working because gas and liquid may blow out Carefully not abruptly cut the assembly Wear protective glasses c When the outer body of the brake booster accumulator assembly is cut gas and liquid discharge HINT The gas is colorless odorless and ...

Page 2668: ... BRAKE HYDRAULIC BRAKE BOOSTER w VSC REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 86 NOTICE Apply lithium soap base glycol grease to the rubber parts indicated by the arrows See page BR 82 ...

Page 2669: ... BRAKE BOOSTER w VSC BR 93 INSTALLATION Installation is in the reverse order of removal See page BR 84 HINT After installation fill the brake reservoir with brake fluid and bleed the brake system See page BR 4 Check for leaks ...

Page 2670: ...BR0A2 06 F08184 8 0 82 71 in lbf 8 0 82 71 in lbf 8 0 82 71 in lbf Front Speed Sensor Specified torque N m kgf cm ft lbf BR 94 BRAKE FRONT SPEED SENSOR FRONT SPEED SENSOR COMPONENTS ...

Page 2671: ... ft lbf 2 DISCONNECT SPEED SENSOR CONNECTOR 3 REMOVE SPEED SENSOR a Remove the 2 clips and 3 clamp bolts holding the sensor harness from the frame upper arm and steering knuckle Torque 8 0 N m 82 kgf cm 71 in lbf b Remove the bolt and speed sensor from the steering knuckle Torque 8 0 N m 82 kgf cm 71 in lbf ...

Page 2672: ...BR0A4 08 BR 96 BRAKE FRONT SPEED SENSOR INSTALLATION Installation is in the reverse order of removal See page BR 95 HINT After installation check the speed sensor signal See page DI 1387 or DI 1478 ...

Page 2673: ...e along the screw circumfer ence catches on the screw case f Pull out the wheel pad from the steering wheel g Using a screwdriver disconnect the airbag connector CAUTION When storing the steering wheel pad keep the upper surface of the pad facing upward Never disassemble the steering wheel pad NOTICE When removing the steering wheel pad take care not to pull the airbag wire harness h Disconnect th...

Page 2674: ...F19834 BR 98 BRAKE STEERING ANGLE SENSOR 4 REMOVE STEERING ANGLE SENSOR a Disconnect the connector b While pressing the 2 claws remove the steering sensor ...

Page 2675: ...BR1X6 02 BRAKE STEERING ANGLE SENSOR BR 99 INSTALLATION Installation is in the reverse order of removal See page BR 97 ...

Page 2676: ...BR0A5 06 F19542 N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf Rear Speed Sensor Speed Sensor Connector BR 100 BRAKE REAR SPEED SENSOR REAR SPEED SENSOR COMPONENTS ...

Page 2677: ...ED SENSOR BR 101 REMOVAL 1 REMOVE REAR WHEEL Torque 113 N m 1 150 kgf cm 83 ft lbf 2 DISCONNECT SPEED SENSOR CONNECTOR 3 REMOVE SPEED SENSOR a Remove the bolt and speed sensor from the axle carrier Torque 8 0 N m 82 kgf cm 71 ft lbf ...

Page 2678: ...BR0A7 08 BR 102 BRAKE REAR SPEED SENSOR INSTALLATION Installation is in the reverse order of removal See page BR 101 HINT After installation check the speed sensor signal See page DI 1387 or DI 1478 ...

Page 2679: ...quence 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 the RS section When replacing the steering angle sensor drive the vehicle straight ahead at a speed of 6 5 mph 10 5 km h or more Accordingly zero point calibration...

Page 2680: ...ect 5 Steering system joints Worn 6 Suspension arm ball joints Worn 7 Steering column Binding 8 Power steering vane pump 9 Power steering gear SA 3 SR 5 SR 3 SA 5 SA 84 SR 45 SR 59 SR 70 Poor return 1 Tires Improperly inflated 2 Front wheel alignment Incorrect 3 Steering column Binding 4 Power steering gear SA 3 SA 5 SR 70 Excessive play 1 Steering system joints Worn 2 Suspension arm ball joints W...

Page 2681: ... wear frayed cords etc If any defect is found replace the drive belt HINT Cracks on the rib side of a belt are considered acceptable Re place the belt if there are any missing ribs HINT 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 ...

Page 2682: ...5 START ENGINE Run the engine at idle for a few minutes 6 TURN STEERING WHEEL a With the engine idling turn the wheel left or right to the full lock position and keep it there for 2 to 3 seconds then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds b Repeat a several times 7 STOP ENGINE 8 CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice s...

Page 2683: ...k that it is within the COLD range c Start the engine and run at idle d Turn the steering wheel from lock to lock several times to raise fluid temperature Fluid temperature 80 C 176 F e Check for foaming or emulsification If foaming or emulsification is identified bleed air from the pow er steering system See page SR 4 f With the engine idling measure the fluid level in the reser voir g Stop the e...

Page 2684: ...ge SR 61 b Disconnect the pressure feed tube from the PS vane pump 1GR FE engine See page SR 47 2UZ FE engine See page SR 61 c Connect SST as shown in the illustration below SST 09640 10010 09641 01010 09641 01030 09641 01060 NOTICE Check that the valve of the SST is in the open position d Bleed air from the power steering system See page SR 4 e Start the engine and run at idle f Turn the steering...

Page 2685: ...ine speeds of 1 000 rpm and 3 000 rpm Difference in fluid pressure 490 kPa 5 kgf cm2 71 psi or less NOTICE Do not turn the steering wheel j With the engine idling and the valve fully opened turn the steering wheel left or right to the full lock position Minimum fluid pressure 8 336 kPa 85 kgf cm2 1 209 psi NOTICE Do not keep the steering wheel in the full lock position for more than 10 seconds Do ...

Page 2686: ...ALVE 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 vacu um hose of the air control valve is pinched d Check that the engine rotations increase when the hose is released ...

Page 2687: ... Maximum free play 30 mm 1 18 in 2 CHECK STEERING EFFORT a Center the steering wheel b Remove the steering wheel pad See page SR 18 SR 33 c Start the engine and run at idle d Measure the steering effort in both directions Steering effort Reference 4 9 N m 50 kgf cm 43 in lbf HINT Check tire type pressure and contact surface before making your diagnosis e Tighten the steering wheel set nut Torque 5...

Page 2688: ...ROCEDURES 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 steer ing wheel to maintain the course c Draw a line on the masking tape as shown in the illustra ...

Page 2689: ...nt method for steering angle is different de pending on the models Check whether it is type A or B b Draw a line on the RH and LH tie rod and rack ends where it can easily be seen c 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 d Remove the RH and LH boot clips from the rack boots ...

Page 2690: ...Column Lower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel Hood Lock Release Lever No 2 Universal Joint Assembly No 2 Intermediate Shaft Assembly No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Sliding Yoke 35 360 26 Torx Screw SR 12 STEERING STEERING COLUMN Standard Cab Access Cab 4338 Author Da...

Page 2691: ...ower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel No 2 Universal Joint Assembly No 2 Intermediate Shaft Assembly No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Hood Lock Release Lever Transmission Control Cable Assembly Sliding Yoke 35 360 26 Torx Screw Torx Screw STEERING STEERING COLUMN Stand...

Page 2692: ...umn M T Column Lower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel No 2 Universal Joint Assembly Sliding Yoke No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Hood Lock Release Lever 35 360 26 No 2 Intermediate Shaft Assembly Torx Screw Torx Screw SR 14 STEERING STEERING COLUMN Standard Cab Access...

Page 2693: ... Column Lower Cover Steering Column Assembly Brake Pedal Return Spring Lower LH Finish Panel No 2 Universal Joint Assembly No 2 Intermediate Shaft Assembly No 2 Heater to Register Duct Column Hole Cover No 2 26 260 19 8 0 82 71 in lbf 35 360 26 35 360 26 Steering Wheel Pad Hood Lock Release Lever Transmission Control Cable Assembly Sliding Yoke 35 360 26 Torx Screw STEERING STEERING COLUMN Standar...

Page 2694: ...5 65 in lbf Turn Signal Bracket 19 195 14 Main Shaft Stopper Main Shaft Assembly Column Upper Tube Shaft Bearing A T 2 2 23 19 in lbf Spring 2 9 29 25 in lbf Park Lock Cable Assembly 10 5 110 8 Non tilt steering column Column Tube Assembly Non reusable part Molybdenum disulfide lithium base grease Specified torque N m kgf cm ft lbf Column Upper Clamp Tapered head Bolt Clip SR 16 STEERING STEERING ...

Page 2695: ... Bearing Inner Race Seat 7 5 75 65 in lbf Turn Signal Bracket Release Lever Spring Inner Race Tilt No 1 Stopper Steering Column Housing Support Tilt Spring Spring Guide Tilt steering column 19 195 14 Pivot Pin Column Tube Assembly Non reusable part Molybdenum disulfide lithium base grease Specified torque N m kgf cm ft lbf Column Upper Clamp Tapered head Bolt 2 9 29 25 in lbf Park Lock Cable Assem...

Page 2696: ...er c Remove the steering wheel lower No 3 cover d Using a torx socket wrench loosen the 2 torx screws HINT Loosen each screw until the groove along the screw circumfer ence is caught on the screw case e Pull out the wheel pad from the steering wheel and dis connect the airbag connectors and horn terminal CAUTION When storing the wheel pad keep the upper surface of the pad facing upward Never disas...

Page 2697: ...le the cable or apply oil to it 7 REMOVE LOWER LH FINISH PANEL a Remove the 2 screws and disconnect the hood lock re lease lever from the panel b Remove the 4 panel set bolts and lower LH finish panel 8 REMOVE NO 2 HEATER TO REGISTER DUCT 9 REMOVE BRAKE PEDAL RETURN SPRING 10 REMOVE SLIDING YOKE a Put matchmarks on the sliding yoke and No 2 intermedi ate shaft assembly b Remove the A bolt c Remove...

Page 2698: ...nuts c Pull out the steering column assembly with the No 2 uni versal joint assembly 14 DISCONNECT NO 2 UNIVERSAL JOINT ASSEMBLY a Put matchmarks on the steering column assembly and No 2 universal joint assembly b Remove the bolt and No 2 universal joint assembly 15 REMOVE NO 2 INTERMEDIATE SHAFT ASSEMBLY a Put matchmarks on the No 2 intermediate shaft assem bly and control valve shaft b Remove th...

Page 2699: ...ts c Using a screw extractor remove the 2 bolts column up per bracket and column upper clamp 3 A T REMOVE SHIFT LEVER Remove the screw and shift lever 4 A T REMOVE UPPER NO 2 STEERING COVER 5 A T REMOVE PARK LOCK CABLE ASSEMBLY See page AT 21 6 A T REMOVE SHIFT LEVER HOUSING Remove the 3 torx screws and shift lever housing 7 Tilt steering column REMOVE RELEASE LEVER SPRING 8 REMOVE TURN SIGNAL BRA...

Page 2700: ...d the universal joint of the main shaft assembly more than 15 c Remove the tilt spring and spring guide 11 Tilt steering column REMOVE STEERING COLUMN HOUSING SUPPORT a Remove the 4 torx bolts b Remove the 2 tilt No 1 stoppers and steering column housing support 12 REMOVE MAIN SHAFT STOPPER 13 REMOVE MAIN SHAFT ASSEMBLY a Install SST to the main shaft assembly as shown in the illustration SST 0961...

Page 2701: ... 4 IF NECESSARY REPLACE IGNITION SWITCH a Remove the 2 screws and ignition switch b Install a new ignition switch with the 2 screws 5 INSPECT KEY UNLOCK WARNING SWITCH See page BE 37 6 IF NECESSARY REPLACE KEY UNLOCK WARNING SWITCH a Slide out the key unlock warning switch b Install a new key unlock warning switch 7 A T INSPECT BEARING a Check that the bearing rotates smoothly without abnor mal no...

Page 2702: ...ING STEERING COLUMN Standard Cab Access Cab 4350 Author Date b Coat a new shaft bearing with molybdenum disulfide lithi um base grease c Using SST and a press press in the shaft bearing SST 09950 60010 09951 00460 09950 70010 09951 07150 ...

Page 2703: ...bly e Set SST on the main shaft assembly as shown in the il lustration SST 09612 07010 f Using SST push down the retaining ring until it fits into the shaft groove and install the main shaft assembly NOTICE Do not bend the universal joint of the shaft assembly more than 15 HINT Hold the main shaft assembly with your hand to prevent rota tion 3 INSTALL MAIN SHAFT STOPPER 4 Tilt steering column INST...

Page 2704: ...unch and hammer stake at 3 places evenly around the hole as shown in the illustration 7 INSTALL TURN SIGNAL BRACKET Install the turn signal bracket with 2 new torx screws Torque 7 5 N m 75 kgf cm 65 in lbf HINT Make sure that the protrusion on the steering column housing is fitted into the hole of the turn signal bracket 8 Tilt steering column INSTALL RELEASE LEVER SPRING 9 A T INSTALL PARK LOCK C...

Page 2705: ... COLUMN UPPER CLAMP a Install the column upper bracket and column upper clamp with 2 new tapered head bolts HINT Insert the bracket pin into the column tube hole b Tighten the tapered head bolts until the bolt heads break off 14 INSTALL KEY CYLINDER LAMP ASSEMBLY Install the key cylinder lamp assembly with the clip ...

Page 2706: ...O 2 INTERMEDIATE SHAFT ASSEMBLY a Align the matchmark on the No 2 intermediate shaft as sembly with the one on the control valve shaft b Install the bolt Torque 35 N m 360 kgf cm 26 ft lbf 2 CONNECT NO 2 UNIVERSAL JOINT ASSEMBLY a Insert the column hole cover No 2 b Align the matchmarks on the column assembly and No 2 universal joint assembly c Install the bolt Torque 35 N m 360 kgf cm 26 ft lbf 3...

Page 2707: ...L LOWER LH FINISH PANEL a Install the lower LH finish panel with the 4 bolts b Connect the hood lock release lever with the 2 screws 10 INSTALL SPIRAL CABLE See page BE 40 11 INSTALL COMBINATION SWITCH WITH SPIRAL CABLE a Install the combination switch with the 3 screws b Connect the airbag connector c M T Connect the 3 connectors d A T Connect the 4 connectors 12 INSTALL UPPER AND LOWER COLUMN CO...

Page 2708: ... When installing the wheel pad take care that the wir ings do not interfere with other parts and are not pinched between other parts When installing torx screws take care not to scratch other parts ex cruise control switch lower cover with a torx socket wrench a Connect the airbag connectors and horn terminal b Install the wheel pad after confirming that the circumfer ence groove of the torx screw...

Page 2709: ...er Dust Torx Screw 35 360 26 35 360 26 8 0 82 71 in lbf 26 260 19 26 260 19 8 8 90 78 in lbf 50 510 37 8 8 90 78 in lbf Hood Lock Release Lever 8 0 82 71 in lbf No 2 lntermediate Shaft Assembly Brake Pedal Return Spring Column Upper Cover N m kgf cm ft lbf Specified torque Steering Wheel Lower No 3 Cover Steering Wheel Lower No 2 Cover 35 360 26 Sliding Yoke STEERING STEERING COLUMN Double Cab SR ...

Page 2710: ...Column Housing Tilt Lever Release Lever Spring Turn Signal Bracket Compression Spring Spring Retainer Upper Bearing Inner Race Seat Inner Race 12 120 9 Pivot Pin Spring Park Lock Cable Assembly Shaft Bearing Main Shaft Stopper Pivot Pin Shift Lever Housing 18 180 13 Shift Lever No 2 Steering Column Ring Tilt Lever Lock Shaft 9 0 90 78 in lbf 7 5 75 65 in lbf 2 9 29 25 in lbf Key Cylinder Lamp Asse...

Page 2711: ...emove the steering wheel lower No 3 cover d Using a torx socket wrench loosen the 2 torx screws HINT Loosen each screw until the groove along the screw circumfer ence is caught on the screw case e Pull out the wheel pad from the steering wheel and dis connect the airbag connectors and horn terminal CAUTION When storing the wheel pad keep the upper surface of the pad facing upward Never disassemble...

Page 2712: ...il to it 7 REMOVE LOWER LH FINISH PANEL a Remove the 2 screws and disconnect the hood lock re lease lever from the panel b Remove the 4 panel set bolts and lower LH finish panel 8 REMOVE NO 2 HEATER TO REGISTER DUCT 9 REMOVE BRAKE PEDAL RETURN SPRING 10 REMOVE SLIDING YOKE a Put matchmarks on the sliding yoke and No 2 intermedi ate shaft assembly b Remove the A bolt c Remove the B bolt d Slide the...

Page 2713: ...Pull out the steering column assembly with the No 2 uni versal joint assembly 14 DISCONNECT NO 2 UNIVERSAL JOINT ASSEMBLY a Put matchmarks on the steering column assembly and No 2 universal joint assembly b Remove the bolt and No 2 universal joint assembly 15 REMOVE NO 2 INTERMEDIATE SHAFT ASSEMBLY a Put matchmarks on the No 2 intermediate shaft assem bly and control valve shaft b Remove the bolt ...

Page 2714: ...3 to 4 mm 0 12 to 0 16 in drill drill a hole into the 2 bolts c Using a screw extractor remove the 2 bolts and column upper bracket 3 REMOVE SHIFT LEVER Using a torx socket wrench remove the torx screw and shift lever 4 REMOVE PARK LOCK CABLE ASSEMBLY See page AT 21 5 REMOVE SHIFT LEVER HOUSING Using a torx socket wrench remove the 3 torx screws and shift lever housing 6 REMOVE RELEASE LEVER SPRIN...

Page 2715: ... from the column tube assembly NOTICE Do not bend the universal joint of the main shaft assembly more than 15 c Remove the tilt spring and spring guide 9 REMOVE 2 TILT NO 1 STOPPERS 10 REMOVE MAIN SHAFT STOPPER 11 REMOVE MAIN SHAFT ASSEMBLY a Install SST to the main shaft assembly as shown in the illustration SST 09612 07010 b Using SST compress the compression spring SST 09612 07010 NOTICE Do not...

Page 2716: ... IF NECESSARY REPLACE IGNITION SWITCH a Remove the 2 screws and ignition switch b Install a new ignition switch with the 2 screws 5 INSPECT KEY UNLOCK WARNING SWITCH See page BE 37 6 IF NECESSARY REPLACE KEY UNLOCK WARNING SWITCH a Slide out the key unlock warning switch b Install a new key unlock warning switch 7 INSPECT BEARING a Check that the bearing rotates smoothly without abnor mal noise If...

Page 2717: ...RING STEERING COLUMN Double Cab SR 39 4365 Author Date b Coat a new shaft bearing with molybdenum disulfide lithi um base grease c Using SST and a press press in the shaft bearing SST 09950 60010 09951 00460 09950 70010 09951 07150 ...

Page 2718: ... washer of SST on the main shaft assembly SST 09612 07010 d Set SST on the main shaft assembly as shown in the il lustration SST 09612 07010 e Using SST push down the retaining ring until it fits into the shaft groove and install the main shaft assembly NOTICE Do not bend the universal joint of the shaft assembly more than 15 HINT Hold the main shaft assembly with your hand to prevent rota tion 4 ...

Page 2719: ...ed into the hole of the turn signal bracket 8 INSTALL RELEASE LEVER SPRING 9 INSTALL SHIFT LEVER HOUSING Using a torx socket wrench install the shift lever housing with 3 new torx screws Torque 12 N m 120 kgf cm 9 ft lbf 10 INSTALL PARK LOCK CABLE ASSEMBLY See page AT 22 11 INSTALL SHIFT LEVER Using a torx socket wrench install the shift lever with a new torx screw Torque 18 N m 180 kgf cm 13 ft l...

Page 2720: ...NTERMEDIATE SHAFT ASSEMBLY a Align the matchmark on the No 2 intermediate shaft as sembly with the one on the control valve shaft b Install the bolt Torque 35 N m 360 kgf cm 26 ft lbf 2 CONNECT NO 2 UNIVERSAL JOINT ASSEMBLY a Insert the column hole cover No 2 b Align the matchmarks on the column assembly and No 2 universal joint assembly c Install the bolt Torque 35 N m 360 kgf cm 26 ft lbf 3 INST...

Page 2721: ...bolts b Connect the hood lock release lever with the 2 screws 10 INSTALL SPIRAL CABLE See page BE 40 11 INSTALL COMBINATION SWITCH WITH SPIRAL CABLE a Install the combination switch with the 3 screws b Connect the airbag connector c Connect the 4 connectors 12 INSTALL UPPER AND LOWER COLUMN COVERS Install the upper and lower column covers with the 3 screws 13 CENTER SPIRAL CABLE a Check that the f...

Page 2722: ...rts and are not pinched between other parts When installing torx screws take care not to scratch other parts ex cruise control switch lower cover with a torx socket wrench a Connect the airbag connectors and horn terminal b Install the wheel pad after confirming that the circumfer ence groove of the torx screw is caught on the screw case c Using a torx socket wrench tighten the 2 screws while hold...

Page 2723: ...Bolt Suction Hose Vane Pump Assembly 46 5 474 34 N m kgf cm ft lbf Specified torque Non reusable part Drive Belt 21 210 15 Oil Pressure Switch STEERING POWER STEERING VANE PUMP 1GR FE SR 45 4371 Author Date POWER STEERING VANE PUMP 1GR FE COMPONENTS ...

Page 2724: ...Vane Pump Pulley Oil Seal Front Housing Rear Housing Vane Pump Rotor Side Plate Cam Ring Vane Plate O Ring Snap Ring O Ring O Ring N m kgf cm ft lbf Specified torque Non reusable part Power steering fluid 22 220 16 12 120 9 21 210 15 X10 69 700 51 22 220 16 SR 46 STEERING POWER STEERING VANE PUMP 1GR FE 4372 Author Date ...

Page 2725: ...VER 2 REMOVE DRIVE BELT While releasing the belt tension by turning the belt tensioner counterclockwise remove the drive belt 3 DISCONNECT SUCTION HOSE Remove the clip and disconnect the suction hose 4 DISCONNECT PRESSURE FEED TUBE a Remove the bolt and disconnect the pressure feed tube b Remove the gasket 5 REMOVE VANE PUMP ASSEMBLY a Disconnect the oil pressure switch connector ...

Page 2726: ...F17910 SR 48 STEERING POWER STEERING VANE PUMP 1GR FE 4374 Author Date b Remove the 2 bolts and vane pump assembly ...

Page 2727: ...L 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 OIL PRESSURE SWITCH NOTICE If the oil pressure switch is dropped or damaged replace it with a new one 5 REMOVE REAR HOUSING a Remove the 4 bolts and rear housing b Remove the O ring from the rear housing 6 REMOVE VANE PUMP SHAFT WITH VANE PUMP PULLEY a Using 2...

Page 2728: ...E 10 VANE PLATES AND VANE PUMP ROTOR a Remove the 10 vane plates NOTICE Take care not to drop the vane plate b Remove the vane pump rotor 8 REMOVE CAM RING 9 REMOVE SIDE PLATE a Remove the side plate from the front housing b Remove the O ring from the side plate c Remove the O ring from the front housing ...

Page 2729: ...ness 1 405 to 1 411 mm 0 05531 to 0 05555 in b Using a feeler gauge measure the clearance between a side face of the vane pump rotor groove and the vane plate Maximum clearance 0 03 mm 0 0012 in If it is more than the maximum replace the vane pump assem bly 3 INSPECT FLOW CONTROL VALVE a Coat the flow control valve with power steering fluid and check that it falls smoothly into the valve hole of t...

Page 2730: ...calipers measure the free length of the spring Minimum free length 36 9 mm 1 453 in If it is not within the specification replace the vane pump as sembly 5 INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely dam aged it may cause fluid leakage In that case replace the vane pump assembly ...

Page 2731: ...SSARY REPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the bushing of the front housing b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 00280 09950 70010 09951 07100 NOTICE Make sure that the oil seal is installed in the correct direc tion ...

Page 2732: ...INSTALL VANE PUMP SHAFT WITH VANE PUMP PULLEY a Coat the inside surface of the bushing in the front housing with power steering fluid b Gradually insert the vane pump shaft NOTICE Do not damage the oil seal lip in the front housing HINT Wrap the shaft surface with vinyl tape before inserting 3 INSTALL SIDE PLATE a Coat a new O ring with power steering fluid and install it to the front housing b Co...

Page 2733: ...he correct direction 4 INSTALL CAM RING Align the dent of the cam ring with the dent of the side plate and install the cam ring with the inscribed mark facing outward NOTICE Make sure that the cam ring is installed in the correct direc tion 5 INSTALL VANE PUMP ROTOR a Install the vane pump rotor HINT Vane pump rotor has no specific direction b Coat 10 vane plates with power steering fluid c Instal...

Page 2734: ...ing a torque wrench check the pump rotating torque Rotating torque 0 27 N m 2 8 kgf cm 2 4 in lbf or less If the rotating torque is not as specified above check the instal lation of the vane pump housing oil seal 8 INSTALL OIL PRESSURE SWITCH Torque 21 N m 210 kgf cm 15 ft lbf 9 INSTALL SPRING FLOW CONTROL VALVE AND PRESSURE PORT UNION a Coat the spring and flow control valve with power steering f...

Page 2735: ...lbf b Connect the oil pressure switch connector NOTICE Be careful that the oil does not come into contact with the connector 2 CONNECT PRESSURE FEED TUBE a Install a new gasket to the pressure feed tube b Install the pressure feed tube with the union bolt HINT Make sure that the stopper of the pressure feed tube contacts the pump housing as shown in the illustration c Tighten the union bolt Torque...

Page 2736: ... holes to fix the belt tensioner b Install the drive belt c While turning the belt tensioner counterclockwise re move the bar d If it is hard to install the drive belt perform the following procedure 1 Wrap the drive belt around all the pulleys and idlers except for the vane pump assembly as shown in the illustration 2 While releasing belt tension by turning the belt ten sioner counterclockwise wr...

Page 2737: ... Return Hose N m kgf cm ft lbf Specified torque Non reusable part Gasket 46 5 475 34 Clip Vacuum Hose Clip Drive Belt PS Vane Pump Assembly 44 450 33 Pressure Feed Tube 22 220 16 STEERING POWER STEERING VANE PUMP 2UZ FE SR 59 4385 Author Date POWER STEERING VANE PUMP 2UZ FE COMPONENTS ...

Page 2738: ...mp Shaft with Vane Pump Pulley Oil Seal Front Housing Gasket 24 240 17 Rear Housing O Ring Wave Washer Side Plate Cam Ring Straight Pin Vane Pump Rotor Snap Ring x10 Vane Plate N m kgf cm ft lbf Specified torque Non reusable part Power steering fluid SR 60 STEERING POWER STEERING VANE PUMP 2UZ FE 4386 Author Date ...

Page 2739: ...ose connected 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 REM...

Page 2740: ...pressure port union the 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 ...

Page 2741: ...ce Standard clearance 0 03 to 0 05 mm 0 0012 to 0 0020 in Maximum clearance 0 07 mm 0 0028 in If it is more than the maximum replace the shaft and front hous ing 2 INSPECT VANE PUMP ROTOR AND VANE PLATES a Using a micrometer measure the height thickness and length of the 10 plates Minimum height 8 6 mm 0 339 in Minimum thickness 1 397 mm 0 0550 in Minimum length 14 991 mm 0 5902 in b Using a feele...

Page 2742: ...51 0 59059 1 44345 04020 14 997 14 999 0 59043 0 59051 2 44345 04030 14 995 14 997 0 59035 0 59043 3 44345 04040 14 993 14 995 0 59027 0 59035 4 44345 04050 14 991 14 993 0 59020 0 59027 3 INSPECT FLOW CONTROL VALVE a Coat the valve with power steering fluid and check that it falls smoothly into the valve hole under its own weight b Check the flow control valve for leakage Close one of the holes a...

Page 2743: ...ING POWER STEERING VANE PUMP 2UZ FE SR 65 4391 Author Date 4 INSPECT SPRING Using vernier calipers measure the free length of the spring Minimum free length 33 2 mm 1 307 in If it is not within the specification replace the spring ...

Page 2744: ...ighten it IF NECESSARY REPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the front housing b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 00330 09950 70010 09951 07100 NOTICE Make sure to install the oil seal in the correct direction ...

Page 2745: ...ring with the one of 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 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 ho...

Page 2746: ... See page SR 59 c Coat a new O ring with power steering fluid and install it on the pressure port union d Install the pressure port union Torque 83 N m 850 kgf cm 61 ft lbf 11 INSTALL SUCTION PORT UNION a Coat a new O ring with power steering fluid and install it on the suction port union b Install the suction port union with the bolt Torque 13 N m 130 kgf cm 9 ft lbf 12 MEASURE PS VANE PUMP ROTAT...

Page 2747: ... of the pressure feed tube contacts the PS vane pump body as shown in the illustration then tight en the union bolt Torque 46 5 N m 475 kgf cm 34 ft lbf 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 ins...

Page 2748: ...e with SST N m kgf cm ft lbf 29 290 21 Clamp Plate Return Tube 25 250 18 22 227 16 25 250 18 22 227 16 Cotter Pin 91 930 67 165 1 700 123 35 360 26 No 2 Intermediate Shaft Assembly 91 930 67 165 1 700 123 20 200 15 130 1 350 96 SR 70 STEERING POWER STEERING GEAR 4396 Author Date POWER STEERING GEAR COMPONENTS ...

Page 2749: ...l Seal Bushing O Ring Oil Seal Wire N m kgf cm ft lbf Specified touque Power steering fluid For use with SST Non reusable part Molybdenum disulfide lithium base grease O Ring 55 560 41 103 1 050 76 76 770 56 55 560 41 103 1 050 76 76 770 56 Cylinder End Stopper STEERING POWER STEERING GEAR SR 71 4397 Author Date ...

Page 2750: ... Bearing N m kgf cm ft lbf Specified torque Non reusable part Precoated part Molybdenum disulfide lithium base grease Power steering fluid For use with SST Rack Housing Bearing Gasket Control Valve Assembly Oil seal 15 150 11 13 135 10 18 185 13 69 700 51 51 520 38 Rack Guide Spring Cap 30 300 22 18 185 13 15 150 11 13 135 10 15 150 11 13 135 10 15 150 11 13 135 10 SR 72 STEERING POWER STEERING GE...

Page 2751: ...LS FACING STRAIGHT AHEAD 3 REMOVE STEERING WHEEL PAD See page SR 18 SR 33 4 REMOVE STEERING WHEEL See page SR 18 SR 33 5 DISCONNECT RH AND LH TIE ROD ENDS See page SA 84 6 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY See page SR 18 SR 33 7 DISCONNECT CLAMP PLATE Remove the bolt and disconnect the clamp plate 8 DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST disconnect the tube SST 09023 12701 ...

Page 2752: ...nd 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 RH AND LH TIE ROD ENDS AND LOCK NUTS a Put 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 Perform the same procedure on the other side 4 REMOVE RH AND LH CLIPS ...

Page 2753: ...2 10010 HINT Mark the RH and LH rack ends NOTICE Use SST 09922 10010 in the direction shown in the illustra tion c Remove the washer from the rack end d Perform the same procedure on the other side 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 illustra tion 7 REMOVE RACK GUIDE SPRING CAP RACK GUIDE SPR...

Page 2754: ... ASSEMBLY a Put 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 12 REMOVE CONTROL VALVE ASSEMBLY a To prevent oil seal lip damage wind vinyl tape on the ser rated part of the valve shaft b Press out the valve assembly with the oil seal NOTICE Place a shop rag between the va...

Page 2755: ...e hole SST 09631 16010 b Using SST turn the stopper counterclockwise and re move 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 16 REMOVE OIL SEAL Using SST press out the oil seal SST 09950 6...

Page 2756: ...R 78 STEERING POWER STEERING GEAR 4404 Author Date INSPECTION INSPECT STEERING RACK a Using a dial indicator check the rack for runout teeth wear and damage Maximum runout 0 09 mm 0 0035 in b Check the back surface for wear and damage ...

Page 2757: ...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 NOTICE Make sure to install the oil seal 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...

Page 2758: ...10 09951 07150 3 IF NECESSARY REPLACE OIL SEAL a Using SST remove the oil seal from the bushing SST 09527 2001 1 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 in the correct direction 4 IF NECESSARY ...

Page 2759: ...N 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 Ca...

Page 2760: ...n the correct direc tion 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 bur nish 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 200...

Page 2761: ...vacuum check the installation of the oil seals 7 INSTALL CONTROL VALVE ASSEMBLY a To prevent oil seal lip damage wind vinyl tape on the ser rated 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 f...

Page 2762: ...010 Torque 59 N m 600 kgf cm 43 ft lbf 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 T...

Page 2763: ...RING 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 tighten the lock nut SST 09922 10010 Torque 51 N m 520 kgf cm 38 ft lbf NOTICE Use SST 09922 10010 in the direction shown in the illustra tion HINT Use a ...

Page 2764: ...e 17 INSTALL RH AND LH 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 t...

Page 2765: ...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 34201 Torque 13 N m 135 kgf cm 10 ft lbf HINT Use a torque wrench with a fulcrum length of 250 mm 9 84 in This torque value is effective in case that SST is parallel to a torque wrench ...

Page 2766: ... SST connect the tubes SST 09023 12701 Torque 22 N m 227 kgf cm 16 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm 11 81 in 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 N m 290 kgf cm 21 ft lbf 5 CONNECT NO 2 INTERMEDIATE SHAFT ASSEMBLY See page SR 28 SR 42 6 CONNECT RH AN...

Page 2767: ...2 TORQUE STEERING WHEEL SET NUT Torque 50 N m 510 kgf cm 37 ft lbf 13 INSTALL STEERING WHEEL PAD See page SR 28 SR 42 14 CHECK FRONT WHEEL ALIGNMENT See page SA 5 15 CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 16 PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION See page DI 1494 ...

Page 2768: ...e page DI 1849 If the initialization is not performed the SRS may not oper ate properly The occupant classification ECU is replaced Accessories seatback tray seat cover etc are installed to the vehicle The passenger seat is removed from the vehicle and then reinstalled or replaced The passenger airbag ON OFF indicator light OFF comes on when the passenger seat is not occupied The vehicle is brough...

Page 2769: ...a new one Use a volt ohmmeter with high impedance 10 kΩ V minimum for troubleshooting the electrical circuits Information labels are attached to the periphery of the SRS components Follow the instruc tions in the caution After work on the SRS is completed perform the SRS warning light check see page DI 1859 When the negative terminal cable is disconnected from the battery the memory will be cleare...

Page 2770: ...t to the workshop for repair due to an accident or collision 1 STEERING WHEEL PAD The inflator and bag of the SRS are stored in the steering wheel pad and cannot be disassembled The inflator contains a squib igniter charge and gas generator etc and inflates the bag when instructed by the airbag sensor assembly The steering wheel pad cannot be disassembled 2 SPIRAL CABLE A spiral cable is used as a...

Page 2771: ...embly The side airbag assembly cannot be disassembled 5 CURTAIN SHIELD AIRBAG ASSEMBLY The inflator and bag of the SRS are stored in the curtain shield airbag assembly and cannot be disassembled The inflator con tains a squib igniter charge gas generator etc and inflates the bag when instructed by the airbag sensor assembly The curtain shield airbag assembly cannot be disassembled 6 SEAT BELT PRET...

Page 2772: ... etc It receives signals from the airbag sen sor front airbag sensor side and curtain shield airbag sensor and curtain shield airbag sensor and judges whether the SRS must be activated or not The airbag sensor assembly cannot be disassembled 9 FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the radiator support The front airbag sensor consists of an airbag sensor diagnosis ci...

Page 2773: ...en sor assembly cannot be disassembled 12 SEAT POSITION SENSOR ASSEMBLY The seat position sensor assembly is mounted in the driver s seat The sensor unit consists of a magnet sensor etc It judges the seat sliding position and sends the signal to the airbag sen sor assembly The seat position sensor assembly cannot be disassembled 13 OCCUPANT CLASSIFICATION ECU The occupant classification ECU is mou...

Page 2774: ...lso in order to inform the passenger that the front passenger airbag is disabled the OFF indicator inside the switch illuminates Switch Position Passenger Airbag Indicator Light ON or AUTO Operative OFF OFF Disabled ON 15 RSCA OFF SWITCH The RSCA OFF switch is located on the switch base The cur tain shield airbag can be switched ON and OFF by pushing the RCSA OFF switch Also the RCSA OFF indicator...

Page 2775: ... 25 26 27 28 19 20 23 24 1 w Occupart Classification System Steering Wheel Pad Squib RS 8 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG 4423 Author Date 16 SRS CONNECTORS HINT SRS connectors are located as shown in the following illustration No Connector Type Application 1 Terminal Twin Lock Mechanism Connectors 2 4 16 17 21 22 2 Activation Prevention Mechanism Connectors 2 4 18 20 22 24 3 Half Connect...

Page 2776: ... Occupant Classification ECU 2 Curtain Shield Airbag Sensor Assembly RH 1 Curtain Shield Airbag Sensor Assembly LH 1 Steering Wheel Pad Squib RCSA OFF Switch 1 RCSA OFF Indicator 1 1 w Side Airbag and Curtain Shield Airbag 34 33 Passenger Airbag ON OFF Indicator 3 2 w Occupant Classification System 3 Separate Seat Type Double Cab SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG RS 9 4424 Author Date No Co...

Page 2777: ...r connectors These connectors have special functions and are specially designed for the SRS All SRS connec tors use durable gold plated terminals and are placed in the locations shown on the previous page to ensure high reliability 1 Terminal Twin Lock Mechanism Each connector has a two piece component con sisting of a housing and a spacer This design al lows the terminal to be locked securely by ...

Page 2778: ...ENTAL RESTRAINT SYSTEM SRS AIRBAG RS 1 1 4426 Author Date 3 Half connection prevention mechanism If the connector is not completely connected the connector is disconnected due to the spring opera tion to the extent that no continuity exists 4 Connector lock mechanism 1 Locking the connector lock button securely con nects the connector ...

Page 2779: ... 5 Connector lock mechanism 2 Both the primary lock with holder lances and the secondary lock with retainer prevent the connectors from becoming disconnected 6 Improper connection prevention lock mechanism When connecting the holder the lever is pushed into the end by rotating around the A axis to lock the holder securely ...

Page 2780: ...CTORS FOR STEERING WHEEL PAD a Release the lock button yellow part of the connector using a screwdriver b Insert the screwdriver tip between the connector and the base and then raise the connector 18 CONNECTION OF CONNECTORS FOR STEERING WHEEL PAD a Connect the connector b Push down securely on the lock button yellow part of the connector When locking a click sound can be heard ...

Page 2781: ...nger on the slider slide the slider to release the lock and then disconnect the connector 20 CONNECTION OF CONNECTORS FOR FRONT PASSENGER AIRBAG ASSEMBLY AND CUR TAIN SHIELD AIRBAG ASSEMBLY a Connect the connector as shown in the illustration When locking make sure that the slider returns to its original position and a click sound can be heard HINT When connecting the slider will slide Be sure not...

Page 2782: ...G RS 15 4430 Author Date 21 DISCONNECTION OF CONNECTOR FOR AIRBAG SENSOR ASSY CENTER a Pull the lever by pushing part A as shown in the illustration and disconnect the holder with connectors HINT Perform the following procedures when replacing the holder b Remove the holder 1 Using a screwdriver unlock the retainer ...

Page 2783: ...AINT SYSTEM SRS AIRBAG 4431 Author Date 2 Release the fitting lances and remove the holder c Install the holder 1 Install the connectors to the holder When locking a click sound can be heard HINT The retainer is locked when the holder is connected ...

Page 2784: ...F CONNECTOR FOR AIRBAG SENSOR ASSY CENTER a Firmly insert the holder with connectors until it can not be pushed any further b Push the lever to connect the holder with connectors When locking a click sound can be heard HINT The holder slides when connecting Be sure not to hold the holder while connecting as it may result in an insecure fit ...

Page 2785: ...R a Push down the housing lock white part and slide the CPA yellow part At this time the connector cannot be disconnected yet b Push down the housing lock white part again and disconnect the connector HINT Do not push down the A part shown in the illustration when disconnecting c After disconnecting the connector check that the position of the housing lock white part is as shown in the illustratio...

Page 2786: ...SOR a Before connecting the connectors check that the position of the housing lock white part is as shown in the illustration b Be sure to engage the connectors until they are locked When locking make sure that a click sound can be heard HINT When connecting them the housing lock white part slides Be sure not to hold the housing lock white part and A part as it may result in an insecure fit ...

Page 2787: ...slider slide the slider to release the lock and then disconnect the connector 26 CONNECTION OF CONNECTOR FOR SIDE AIRBAG ASSEMBLY a Connect the connector as shown in the illustration When locking make sure that the slider returns to its original position and a click sound can be heard HINT When connecting the slider will slide Be sure not to touch the slider while connecting as it may result in an...

Page 2788: ...the arrow b When the connector lock is released the connectors are disconnected HINT Be sure to hold both outer flank sides Holding the top and bot tom sides will make disconnection difficult 28 CONNECTION OF CONNECTORS FOR SIDE AIRBAG SENSOR AND CURTAIN SHIELD AIRBAG SENSOR a Connect the connector as shown in the illustration When locking make sure that the outer returns to its original position ...

Page 2789: ...lbf Specified torque Steering Wheel Steering Wheel Cover Lower No 2 Steering Wheel Cover Lower No 3 8 8 90 78 in lbf 8 8 90 78 in lbf Torx Screw Torx Screw RS 22 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 4437 Author Date STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS ...

Page 2790: ...ag parts from another vehicle When replacing parts replace them with new ones 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE STEERING WHEEL PAD SEE PAGE SR 18 AND SR 33 4 REMOVE STEERING WHEEL SEE PAGE SR 18 AND SR 33 5 REMOVE STEERING COLUMN COVER LOWER SEE PAGE SR 18 AN...

Page 2791: ...page DI 1871 b With the steering wheel pad removed from the vehicle perform a visual check If there are any defects as men tioned below replace the steering wheel pad or steering wheel assembly with a new one Cuts minute cracks or marked discoloration on the steering wheel pad top surface or in the grooved portion Cracks or other damage to the connectors Deformation of the steering wheel assembly ...

Page 2792: ...hen deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise When deploying an airbag perform the operation at least 10 m 33 ft away from the steering wheel pad The steering wheel pad becomes extremely hot when the airbag is deployed so do not touch it for at least 30 minutes after deployment Use gloves and safety gla...

Page 2793: ...tch is not being pressed SST malfunction is possible so re place the SST with a new one 3 Disconnect the SST from the battery b Precaution see page RS 1 and RS 3 c Disconnect the cable from the negative battery terminal Wait for 90 seconds after disconnecting the cable to prevent the airbag working d Remove the steering column cover lower 1 While turning the steering wheel assembly to the right an...

Page 2794: ...ve terminal f Deploy the airbag 1 Check that no one is inside the vehicle or within a 10 m 33 ft radius of the vehicle 2 Press the SST activation switch and deploy the air bag CAUTION When deploying the airbag make sure that no one is near the vehicle The steering wheel pad becomes extremely hot when the airbag is deployed so do not touch it for at least 30 minutes after deployment Use gloves and ...

Page 2795: ...the disc wheel Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more CAUTION If the wire harness is too thin or an alternative object is used to tie down the steering wheel pad it may be snapped by the shock when the airbag is deployed Always use a wire harness for vehicle use with an area of at least 1 25 mm2 0 0019 in 2 HINT To calculate the area of the stripped wire har...

Page 2796: ... and right sides of the steering wheel pad to the disc wheel through the hub nut holes Position the SST con nector so that it hangs downward through the hub hole in the disc wheel CAUTION Make sure that the wire harness is tight If there is slack in wire harness the steering wheel pad may be come loose due to the shock when the airbag is deployed Always tie down the steering wheel pad with the air...

Page 2797: ...mension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the steering wheel pad is tied to X should be the following size X 460 mm 18 11 in width of tire If a cardboard box whicn is 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 wheels on th...

Page 2798: ...l pad is tied to 3 Press the SST activation switch and deploy the air bag CAUTION When deploying the airbag make sure that no one is near the tire HINT The airbag is deployed as the LED of the SST activation switch comes on g Dispose of the steering wheel pad CAUTION The steering wheel pad becomes extremely hot when the airbag is deployed so do not touch it for at least 30 minutes after deployment...

Page 2799: ...ering wheel pad The spiral cable has been found to be faulty in troubleshooting Spiral cable The steering wheel pad has been found to be faulty while checking items see page RS 24 Steering wheel pad The steering wheel has been found to be faulty while checking items see page RS 24 Steering wheel The spiral cable has been found to be faulty while checking items see page RS 24 Spiral cable The steer...

Page 2800: ...installing the steering wheel pad take care that it is not pinched between other parts Never use airbag parts from another vehicle When replacing parts replace them with new ones 1 INSTALL SPIRAL CABLE SEE PAGE SR 28 AND SR 42 2 INSTALL STEERING COLUMN COVER LOWER SEE PAGE SR 28 AND SR 42 3 INSTALL STEERING WHEEL SEE PAGE SR 28 AND SR 42 4 INSTALL STEERING WHEEL PAD SEE PAGE SR 28 AND SR 42 5 CONN...

Page 2801: ... Door Front Door Scuff Plate Front Console Box Lower Instrument Cover Upper Console Panel Rear Console Box Cowl Side Trim 5 0 51 44 in lbf Shifting Hole Cover Cowl Side Trim Lower Center Cover Standard Cab Access Cab Access Cab Large Type Console Box RS 34 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY 4449 Author Date FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS ...

Page 2802: ... Glove Compartment Door Cowl Side Trim Board Side Panel Front Door Scuff Plate Cowl Side Trim Board Side Panel Upper Console Panel Shifting Hole Cover Disc Player Cover Disc Player Front Console Box Double Cab w Rear seat audio or Rear seat entertainment Rear Console Box Lower Center Cover Split Type Seat SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY RS 35 4450 Author Date ...

Page 2803: ...OWL SIDE TRIMS SEE PAGE BO 1 11 5 Double cab REMOVE COWL SIDE TRIM BOARDS SEE PAGE BO 1 11 6 Double cab REMOVE SIDE PANELS SEE PAGE BO 1 11 7 REMOVE LOWER FINISH PANEL SEE PAGE BO 1 11 8 REMOVE GLOVE COMPARTMENT DOOR SEE PAGE BO 1 11 9 REMOVE LOWER NO 2 FINISH PANEL SEE PAGE BO 1 11 10 Standard cab Access cab w o Large type console box Double cab Split type seat REMOVE LOWER CENTER COVER SEE PAGE ...

Page 2804: ...NOTICE When handling the airbag connector take care not to dam age the airbag wire harness c Remove the bolt holding the front passenger airbag as sembly and instrument panel d Remove the 2 bolts holding the front passenger airbag assembly and instrument panel reinforcement e Remove the front passenger airbag assembly CAUTION Do not store the front passenger airbag assembly with the airbag deploym...

Page 2805: ...bly 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Perform a diagnostic system check see page DI 1871 b With the front passenger airbag assembly removed from the vehicle perform a visual check If there are any de fects as mentioned below replace the front passenger airbag assembly instrument panel or instrument panel re inforcement with a new one Cuts minute cracks or marked discol...

Page 2806: ...n outdoors and where it will not create a nuisance to nearby resi dents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise When deploying the airbag perform the operation at least 10 m 33 ft away from the front passenger air bag assembly The front passenger airbag assembly becomes ex tremely hot when the ai...

Page 2807: ...the front passenger airbag assembly 1 Using a clip remover disengage the connector clamp 2 Disconnect the airbag connector NOTICE When handling the airbag connector take care not to dam age the airbag wire harness g Install the SST 1 Connect the SST connector to the front passenger airbag assembly SST 09082 00700 09082 00780 NOTICE To avoid damaging the SST connector and wire harness do not lock t...

Page 2808: ... Always wash your hands with water after completing the operation HINT The airbag deploys as the LED of the SST activation switch comes on 2 DEPLOYMENT WHEN DISPOSING OF FRONT PAS SENGER AIRBAG ASSEMBLY ONLY NOTICE When disposing of the front passenger airbag assem bly never use the customer s vehicle to deploy the airbag Be sure to follow the procedure detailed below when deploying the airbag HIN...

Page 2809: ... use a wire harness for vehicle use with an area of at least 1 25 mm2 0 0019 in 2 HINT To calculate the area of the stripped wire harness section Area 3 14 X Diameter 2 divided by 4 1 Position the front passenger airbag assembly in side the tire with the airbag deployment side facing inside Tire size Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION M...

Page 2810: ...s in the tires coming free due to the shock when the airbag is deployed e Install the SST Connect the SST connector SST 09082 00700 09082 00780 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock Also se cure some slack for the SST wire harness inside the tire f Deploy the airbag 1 Connect the red clip of the SST to the battery posi tive term...

Page 2811: ...east 30 minutes after deployment Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag Do not apply water etc to a front passenger airbag assembly with a deployed airbag Always wash your hands with water after completing the operation 1 Remove the front passenger airbag assembly from the tire 2 Place the front passenger airbag assembly in a plastic ba...

Page 2812: ... shooting Front passenger airbag assembly The front passenger airbag assembly has been found to be faulty while checking items see page RS 38 Front passenger airbag assembly The instrument panel has been found to be faulty while checking items see page RS 38 Instrument panel The instrument panel reinforcement has been found to be faulty while check ing items see page RS 38 Instrument panel reinfor...

Page 2813: ...he front passenger airbag assem bly and instrument panel reinforcement Torque 20 N m 204 kgf cm 15 ft lbf b Install the 2 bolts to hold the front passenger airbag as sembly and instrument panel Torque 5 0 N m 51 kgf cm 44 in lbf 2 INSTALL LOWER INSTRUMENT COVER SEE PAGE BO 120 3 Access cab w Large type console box Double cab INSTALL FRONT CONSOLE BOX SEE PAGE BO 120 4 Access cab w Large type conso...

Page 2814: ... 2 FINISH PANEL SEE PAGE BO 120 10 INSTALL GLOVE COMPARTMENT DOOR SEE PAGE BO 120 11 INSTALL LOWER FINISH PANEL SEE PAGE BO 120 12 Double cab INSTALL SIDE PANELS SEE PAGE BO 120 13 Double cab INSTALL COWL SIDE TRIM BOARDS SEE PAGE BO 120 14 Standard cab Access cab INSTALL COWL SIDE TRIMS SEE PAGE BO 120 15 INSTALL FRONT DOOR SCUFF PLATES SEE PAGE BO 120 16 CONNECT CABLE TO NEGATIVE BATTERY TERMI N...

Page 2815: ...t Cushion Inner Shield Driver s seat Torx Screw Seat Position Sensor Protector Driver s seat Hog Ring Front Seat Inner Belt Headrest Support Seat Frame Assembly Seatback Cover Seatback Pad Spacer Seat Track Cover Seat Track Cover Armrest Assembly Armrest Cap Armrest Spacer Armrest Lock Plate Headrest 8 0 82 72 in lbf RS 48 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY Power Adjuster Type 4463...

Page 2816: ...E BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE SEAT TRACK COVERS Using a screwdriver remove the 2 seat track covers HINT Tape the screwdriver tip before use 4 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c Remove the front seat CAUTION Be careful not to damage the body 5 REMOVE HEADREST 6 REMOVE SLIDE KNOB AND RECLI...

Page 2817: ... g Remove the screw and separate the seat cushion lower shield and seat cushion outer shield h Perform the same procedure as for the other side 8 REMOVE FRONT SEAT INNER BELT a Disconnect the wire harness clamps and connectors b Remove the nut and front seat inner belt 9 REMOVE LUMBAR SWITCH Remove the 2 screws and lumbar switch from the seat cushion outer shield 10 REMOVE POWER SEAT SWITCH Remove...

Page 2818: ...OVE SEATBACK COVER AND PAD a Remove the seatback cover belt from the seat frame as sembly b Open the fastener c Remove the hog rings from the seat frame assembly d Remove the hog rings from the seat frame assembly e Remove the 2 headrest supports from the seat frame as sembly f Remove the seatback cover and pad from the seat frame assembly ...

Page 2819: ...ne Cuts minute cracks or marked discoloration on the front seatback assy around the front seat airbag assy 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Perform a diagnostic system check see page DI 1871 b Perform a visual check which includes the following items with the seatback assembly removed from the vehicle Cuts tears and cracks on the side airbag assembly Cuts and cracks i...

Page 2820: ...xploding sound when it is deployed so perform the operation outdoors and where it will not create a nuisance to nearby resi dents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the operation in a place away from electrical noise When deploying the airbag perform the operation at least 10 m 33 ft away from the front seat airbag as sembly The front seat air...

Page 2821: ...HINT Keep the front seat assy LH in the cabin e Disconnect the connector yellow colored one from the front seat airbag assy LH NOTICE When handling the airbag connector take care not to dam age the airbag wire harness f Install the SST 1 Connect the connectors of the SST to the airbag connector SST 09082 00700 09082 00750 NOTICE To avoid damaging the SST connector and wire harness do not lock the ...

Page 2822: ...r etc to a front seat airbag assem bly with a deployed airbag Always wash your hands with water after completing the operation HINT The airbag deploys as the LED of the SST activation switch comes on 2 DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY NOTICE When disposing of the side airbag assembly never use the customer s vehicle to deploy the airbag Be sure to follow the procedure given below ...

Page 2823: ...ssenger airbag assembly keep the airbag deployment side facing upward e Using a service purpose wire harness for the vehicle tie down the front passenger airbag assembly to the tire Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more HINT To calculate the area of the stripped wire harness section Area 3 14 x Diameter 2 divided by 4 CAUTION If the wire harness is too thin...

Page 2824: ...s tight If there is slack in wire harness the side airbag assembly may become loose due to the shock when the airbag is deployed Always tie down the side airbag assembly with the airbag deployment side facing inside the tire NOTICE The tire will be marked by the airbag deployment so use an extra tire f Install the SST 1 Connect the SST connector to the side airbag as sembly connector SST 09082 007...

Page 2825: ...ector SST 09082 00700 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock Also se cure some slack for the SST wire harness inside the tire i Deploy the airbag 1 Connect the red clip of the SST to the battery posi tive terminal and the black clip of the SST to the battery negative terminal 2 Check that no one is within a 10 m 33 ft radius of t...

Page 2826: ... assembly has been found to have cuts while checking items see page RS 52 Seat frame assembly The seatback cover has been found to have cuts and frayed seams while checking items see page RS 52 Seatback cover The side airbag assembly has been found to be faulty while checking items see page RS 52 Seat frame assembly The seatback cover has been found to be faulty while checking items see page RS 52...

Page 2827: ...ctor replace the side airbag assembly with a new one When installing the side airbag assembly take care it is not pinched between other parts Never use airbag parts from another vehicle When replacing parts replace them with new ones 1 INSTALL SEATBACK COVER AND PAD a Install the seatback cover and pad to the seat frame as sembly b Install the 2 headrest supports to the seat frame assem bly c Inst...

Page 2828: ... cushion outer shield 5 INSTALL FRONT SEAT INNER BELT a Install the front seat inner belt with the nut Torque 42 N m 428 kgf cm 31 ft lbf b Connect the connectors and wire harness clamps 6 INSTALL SEAT CUSHION LOWER SHIELD SEAT CUSHION OUTER SHIELD AND SEAT CUSHION IN NER SHIELD a Assemble the seat cushion lower shield and seat cushion outer shield with the screw b Perform the same procedure as fo...

Page 2829: ...connectors b Slide the front seat to the rearmost position c Temporarily tighten the bolts on the front side starting from the bolt on the inner side and fully tighten them Torque 37 N m 377 kgf cm 27 ft lbf d Slide the front seat to the most front position e Temporarily tighten the bolts on the rear side starting from the bolt on the inner side and fully tighten them Torque 37 N m 377 kgf cm 27 f...

Page 2830: ... Armrest Assembly Seat Track Cover Seat Track Cover Seat Position Sensor Protector Driver s seat Seat Position Sensor Driver s seat Torx Screw Seat Frame Assembly Hog Ring N m kgf cm ft lbf Specified torque Non reusable part Spacer Reclining Adjuster Release Handle Vertical Adjuster Handle Cap Vertical Adjuster Handle SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY Manual Adjuster Type RS 63 44...

Page 2831: ...for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 4 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c w Side airbag Disconnect the airbag connector d Remove the front seat NOTICE Be careful not to damage the body 5 REMOVE HEADREST 6 REMOVE...

Page 2832: ...river tip before use 10 REMOVE FRONT SEAT INNER BELT a Disconnect the wire harness clamps and connectors b Remove the nut and front seat inner belt 11 REMOVE ARMREST ASSEMBLY a Using a screwdriver remove the armrest cap b Remove the bolt armrest spacer armrest lock plate and armrest assembly c Remove the spacer from the armrest assembly 12 REMOVE SEATBACK COVER AND PAD a Remove the seatback cover ...

Page 2833: ...eat frame assembly e Remove the hog rings from the seat frame assembly f Remove the hog rings shown in the illustration from the seat frame assembly g Remove the seatback cover and pad from the seat frame assembly 13 REMOVE SEATBACK COVER a Turn up the seatback cover and remove the hog rings b Remove the 2 headrest supports c Remove the seatback cover from the seatback pad ...

Page 2834: ...one Cuts minute cracks or marked discoloration on the front seatback assy around the front seat airbag assy 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Perform a diagnostic system check see page DI 1871 b Perform a visual check which includes the following items with the seatback assembly removed from the vehicle Cuts tears and cracks on the side airbag assembly Cuts and cracks ...

Page 2835: ...RS12F 01 RS 68 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY Manual Adjuster Type 4483 Author Date DISPOSAL See page RS 53 ...

Page 2836: ...ag assembly has been found to have cuts while checking items see page RS 67 Seat frame assembly The seatback cover has been found to have cuts while checking items see page RS 67 Seatback cover The side airbag assembly has been found to be faulty while checking items see page RS 67 Seat frame assembly The seatback cover has been found to be faulty while checking items see page RS 67 Seatback cover...

Page 2837: ...de airbag assembly with a new one When installing the side airbag assembly take care that it is not pinched between other parts Never use airbag parts from another vehicle When replacing parts replace them with new ones 1 INSTALL SEATBACK COVER AND PAD a Install the seatback cover and pad to the seat frame as sembly b Install the seatback cover tubes with the hog rings to the seat frame assembly c...

Page 2838: ...que 37 N m 377 kgf cm 27 ft lbf HINT Install the armrest lock plate as shown in the illustration c Install the armrest cap 3 INSTALL FRONT SEAT INNER BELT a Install the front seat inner belt with the nut Torque 42 N m 428 kgf cm 31 ft lbf b Connect the connectors and wire harness clamps 4 INSTALL SEAT CUSHION INNER SHIELD Install the seat cushion inner shield with the screw 5 INSTALL VERTICAL ADJU...

Page 2839: ...the connectors b Slide the front seat to the rearmost position c Temporarily tighten the bolts on the front side starting from the bolt on the inner side and fully tighten them Torque 37 N m 377 kgf cm 27 ft lbf d Slide the front seat to the most front position e Temporarily tighten the bolts on the rear side starting from the bolt on the inner side and fully tighten them Torque 37 N m 377 kgf cm ...

Page 2840: ...mrest Assembly 37 377 27 Seat Frame Assembly Seat Cushion Shield RH 20 204 15 Bushing Seatback Pad Seatback Lock Upper Bezel Headrest 42 428 31 Hog Ring Seat Track Cover RH Seat Cushion Lower Shield SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY Passenger Side of Split Type RS 73 4488 Author Date SIDE AIRBAG ASSEMBLY Passenger Side of Split Type COMPONENTS ...

Page 2841: ...ting the cable to prevent the airbag working 3 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 4 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c w Side airbag Disconnect the airbag connector d Remove the front seat NOTICE Be careful not to damage the body 5 REMOVE HEADRESTS 6 REMOVE RECLINING ADJUSTER RELEASE H...

Page 2842: ...ings from the seatback cover belt b Remove the seatback cover belt from the hook c Remove the hog rings from the seatback cover d Open the fastener e Remove the bolt and center armrest assembly f Remove the 2 bushings g Remove the hog rings from the seatback cover h w Side airbag Remove the nut and disconnect the seatback cover brackets from the seatback frame i Remove the hog rings from the seat ...

Page 2843: ...ower shield l Remove the 2 screws and RH reclining adjuster inside cover m Remove the 3 nuts and disconnect the front seat center belt n Remove the 3 bolts o Using a torx socket wrench remove the 2 torx screws and seatback assembly from the seat cushion assembly p Remove the bushing from the seatback frame q Remove the 4 headrest supports from the seatback as sembly r Remove the seatback lock uppe...

Page 2844: ...new one Cuts minute cracks or marked discoloration on the front seatback assy around the front seat airbag assy 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Perform a diagnostic system check see page DI 1871 b Perform a visual check which includes the following items with the seatback assembly removed from the vehicle Cuts tears and cracks on the side airbag assembly Cuts and cra...

Page 2845: ...RS12L 01 RS 78 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY Passenger Side of Split Type 4493 Author Date DISPOSAL See page RS 53 ...

Page 2846: ...rbag assembly has been found to have cuts while checking items see page RS 77 Seat frame assembly The seatback cover has been found to have cuts and frayed seams while checking items see page RS 77 Seatback cover The side airbag assembly has been found to be faulty while checking items see page RS 77 Seat frame assembly The seatback cover has been found to be faulty while checking items see page R...

Page 2847: ... side airbag assembly take care it is not pinched between other parts Never use airbag parts from another vehicle When replacing parts replace them with new ones 1 INSTALL SEATBACK ASSEMBLY a Install the bushing to the seatback frame b Using a torx socket wrench install the seatback assem bly with the 2 torx screws to the seat cushion assembly Torque 42 N m 428 kgf cm 31 ft lbf c Install the 3 bol...

Page 2848: ...o prevent wrinkles as much as possible i w Side airbag Connect the seatback cover brackets with the nut to the seatback frame Torque 5 5 N m 56 kgf cm 49 in lbf j Install the hog rings to the seatback cover HINT When installing hog rings take care to prevent wrinkles as much as possible k Install the 2 bushings l Install the center armrest assembly with the bolt Torque 20 N m 204 kgf cm 15 ft lbf ...

Page 2849: ... inner cover with the 3 screws 7 INSTALL FRONT SEAT a Mount the front seat to the vehicle NOTICE Be careful not to damage the body b w Side airbag Connect the airbag connector c Connect the connectors d Slide the front seat to the rearmost position e Tighten the bolts on the front side temporarily starting from the bolt on the inner side tighten them completely Torque 37 N m 377 kgf cm 27 ft lbf f...

Page 2850: ... Shield Airbag Assembly N m kgf cm ft lbf Specified torque 9 8 100 7 9 8 100 7 9 8 100 7 9 8 100 7 SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIRBAG ASSEMBLY RS 83 4498 Author Date CURTAIN SHIELD AIRBAG ASSEMBLY COMPONENTS ...

Page 2851: ...ver use airbag parts from another vehicle When replacing parts replace them with new ones 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE ROOF HEADLINING SEE PAGE BO 126 AND BO 133 4 REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY a Disconnect the curtain shield airbag connector NOT...

Page 2852: ...he front pillar garnish or roof headlining assy around the curtain shield airbag assembly 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Perform a diagnostic system check see page DI 1871 b With the curtain shield airbag assembly removed from the vehicle perform a visual check If there are any defects as mentioned below replace the curtain shield airbag as sembly with a new one Cut...

Page 2853: ...en it is deployed so perform the operation outdoors and where it will not create a nuisance to nearby resi dents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise When deploying the airbag perform the operation at least 10 m 33 ft away from the curtain shield airbag assembly The curtain shield airbag assem...

Page 2854: ...tain shield airbag connector NOTICE When handling the airbag connector be careful not to dam age the airbag wire harness f Install the SST 1 Connect the connectors of the SST to the curtain shield airbag assembly SST 09082 00700 09082 00760 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 2 Move the SST at least 10 m 33 ft away from the ve...

Page 2855: ...ag Always wash your hands with water after completing the operation HINT The airbag deploys as the LED of the SST activation switch comes on 2 DEPLOYMENT WHEN DISPOSING OF CURTAIN SHIELD AIRBAG ASSEMBLY NOTICE When disposing of the curtain shield airbag assem bly never use the customer s vehicle to deploy the airbag Be sure to follow the procedure given below when de ploying the airbag HINT Prepar...

Page 2856: ... shock when the airbag is deployed Al ways use a wire harness for vehicle use with an area of at least 1 25 mm2 0 0019 in2 HINT To calculate the area of the stripped wire harness section Area 3 14 x Diameter 2 divided by 4 1 Position the curtain shield airbag assembly inside the tire with the airbag deployment side facing in side Tire size Must exceed the following dimensions Width 185 mm 7 28 in ...

Page 2857: ...stalled NOTICE Do not place the SST connector under the tire because it could be damaged 3 Tie the tires together with 2 wire harness CAUTION Make sure that the wire harness is tight Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed g Install the SST Connect the SST connector SST 09082 00700 NOTICE To avoid damaging the SST connector and wi...

Page 2858: ...shield airbag assembly becomes ex tremely hot when the airbag is deployed so do not touch it for at least 30 minutes after deployment Use gloves and safety glasses when handling a cur tain shield airbag assembly with a deployed airbag Do not apply water etc to a curtain shield airbag as sembly with a deployed airbag Always wash your hands with water after completing the operation 1 Remove the curt...

Page 2859: ...le shooting Curtain shield airbag assembly The curtain shield airbag assembly has been found to be faulty while check ing items see page RS 85 Curtain shield airbag assembly The front pillar garnish has been found to be faulty while checking items see page RS 85 Front pillar garnish The roof headlining has been found to be faulty while checking items see page RS 85 Roof headlining The curtain shie...

Page 2860: ... cur tain shield airbag assembly NOTICE If the curtain shield airbag assembly has been dropped or there are cracks dents or other defects in the case or connector replace the curtain shield airbag assembly with a new one When installing the curtain shield airbag assembly take care that it is not pinched between other parts Never use airbag parts from another vehicle When replacing parts replace th...

Page 2861: ... Center Cover Standard Cab 17 5 179 13 17 5 179 13 Rear Console Box Upper Console Panel Shifting Hole Cover Front Console Box Access Cab Access Cab Large Type Console Box RS 94 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY 4509 Author Date AIRBAG SENSOR ASSEMBLY COMPONENTS ...

Page 2862: ...r Console Box Upper Console Panel Shifting Hole Cover Front Console Box Disc Player Cover Disc Player w Rear seat audio or Rear seat entertainment 17 5 179 13 17 5 179 13 Lower Center Cover Split Type Seat SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY RS 95 4510 Author Date ...

Page 2863: ...econds after disconnecting the cable to prevent the airbag working 3 Standard cab Access cab w o Large type console box Double cab Split type seat REMOVE LOWER CENTER COVER SEE PAGE BO 1 11 4 Access cab w Large type console box Double cab REMOVE SHIFTING HOLE COVER SEE PAGE BO 1 11 5 Access cab w Large type console box Double cab REMOVE UPPER CONSOLE PANEL SEE PAGE BO 1 11 6 Access cab w Large typ...

Page 2864: ...CLE NOT INVOLVED IN A COLLISION Perform a diagnostic system check see page DI 1871 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED Perform a diagnostic system check see page DI 1871 3 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly see page DI 1871 ...

Page 2865: ...s replace the airbag sensor assembly with a new one The SRS has been deployed in a collision The airbag sensor assembly has been found to be faulty in troubleshooting The airbag sensor assembly has been dropped CAUTION For removal and installation of the airbag sensor assembly see page RS 101 and RS 104 Be sure to follow the correct procedure ...

Page 2866: ...alling shake the airbag sensor assembly to check that there is no looseness 1 INSTALL AIRBAG SENSOR ASSEMBLY a Install the airbag sensor assembly with the 4 bolts Torque 17 5 N m 179 kgf cm 13 ft lbf b Connect the airbag sensor holder with connectors 2 Access cab w Large type console box Double cab INSTALL FRONT CONSOLE BOX SEE PAGE BO 120 3 Access cab w Large type console box Double cab INSTALL R...

Page 2867: ...878 N m kgf cm ft lbf Specified torque Front Airbag Sensor LH Front Airbag Sensor RH 17 5 179 13 17 5 179 13 RS 100 SUPPLEMENTAL RESTRAINT SYSTEM FRONT AIRBAG SENSOR 4515 Author Date FRONT AIRBAG SENSOR COMPONENTS ...

Page 2868: ...use airbag parts from another vehicle When replacing parts replace them with new ones Never reuse a front airbag sensor if the airbag has previously deployed in a collision 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE FRONT AIRBAG SENSOR LH a Disconnect the front airbag...

Page 2869: ...NOT INVOLVED IN A COLLISION Perform a diagnostic system check see page DI 1871 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED Perform a diagnostic system check see page DI 1871 3 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS DEPLOYED Replace the front airbag sensor RH and LH see page DI 1871 ...

Page 2870: ...en deployed in a collision Replace both the left and right airbag sensors The front airbag sensor has been found to be faulty in troubleshooting The front airbag sensor has been found to be faulty while checking items see page RS 102 The front airbag sensor has been dropped CAUTION For removal and installation of the front airbag sensor see page RS 101 and RS 104 Be sure to fol low the correct pro...

Page 2871: ...er has been dropped or there are any cracks dents or other defects in the case bracket or connector replace it with a new one When installing the front airbag sensor center be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts After installing shake the front airbag sensor to check that there is no looseness 1 INSTALL FRONT AIRBAG SENSOR ...

Page 2872: ...illar Lower Garnish Front Seat Outer Belt Retractor Side Airbag Sensor Assembly LH Rear Door Scuff Plate Front Seat Outer Belt Floor Anchor 17 5 179 13 17 5 179 13 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG SENSOR ASSEMBLY RS 105 4520 Author Date SIDE AIRBAG SENSOR ASSEMBLY COMPONENTS ...

Page 2873: ...assembly if the air bag has previously deployed in a collision 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE FRONT DOOR SCUFF PLATE SEE PAGE BO 133 4 REMOVE REAR DOOR SCUFF PLATE SEE PAGE BO 133 5 REMOVE FRONT SEAT OUTER BELT FLOOR AN CHOR SEE PAGE BO 133 6 REMOVE CENTER...

Page 2874: ...ICLE NOT INVOLVED IN A COLLISION Perform a diagnostic system check see page DI 1871 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED Perform a diagnostic system check see page DI 1871 3 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly see page DI 1871 ...

Page 2875: ...ide airbag sensor assembly with a new one The side airbag assembly has been deployed in a collision The side airbag sensor assembly has been found to be faulty in troubleshooting The side airbag sensor assembly has been dropped CAUTION For removal and installation of the side airbag sensor assembly see page RS 106 and RS 109 Be sure to follow the correct procedure ...

Page 2876: ...side airbag sensor assembly be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts After installing shake the side airbag sensor assem bly to check that there is no looseness 1 INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH a Install the side airbag sensor assembly LH with the 3 bolts Torque 17 5 N m 179 kgf cm 13 ft lbf b Connect the connector to...

Page 2877: ...ag Sensor Assembly LH Rear Seat Outer Belt Retractor Rear Seat Outer Belt Floor Anchor Back Panel Trim Assembly Quarter Trim Panel Lower LH 17 5 179 13 RS 1 10 SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIRBAG SENSOR ASSEMBLY 4525 Author Date CURTAIN SHIELD AIRBAG SENSOR ASSEMBLY COMPONENTS ...

Page 2878: ...iously deployed in a collision 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE REAR DOOR SCUFF PLATE SEE PAGE BO 133 4 REMOVE BACK PANEL TRIM ASSEMBLY SEE PAGE BO 133 5 REMOVE REAR SEAT OUTER BELT FLOOR ANCHOR SEE PAGE BO 133 6 REMOVE QUARTER TRIM PANEL LOWER LH SEE PAGE B...

Page 2879: ...ICLE NOT INVOLVED IN A COLLISION Perform a diagnostic system check see page DI 1871 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED Perform a diagnostic system check see page DI 1871 3 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS DEPLOYED Replace the curtain shield airbag sensor assembly see page DI 1871 ...

Page 2880: ...r assembly with a new one The curtain shield airbag assembly has been deployed in a collision The curtain shield airbag sensor assembly has been found to be faulty in troubleshooting The curtain shield airbag sensor assembly has been dropped CAUTION For removal and installation procedures of the curtain shield airbag sensor assembly see page RS 1 18 and RS 122 Be sure to follow the correct procedu...

Page 2881: ...hield airbag sensor as sembly center be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts After installing shake the curtain shield airbag sen sor assembly to check that there is no looseness 1 INSTALL CURTAIN SHIELD AIRBAG SENSOR AS SEMBLY LH a Install the curtain shield airbag sensor assembly LH with the 2 nuts Torque 17 5 N m 179 kgf ...

Page 2882: ...ield Seat Position Sensor Assembly Protector 8 0 82 71 in lbf Torx Screw Separate Type Manual Adjuster Split Type Reclining Adjuster Release Handle Vertical Adjuster Handle Cap Vertical Adjuster Handle SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION SENSOR ASSEMBLY RS 1 15 4530 Author Date SEAT POSITION SENSOR ASSEMBLY COMPONENTS ...

Page 2883: ...Seat Cushion Inner Shield Seat Position Sensor Assembly Protector Torx Screw Front Seat Assembly LH Seat Cushion Inner Shield Seat Cushion Outer Shield Reclining Knob Slide Knob Separate Type Power Adjuster RS 1 16 SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION SENSOR ASSEMBLY 4531 Author Date ...

Page 2884: ...N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf Torx Screw Seat Position Sensor Assembly Front Seat Assembly Bench Type SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION SENSOR ASSEMBLY RS 1 17 4532 Author Date ...

Page 2885: ...ISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 Separate type Split type REMOVE FRONT SEAT ASSEMBLY LH SEE PAGE BO 141 4 Bench type REMOVE FRONT SEAT ASSEMBLY SEE PAGE BO 166 5 Separate type Manual adjuster Split type REMOVE VERTICAL ADJUSTER HANDLE SEE PAGE BO 156 6 Separate type Manual adjuster Split type REMOVE SEA...

Page 2886: ... Date 9 Separate type Split type REMOVE SEAT POSITION SENSOR ASSEMBLY PRO TECTOR Remove the seat position sensor assembly protector from the seat position sensor assembly 10 REMOVE SEAT POSITION SENSOR ASSEMBLY a Disconnect the connector from the seat position sensor assembly b Using a torx socket wrench T30 remove the torx screw and the seat position sensor assembly ...

Page 2887: ... check see page DI 1871 b Even if the airbag was not deployed perform a visual check for damage to the seat position sensor assembly If there are any defects mentioned below replace the seat position sensor assembly with a new one Cracks dents or chips in the case Cracks or other damage to the connector CAUTION For removal and installation procedures of the seat position sensor assembly see page R...

Page 2888: ... cases replace the seat position sensor assembly with a new one The seat position sensor assembly has been found to be faulty in troubleshooting The seat position sensor assembly has been dropped CAUTION For removal and installation procedures of the seat position sensor assembly see page RS 1 18 and RS 122 Be sure to follow the correct procedure ...

Page 2889: ... parts After installing shake the seat position sensor as sembly to check that there is no looseness 1 INSTALL SEAT POSITION SENSOR ASSEMBLY a Using a torx socket wrench install the seat position sen sor assembly Torque 8 0 N m 82 kgf cm 71 in lbf NOTICE Using a feeler gauge of 1 mm 0 039 in make a clearance between the seat position sensor assembly and the seat rail b Make sure that a clearance b...

Page 2890: ...ION OUTER SHIELD SEE PAGE BO 160 6 Separate type Manual adjuster Split type INSTALL VERTICAL ADJUSTER HANDLE SEE PAGE BO 160 7 Separate type Split type INSTALL FRONT SEAT ASSEMBLY LH SEE PAGE BO 153 8 Bench type INSTALL FRONT SEAT ASSEMBLY SEE PAGE BO 175 9 CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 10 INSPECT SRS WARNING LIGHT SEE PAGE DI 1859 ...

Page 2891: ...RS0UU 06 H23886 Front Seat Assembly RH Occupant Classification ECU RS 124 SUPPLEMENTAL RESTRAINT SYSTEM OCCUPANT CLASSIFICATION ECU 4539 Author Date OCCUPANT CLASSIFICATION ECU COMPONENTS ...

Page 2892: ...place them with new ones Never reuse an occupant classification ECU if the air bag has previously deployed in a collision 1 PRECAUTION SEE PAGE RS 1 AND RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE FRONT SEAT ASSEMBLY RH SEE PAGE BO 141 4 REMOVE OCCUPANT CLASSIFICATION ECU a Disconnect the 2 connecto...

Page 2893: ...tem check see page DI 1871 b Even if the airbag was not deployed perform a visual check for damage to the occupant classification ECU If there are any defects mentioned below replace the occupant classification ECU with a new one Cracks dents or chips in the case Cracks or other damage to the connector CAUTION For removal and installation procedures of the occupant classification ECU see page RS 1...

Page 2894: ...ing cases replace the occupant classification ECU with a new one The occupant classification ECU has been found to be faulty in troubleshooting The occupant classification ECU has been dropped CAUTION For removal and installation procedures of the occupant classification ECU see page RS 125 and RS 128 Be sure to follow the correct procedure ...

Page 2895: ...ed or there are any cracks dents or other de fects in the case bracket or connector replace it with a new one When installing the seat position sensor assembly center be careful that the SRS wiring does not inter fere with other parts and that it is not pinched be tween other parts 1 INSTALL OCCUPANT CLASSIFICATION ECU a Install the occupant classification ECU b Connect the 2 connectors to the occ...

Page 2896: ...n Panel Lower Center Cover Passenger Airbag Manual AUTO ON OFF Switch Standard Cab Access Cab w o Large Type Console Box SUPPLEMENTAL RESTRAINT SYSTEM PASSENGER AIRBAG MANUAL ON OFF SWITCH RS 129 4544 Author Date PASSENGER AIRBAG MANUAL ON OFF SWITCH COMPONENTS ...

Page 2897: ... Cluster Integration Panel Knob Sub Assembly Passenger Airbag Manual AUTO ON OFF Switch Access Cab w Large Type Console Box RS 130 SUPPLEMENTAL RESTRAINT SYSTEM PASSENGER AIRBAG MANUAL ON OFF SWITCH 4545 Author Date ...

Page 2898: ... 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE PASSENGER AIRBAG MANUAL AUTO ON OFF SWITCH a Using a screwdriver release the 2 claws and remove the passenger airbag manual AUTO ON OFF switch HINT Tape up the screwdriver tip before use b Disconnect the connector ...

Page 2899: ...n Tester Connection Specified Condition ON 1 2 360 to 440 Ω OFF 1 2 90 to 110 Ω If the result is not as specified replace the switch 2 INSPECT PASSENGER AIRBAG MANUAL ON OFF INDICATOR OPERATION a Remove the center cluster integration panel assembly see page BO 1 11 b Using a service wire connect terminals B1 and B2 c Connect the battery s positive lead from the battery to terminal A17 and the nega...

Page 2900: ...WITCH RS 133 4548 Author Date e Using a service wire connect terminals B1 and B2 f Connect the battery s positive lead from the battery to terminal A17 and the negative lead to terminal A2 g Check that the indicator OFF light illuminates If it does not illuminate replace the center cluster integration panel assembly ...

Page 2901: ... MANUAL ON OFF SWITCH 4549 Author Date INSTALLATION 1 INSTALL PASSENGER AIRBAG MANUAL AUTO ON OFF SWITCH a Connect the connector b Install the passenger airbag manual AUTO ON OFF switch 2 CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 3 INSPECT SRS WARNING LIGHT SEE PAGE DI 1859 ...

Page 2902: ...RS130 01 H23892 Switch Base Lower Finish Panel SUPPLEMENTAL RESTRAINT SYSTEM RSCA OFF SWITCH RS 135 4550 Author Date RSCA OFF SWITCH COMPONENTS ...

Page 2903: ... RS 3 2 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 3 REMOVE LOWER FINISH PANEL SEE PAGE BO 1 11 4 REMOVE SWITCH BASE a Using a screwdriver remove the 3 claws and switch base HINT Tape up the screwdriver tip before use b Disconnect the connectors ...

Page 2904: ...SCA OFF indicator light goes off after it comes on for 3 seconds c Check that the RSCA OFF indicator light comes on after pressing the RSCA OFF switch for approx 2 seconds 2 INSPECT RSCA OFF SWITCH CONTINUITY a Inspect the continuity between each terminal Switch Position Tester Connection Specified Condition OFF SW 1 E 4 No Continuity Hold ON SW 1 E 4 Continuity If continuity is not as specified r...

Page 2905: ...EM RSCA OFF SWITCH 4553 Author Date INSTALLATION 1 INSTALL SWITCH BASE a Connect the connectors b Install the switch base 2 INSTALL LOWER FINISH PANEL SEE PAGE BO 120 3 CONNECT CABLE TO NEGATIVE BATTERY TERMI NAL 4 INSPECT SRS WARNING LIGHT SEE PAGE DI 1859 ...

Page 2906: ... Sensor RH Seat Position Airbag Sensor LHD Airbag Sensor Assembly Combination Meter Warning Light Occupant Classification ECU 1 Standard Cab Access Cab Seat Belt Pretensioner RH Seat Belt Pretensioner LH 1 w Occupart Classification System SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR RS 139 4554 Author Date WIRE HARNESS AND CONNECTOR LOCATION ...

Page 2907: ...rbag Sensor Assembly RH 1 Curtain Shield Airbag Sensor Assembly RH 1 Double Cab Curtain Shield Airbag Sensor Assembly LH 1 Side Airbag Assembly LH 1 Side Airbag Sensor Assembly LH 1 Seat Belt Pretensioner LH RSCA OFF Switch 1 Curtain Shield Airbag Assembly RH 1 3 Separate Seat Type Passenger Airbag ON OFF Indicator 3 1 w Side Airbag and Curtain Shield Airbag 2 w Occupant Classification System RS 1...

Page 2908: ...connectors in the system except the seat position airbag sensor connector and occupant classification ECU connectors are colored yellow 1 VEHICLE NOT INVOLVED IN A COLLISION Perform a diagnostic system check see page DI 1871 2 VEHICLE INVOLVED IN A COLLISION a Perform a diagnostic system check see page DI 1871 b Check breaks in all wires of the SRS wire harness and exposed conductors c Check if th...

Page 2909: ... replace the wire harness or connector with a new one Any of the SRS wire harness and connectors has been found to be faulty in troubleshooting Any of the SRS wire harness and connectors has been found to be faulty while checking items see page RS 141 CAUTION If the wire harness used in the SRS is damaged replace the whole SRS wire harness assembly ...

Page 2910: ...raint System SRS for example the driver airbag Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing including removal installa tion inspection and replacement be sure to read the precautionary notices in the RS section 3 AUDIO SYSTEM If the battery negative terminal is dis...

Page 2911: ... 2 Power Source Circuit BE 37 Key unlock warning system does not operate 1 DOME Fuse 2 ECU B Fuse 3 Key Unlock Warning Switch 4 Door Courtesy Switch 5 Meter Circuit Plate 6 Wire Harness 7 Body ECU BE 24 BE 24 BE 37 BE 57 BE 82 DI 2411 w Daytime running light HEADLIGHT AND TAILLIGHT SYSTEM This system uses the multiplex communication system Check diagnosis system of the multiplex commu nication sys...

Page 2912: ... with light control switch in TAIL position 1 TAIL Fuse 2 Light Control Switch 3 Body ECU 4 Bulb 5 Wire Harness BE 24 BE 41 DI 2411 w o Daytime running light HEADLIGHT AND TAILLIGHT SYSTEM This system uses the multiplex communication system Check the diagnosis system of the multiplex commu nication system before you proceed with this troubleshooting Symptom Suspected Area See Page Only one headlig...

Page 2913: ...switch in HEAD posi tion Headlights do not light up 1 Other Parts 2 Wire Harness Only one fog light does not light up 1 Bulb 2 Wire Harness HINT Inspect the headlight system TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT SYSTEM Symptom Suspected Area See Page Hazard warning lights and turn signal lights do not flash 1 TURN HAZ Fuse 2 GAUGE Fuse 3 Ignition Switch 4 Turn Signal Switch 5 Turn Signal Flas...

Page 2914: ... light up 1 DOME Fuse 2 Bulb 3 Front Personal Light 4 Wire Harness BE 24 BE 57 Dome light does not light up 1 DOME Fuse 2 Bulb 3 Doom Light 4 Wire Harness BE 24 BE 57 Vanity light does not light up 1 DOME Fuse 2 Bulb 3 Vanity Light 4 Wire Harness BE 24 BE 57 Door courtesy light does not light up 1 DOME Fuse 2 Bulb 3 Door Courtesy Switch 4 Wire Harness BE 24 BE 57 BACK UP LIGHT SYSTEM Symptom Suspe...

Page 2915: ... Suspected Area See Page Tachometer fuel gauge and engine coolant temperature gauge do not operate 1 GAUGE Fuse 2 Meter Circuit Plate 3 Wire Harness BE 24 BE 82 Speedometer does not operate 1 Vehicle Speed Sensor 2 Meter Circuit Plate 3 Wire Harness BE 86 BE 82 Tachometer does not operate 1 ECM 2 Meter Circuit Plate 3 Wire Harness DI 428 BE 82 Fuel gauge does not operate or operates abnormally 1 F...

Page 2916: ... 82 DI 1405 DI 1489 Seat belt warning light does not light up 1 LED 2 Seat Belt Buckle Switch 3 Meter Circuit Plate 4 Wire Harness BE 86 BE 82 Discharge warning light does not light up 1 IGN Fuse 2 LED 3 Meter Circuit Plate 4 Wire Harness 5 Generator BE 24 BE 82 Brake warning light does not light up 1 LED 2 Parking Brake Switch 3 Brake Fluid Level Warning Switch 4 Meter Circuit Plate 5 Skid Contro...

Page 2917: ... OFF indicator light does not light up 1 LED 2 O D Main Switch 3 ECM 4 Meter Circuit Plate 5 Wire Harness DI 1112 DI 1294 DI 428 BE 82 AUTO LSD indicator light does not light up 1 LED 2 Skid Control ECU 3 Meter Circuit Plate 4 Wire Harness DI 1405 DI 1489 BE 82 VSC OFF indicator light does not light up 1 LED 2 Skid Control ECU 3 Meter Circuit Plate 4 Wire Harness DI 1405 DI 1489 BE 82 SLIP indicat...

Page 2918: ...ess BE 24 BE 103 BE 37 BE 103 BE 103 Mirror defogger does not operate 1 MIR HTR Fuse E G Room J B 2 MIR HTR Relay 3 Mirror Heater 4 Wire Harness BE 24 BE 107 BE 107 POWER WINDOW CONTROL SYSTEM This system uses the multiplex communication system Check the diagnosis system of the multiplex commu nication system before you proceed with this troubleshooting Symptom Suspected Area See Page Power window...

Page 2919: ... BE 119 BE 119 BE 37 BE 119 BE 119 DI 2411 POWER DOOR LOCK CONTROL SYSTEM This system uses the multiplex communication system Check the diagnosis system of the multiplex commu nication system before you proceed with this troubleshooting Symptom Suspected Area See Page Entire door lock system does not operate 1 POWER NO 1 Fuse 2 POWER NO 2 Fuse 3 Body ECU 4 Wire Harness BE 24 BE 24 DI 2411 Manual d...

Page 2920: ...ea See Page Power seat does not operate 1 POWER SEAT Fuse 2 Power Seat Switch 3 Wire Harness BE 24 BE 184 Slide operation does not operate 1 Power Seat Switch 2 Slide Motor 3 Wire Harness BE 184 BE 184 Front tilt operation does not operate 1 Power Seat Switch 2 Front Tilt Motor 3 Wire Harness BE 184 BE 184 Rear lifter operation does not operate 1 Power Seat Switch 2 Rear Lifter Motor 3 Wire Harnes...

Page 2921: ...loses or gains time TROUBLESHOOTING NO 2 BE 200 GARAGE DOOR OPENER SYSTEM Symptom Suspected Area See Page The equipment of which code has been registered does not oper ate 1 Garage Door Opener Switch 2 Wire Harness 3 BE 208 LED does not turn on Even though either switch is pressed 1 Garage Door Opener Switch 2 Wire Harness BE 208 LED does not turn on Only one switch is pressed Garage Door Opener S...

Page 2922: ... Author Date TRAILER TOWING Symptom Suspected Area See Page Trailer towing does not operate 1 TOWING Fuse 2 TOWING TAIL Fuse 3 TOWING BRK Fuse 4 TOWING TAIL Relay 5 BATT CHARGE Relay 6 Towing Converter 7 Wire Harness BE 24 BE 24 BE 24 BE 210 BE 210 BE 210 ...

Page 2923: ...Wire Harness 6 Integration Relay Driver Side J B BE 29 BE 37 BE 61 BE 82 BE 41 w Daytime running light HEADLIGHT AND TAILLIGHT SYSTEM Symptom Suspected Area See Page Only one headlight does not light up 1 HEAD LL RL LH RH Fuse 2 Bulb 3 Wire Harness BE 29 Both headlights do not light up 1 HEAD LL RL LH RH Fuse 2 TAIL Fuse 3 ECU IG Fuse 4 H LP Relay 5 DIMMER Relay 6 DRL NO 4 Relay 7 Daytime Running ...

Page 2924: ...ontrol Switch 3 Integration Relay 4 Bulb 5 Wire Harness BE 29 BE 41 BE 41 w o Daytime running light HEADLIGHT AND TAILLIGHT SYSTEM Symptom Suspected Area See Page Only one headlight does not light up 1 HEAD LH RH Fuse 2 Bulb 3 Wire Harness BE 29 Both headlights do not light up 1 HEAD LH RH Fuse 2 H LP Relay 3 Light Control Switch 4 Bulb 5 Integration Relay 6 Wire Harness BE 29 BE 41 BE 41 BE 41 Lo...

Page 2925: ...5 Turn Signal Flasher Relay 6 Wire Harness BE 29 BE 29 BE 37 BE 53 BE 53 Hazard warning lights do not flash Turn signal lights are normal 1 Hazard Warning Switch 2 Wire Harness BE 53 Turn signal lights do not flash 1 Turn Signal Flasher Relay 2 Wire Harness BE 53 Turn signal lights do not flash on one side 1 Turn Signal Switch 2 Wire Harness BE 53 Only one bulb does not flash 1 Bulb 2 Wire Harness...

Page 2926: ...main on 1 Back up Light Switch M T 2 Park neutral Position Switch A T 3 Wire Harness BE 67 BE 67 Only one light does not light up 1 Bulb 2 Wire Harness STOP LIGHT SYSTEM Symptom Suspected Area See Page Stop lights do not light up 1 STOP Fuse 2 Stop Light Switch 3 Wire Harness BE 29 BE 70 Stop lights remain on 1 Stop Light Switch 2 Wire Harness BE 70 Only one light does not light up 1 Bulb 2 Wire H...

Page 2927: ... operate or operates abnormally 1 Engine Coolant Temperature Receiver Gauge 2 Engine Coolant Temperature Sender Gauge 3 Meter Circuit Plate 4 Wire Harness BE 86 BE 86 BE 82 Voltmeter does not operate 1 Voltmeter 2 Meter Circuit Plate 3 Wire Harness BE 86 BE 82 All illumination lights do not light up 1 TAIL Fuse 2 Light Control Rheostat 3 Integration Relay 4 Wire Harness BE 29 BE 86 BE 41 Brightnes...

Page 2928: ...t does not light up 1 LED 2 Skid Control ECU 3 Meter Circuit Plate 4 Wire Harness DI 1405 DI 1489 BE 82 ATF temperature warning light does not light up 1 LED 2 ATF Temperature Sensor 3 ECM 4 Meter Circuit Plate 5 Wire Harness DI 1009 DI 1186 BE 82 SRS warning light does not light up 1 LED 2 Airbag Sensor Assembly 3 Meter Circuit Plate 4 Wire Harness DI 1847 BE 82 Door open warning light does not l...

Page 2929: ...1405 DI 1489 BE 82 SLIP indicator light does not light up 1 LED 2 Skid Control ECU 3 Meter Circuit Plate 4 Wire Harness DI 1405 DI 1489 BE 82 Cruise control indicator light does not light up 1 LED 2 ECM 3 Meter Circuit Plate 4 Wire Harness DI 9 DI 428 BE 82 High beam indicator light does not light up 1 LED 2 Headlight and Taillight System 3 Meter Circuit Plate 4 Wire Harness BE 41 BE 82 Turn signa...

Page 2930: ...ch power window system does not operate Power Window Master Switch BE 114 Only one window does not move 1 Power Window Master Switch 2 Power Window Control Switch 3 Power Window Motor 4 Wire Harness BE 114 BE 114 BE 114 Window lock system does not operate Power Window Master Switch BE 114 Key off power window does not operate 1 ECU IG Fuse 2 POWER Relay 3 Ignition Switch 4 Door Courtesy Switch 5 I...

Page 2931: ...r lock control system is operating normally Accordingly before troubleshooting the wireless door lock control system first make certain that the door lock control system is operating normally Symptom Suspected Area See Page Entire wireless door lock control system does not operate 1 Transmitter 2 TVIP ECU 3 Wire Harness BE 180 DI 2317 Wireless door lock operates but the buzzer does not sound 1 TVI...

Page 2932: ...l Panel Symptom Suspected Area See Page Clock does not operate TROUBLESHOOTING NO 1 BE 200 Clock loses or gains time TROUBLESHOOTING NO 2 BE 200 NAVIGATION SYSTEM Symptom Suspected Area See Page Navigation system operates abnormally TROUBLESHOOTING DI 2786 AUDIO SYSTEM Symptom Suspected Area See Page Audio system operates abnormally TROUBLESHOOTING DI 2545 Rear seat audio system operates abnormall...

Page 2933: ...I27014 No 2 Engine Room R B Engine Room J B and FL Block Instrument Panel J B Driver Side R B No 3 Engine Room R B BE 24 BODY ELECTRICAL POWER SOURCE Double Cab 4581 Author Date POWER SOURCE Double Cab LOCATION ...

Page 2934: ...26 5 CIG Fuse 6 PWR NO 1 Fuse 7 HTR Fuse 8 WSH Fuse 9 RAD NO 2 Fuse 10 WIP Fuse 11 FOG Fuse 12 AC INV Fuse 13 4WD Fuse 14 IGN1 Fuse 15 GAUGE Fuse 16 IGN2 Fuse 17 STOP Fuse 18 SUN ROOF Fuse 19 PWR OUTLET Fuse 20 PWR NO 3 Fuse 21 OBD Fuse 22 PWR NO 2 Fuse 23 SEAT HTR Fuse 24 PWR SEAT M fuse 25 AM1 M fuse 26 PWR NO 5 Fuse 15 A 10 A 20 A 7 5 A 10 A 15 A 25 A 10 A 25 A 7 5 A 25 A 15 A 20 A 15 A 20 A 15...

Page 2935: ...4 15 A 13 EFI NO 1 Fuse 20 A 14 ETCS Fuse 10 A 15 DRL Fuse 3 15 A H LP LH Fuse 4 15 A 16 ALT S Fuse 7 5 A 17 TOWING Fuse 30 A 18 ST Fuse 30 A 19 RAD No 3 Fuse 20 A 20 TURN HAZ Fuse 20 A 21 AM2 Fuse 25 A 22 EFI NO 2 Fuse 10 A 23 SHORT PIN 24 HORN Fuse 10 A 25 MIR HTR Fuse 15 A 26 ECU B Fuse 7 5 A 27 DOME Fuse 10 A 28 RAD NO 1 Fuse 25 A 1 w VSC 2 w o VSC 3 w Daytime Running Light 4 w o Daytime Runni...

Page 2936: ...e 5 H LP RH Fuse A G F E D B C 1 2 3 4 5 A B MIR HTR Relay C ABS SOL Relay D E DRL NO 4 Relay F HEATER Relay G DIMMER Relay H ST Relay w Daytime Running Light No 2 Engine Room R B H 10 A 10 A 7 5 A 10 A 10 A BODY ELECTRICAL POWER SOURCE Double Cab BE 27 4584 Author Date ...

Page 2937: ... Fuse A BATT CHARGE Relay B TOWING TAIL Relay 2 BATT CHARGE Fuse 3 TOWING TAIL Fuse 4 RSE Fuse A B 1 2 3 4 Driver Side R B Relays A INVERTER Relay B SEAT HEATER Relay A B 30 A 30 A 30 A 7 5 A BE 28 BODY ELECTRICAL POWER SOURCE Double Cab 4585 Author Date ...

Page 2938: ...BE2JZ 02 I24701 Engine Room R B Driver Side J B Integration Relay BODY ELECTRICAL POWER SOURCE Except Double Cab BE 29 4586 Author Date POWER SOURCE Except Double Cab LOCATION ...

Page 2939: ...SUB BATT Relay F EFI Relay 1 Towing Package 2 Except Towing Package Engine Room R B 14 TOWING Fuse 50 A 50 A 30 A 140 A 40 A 50 A 50 A 7 5 A 15 A 15 A 20 A 30 A 10 A 10 A 20 A 10 A 15 A 10 A 30 A 5 A 12 EFI NO 1 Fuse 3 ST3 M fuse 10 A 25 PWR OUTLET1 Fuse 27 H LP RH Fuse 15 A 10 A 28 MIR HTR Fuse 29 FOG Fuse 30 TOW BRK Fuse 31 SUB BATT Fuse 32 TOW TAIL Fuse 33 34 35 15 A 15 A 30 A 30 A 30 A D F PMP...

Page 2940: ... 14 STA Fuse 15 STOP Fuse Relays A Integration Relay B POWER Relay D Turn Signal Flasher E BACK UP LIGHT Relay 2 1 2 3 4 5 6 7 8 9 11 12 13 14 A B C D 2 A T 20 A 5 A 5 A 20 A 15 A 10 A 5 A 30 A 7 5 A 10 A 5 A 15 A 5 A 15 A w o Daytime Running Light w Daytime Running Light E C ACC CUT Relay 10 15 1 1 Towing Package BODY ELECTRICAL POWER SOURCE Except Double Cab BE 31 4588 Author Date ...

Page 2941: ...le Cab Engine Room R B PWR OUTLET1 Fuse PWR OUTLET2 Fuse EUC B Fuse DOME Fuse PWR OUTLET Relay Double Cab w Rear Seat Entertainment System Voltage Inverter BE 32 BODY ELECTRICAL POWER OUTLET 4589 Author Date POWER OUTLET LOCATION ...

Page 2942: ...m Power Outlet 115 V Double Cab w Rear Seat Entertainment System Main Switch Except Double Cab w o Front Console Power Outlet 12 V Cigarette Lighter Except Double Cab w Front Console Power Outlet 12 V Double Cab Power Outlet 12 V Double Cab Driver Side R B INVERTER Relay Except Double Cab Driver Side J B ACC Fuse Except Double Cab ACC CUT Relay BODY ELECTRICAL POWER OUTLET BE 33 4590 Author Date ...

Page 2943: ...peration is not as specified replace the switch 3 Double cab 115 V INSPECT INVERTER RELAY CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the switch 4 Double cab 12 V INSPECT ACC RELAY AND ACC CUT RELAY CONTI NUITY Tester Connection Specified Condition 3 5 No continu...

Page 2944: ...ECT VOLTAGE INVERTER CIRCUIT Disconnect the connector from the voltage inverter and check the connector on the wire harness side as shown in the table Main Switch Position Tester Connection Specified Condition ON 1 4 10 14 V OFF 1 4 No continuity If the result is not as specified replace the inverter ...

Page 2945: ...BE02W 05 I27137 Ignition Switch Key Unlock Warning Switch BE 36 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 4593 Author Date IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH LOCATION ...

Page 2946: ...tinuity If the continuity is not as specified replace the switch 2 Except double cab INSPECT IGNITION SWITCH CONTINUITY Switch Position Tester Connection Specified Condition ACC 2 3 Continuity ON 2 3 4 6 7 Continuity START 1 2 4 6 7 8 Continuity If the continuity is not as specified replace the switch 3 INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY Switch Position Tester Connection Specified Condit...

Page 2947: ...L Fuse Integration Relay TAILLIGHT Relay Engine Room J B H LP LH Fuse 2 H LP RH Fuse 2 HEAD Relay DRL Fuse 1 Turn Signal Light Parking Light Rear Combination Light Taillight Licence Plate Light Daytime Running Light Resistor 1 Double Cab 1 w Daytime Running Light 2 w o Daytime Running Light Body ECU Located behind the Instrument Panel BE 38 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 4595 Author...

Page 2948: ...me Running Light Resistor Rear Combination Light Taillight Licence Plate Light Turn Signal Light Parking Light Headlight w Daytime Running Light Engine Room R B HEAD LL Fuse HEAD RL Fuse HEAD LH Fuse HEAD RH Fuse H LP Relay DIMMER Relay DRL NO 4 Relay Except Double Cab BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 39 4596 Author Date ...

Page 2949: ...BE171 02 I10557 Light Control Switch Wiper Switch Headlight Dimmer and Turn Signal Switch Spiral Cable Switch Body BE 40 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 4597 Author Date COMPONENTS ...

Page 2950: ...tinuity is not as specified replace the switch 3 INSPECT HEADLIGHT RELAY Marking HEAD Double Cab or H LP Except Double Cab CONTI NUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the relay 4 Double cab INSPECT TAILLIGHT RELAY CONTINUITY Tester Connection Specified Condition...

Page 2951: ...and 1N driver side J B con nectors and check the voltage or continuity of each termi nal of the wire harness side connectors Tester Connection Condition Specified Condition 1I 2 Body ground Ignition switch LOCK or ACC No voltage 1I 2 Body ground Ignition switch ON or START 10 14 V 1J 8 Body ground Constant Continuity 1K 2 Body ground Constant 10 14 V 1K 5 Body ground Constant 10 14 V 1M 5 Body gro...

Page 2952: ...r switch low or high beam No continuity 1N 8 Body ground Headlight dimmer switch flash Continuity 1N 13 Body ground Brake fluid level warning light OFF No continuity 1N 13 Body ground Brake fluid level warning light ON Continuity 1N 24 Body ground Constant Continuity If the result is not as specified there may be a malfunction on the wire harness side b Reconnect the 1I 1J 1K 1M and 1N J B connect...

Page 2953: ...tinuity of each terminal of the wire harness side con nector Tester Connection Condition Specified Condition 1L 5 Body ground Light control switch OFF No continuity 1L 5 Body ground Light control switch TAIL or HEAD Continuity 1L 6 Body ground Constant 10 14 V 1L 13 Body ground Light control switch OFF No continuity 1L 13 Body ground Light control switch TAIL or HEAD Continuity If the result is as...

Page 2954: ...NO 4 CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the relay 9 INSPECT DAYTIME RUNNING LIGHT RESISTOR Tester Condition Specified Condition 1 2 Approx 337 m Ω If the result is not as specified replace the resistor ...

Page 2955: ...BE173 05 I27016 For Adjustment in Vertical Direction BE 46 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 4603 Author Date ADJUSTMENT ...

Page 2956: ...ke sure that the center line of the vehicle and the paper face forms a 90 degree angle as shown in the illustration 4 Draw a horizontal line H line across the paper so that it is at the same height as the center mark of the low beam lamp on the vehicle 5 Draw a vertical line V line to where the center line of the vehicle is to be 6 Draw 2 vertical lines to where the headlights should strike V RH a...

Page 2957: ...Combination Switch Fog Light Switch Except Double Cab Engine Room R B FOG Fuse FOG Relay Double Cab Instrument Panel J B FOG Fuse FOG LIGHT Relay BE 48 BODY ELECTRICAL FOG LIGHT SYSTEM 4605 Author Date FOG LIGHT SYSTEM LOCATION ...

Page 2958: ...cified replace the switch 2 Double cab INSPECT FOG LIGHT RELAY CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the switch 3 Except double cab INSPECT FOG LIGHT RELAY Marking FOG CONTI NUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When b...

Page 2959: ...I24696 Adjusting Screw BE2CF 02 BE 50 BODY ELECTRICAL FOG LIGHT SYSTEM 4607 Author Date ADJUSTMENT ADJUST FOG LIGHT AIM Adjusting screw Vertical direction ...

Page 2960: ...t Panel J B Turn Signal Flasher Relay GAUGE Fuse Turn Signal Light Combination Switch Turn Signal Switch Ignition Switch Rear Combination Light Turn Signal Light Double Cab BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM BE 51 4608 Author Date TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION ...

Page 2961: ...ight Instrument Panel J B Turn Signal Flasher Relay TURN Fuse Turn Signal Light Combination Switch Turn Signal Switch Ignition Switch Rear Combination Light Turn Signal Light Except Double Cab BE 52 BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM 4609 Author Date ...

Page 2962: ...er and in spect the connector on the wire harness side as shown in the table Tester Connection Condition Specified Condition 1 Body ground Ignition switch LOCK or ACC Below 1 V 1 Body ground Ignition switch ON 10 14 V 2 Body ground Constant Continuity 3 Body ground Constant Continuity 4 Body ground Constant 10 14 V 5 Body ground Turn signal switch RIGHT or OFF No Continuity 5 Body ground Turn sign...

Page 2963: ... ON c Check that no continuity exists between terminal 16 and terminal 10 with the switch OFF If the continuity is not as specified replace the panel 4 Except double cab INSPECT HAZARD WARNING SWITCH CONTINUITY a Remove the integration control panel b Check that the continuity exists between terminal 17 and terminal 1 with the switch ON c Check that no continuity exists between terminal 17 and ter...

Page 2964: ... Courtesy Switch Engine Room J B DOME Fuse Door Courtesy Switch Body ECU Located behind the Instrument Panel BODY ELECTRICAL INTERIOR LIGHT SYSTEM Double Cab BE 55 4612 Author Date INTERIOR LIGHT SYSTEM Double Cab LOCATION ...

Page 2965: ...I27063 Vanity Light Door Courtesy Light Front Personal Light Dome Light Roof Console Box Assembly Front Personal Light BE 56 BODY ELECTRICAL INTERIOR LIGHT SYSTEM Double Cab 4613 Author Date ...

Page 2966: ...ty exists between terminals 1 and 3 If the continuity is not as specified replace the bulb or light c Turn the light switch to the DOOR position check that continuity exists between terminals 2 and 3 If the continuity is not as specified replace the light 3 INSPECT DOOR COURTESY SWITCH CONTINUITY a Check that continuity exists between the terminal and the switch body with the switch ON switch pin ...

Page 2967: ...YSTEM Double Cab 4615 Author Date 5 INSPECT VANITY LIGHT CONTINUITY Switch Position Tester Connection Specified Condition OFF Closed 1 2 No continuity ON Opened 1 2 Continuity If the continuity is not as specified replace the bulb or vanity light ...

Page 2968: ... B Integration Relay Access Door Rear Upper Door Lock Rear Upper Door Courtesy Switch Access Door Rear Lower Door Lock Rear Lower Door Courtesy Switch BODY ELECTRICAL INTERIOR LIGHT SYSTEM Except Double Cab BE 59 4616 Author Date INTERIOR LIGHT SYSTEM Except Double Cab LOCATION ...

Page 2969: ...I10550 Front Personal Light Room Light Vanity Light Door Courtesy Light BE 60 BODY ELECTRICAL INTERIOR LIGHT SYSTEM Except Double Cab 4617 Author Date ...

Page 2970: ...e the bulb or light 2 INSPECT ROOM LIGHT CONTINUITY a Disconnect the connector from the light b Turn the interior light switch ON check that continuity ex ists between terminal 2 and body ground c Turn the light switch to the DOOR position check that continuity exists between terminals 1 and 2 If the result is not as specified replace the bulb or light 3 INSPECT FRONT DOOR COURTESY SWITCH CON TINU...

Page 2971: ...ty OFF Full latch 1 2 No continuity If the continuity is not as specified replace the upper door lock 5 Access door INSPECT REAR LOWER DOOR COURTESY SWITCH CONTINUITY Switch Position Tester Connection Specified Condition ON Open 1 2 Continuity ON Half latch 1 2 Continuity OFF Full latch 1 2 No continuity If the continuity is not as specified replace the lower door lock 6 INSPECT DOOR COURTESY LIGH...

Page 2972: ...M Except Double Cab BE 63 4620 Author Date 7 INSPECT VANITY LIGHT CONTINUITY Switch Position Tester Connection Specified Condition OFF Closed 1 2 No continuity ON Opened 1 2 Continuity If the continuity is not as specified replace the bulb or vanity light ...

Page 2973: ...27619 Ignition Switch Rear Combination Light Back up Light Instrument Panel J B BACK UP LIGHT Relay GAUGE Fuse Double Cab BE 64 BODY ELECTRICAL BACK UP LIGHT SYSTEM 4621 Author Date BACK UP LIGHT SYSTEM LOCATION ...

Page 2974: ...I25228 I27621 Ignition Switch Rear Combination Light Back up Light Driver Side J B BACK UP LIGHT Relay A T GAUGE Fuse Except Double Cab BODY ELECTRICAL BACK UP LIGHT SYSTEM BE 65 4622 Author Date ...

Page 2975: ...I27167 M T Back up Light Switch A T Park neutral Position Switch BE 66 BODY ELECTRICAL BACK UP LIGHT SYSTEM 4623 Author Date ...

Page 2976: ...ition Not pushed 1 2 No continuity Pushed 1 2 Continuity If the continuity is not as specified replace the switch 2 A T INSPECT PARK NEUTRAL POSITION SWITCH CON TINUITY see page DI 1003 or DI 1 179 3 A T INSPECT BACK UP LIGHT RELAY CONTINUITY Tester Connection Specified Condition 3 5 No Continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as speci...

Page 2977: ... I27620 High mounted Stop Light Stop Light Switch Rear Combination Light Stop Light Instrument Panel J B STOP Fuse Double Cab BE 68 BODY ELECTRICAL STOP LIGHT SYSTEM 4625 Author Date STOP LIGHT SYSTEM LOCATION ...

Page 2978: ...I27618 High mounted Stop Light Stop Light Switch Rear Combination Light Stop Light Driver Side J B STOP Fuse Except Double Cab BODY ELECTRICAL STOP LIGHT SYSTEM BE 69 4626 Author Date ...

Page 2979: ...d in 2 3 Continuity If the continuity is not as specified replace the switch 2 Except double cab INSPECT STOP LIGHT SWITCH CONTINUITY Switch Position Tester Connection Specified Condition Not pushed 1 2 Continuity Pushed in 1 2 No continuity Not pushed 3 4 No continuity Pushed in 3 4 Continuity If the continuity is not as specified replace the switch 3 INSPECT HI MOUNTED STOP LIGHT ASSEMBLY CONTIN...

Page 2980: ...mounted Stop Light Cargo Light FL Block CARGO Fuse Cargo Light Switch Body ECU Located behind the Instrument Panel BODY ELECTRICAL CARGO LIGHT SYSTEM Double Cab BE 71 4628 Author Date CARGO LIGHT SYSTEM Double Cab LOCATION ...

Page 2981: ...t continuity exists between terminals 3 and 10 with the switch ON c Check that no continuity exists between terminals 3 and 10 with the switch OFF If the continuity is not as specified replace the panel 2 INSPECT CARGO LIGHT ASSEMBLY CONTINUITY Using an ohmmeter check that continuity exists between termi nals 3 and 2 If the continuity is not as specified replace the bulb or the stop light assembly...

Page 2982: ...h mounted Stop Light Cargo Light Cargo Light Switch Driver Side J B CARGO LP Fuse Integration Relay BODY ELECTRICAL CARGO LIGHT SYSTEM Except Double Cab BE 73 4630 Author Date CARGO LIGHT SYSTEM Except Double Cab LOCATION ...

Page 2983: ... that continuity exists between terminals 9 and 1 with the switch ON c Check that no continuity exists between terminals 9 and 1 with the switch OFF If the continuity is not as specified replace the panel 2 INSPECT CARGO LIGHT ASSEMBLY CONTINUITY Using an ohmmeter check that continuity exists between termi nals 3 and 2 If the continuity is not as specified replace the bulb or the stop light assemb...

Page 2984: ... Side J B WIP Fuse Ignition Switch Washer Tank Front Washer Motor Combination Switch Wiper and Washer Switch Double Cab Instrument Panel J B WIP Fuse WSH Fuse BODY ELECTRICAL WIPER AND WASHER SYSTEM BE 75 4632 Author Date WIPER AND WASHER SYSTEM LOCATION ...

Page 2985: ...y HI 8 17 Continuity Washer ON 2 11 Continuity w Intermittent Switch Position Tester Connection Specified Condition OFF 7 16 Continuity INT 7 16 Continuity LO 7 17 Continuity HI 8 17 Continuity Washer ON 2 11 Continuity If the continuity is not as specified replace the switch 2 INSPECT INTERMITTENT OPERATION a Turn the wiper switch to the INT position b Turn the intermittent time control switch to...

Page 2986: ... wash er switch 4 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 termi nal 4 and check that the motor operates at low speed If operation is not as specified replace the motor 5 High speed INSPECT WIPER MOTOR OPERATION Connect the positive lead from the battery to terminal 3 and the negativ...

Page 2987: ... check that the motor stops run ning at the stop position after the motor operates again If operation is not as specified replace the motor 7 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 op erates NOTICE These tests must be performed quickly within 20 seconds to prevent the coil from burning out...

Page 2988: ...ination Meter Assembly Parking Brake Switch Ignition Switch Seat Belt Buckle Switch Double Cab Light Control Rheostat Washer Tank Washer Level Sensor Instrument Panel J B IGN2 Fuse GAUGE Fuse Passenger Seat Belt Warning BODY ELECTRICAL COMBINATION METER BE 79 4636 Author Date COMBINATION METER LOCATION ...

Page 2989: ...tat Driver Side J B IGN Fuse GAUGE Fuse Integration Relay M T Parking Brake Switch Ignition Switch Seat Belt Buckle Switch Washer Tank Washer Level Sensor Except Double Cab A T Parking Brake Switch Combination Meter Assembly Passenger Seat Belt Warning BE 80 BODY ELECTRICAL COMBINATION METER 4637 Author Date ...

Page 2990: ...I10538 Fuel Tank Fuel Sender Gauge Fuel Level Warning Switch Seat Belt Occupant Detection Sensor BODY ELECTRICAL COMBINATION METER BE 81 4638 Author Date ...

Page 2991: ...BE2MD 01 I28305 A B BE 82 BODY ELECTRICAL COMBINATION METER 4639 Author Date CIRCUIT ...

Page 2992: ...A31 KEY ILL B22 KEY ILL A25 4P OUT B24 IG2 A21 ILL B23 B 2 B17 BEAM 1 B18 BEAM A39 A T 2 A38 A T 3 A37 A T D A36 A T N A35 A T R A34 A T P A33 TURN R B19 TURN L A20 TIRE PRS B12 GND A2 PKB SW A1 BRAKE B21 ABS A40 RSCA OFF A16 AIR BAG 3 A27 OIL PRESS 4 A28 OIL PRESS B11 FE A26 FS B10 SPEED GND A24 SP A23 TM A32 TEMP A22 ILL A5 D SEAT SW A29 KEY SW A30 D DOOR A4 DOOR A19 A T L 1 w DRL 2 w o DRL 3 1G...

Page 2993: ... A18 CHECK E G A15 A T OIL TEMP 5 A3 CRUISE B3 AUTO LSD A7 SLIP B2 VSC TRAC 5 B1 VSC OFF A14 O D OFF WASHER CHARGE 4HI L4 CHECK E G A T OIL TEMP CRUISE AUTO LSD SLIP VSC TRAC VSC OFF O D OFF 5 6 Gauge Meter Only BE 84 BODY ELECTRICAL COMBINATION METER 4641 Author Date ...

Page 2994: ...rminal No Wire Harness Side 3 ABS Traction Actuator Assy VSC 4 Vehicle Speed Sensor Park Neutral Position Switch Park Neutral Position Switch Park Neutral Position Switch Park Neutral Position Switch Park Neutral Position Switch Airbag Sensor Assy Center Transfer Control ECU Generator Fuel Sender Gauge Assy Body Ground 7 Headlight Assy 8 Body ECU 1 2 4 5 8 10 11 12 17 18 Terminal No Wire Harness S...

Page 2995: ... to 42 5 40 38 to 42 60 59 5 to 63 5 60 58 to 63 80 79 5 to 84 80 78 to 84 100 100 to 105 100 98 5 to 104 5 120 119 to 125 140 139 to 146 160 159 to 167 If the error is excessive replace the speedometer 2 INSPECT INPUT VEHICLE SPEED SIGNAL WAVE FORM A T a Remove the combination meter with connectors still con nected b Connect the oscilloscope to terminal A 24 and body ground c Start the engine d C...

Page 2996: ...e NOTICE Reversing the connection of the tachometer will dam age the transistors and diodes inside the tachometer When removing or installing the tachometer be care ful not to drop or subject it to heavy shocks b Compare the tester and tachometer indications DC 13 5 V at 20 C 68 F 2UZ FE 1GR FE Standard Indication Allowable Range Standard Indication Allowable Range 700 630 to 770 700 630 to 770 1 ...

Page 2997: ...nal waveform according to the condition s in the table below Item Condition Tool setting 5 V DIV 10 ms DIV Vehicle condition Engine idle speed OK As shown in the illustration 6 INSPECT OUTPUT TACHO SIGNAL WAVEFORM a Remove the combination meter with connector still con nected b Connect the oscilloscope to terminal A 25 and body ground c Start the engine d Check the signal waveform according to the...

Page 2998: ... 3 4 W test bulb d Turn the ignition switch ON and 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 the operation is not as specified inspect the receiver gauge resistance 8 INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3 at ...

Page 2999: ...ct the bulb or wire har ness 10 INSPECT FUEL LEVEL WARNING SWITCH a Apply battery voltage between terminals 1 and 3 through a 3 4 W test bulb and check that the bulb lights up HINT It will take a short time for the bulb to light up b Submerge the switch in fuel and check that the bulb turns off If operation is not as specified replace the sender gauge 11 INSPECT ENGINE COOLANT TEMPERATURE RE CEIVE...

Page 3000: ...cording to the condition s in the table below Item Condition Tool setting 5 V DIV 10 ms DIV Vehicle condition Ignition switch ACC or ON OK As shown in the illustration 13 INSPECT ENGINE COOLANT TEMPERATURE SEND ER GAUGE RESISTANCE a Disconnect the connector from the engine coolant tem perature sender gauge b Measure the resistance according to the value s in the table below Temperature C F Resista...

Page 3001: ...UZ FE INSPECT OIL PRESSURE SENDER GAUGE CONTI NUITY 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 seder ...

Page 3002: ...minal and switch body with the switch ON switch pin released b Check that there is no continuity between the terminals with the switch OFF switch pin pushed in If the continuity is not as specified replace the switch 19 Except double cab A T INSPECT PARKING BRAKE SWITCH CONTINUITY a Check that there is continuity between the terminal and switch body with the switch ON switch pin released b Check t...

Page 3003: ...ector 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 har ness 24 Except regular cab w o Power seat Driver side INSPECT BUCKLE SWITCH CONTINUITY a Check that continuity exists between terminals 3 and 13 of the switch connec...

Page 3004: ...ity is not as specified replace the inner seat belt 28 Regular cab Passenger side INSPECT BUCKLE SWITCH CONTINUITY a Check that continuity exists between terminals 1 and 3 on the switch connector with the switch ON belt fastened b Check that no continuity exists between terminals 1 3 and 4 on the switch side connector with the switch OFF belt unfastened If the continuity is not as specified replac...

Page 3005: ...ng light lights up If the warning light does not light up inspect the bulb 32 Double cab Passenger s seat only INSPECT SEAT BELT WARNING OCCUPANT DETEC TION SENSOR CONTINUITY Check that continuity exists between terminals 1 and 2 when pressing the sensing part If the continuity is not as specified replace the sensor 33 Except double cab Passenger s seat only INSPECT SEAT BELT WARNING OCCUPANT DETE...

Page 3006: ...c Pressing the reset switch turn the ignition switch to the ON position keep pressing for at least 5 seconds d Reset procedure is completed HINT If the ignition switch is turned off during the reset proce dure LCD off IND off If the reset switch is pressed off during the reset proce dure LCD return to ODO IND Keep the previous state of reset Indicator Condition State Condition Specified State Blin...

Page 3007: ...BE2L8 01 I27185 Instrument Panel J B ECU IG Fuse Roof Console Box Assembly Compass Overhead Module Ignition Switch BE 98 BODY ELECTRICAL COMPASS Double Cab 4655 Author Date COMPASS Double Cab LOCATION ...

Page 3008: ...ndition differs depending on the area where the vehicle is used it is necessary for each user to set the zone Refer to Compass Zone Map The zone setting can be changed using the E M switch of the display 3 PERFORMING CALIBRATION Because each vehicle has its own magnetic field calibration should be performed for each vehicle This com pass function is used when storing the record of the vehicle s ma...

Page 3009: ...57 Author Date 6 ZONE SETTING MODE a Turn the ignition switch ON b To keep pressing the E M switch and MODE switch for 5 seconds when outer temperature is displayed will activate the zone setting mode A number 1 to 15 is displayed on the compass display ...

Page 3010: ...one is displayed if the E M switch and MODE switch remains pressed another 5 seconds will activate the calibration setting mode b To keep pressing the E M switch and MODE switch for 10 seconds when outer temperature is dis played will also activate this mode c Drive the vehicle at a slow speed of 8 km h 5 mph or less in the circular direction d Driving round the circle 1 to 3 times will display th...

Page 3011: ... Heater Rear Window Defogger Ignition Switch Defogger Switch Engine Room J B MIR HTR Fuse DEFOG Relay No 2 Engine Room R B MIR HTR Relay BE 102 BODY ELECTRICAL DEFOGGER SYSTEM Double Cab 4659 Author Date DEFOGGER SYSTEM Double Cab LOCATION ...

Page 3012: ... or ACC Below 1 V 4 Ground Ignition switch ON 10 14 V 6 Ground Constant Continuity 10 Ground Constant Continuity 14 Ground Ignition switch OFF or ACC Below 1 V 14 Ground Ignition switch ON 10 14 V 15 Ground Constant 10 14 V If the result is as specified replace the panel 2 INSPECT DEFOGGER RELAY Making DEFOG CON TINUITY Tester Connection Specified Condition 3 4 Continuity 3 4 No continuity When ba...

Page 3013: ... wire with your finger as shown in the il lustration a Turn the ignition switch ON b Turn the defogger switch on c Inspect the voltage at the center of each heat wire as shown in the illustration Voltage Criteria Approx 5 V Okay No break in wire Approx 10 V or 0 V Broken wire HINT If there is approximately 10 V the wire is broken between the center of the wire and the positive end If there is no v...

Page 3014: ...oroughly mix the repair agent Dupont paste No 4817 d Using a fine tip brush apply a small amount of the agent to the wire e After a few minutes remove the masking tape f Do not repair the defogger wire for at least 24 hours 6 INSPECT MIRROR HEATER OPERATION a Connect the positive lead from the battery to terminal 6 and the negative lead to terminal 4 b Check that the mirror becomes warm HINT It wi...

Page 3015: ...Heater Ignition Switch Engine Room R B MIR HTR Fuse MIR HTR Relay Mirror Heater Switch Driver Side J B GAUGE Fuse BE 106 BODY ELECTRICAL MIRROR HEATER SYSTEM Except Double Cab 4663 Author Date MIRROR HEATER SYSTEM Except Double Cab LOCATION ...

Page 3016: ...irror heater switch on and check that the indi cator lights up and that the voltage is less than 1 V e After 15 minutes check that the switch is OFF and the voltage is approximately 12 V If the result is not as specified replace the switch 2 INSPECT MIRROR HEATER RELAY Marking MIR HTR CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied ...

Page 3017: ...ster Switch Driver Door ECU Ignition Switch Instrument Panel J B PWR NO 1 Fuse PWR NO 2 Fuse PWR NO 3 Fuse PWR NO 4 Fuse POWER MAIN Relay Power Window Regulator Switch Front Passenger Door ECU Body ECU Located behind the Instrument Panel BE 108 BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM Double Cab 4665 Author Date POWER WINDOW CONTROL SYSTEM Double Cab LOCATION ...

Page 3018: ...ondition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the relay 3 Driver side door INSPECT POWER WINDOW MOTOR OPERATION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the motor turns clockwise b Reverse the polarity and check that the motor turns cou...

Page 3019: ...om the battery to terminal 1 and the negative lead to terminals 2 then check that the motor turns clockwise b Reverse the polarity and check that the motor turns coun terclockwise If operation is not as specified replace the motor 6 Rear left door INSPECT POWER WINDOW MOTOR OPERATION a Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 then check that the ...

Page 3020: ...r INSPECT POWER WINDOW MOTOR PTC THERM ISTOR OPERATION a Disconnect the connector from the motor b Connect the positive lead from the ammeter to termi nal 2 of the motor connector and the negative lead to negative terminal of the battery c Connect the positive lead from the battery to terminal 1 of the motor connector and raise the window to the fully closed position d Continue to apply voltage an...

Page 3021: ...WINDOW MOTOR PTC THERM ISTOR OPERATION a Disconnect the connector from the motor b Connect the negative lead from the ammeter to termi nal 2 of the motor connector and the negative lead to negative terminal of the battery c Connect the positive lead from the battery to terminal 1 of the motor connector and raise the window to the fully closed position d Continue to apply voltage and check that the...

Page 3022: ...ow Regulator Switch Driver Side J B ECU IG Fuse POWER Relay Integration Relay Power Window Regulator Assembly Power Window Motor BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM Except Double Cab BE 1 13 4670 Author Date POWER WINDOW CONTROL SYSTEM Except Double Cab LOCATION ...

Page 3023: ...N 1 8 9 10 Continuity Passenger s switch Window lock Switch Position Tester Connection Specified Condition UP 8 9 Continuity OFF 8 10 Continuity DOWN 9 10 Continuity If the continuity is not as specified replace the switch 2 Using an ammeter INSPECT ONE TOUCH POWER WINDOW SYSTEM CURRENT OF CIRCUIT a Disconnect the connector from the master switch b Connect the positive lead from the ammeter to ter...

Page 3024: ... the ignition switch ON and set the power window switch in the down position d When the window moves down check that the current is approximately 7 A e Check that the current increases to approximately 14 5 A or more when the window stops moving down HINT Since the circuit breaker opens in 4 to 90 seconds after the win dow stops moving down the check must be performed before the PTC starts operati...

Page 3025: ...the connector from the motor b Connect the positive lead from the ammeter to termi nal 1 of the wire motor connector and the negative lead to the negative terminal of the battery c Connect the positive lead from the battery to terminal 2 of the motor connector and raise the window to the fully closed position d Continue to apply voltage and check that the current changes to less than 1 A in 4 to 9...

Page 3026: ...seconds e Disconnect the leads from the terminals f Approximately 60 seconds later connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 and check that the window begins to move down If operation is not as specified replace the motor 10 CHECK INTEGRATION RELAY Remove the integration relay from the driver side J B and check the voltage or continuity of each te...

Page 3027: ...DOW Relay Body ECU Located behind the Instrument Panel Ignition Switch Back Power Window Regulator and Motor Assembly Window Limit Switch Back Window Control Relay BE 1 18 BODY ELECTRICAL BACK POWER WINDOW SYSTEM Double Cab 4675 Author Date BACK POWER WINDOW SYSTEM Double Cab LOCATION ...

Page 3028: ...ition switch OFF or ACC ON 0 V 10 to 14 V 8 Body ground Limit switch OFF ON 10 kΩ or higher Below 1 Ω 9 Body ground Constant Continuity 11 Body ground Constant Continuity 12 Body ground Ignition switch OFF or ACC ON 0 V 10 to 14 V If the result is not as specified there may be a malfunction on the wire harness side or limit switch b Reconnect the connector to the relay and check the con nector on ...

Page 3029: ...ly 60 seconds later connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the window begins to moves down If operation is not as specified replace the power back window regulator and motor assembly 4 INSPECT POWER MAIN RELAY CONTINUITY Tester Connection Specified Condition 3 5 No Continuity 3 5 Continuity When battery voltage is applied to term...

Page 3030: ...egration Relay Ignition Switch Power Slide Back Window Regulator and Motor Assembly Power Slide Back Window Switch BODY ELECTRICAL POWER SLIDE BACK WINDOW SYSTEM Except Double Cab BE 121 4678 Author Date POWER SLIDE BACK WINDOW SYSTEM Except Double Cab LOCATION ...

Page 3031: ...y c Connect the positive lead from the battery to terminal 2 of the motor connector and slide the window to the fully closed position d Continue to apply voltage and check that the current changes to less than 1 A in 4 to 90 seconds e Disconnect the leads from the terminals f Approximately 60 seconds later connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2...

Page 3032: ...hind the Instrument Panel Door Lock Assembly Door Lock Motor Door Key Lock and Unlock Switch Door Unlock Detection Switch Rear Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Rear Door Lock Assembly Door Lock Motor Door Unlock Detection Switch BODY ELECTRICAL POWER DOOR LOCK CONTROL SYSTEM Double Cab BE 123 4680 Author Date POWER DOOR LOCK CONTROL SYSTEM Double Cab LOCATION ...

Page 3033: ...er Connection Specified Condition LOCK 2 4 Continuity OFF 1 4 2 4 No continuity UNLOCK 1 4 Continuity If the continuity is not as specified replace the door lock assem bly 3 INSPECT DRIVER SIDE DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch Position Tester Connection Specified Condition OFF Door lock set to LOCK 3 4 No continuity ON Door lock set to UNLOCK 3 4 Continuity If the continuity is not a...

Page 3034: ...OCK 6 9 Continuity If the continuity is not as specified replace the door lock assem bly 7 INSPECT DRIVER SIDE DOOR LOCK MOTOR OPERA TION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the door lock cable moves to the UNLOCK position b Reverse the polarity and check that the door lock cable moves to the LOCK position If operation is no...

Page 3035: ...osition b Reverse the polarity and check that the door lock cable moves to the LOCK position If operation is not as specified replace the door lock assembly 10 INSPECT REAR RIGHT SIDE DOOR LOCK MOTOR OPERATION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 4 and check that the door lock cable moves to the UNLOCK position b Reverse the polarity and chec...

Page 3036: ...r Key Lock and Unlock Switch Door Lock Control Switch Power Window Master Switch Door Lock Control Switch Driver Side J B ECU IG Fuse POWER Fuse Integration Relay BODY ELECTRICAL POWER DOOR LOCK CONTROL SYSTEM Except Double Cab BE 127 4684 Author Date POWER DOOR LOCK CONTROL SYSTEM Except Double Cab LOCATION ...

Page 3037: ...LOCK CONTROL SWITCH CONTINU ITY Switch Position Tester Connection Specified Condition LOCK 3 6 Continuity OFF 3 5 3 6 No continuity UNLOCK 3 5 Continuity If the continuity is not as specified replace the switch 3 INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch Position Tester Connection Specified Condition LOCK 1 2 Continuity OFF 1 2 2 3 No continuity UNLOCK 2 3 Continuity If the continu...

Page 3038: ... INSPECT DOOR LOCK ACTUATOR 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 the UNLOCK position b Reverse the polarity and check that the door lock link moves to the LOCK position If operation is not as specified replace the actuator ...

Page 3039: ...e or continuity of each termi nal of the wire harness side connectors Tester Connection Condition Specified Condition 1H 6 Body ground Passenger s door opened Continuity 1H 6 Body ground Passenger s door closed No continuity 1H 7 Body ground Driver s door opened Continuity 1H 7 Body ground Driver s door closed No continuity 1I 2 Body ground Ignition switch LOCK or ACC Below 1 V 1I 2 Body ground Ig...

Page 3040: ...ty 1N 20 Body ground Door key lock and unlock switch OFF or UN LOCK No continuity 1N 21 Body ground Door lock manual switch or door lock control switch UNLOCK Continuity 1N 21 Body ground Door lock manual switch and door lock control switch OFF or LOCK No continuity 1N 22 Body ground Front passenger s door key lock and unlock switch UNLOCK Continuity 1N 22 Body ground Front passenger s door key lo...

Page 3041: ...und Constant Continuity 5 Body ground Constant 10 14 V 6 Body ground Constant 10 14 V 7 Body ground Constant 10 14 V 8 Body ground Constant Continuity 10 Body ground Ignition switch ON 10 14 V 11 Body ground Constant Continuity 12 Body ground Constant No continuity 13 Body ground Constant No continuity 14 Body ground Left door courtesy switch OFF Door closed No continuity 14 Body ground Left door ...

Page 3042: ... or continuity of each termi nal of the wire harness side connectors Tester Connection Condition Specified Condition 1H 6 Body ground Passenger s door opened Continuity 1H 6 Body ground Passenger s door closed No continuity 1H 7 Body ground Driver s door opened Continuity 1H 7 Body ground Driver s door closed No continuity 1I 2 Body ground Ignition switch LOCK or ACC No voltage 1I 2 Body ground Ig...

Page 3043: ...inuity 1L 6 Body ground Key unlock warning switch ON Ignition key inserted Continuity 1L 8 Body ground Passenger s door unlock detection switch OFF No continuity 1L 8 Body ground Passenger s door unlock detection switch ON Continuity 1L 9 Body ground Driver s door unlock detection switch OFF No continuity 1L 9 Body ground Driver s door unlock detection switch ON Continuity 1L 10 Body ground Cargo ...

Page 3044: ...active arming mode that is an initially set mode and another is the passive arming mode that can be switched by the hand held tester c Each mode active and passive has 4 states the disarmed state the arming preparation state the armed state and the alarm sounding state 1 Disarmed state The alarm function is not operating The theft deterrent system is not operating 2 Arming preparation state The th...

Page 3045: ...orming any of the following will cause the system to return to disarmed state Unlock any door by wireless operation Unlock any door by key operation Unlock any door Open any door Open engine hood Insert key into ignition key cylinder Turn ignition switch from OFF to ON Disconnect battery once and then reconnect it Performing the following will cause the system to go into armed state With all doors...

Page 3046: ...ra tion Unlock any door by key operation Insert key into ignition key cylinder and turn ignition switch from OFF to ON Performing any of the follow ing will cause the system to set off the alarm Open engine hood Open any door Unlock any door without key and wireless operation Directly connect ignition switch without key or turn ignition switch ON without key Disconnect battery once and then reconn...

Page 3047: ...d Detecting that the doors are unlocked does not set off the alarm during passive arming mode A forced door lock signal is not output during passive arming mode see step 4 When the theft deterrent system detects that the doors are opened during passive arming mode the alarm is not set off immediately because an entry delay time is set If any of the following conditions is met during passive arming...

Page 3048: ...ion switch OFF pull out key from ignition key cylinder and open any door or the engine hood Performing any of the following will cause the system to return to disarmed state 1 Unlock any door by wireless operation Unlock any door by key operation Insert key into ignition key cylinder Turn ignition switch from OFF to ON Disconnect battery once and then re connect it Performing any of the following ...

Page 3049: ...pen engine hood Disconnect battery once and then reconnect it Directly connect ignition switch without key or turn ignition switch ON without key Performing any of the following will cause the system to return to dis armed state 1 Unlock any door by wireless operation Unlock any door by key opera tion Insert key into ignition key cyl inder and turn ignition switch from OFF to ON HINT 3 When any do...

Page 3050: ...by the theft deterrent system switched to the alarm sounding state from the armed state 1 Conditions that cause the panic alarm control to set off the panic alarm The panic alarm control sets off the panic alarm by pressing the PANIC switch on the wireless transmitter under the following conditions The ignition switch is OFF The theft deterrent system is not in the alarm sounding state common to a...

Page 3051: ...ate of the active arming mode In this case the active arming mode will continue until the system switches to the disarmed state State of Passive Arming Mode Before Switch State of Active Arming Mode After Switch Disarmed state Arming preparation state Arming preparation state Arming preparation state continuing for 30 seconds Armed state during entry delay time After alarming time has elapsed the ...

Page 3052: ...e positive lead from the battery to terminal 1 and the negative lead to the horn body and check that the horn blows If operation is not as specified replace the horn 2 INSPECT ENGINE HOOD COURTESY SWITCH CON TINUITY Condition Tester Connection Specified Condition Push 1 2 No continuity Not pushed 1 2 Continuity If the continuity is not as specified replace the switch ...

Page 3053: ...et The ignition switch is OFF HINT The key can be inserted however it must be in the OFF position c The wireless door lock remote control operational area differs depending on the situation 1 The operational area differs depending on the operators and the ways the transmitter is held 2 In certain areas the remote control function will only operate partially for the operational area will be reduced...

Page 3054: ...odes will be erased in order starting from the first registered code The rewrite mode is used to erase all the previously registered recognition codes in order to register new recognition codes This mode is used when the transmitter or the door control receiver is replaced a new one The confirmation mode is used to confirm how many recognition codes have already been registered before an additiona...

Page 3055: ...on 5 times to LOCK UNLOCK at approx 1 sec interval 1st time 2nd time 3rd time 4th time 5th time LOCK OFF UNLOCK Approx 1 sec Approx 1 sec Insert key into ignition key cylinder Within 40 sec START Flow Chart of Recognition Code Registration Make sure that the following conditions are met No key in ignition key cylinder Driver side door is open other doors are closed Driver side door is unlocked Ins...

Page 3056: ...nd intervals according to the number of times shown below Mode Selection If the number of the ON LOCK operations of the ignition switch is 0 4 or 6 or more there will be no response power door lock and unlock operation to show which mode has been selected Remove key from ignition key cylinder 7 6 Within 3 sec T1 T1 Approx 1 sec Continued from previous page Continued on next page ON LOCK T1 T1 ON L...

Page 3057: ...tered codes 1 5 times LOCK UNLOCK operation 5 times UNLOCK LOCK UNLOCK LOCK UNLOCK LOCK Continued on next page Registration procedures are completed HINT In the confirmation mode when LOCK UNLOCK operation is performed twice the number of registered recognition codes is 2 In the confirmation mode when 0 codes are registered LOCK UNLOCK operation is automatically performed 5 times T2 Approx 2 sec C...

Page 3058: ...in 40 sec If other transmitter is to be registered Within 3 sec Registration of recognition codes add mode and rewrite mode is completed Body ECU automatically performs power door LOCK UNLOCK operation to show whether registration has been completed correctly or not HINT 4 recognition codes can be registered at once HINT If LOCK UNLOCK operation is performed twice registration of recognition code ...

Page 3059: ...nsmitter toward vehicle and press one of transmitter switches for approximately 1 second Normal Reference Operative distance may differ according to an operator way of holding transmitter or position As weak electric wave is used when there is strong wave or noise in used frequency operation distance might be shortened No Yes Only wireless function Remote control does not operate If a new transmit...

Page 3060: ...witch OFF ON OFF once within 5 seconds after pulling it out 2 Within 30 seconds after completing above step turn ignition switch OFF ON OFF 9 times HINT If neither of 1 or 2 conditions is satisfied vehicle returns to normal mode Reference When completing self diagnostic mode turn ignition switch ON LOCK and UNLOCK operation is not performed under self diagnostic mode 1 time 9 times ON OFF Transmit...

Page 3061: ...key unlock warning switch Self diagnostic mode check Check that how buzzer chirps when pressing each transmitter switch ON OFF Buzzer 0 13 sec 0 5 sec 1 Receiver normal wave of LOCK switch ON OFF Buzzer 0 13 sec 0 25 sec 2 Receiver normal wave of UNLOCK switch 0 5 sec ON OFF 3 Incompatibility of recognition code or out from synchronization of rolling code While receiving Reference While turning ig...

Page 3062: ...ss door control receiver check Check diagnosis wireless door lock signal error see page DI 2447 Check that diagnostic code 42 is output Wire harness faulty short circuit Between receiver terminal 2 RDA and body ECU terminal B11 9 RDA Between receiver terminal 3 PRG and body ECU terminal B11 10 PRG Yes No When pressing each switch of new or normal transmitter used in same type vehicle check that al...

Page 3063: ...ervals check that the corresponding operation is carried out d Check the automatic lock function 1 Check that all the doors lock automatically as long as none of them have been opened or all the doors have not been locked within approximately 30 seconds after they are unlocked by pressing the UNLOCK switch 2 Check that the automatic locking function does not operate when any door has been opened o...

Page 3064: ...t the horn stops sounding and the lights stop flashing when either PANIC or UNLOCK switch on the transmitter is pressed or any door is un locked using the key 7 CHECK DOOR CONTROL RECEIVER a Disconnect the receiver connector b Check the voltage and resistance between the terminals of the wire harness side connector of the receiver and body ground Standard Tester Connection Specified Condition 5 B ...

Page 3065: ...ight Front Door Lock Assembly Door Courtesy Switch Door Courtesy Switch Body ECU Located behind the Instrument Panel Instrument Panel J B TAIL Fuse PWR NO 1 Fuse PWR NO 2 Fuse No 2 Engine Room R B H LP LL Fuse 1 H LP RL Fuse 1 H LP LH Fuse 1 H LP RH Fuse 1 1 w Daytime Running Light 2 w o Daytime Running Light Door Lock Control Receiver BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Double Cab B...

Page 3066: ...ted via the remote control HINT The minimum operational distance differs depending on the operator the way the transmitter is held and the loca tion Since the transmitter uses faint electric waves the opera tional distance might be shortened if noise or strong elec tric wave occurs in the area where the frequency is used 4 Install the battery lithium battery b Inspect the battery capacity HINT The...

Page 3067: ...s low the inspection cannot be made correctly When the outcome of the test is less than 2 2 V conduct the test again after leaving the battery in a place with a temperature of 18 C 64 F for more than 30 minutes The automatic power off function causes the voltage of the battery to be 2 5 V or more a voltage with no resis tance applied to the battery when 0 8 seconds have passed after the switch is ...

Page 3068: ...p the batteries lithium battery to forcibly re move it will cause deformation of the terminals Do not touch the battery with wet hands Water may cause unexpected rust Do not touch or move any components inside the transmitter as it may interfere with proper operation 2 INSTALL TRANSMITTER BATTERY a Install a new battery lithium battery with the positive side up as shown in the illustration NOTICE ...

Page 3069: ...tion key cylinder c The wireless door lock remote control operational area differs depending on the situation 1 The operational area differs depending on the operators and the ways the transmitter is held 2 In certain areas the remote control function will only operate partially for the operational area will be reduced due to the vehicle body shape and the influence of the surrounding environment ...

Page 3070: ... rolling code of the transmitter and synchronize it with the registered recognition code This mode is used when the transmitter does not function because they are unsynchronized 1 Up to 4 transmitters can be synchronized at one time The setting mode is used to set the optional operation via the transmitter that has the recognition code already registered Double switch operation 2 is available as t...

Page 3071: ...her doors are closed Driver s door is unlocked Close and open driver s door twice Close and open driver s door twice Insert key into ignition key cylinder and close driver s door START Insert key into ignition key cylinder then pull it out Insert key into ignition key cylinder then pull it out Flow Chart of Recognition Code Registration BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Except Doub...

Page 3072: ... approximately 1 second interval 1 to 6 times to select a mode Mode Selection If the number of ON LOCK operation of ignition switch is 0 3 or 7 or more there will be no response power door lock and unlock opera tion to inform which mode has been selected 7 T1 T1 Approx 1 sec ON LOCK T1 T1 ON LOCK T1 T1 ON LOCK T1 T1 Synchronization Mode ON LOCK T1 T1 Continued from previous page ON LOCK operation ...

Page 3073: ...CK LOCK LOCK UNLOCK operation 1 time Add Mode Rewrite Mode Setting Mode Erase Mode T1 T1 Approx 1 sec T1 T1 T1 T1 T1 T1 Synchronization Mode T1 T1 LOCK UNLOCK operation 2 times LOCK UNLOCK operation 4 times LOCK UNLOCK operation 5 times LOCK UNLOCK operation 6 times UNLOCK LOCK UNLOCK LOCK UNLOCK LOCK UNLOCK LOCK Continued on next page Registration procedure is completed Add Rewrite Setting or Syn...

Page 3074: ...ail 10 LOCK UNLOCK T1 LOCK UNLOCK T1 T1 Press UNLOCK switch for more than 1 0 second 10 Press LOCK switch for more than 1 0 second 10 Setting Mode Add Rewrite or Synchronization Mode Within 40 sec w o Double switch operation w Double switch operation If another transmitter is to be registered Within 2 sec Registration of recognition codes add rewrite setting or synchronization mode is completed TV...

Page 3075: ... does not activate lights and buzzer start over Continued on next page Continued on next page Lights and buzzer operation 1 time BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Except Double Cab BE 175 4732 Author Date 2 PROGRAM IGNITION CONTROLLED AUTOMATIC DOOR LOCK UNLOCK FUNCTION HINT With this function on when the key is inserted into the ignition key cylinder and turned to the ON or START ...

Page 3076: ...LOCK Response of selected mode OFF ON Ignition controlled door locks ON Ignition controlled door locks OFF OFF ON Lights and buzzer operation 1 time Programming is completed If system does not activate lights and buzzer start over Continued from previous page Lights and buzzer operation 2 time TVIP ECU automatically causes taillights and side marker lights to flash once and TVIP buzzer to chirp on...

Page 3077: ...hile the switch is held However when the switch is operated repeatedly at 1 second intervals check that the corresponding operation is carried out d Check the automatic lock function 1 Check that all the doors lock automatically as long as none of them have been opened or all the doors have not been locked within approximately 30 seconds after they are unlocked by pressing the UNLOCK switch 2 Chec...

Page 3078: ... flash for 60 seconds by the TVIP alarm function when the PANIC switch is pressed Also check that the horn stops sounding and the lights stop flashing when either switch of the transmitter is pressed or any door is either locked or unlocked using the key k Check the ignition controlled automatic door lock unlock function HINT This function s initial mode is OFF however the program for this functio...

Page 3079: ...oor Courtesy Switch Access Door Rear Lower Door LOCK Rear Lower Door Courtesy Switch Interior Light Headlight Combination Light Taillight Ignition Switch TVIP ECU TVIP Buzzer Front Door Lock Assembly Turn Signal Light Parking Light Transmitter BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM Except Double Cab BE 179 4736 Author Date LOCATION ...

Page 3080: ...be operated via the remote control HINT The minimum operational distance differs depending on the operator the way the transmitter is held and the loca tion Since the transmitter uses faint electric waves the opera tional distance might be shortened if noise or strong elec tric wave occurs in the area where the frequency is used 4 Install the battery lithium battery b Inspect the battery capacity ...

Page 3081: ...y is low the inspection cannot be made correctly When the outcome of the test is less than 2 2 V conduct the test again after leaving the battery in a place with a temperature of 18 C 64 F for more than 30 minutes The automatic power off function causes the voltage of the battery to be 2 5 V or more a voltage with no resis tance applied to the battery when 0 8 seconds have passed after the switch ...

Page 3082: ...he terminals Do not touch the battery with wet hands Water may cause unexpected rust Do not touch or move any components inside the transmitter as it may interfere with proper operation 2 INSTALL TRANSMITTER BATTERY a Install a new battery lithium battery with the positive side up as shown in the illustration NOTICE Be sure that the positive side and the negative side of the transmitter battery ar...

Page 3083: ...at Slide Motor Reclining Motor Front Tilt Motor Rear Lifter Motor Lumbar Support Motor Power Seat Switch Lumbar Support Switch Double Cab Instrument Panel J B PWR SEAT Fuse BODY ELECTRICAL POWER SEAT CONTROL SYSTEM BE 183 4740 Author Date POWER SEAT CONTROL SYSTEM LOCATION ...

Page 3084: ...ion UP 1 7 4 8 Continuity OFF 4 7 8 Continuity DOWN 1 8 4 7 Continuity Reclining switch Switch Position Tester Connection Specified Condition FORWARD 1 3 2 4 Continuity OFF 2 3 4 Continuity REAR 1 2 3 4 Continuity If the continuity is not as specified replace the switch 2 INSPECT LUMBAR SUPPORT SWITCH CONTINUITY Switch Position Tester Connection Specified Condition FORWARD 1 4 2 3 Continuity OFF 1...

Page 3085: ...at adjuster 5 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 and check that the motor turns coun terclockwise If operation is not as specified replace the seat adjuster 6 INSPECT FRONT TILT MOTOR PTC THERMISTOR OP ERATION a Connect the positive lead from th...

Page 3086: ... 1 A 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 9 INSPECT RECLINING MOTOR OPERATION a Connect the positive lead from the battery to terminal 1 and t...

Page 3087: ... that the lumbar support moves to the release side b Reverse the polarity and check that the lumbar support moves forward If operation is not as specified replace the lumbar support ad juster 12 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 Move the lumbar s...

Page 3088: ...itch Mirror Switch Outer Mirror Assembly Mirror Motor ACC CUT Relay Instrument Panel J B RAD NO 2 Fuse BE 188 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM Double Cab 4745 Author Date POWER MIRROR CONTROL SYSTEM Double Cab LOCATION ...

Page 3089: ...INSPECT MIRROR SWITCH CONTINUITY Switch Position Tester Connection Specified Condition UP 3 8 6 7 Continuity DOWN 3 7 6 8 Continuity LEFT 5 8 6 7 Continuity RIGHT 5 7 6 8 Continuity If the continuity is not as specified replace the switch 3 INSPECT ACC CUT RELAY CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If...

Page 3090: ...uble Cab 4747 Author Date c Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 Check that the mirror turns upward d Reverse the polarity check that the mirror turns down ward If operation is not as specified replace the mirror assembly ...

Page 3091: ...Ignition Switch Driver Side J B ACC Fuse Mirror Switch 2UZ FE only ACC Cut Relay 2UZ FE only Engine Room R B ECU B Fuse BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM Except Double Cab BE 191 4748 Author Date POWER MIRROR CONTROL SYSTEM Except Double Cab LOCATION ...

Page 3092: ...lace the switch 2 Right side INSPECT MIRROR SWITCH CONTINUITY Switch Position Tester Connection Specified Condition UP 3 8 6 7 Continuity DOWN 3 7 6 8 Continuity LEFT 5 8 6 7 Continuity RIGHT 5 7 6 8 Continuity If the continuity is not as specified replace the switch 3 2UZ FE INSPECT ACC CUT RELAY CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltag...

Page 3093: ...ODY ELECTRICAL POWER MIRROR CONTROL SYSTEM Except Double Cab BE 193 4750 Author Date b Reverse the polarity check that the mirror turns to the right c Connect the positive lead from the battery to terminal 3 2 and the negative lead to terminal 5 1 Check that the mirror turns upward w o Mirror heater ...

Page 3094: ...w Mirror Heater 2 5 BE 194 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM Except Double Cab 4751 Author Date d Reverse the polarity and check that the mirror turns downward If operation is not as specified replace the mirror assembly ...

Page 3095: ...BE2MG 01 I28660 Ignition Switch Driver Side J B GAUGE Fuse Electro Chromic Inner Mirror BODY ELECTRICAL ELECTRO CHROMIC MIRROR SYSTEM BE 195 4752 Author Date ELECTRO CHROMIC MIRROR SYSTEM LOCATION ...

Page 3096: ...turned to AUTO check that indicator light lights up d Snhine an electric light on the mirror Check that the mirror surface changes from bright to dark If operation is not as specified replace the inner mirror 2 INSPECT ELECTRO CHROMIC INNER MIRROR CIR CUIT Disconnect the connector from the mirror and inspect the con nector on the wire harness side as shown Tester connection Condition Specified con...

Page 3097: ... Seat Heater Switch Instrument Panel J B SEAT HTR Fuse Seat Cushion Heater Seatback Heater Driver Side R B SEAT HEATER Relay BODY ELECTRICAL SEAT HEATER SYSTEM Double Cab BE 197 4754 Author Date SEAT HEATER SYSTEM Double Cab LOCATION ...

Page 3098: ...ontinuity LO 4 5 Continuity Illumination circuit 1 2 Continuity If the continuity is not as specified replace the switch 2 INSPECT SEAT HEATER INDICATOR LIGHT OPERA TION a Connect the positive lead from the battery to terminal 4 and the negative lead to terminal 6 b Push the seat heater switch on the HI position and check that the HI indicator light turns on c Push the seat heater switch on the LO...

Page 3099: ...is not as specified replace the seat cushion pad 4 INSPECT SEATBACK HEATER CONTINUITY a Heat the thermostat with a light b Inspect the seatback heater continuity between termi nals as shown in the illustration Tester Connection Condition Specified Condition 2 3 Constant Continuity 1 2 1 3 Seat heater temperature below 30 C 86 F Continuity 1 2 1 3 Seat heater temperature above 50 C 122 F No continu...

Page 3100: ... Fuse Double Cab Integration Control Panel Except Double Cab Integration Control Panel A B BE 200 BODY ELECTRICAL CLOCK 4757 Author Date CLOCK TROUBLESHOOTING HINT Troubleshoot the clock according to the table below Problem No Clock does not operate 1 Clock loses or gains time 2 1 5 seconds day ...

Page 3101: ...k Open or short circuit in wire harness between terminal B and DOME fuse Open circuit in wire harness between terminal GND and body ground BODY ELECTRICAL CLOCK BE 201 4758 Author Date 1 PROBLEM NO 1 a Check that the battery positive voltage is between 10 to 14 V If voltage is not as specified replace the battery b Check that the DOME fuse is not blown If the fuse is blown replace the fuse and che...

Page 3102: ...CAL CLOCK 4759 Author Date 2 PROBLEM NO 2 a Check that the battery positive voltage is between 10 to 14 V If voltage is not as specified replace the battery b Inspect the error of the clock Allowable error per day 1 5 seconds If the error exceeds the allowable error replace the clock c Check that the clock adjusting button is stuck in position and has failed to return If the error exceeds the allo...

Page 3103: ... a system if people or objects are near the system to be registered When registering transmitter codes inju ry or damage can occur as the system may open close unlock or otherwise operate Before transmitter code registration stop the engine and remove the key from the ignition switch The garage door opener cannot be used with 1 sys tems that 1 were manufactured before April 1 1982 or 2 systems tha...

Page 3104: ...ener and press and hold one of the garage door opener switches Then press the origi nal transmitter switch 4 If the transmitter code registration was successful the indicator of the garage door opener flashes at a cycle of 5 6 Hz If no malfunction occurs release both the garage door opener switch and the original transmitter switch HINT If transmitter code registration fails 1 the original trans m...

Page 3105: ...itter codes must be erased at the same time If the switches are released within 10 seconds after the transmitter codes have been erased the garage door opener will enter registration mode If the switches are held for 10 seconds or more after the transmitter codes have been erased default codes will be set to the 3 switches of the garage door opener Using these default codes you can check operation...

Page 3106: ...N OFF Enter clear mode to erase all 3 codes BE 206 BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM Double Cab 4763 Author Date Timing chart of clear mode c Low power mode If a garage door opener switch is held for 55 seconds or more the garage door opener will enter low power mode to economize on power consumption When the garage door opener has entered low power mode the indicator turns off ...

Page 3107: ... I27185 Instrument Panel J B ECU IG Fuse Roof Console Box Assembly GARAGE Door Opener Switch Overhead Module Ignition Switch BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM Double Cab BE 207 4764 Author Date LOCATION ...

Page 3108: ...ON AND TRANSMITTING HINT Use the KENTMORE home link tester and a tester transmitter for this test First erase the customer s transmitter code and then register the tester transmitter code a Check if the tester transmitter code was successfully reg istered b Press the garage door opener switch that was registered to the tester transmitter Check if the home link tester s green LED illuminates HINT I...

Page 3109: ...No 3 Engine Room R B TOWING TAIL Fuse BATT CHARGE Fuse TOWING BRK Fuse TOW TAIL Relay BATT CHARGE Relay Ignition Switch Towing Converter Engine Room J B TOWING Fuse BODY ELECTRICAL TRAILER TOWING Double Cab BE 209 4766 Author Date TRAILER TOWING Double Cab LOCATION ...

Page 3110: ...tch RIGHT or hazard warning switch ON 10 14 V Below 1 V 3 6 Turn signal switch OFF or LEFT and hazard warning switch OFF Below 1 V Turn signal switch LEFT or hazard warning switch ON 10 14 V Below 1 V Turn signal switch LEFT and stop light switch ON brake pedal depressed 10 14 V Below 1 V 4 6 Turn signal switch OFF hazard warning switch OFF and stop light switch OFF brake pedal released Below 1 V ...

Page 3111: ...BE 21 1 4768 Author Date 3 INSPECT BATTERY CHARGE RELAY Marking BATT CHARGE CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the relay ...

Page 3112: ...Socket Engine Room R B TOWING Fuse TOW TAIL Fuse TOW BRK Fuse SUB BATT Fuse TOW TAIL Relay SUB BATT Relay Ignition Switch Towing Converter BE 212 BODY ELECTRICAL TRAILER TOWING Except Double Cab 4769 Author Date TRAILER TOWING Except Double Cab LOCATION ...

Page 3113: ... or hazard warning switch ON 10 14 V Below 1 V 3 6 Turn signal switch OFF or LEFT and hazard warning switch OFF Below 1 V Turn signal switch LEFT or hazard warning switch ON 10 14 V Below 1 V Turn signal switch LEFT and stop light switch ON brake pedal depressed 10 14 V Below 1 V 4 6 Turn signal switch OFF hazard warning switch OFF and stop light switch OFF brake pedal released Below 1 V Stop ligh...

Page 3114: ...ouble Cab 4771 Author Date 3 INSPECT SUB BATTERY RELAY Marking SUB BATT CONTINUITY Tester Connection Specified Condition 3 5 No continuity 3 5 Continuity When battery voltage is applied to terminals 1 and 2 If the continuity is not as specified replace the relay ...

Page 3115: ... front or rear using clip remover or pliers Remove clips from front or rear using clip remover or pliers Protective Tape Protective Tape BODY CLIP BO 1 4772 Author Date CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below HINT If the clip is damaged during the operation always replace it with a new clip ...

Page 3116: ...wdriver Clip Remover Clip Remover Clip Remover Push Push Push Small Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell Remove rivet by unscrewing the center pin and prying out the rivet shell Remove rivet by prying out the pin and then prying out the rivet shell BO 2 BODY CLIP 4773 Author Date ...

Page 3117: ...he driver airbag and front passenger airbag 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 in cluding removal or installation of parts inspection or replacement be sure to read the precautionary notices in the RS section ...

Page 3118: ...ket Turn Signal Light Front Bumper Cover Front Bumper Reinforcement Front Bumper Arm Turn Signal Light x 8 Headlight Front Bumper Arm Headlight 4 9 50 43 in lbf 4 9 50 43 in lbf x 12 12 120 9 58 590 43 12 120 9 Front Bumper Side Mounting Bracket 4 9 50 43 in lbf Front Fog Light Front Fog Light Steel Bumper Type w o Fog Light Front Bumper Hole Cover BO 4 BODY FRONT BUMPER 4775 Author Date FRONT BUM...

Page 3119: ...w o Fog Light Front Fog Light Front Fog Light x 14 50 510 37 Front Bumper Cover Front Bumper Hole Cover Front Bumper Hole Cover w Over Fender Front Bumper Extension Front Bumper Moulding Front Bumper Energy Absorber N m kgf cm ft lbf Specified torque 7 0 71 61 in lbf 5 0 51 44 in lbf BODY FRONT BUMPER BO 5 4776 Author Date ...

Page 3120: ...per Bar Rear Bumper Bar Corner Reinforcement Rear Bumper Arm Rear Bumper Arm Rear Bumper Bar Corner Reinforcement w Towing Hitch 80 810 59 100 1 020 74 160 1 632 118 100 1 020 74 100 1 020 74 Receiver Hitch Bracket Rear Bumper Reinforcement Access Cab Wide Body Type Side Rear Step LH Access Cab Wide Body Type Side Rear Step RH BO 6 BODY REAR BUMPER 4777 Author Date REAR BUMPER COMPONENTS ...

Page 3121: ... IN FORWARD REARWARD Adjust the hood by loosening the hood side hinge bolts Torque 13 N m 133 kgf cm 10 ft lbf 2 ADJUST HOOD IN VERTICAL DIRECTIONS a Remove the bolts and increase or decrease the number of washers between the hinge and hood b Install the bolts again Torque 13 N m 133 kgf cm 10 ft lbf 3 ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION Adjust the hood by turning the cushions 4 ADJUST...

Page 3122: ...e replaced drill a 2 0 to 3 0 mm 0 079 to 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 ...

Page 3123: ... Window w o Courtesy Light w o Power Window w Courtesy Light Door Assist Grip Courtesy Light Inner Weatherstrip Door Assist Grip Door Assist Grip Door Assist Grip Courtesy Light Door Trim Door Trim Door Trim Door Trim Handle Plate Snap Ring Handle Plate Snap Ring w Power Window w Courtesy Light Cover 23 235 17 5 0 51 44 in lbf 8 0 82 71 in lbf N m kgf cm ft lbf Specified torque 27 275 20 23 235 17...

Page 3124: ...n No 1 Glass Run w o Power Door Lock w o Power Window Front Lower Frame 5 5 56 49 in lbf 5 0 51 44 in lbf 5 0 51 44 in lbf 5 0 51 44 in lbf 5 0 51 44 in lbf 8 0 82 71 in lbf 8 0 82 71 in lbf 8 0 82 71 in lbf 5 0 51 44 in lbf N m kgf cm ft lbf Specified torque Precoated part BO 10 BODY FRONT DOOR 4781 Author Date ...

Page 3125: ... 3 w Power window REMOVE POWER WINDOW SWITCH a Using a screwdriver remove the power window switch HINT Tape the screwdriver tip before use b Disconnect the connectors 4 w Courtesy light REMOVE COURTESY LIGHT a Using a screwdriver remove the courtesy light HINT Tape the screwdriver tip before use b Disconnect the connector 5 w o Courtesy light REMOVE COURTESY LIGHT COVER Using a screwdriver remove ...

Page 3126: ...d to remove it 8 REMOVE DOOR ASSIST GRIP Remove the 2 screws and door assist grip from the door trim 9 REMOVE INNER WEATHERSTRIP 10 REMOVE LOWER WEATHERSTRIP 11 REMOVE INSIDE HANDLE a Remove the screw b Slide the inside handle backward to remove it c Disconnect the 2 cables from the inside handle as shown in the illustration 12 REMOVE SERVICE HOLE COVER a Disconnect the clamps and connector b Remo...

Page 3127: ...DOOR GLASS RUN 17 REMOVE FRONT LOWER FRAME Remove the 2 bolts nut and front lower frame as shown in the illustration 18 REMOVE REAR LOWER FRAME Remove the bolt nut and rear lower frame as shown in the il lustration 19 REMOVE DOOR GLASS a Open the door glass until the bolts appear in the service hole b Remove the 2 bolts and door glass NOTICE Do not damage the door glass ...

Page 3128: ... Remove the window regulator through the service hole 21 REMOVE DOOR LOCK a Disconnect the 2 links from the outside handle and door lock cylinder b w Power door lock Disconnect the connector and remove the bolt c Using a torx socket wrench remove the 3 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool 22 REMOVE OUTSIDE HANDLE WITH DOOR LOCK CYL INDER a Remove the ...

Page 3129: ...T AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts HINT Substitute the standard bolt for the centering bolt see page BO 7 Torque 23 N m 235 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and door lock linkages are adjusted correctly b Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a ham...

Page 3130: ...TALL DOOR LOCK HINT Apply MP grease to the sliding and rotating parts of the door lock a Using a torx socket wrench install the door lock with the 3 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool Torque 5 0 N m 51 kgf cm 44 in lbf HINT Apply adhesive to the 3 screws Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b w Power door lock Connect the conne...

Page 3131: ... and nut Torque 8 0 N m 82 kgf cm 71 in lbf for bolt 5 0 N m 51 kgf cm 44 in lbf for nut HINT When installing the window regulator tighten the bolts and nut in the order shown in the illustration c w o Power window Install the window regulator with the 4 bolts and nut Torque 5 0 N m 82 kgf cm 71 in lbf for bolt 5 0 N m 51 kgf cm 44 in lbf for nut HINT When installing the window regulator tighten t...

Page 3132: ...nector 10 INSTALL SPEAKER a Install the speaker with the 3 screws b Connect the connector 11 INSTALL SERVICE HOLE COVER a Install the service hole cover HINT When installing the service hole cover pull out the cables and connectors through the service hole cover There should be no wrinkles or folds after attaching the service hole cover After attaching the service hole cover confirm the sealing co...

Page 3133: ...2 caps 17 w Tweeter speaker INSTALL TWEETER SPEAKER a Install the tweeter speaker with the 3 screws then con nect the connector b Install the tweeter speaker cover 18 w Courtesy light INSTALL COURTESY LIGHT a Connect the connector b Install the courtesy light 19 w o Courtesy light INSTALL COURTESY LIGHT COVER 20 w Power window INSTALL POWER WINDOW SWITCH a Connect the connectors b Install the powe...

Page 3134: ...4791 Author Date 22 w o Power window INSTALL REGULATOR HANDLE Install the regulator handle with the snap ring HINT With the door window fully closed install the plate and the regu lator handle with the snap ring as shown in the illustration ...

Page 3135: ...t Door Lock Cylinder Front Door Lock Front Door Lock Control Link Protector Front Door Lock Cover Power Window Regulator Motor Front Door Glass Weatherstrip Inner Door Inside Bezel Front Door Trim Panel Courtesy Light Speaker Power Window Switch Front Armrest Base Panel Upper Front Door Power Window Regulator Front Door Service Hole Cover Front Door Inside Handle 23 235 17 30 306 22 23 235 17 5 0 ...

Page 3136: ...R WINDOW SWITCH a Using a screwdriver remove the front armrest base panel upper together with the power window switch HINT Tape the screwdriver tip before use b Disconnect the connector c Remove the power window switch from the front armrest base panel upper 4 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH Using a screwdriver remove the front door lower frame bracket garnish HINT Tape the screwdriv...

Page 3137: ...rews and speaker 9 REMOVE FRONT DOOR INSIDE HANDLE a Slide the front door inside handle backward to remove it b Disconnect the 2 cables from the front door inside handle as shown in the illustration 10 REMOVE FRONT DOOR SERVICE HOLE COVER a Using a clip remover remove the clamps and grommets b Remove the front door service hole cover NOTICE Do not tear the front door service hole cover 11 REMOVE F...

Page 3138: ...moulding remover remove the front door belt moulding 15 REMOVE FRONT DOOR FRAME FRONT LOWER a Remove the 2 bolts nut and front door frame front lower as shown in the illustration b Remove the front door glass run No 2 from the front door frame front lower 16 REMOVE FRONT DOOR FRAME REAR LOWER Remove the bolt nut and front door frame rear lower as shown in the illustration HINT Remove the front doo...

Page 3139: ...e bolt f Using a torx socket wrench remove the 3 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool g Remove the front door lock HINT Remove the front door lock through the service hole h Remove the 2 screws and front door lock cover from the front door lock 19 REMOVE FRONT DOOR OUTSIDE HANDLE WITH LOCK CYLINDER a Remove the service hole plug b Remove the 2 bolts a...

Page 3140: ...T RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts HINT Substitute the standard bolt for the centering bolt see page BO 7 Torque 23 N m 235 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and door lock linkages are adjusted correctly b Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with...

Page 3141: ...iding and rotating parts of the front door lock a Install the front door lock cover to the front door lock with the 2 screws b Using a torx socket wrench install the front door lock with the 3 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool Torque 5 0 N m 51 kgf cm 44 in lbf for bolt 5 0 N m 51 kgf cm 44 in lbf for screw HINT Apply adhesive to the 3 screws Adhes...

Page 3142: ...he 6 bolts Torque 8 0 N m 82 kgf cm 71 in lbf HINT Tighten the 6 bolts in the order shown in the illustration c Connect the connector 6 INSTALL FRONT DOOR FRAME REAR LOWER Install the front door frame rear lower with the bolt and nut 7 INSTALL FRONT DOOR FRAME FRONT LOWER a Install the front door glass run No 2 to the front door frame front lower b Install the front door frame front lower with the...

Page 3143: ... hole cover After attaching the service hole cover confirm the sealing condition b Connect the clamps and connector 13 INSTALL FRONT DOOR INSIDE HANDLE a Connect the 2 cables to the inside handle b Slide the inside handle forward to install it 14 INSTALL SPEAKER 15 INSTALL OUTER REAR VIEW MIRROR Torque 8 0 N m 82 kgf cm 71 in lbf 16 INSTALL TWEETER SPEAKER 17 INSTALL FRONT DOOR TRIM PANEL 18 INSTA...

Page 3144: ...ng a screwdriver remove the rear armrest base panel upper together with the power window switch HINT Tape the screwdriver tip before use c Disconnect the connector d Remove the power window switch from the rear armrest base panel upper 4 REMOVE REAR DOOR TRIM PANEL a Using a screwdriver remove the cap HINT Tape the screwdriver tip before use b Remove the screw and 2 clips c Insert a screwdriver be...

Page 3145: ...p and grommets b Remove the rear door service hole cover NOTICE Do not tear the rear door service hole cover 8 REMOVE REAR DOOR GLASS a Open the rear door glass until the bolts appear in the ser vice hole b Remove the 2 bolts NOTICE Do not damage the door glass c Pull the rear door glass upward to remove it 9 REMOVE REAR DOOR GLASS RUN 10 REMOVE REAR DOOR WINDOW FRAME MOULDING UPPER a Remove the 7...

Page 3146: ...VE REAR DOOR POWER WINDOW REGULA TOR a Disconnect the connector b Remove the 5 bolts c Loosen the bolt and remove the rear door power window regulator HINT Remove the rear door power window regulator through the ser vice hole d Remove the 3 screws and power window regulator motor from the rear door power window regulator 14 REMOVE REAR DOOR LOCK a Disconnect the 2 control cables from the clamp b R...

Page 3147: ...BO 34 BODY REAR DOOR Double Cab 4805 Author Date 16 REMOVE REAR DOOR WEATHERSTRIP Using a clip remover remove the rear door weatherstrip 17 REMOVE REAR DOOR WEATHERSTRIP NO 2 ...

Page 3148: ...rip Inner Power Window Regulator Motor Child Protection Cover Rear Door Trim Panel Door Inside Bezel Courtesy Light Speaker Rear Door Service Hole Cover Rear Armrest Bace Panel Upper Rear Door Inside Handle Rear Door Power Window Regulator Rear Ash Receptacle Power Window Switch 23 235 17 30 306 22 5 5 56 49 in lbf 23 235 17 23 235 17 5 5 56 49 in lbf 5 0 51 44 in lbf 8 0 82 71 in lbf Door Hinge D...

Page 3149: ... Torque 23 N m 230 kgf cm 17 ft lbf e Install the front seat outer belt and center pillar lower gar nish see page BO 133 f Install the front and rear door scuff plates 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust Torque 23 N m 230 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and door lock linkages are adjusted correctly b L...

Page 3150: ...ket wrench install the rear door lock with the 3 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool Torque 5 N m 51 kgf cm 44 in lbf HINT Apply adhesive to the 3 screws Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b Connect the connector c Install the clamp d Connect the 2 control cables to the clamp 5 INSTALL REAR DOOR POWER WINDOW REGULA TOR HINT Ap...

Page 3151: ...LASS Torque 8 0 N m 82 kgf cm 71 in lbf 11 INSTALL REAR DOOR SERVICE HOLE COVER a Install the service hole cover HINT When installing the service hole cover pull out the cables and connectors through the service hole cover There should be no wrinkles or folds after attaching the service hole cover After attaching the service hole cover confirm the sealing condition b Connect the clamps and connect...

Page 3152: ...k Inside Handle Service Hole Cover Door Armrest Inside Handle Bezel Access Door Trim Inner Weatherstrip Cancel Lever 23 235 17 23 235 17 5 0 51 44 in lbf 27 275 20 23 235 17 23 235 17 5 5 56 49 in lbf 12 5 128 9 5 0 51 44 in lbf 5 0 51 44 in lbf 12 5 128 9 12 5 128 9 N m kgf cm ft lbf Specified torque Lower Weatherstrip Access Door Controller Precoated part Retainer BO 38 BODY ACCESS DOOR 4809 Aut...

Page 3153: ...rewdriver tip before use 3 REMOVE ACCESS DOOR TRIM a Release the quarter window lock b Insert a screwdriver between the door trim and door panel to remove the door trim HINT Tape the screwdriver tip before use 4 REMOVE DOOR ARMREST BASE Remove the 2 screws and door armrest base 5 REMOVE SPEAKER a Disconnect the connector b Remove the 4 screws and speaker 6 REMOVE DOOR INSIDE HANDLE a Remove the sc...

Page 3154: ...0 Part No 09042 00010 or locally manufactured tool 10 REMOVE UPPER DOOR LOCK a Disconnect the connector b Remove the 3 bolts and upper door lock 11 REMOVE OUTSIDE HANDLE Remove the 2 bolts and outside handle 12 REMOVE CANCEL LEVER Using a torx socket wrench remove the 2 torx screws and cancel lever Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool 13 REMOVE OUTER WEATHERSTRIP...

Page 3155: ...RTER WINDOW AND WEATHERSTRIP a Remove the 2 bolts 4 nuts and quarter window b Remove the weatherstrip 16 REMOVE QUARTER WINDOW LOCK AND HINGES a Remove the screws and window lock from the quarter window b Remove the 2 screws and 2 hinges from the quarter win dow ...

Page 3156: ...235 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK UPPER STRIKER a Check that the door fit and door lock linkages are adjusted correctly b Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer c Tighten the striker mounting screws again Torque 23 N m 235 kgf cm 17 ft lbf 4 ADJUST DOOR LOCK LOWER STRIKER a Check that the door fit and door lock link...

Page 3157: ...and 4 nuts 3 INSTALL INNER WEATHERSTRIP 4 INSTALL OUTER WEATHERSTRIP Install the outer weatherstrip with the 2 screws and 4 clips 5 INSTALL CANCEL LEVER Using a torx socket wrench install the cancel lever with the 2 torx screws Torx socket wrench T30 Part No 09042 00010 or locally manufactured tool Torque 5 0 N m 51 kgf cm 44 in lbf 6 INSTALL OUTSIDE HANDLE Install the outside handle with the 2 bo...

Page 3158: ...342 or equivalent 9 INSTALL ACCESS DOOR CONTROLLER HINT Apply MP grease to the sliding and rotating parts of the access door controller a Install the access door controller with the 3 bolts Torque 12 5 N m 128 kgf cm 9 ft lbf b Attach the 2 clamps c Connect the 2 cables and 2 links 10 INSTALL SERVICE HOLE COVER a Install the service hole cover HINT When installing the service hole cover pull out t...

Page 3159: ...NSTALL SPEAKER a Install the speaker with the 4 screws b Connect the connector 13 INSTALL DOOR ARMREST BASE Install the door armrest base with the 2 screws 14 INSTALL ACCESS DOOR TRIM a Install the door trim b Lock the quarter window lock 15 INSTALL DOOR ARMREST Install the door armrest with the screw 16 INSTALL DOOR INSIDE HANDLE BEZEL Install the door inside handle bezel with the screw ...

Page 3160: ...ink N m kgf cm ft lbf Specified torque 20 204 15 20 204 15 Wiper Arm 5 5 56 49 in lbf Washer Nozzle Washer Nozzle Cap Cap Hood to Cowl Seal 5 5 56 49 in lbf 5 5 56 49 in lbf BO 46 BODY FRONT WIPER AND WASHER 4817 Author Date FRONT WIPER AND WASHER COMPONENTS ...

Page 3161: ...ntilator louver 3 REMOVE HOOD TO COWL TOP SEAL Remove the hood to cowl top seal from the cowl top ventilator louver 4 REMOVE WIPER MOTOR a Disconnect the connector b Unfasten the 4 bolts c Disconnect the wiper motor from the wiper link then re move the wiper motor 5 REMOVE WIPER LINK a Remove the 6 bolts b Remove the wiper link through the service hole 6 REMOVE WASHER NOZZLE a Disconnect the washe...

Page 3162: ...e area are within the range indicated by the hatched line A Approx 150 mm 5 90 in B Approx 50 mm 1 97 in C Approx 312 3 mm 12 295 in D Approx 299 2 mm 11 780 in 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 illustra...

Page 3163: ...75 mm 0 028 to 0 0295 in BODY FRONT WIPER AND WASHER BO 49 4820 Author Date 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 3164: ...e connector 4 INSTALL HOOD TO COWL TOP SEAL Install the hood to cowl top seal to the cowl top ventilator louver 5 INSTALL COWL TOP VENTILATOR LOUVER Install the cowl top ventilator louver with the 8 screws and 6 clips 6 INSTALL WIPER ARMS a Operate the wiper 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 arm...

Page 3165: ...nel Outside Moulding Side Panel No 1 Moulding Front Door Outside Moulding Access Panel Outside Moulding Standard Cab Access Cab Standard Body Type Access Cab Wide Body Type BODY BODY OUTSIDE MOULDING BO 51 4822 Author Date BODY OUTSIDE MOULDING COMPONENTS ...

Page 3166: ...B17041 Double Cab Front Door Outside Moulding Rear Door Outside Moulding BO 52 BODY BODY OUTSIDE MOULDING 4823 Author Date ...

Page 3167: ...o 30 C 68 to 86 F NOTICE Do not heat the moulding excessively 2 REMOVE MOULDING a Insert piano wire between the vehicle body and moulding b Tie objects that can serve a handle for example wooden blocks to all wire ends c Cut off the double sided tape by pulling the piano wire as shown in the illustration NOTICE Do not damage the body d Remove the moulding ...

Page 3168: ...ing a heat light heat the body and moulding Heating Temperature Item Temperature Body 40 to 60 C 104 to 14 F Moulding 20 to 30 C 68 to 86 F NOTICE Do not heat the body and moulding excessively b Remove the moulding peeling paper from the face of the moulding NOTICE After removing the peeling paper keep the exposed adhe sive away from dirt and other contaminants c Align the bosses with their corres...

Page 3169: ...0IF 05 H21129 Front Mudguard Rear Mudguard w Front Mudguard w Rear Mudguard Front Wheel Arch Moulding Rear Wheel Arch Moulding BODY WHEELARCH MOULDING BO 55 4826 Author Date WHEEL ARCH MOULDING COMPONENTS ...

Page 3170: ...ard Rear Mudguard w Rear mudguard w Front mudguard Resin Bumper Type Front Bumper Extension Protector Protector Protector Non reusable part N m kgf cm ft lbf Specified torque 5 0 51 44 in lbf BO 56 BODY WHEEL OPENING MOULDING 4827 Author Date WHEEL OPENING MOULDING COMPONENTS ...

Page 3171: ...the 6 screws b Using a heat light heat the moulding to 20 to 30 C 68 to 86 F NOTICE Do not heat the moulding excessively c Cut off the adhesive tape with a knife NOTICE Do not damage the body d Remove the moulding NOTICE If the clips are damaged exchange them for new clips 4 w Rear mudguard REMOVE REAR MUDGUARD Remove the 4 screws and rear mudguard 5 REMOVE QUARTER OUTSIDE MOULDING a Remove the 6 ...

Page 3172: ...E When removing the moulding release sheet be careful that dirt or dust will not adhere to the face of the moulding 3 Align the bosses with their corresponding holes on the body and press the moulding firmly NOTICE Do not apply excessive force onto the moulding but steady pressure with your thumbs 4 Install the 6 screws 2 w Rear mudguard INSTALL REAR MUDGUARD Install the rear mudguard with the 4 s...

Page 3173: ...lign the bosses with their corresponding holes on the body and press the moulding firmly NOTICE Do not apply excessive force onto the moulding but steady pressure with your thumbs 4 Install the 6 screws 4 w Rear mudguard INSTALL FRONT MUDGUARD Install the front mudguard with the 4 screws 5 Resin bumper type INSTALL FRONT BUMPER EXTENSION a Install the new protector as shown in the illustration b I...

Page 3174: ...H11362 Roof Drip Side Finish Moulding Roof Drip Side Finish Moulding Standard cab Access cab Non reusable part BO 60 BODY ROOF DRIP SIDE FINISH MOULDING 4831 Author Date ROOF DRIP SIDE FINISH MOULDING COMPONENTS ...

Page 3175: ... surface from being scratched b Using a heat light heat the moulding to 20 to 30 C 68 to 86 F NOTICE 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 NOTICE Do not damage ...

Page 3176: ...he 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 NOTICE 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 to 60 C 104 to 140 F Moulding...

Page 3177: ...dy Type RH Rear Body Side Panel Protector Access Cab Standard Body Type LH Rear Body Side Panel Protector Cap Cap Cap Cap x 6 x 10 Access Cab Standard Body Type Standard Cab Pin Clip BODY DECK TOP PROTECTOR BO 63 4834 Author Date DECK TOP PROTECTOR COMPONENTS ...

Page 3178: ...H20693 Tail Gate Protector Rear Body Side Panel Protector RH Rear Body Side Panel Protector LH Access Cab Wide Body Type BO 64 BODY DECK TOP PROTECTOR 4835 Author Date ...

Page 3179: ...H23622 Double Cab Double Cab RH Rear Body Side Panel Protector Cap Cap Tail Gate Protector Cap Double Cab LH Rear Body Side Panel Protector Cap x 6 Pin BODY DECK TOP PROTECTOR BO 65 4836 Author Date ...

Page 3180: ...ps 2 Access cab Wide body type REMOVE REAR BODY SIDE PANEL PROTECTOR Using a moulding remover remove the 2 protectors NOTICE Each protector has 19 clips as shown in the illustra tion Be careful not to damage the clips 3 Access cab Standard body type Standard cab REMOVE TAIL GATE PROTECTOR a Remove the 6 pins b Using a clip remover remove the protector and 10 clips 4 Access cab Wide body type only ...

Page 3181: ...PROTECTOR Using a moulding remover remove the 2 protectors a Using a torx socket wrench T30 remove the 4 screws b Using a moulding remover remove the protector and 8 clips NOTICE Each protector has 22 clips 3 types as shown in the illustration Be careful not to damage the clips 6 Double cab REMOVE TAIL GATE PROTECTOR a Remove the 6 pins ...

Page 3182: ...BO40O 04 BO 68 BODY DECK TOP PROTECTOR 4839 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 66 ...

Page 3183: ...ndshield Glass Wiper Arm Cap Cowl Louver Windshield Outside Moulding Spacer Front Personal Light Inner Rear View Mirror Lens Sun Visor Front Pillar Garnish Assist Grip Windshield Outside Moulding Wiper Arm Cap 20 204 15 20 204 15 N m kgf cm ft lbf Specified torque Dam Non reusable part Sub visor w Standerd cab w Access cab BODY WINDSHIELD BO 69 4840 Author Date WINDSHIELD COMPONENTS ...

Page 3184: ...strip Windshield Outside Moulding Windshield Glass Wiper Arm Wiper Arm Cowl Top Ventilator Louver Hood to Cowl Top Seal Non reusable part N m kgf cm ft lbf Specified torque No 2 Stopper Dam w Sliding roof Roof Side Rail Weatherstrip w Electro chrmic inner rear view mirror Mirror Cover Inner Rear View Mirror 2 5 25 22 in lbf Front Door Opening Trim Weatherstrip w Double sun visor Sun Visor 2 5 25 2...

Page 3185: ... No 09041 00030 or locally manufactured tool c Standerd cab Access cab Passenger side Using a torx driver remove the 4 torx screws and 2 as sist grips Torx driver T30 Part No 09041 00030 or locally manufactured tool d Double cab cab Passenger side Using a torx driver remove the 2 torx screws and assist grips Torx driver T30 Part No 09041 00030 or locally manufactured tool 3 REMOVE FRONT PILLAR GAR...

Page 3186: ...roof REMOVE ROOF CONSOLE BOX a Remove the 2 screws b Using a screwdriver remove the roof console box HINT Tape the screwdriver tip before use c Disconnect the connectors 8 w o Sliding roof REMOVE ROOF CONSOLE BOX a Remove the 4 screws b Using a screwdriver remove the roof console box HINT Tape the screwdriver tip before use c Disconnect the connectors 9 REMOVE SUN VISOR HOLDERS Remove the 2 screws...

Page 3187: ...ding b Perform the same procedure on the other side 15 w Standed cab Access cab REMOVE WINDSHIELD OUTSIDE UPPER MOULDING a Using a knife cut off the moulding as shown in the illustra tion NOTICE Do not damage the body with the knife b Remove the remaining moulding 16 w Double cab REMOVE WINDSHIELD OUTSIDE UPPER MOULDING Using a knife cut off the moulding as shown in the illustration NOTICE Do not ...

Page 3188: ...t and exterior ornaments To prevent scratching the safety pad when removing the windshield place a plastic sheet between the piano wire and safety pad c Cut the adhesive by pulling the piano wire around it d Remove the glass NOTICE Leave as much of the adhesive on the body as possible when cutting off the glass ...

Page 3189: ...ean the glass with cleaner NOTICE Be careful not to damage the glass Do not touch the glass face after cleaning it 3 w No 1 stopper REPLACE NO 1 STOPPERS a Remove the damaged stoppers b Cut off the old adhesive around the stopper installation area NOTICE Be careful not to damage the body c Clean the installation area d Attach new stoppers to the body so that the notches on the body will align with...

Page 3190: ...ontacting parts of the glass rim are perfect ly even c Place reference marks between the glass and body d Remove the glass 7 CLEAN CONTACT SURFACE OF GLASS Using a cleaner clean the contact surface which is black col ored area around the entire glass rim NOTICE Do not touch the glass face after cleaning it 8 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat Primer M to the exposed part...

Page 3191: ...to the area other than the specified wipe it off with a clean shop rag before the primer dries NOTICE Let the primer coating dry for 3 minutes or more Do not keep any of the opened Primer G for later use 10 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 de scribed in the table below Temperat...

Page 3192: ... correctly viewing b Lightly press the glass front surface for close contact 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 HINT Install the moulding aligning the center of moulding with the center of body e Us...

Page 3193: ...tach the upper edge of the weatherstrip to body flange Tap on the weatherstrip by hand 14 INSTALL WINDSHIELD OUTSIDE MOULDING a Install the 4 screws and windshield outside moulding b Employ the same manner described above to the other side 15 INSTALL FRONT PART OF ROOF SIDE RAIL WEATH ERSTRIP LH AND RH Install the front part of roof side rail weatherstrip LH and RH 16 INSTALL COWL TOP VENTILATOR L...

Page 3194: ... 204 kgf cm 15 ft lbf e Install the caps 18 INSTALL FRONT PART OF ROOF HEADLINING 19 INSTALL SUN VISOR HOLDERS Install the 2 sun visor holders with the 2 screws 20 w o Sliding roof INSTALL ROOF CONSOLE BOX a Connect the connector b Install the console box with the 4 screws 21 w Sliding roof INSTALL ROOF CONSOLE BOX a Connect the connector b Install the console box with the 2 screws 22 INSTALL FRON...

Page 3195: ... Perform the same procedure on the other side 26 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 Standerd cab Access cab Passenger side Using a torx driver install the 2 assist grips with the 4 torx screws Torx driver T30 Part No 09041 00030 or locally manufactured tool...

Page 3196: ...H11169 BO 82 BODY WINDSHIELD 4853 Author Date 27 INSTALL INNER REAR VIEW MIRROR Install the inner rear view mirror as shown in the illustration ...

Page 3197: ...BO4H8 02 H11406 Back Window Glass Fixed Type Slide Type Back Window Glass BODY BACK WINDOW GLASS BO 83 4854 Author Date BACK WINDOW GLASS COMPONENTS ...

Page 3198: ...er Pad Back Window Regulator Assembly Glass Run Back Window Moulding Back Window Glass Weatherstrip Inner Service Hole Cover Weatherstrip Outer Back Window Regulator Assembly N m kgf cm ft lbf Specified torque 5 5 56 49 in lbf 20 200 15 5 5 56 49 in lbf 8 0 82 71 in lbf 8 0 82 71 in lbf BO 84 BODY BACK WINDOW GLASS 4855 Author Date ...

Page 3199: ...see page BO 126 4 Access cab Standard body type Access cab Wide body type REMOVE ACCESS DOOR SCUFF PLATES See page BO 126 5 Double cab REMOVE BACK PANEL TRIM See page BO 133 6 REMOVE ASSIST GRIPS See page BO 126 BO 133 7 Standard cab REMOVE FRONT PILLAR GARNISHES See page BO 126 8 Access cab Standard body type Access cab Wide body type REMOVE ROOF SIDE RAIL GARNISHES See page BO 126 9 REMOVE ROOM ...

Page 3200: ...n ing b Access cab Standard body type Access cab Wide body type Remove the 3 clips and the rear part of the roof headlin ing 16 Power slide type REMOVE BACK WINDOW REGULATOR ASSEMBLY a Remove the 2 bolts and tether anchor brackets b Remove the 4 clips and 2 back panel silencer pads c Using a screwdriver remove the back door glass channel cover HINT Tape the screwdriver tip before use d Remove the ...

Page 3201: ... clips and cover NOTICE When the clips are removed the cover may fall and become deformed 18 Power vertical type REMOVE WEATHERSTRIP OUTER a Put protective tape under the weatherstrip b Using a screwdriver disengage the claws and remove the weatherstrip HINT Tape the screwdriver tip before use 19 Power vertical type REMOVE WEATHERSTRIP INNER Using a screwdriver remove the weatherstrip ...

Page 3202: ...nect the connector b Remove the 7 bolts and regulator HINT Remove the back window regulator assembly through the ser vice hole NOTICE When the bolts are removed the back window regulator as sembly may fall and become deformed 22 Power vertical type REMOVE BACK WINDOW MOULDING a Remove the 8 bolts and the bracket LH and RH b Remove the 2 clips c Using a drill of less than ø 4 mm 0 16 in drill out t...

Page 3203: ... tat can serve as handle for example wooden blocks to all wire ends HINT Apply protective tape to the outer surface to prevent the surface from being scratched NOTICE When separating the glass take care not to damage the body paint and exterior e Cut off the adhesive by pulling the piano wire around it HINT Cut off the adhesive on the areas as shown in the illustration but leave the adhesive where...

Page 3204: ...ontact surface of the body with a piece of shop rag saturated with cleaner 2 Fix type Slide type Power slide type POSITION GLASS a Place the glass in the correct position b Check that the whole contact surface of the glass rim is perfectly even c Place reference marks on the glass and body d Remove the glass 3 Fix type Slide type Power slide type COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a ...

Page 3205: ... is coated by accident wipe off the primer with a clean shop rag before it dries NOTICE Allow the primer coating for 3 minutes or more Throw away leftover Primer G 5 Slide type Power slide type COAT CONTACT SURFACE OF GLASS WITH PRIMER G Using a brush or sponge coat the edge of the glass and the contact surface with Primer G as shown in the illustration HINT If the area other than that specified i...

Page 3206: ...a Measurement A 8 0 mm 0 314 in B 12 0 mm 0 472 in 7 Slide type Power slide type 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 de scribed in the table below Usage timeframe Temperature Usage Timeframe 35 C 95 F 15 minutes 20 C 68 F 100 minutes 5 C 41 F 8 hours b Load the cartridge into a se...

Page 3207: ...Usage Timeframe 35 C 95 F 1 5 hours 20 C 68 F 5 hours 5 C 41 F 24 hours 9 INSPECT FOR LEAK AND REPAIR NOTICE Conduct a leak test after the adhesive has completely hard ened Adhesive Part No 08833 00030 or equivalent 10 Power vertical type INSTALL BACK WINDOW MOULDING a Using a hand riveter or an air riveter install the 14 drive pulley assemblies NOTICE Do not prize the riveter The riveter will be ...

Page 3208: ... with the 8 bolts 11 Power vertical type INSTALL BACK DOOR WINDOW REGULATOR AS SEMBLY a Apply MP grease to the sliding and rotating parts of the window regulator assembly NOTICE Do not apply grease to the spring of the window regulator assembly b Install the window regulator assembly with the 7 bolts Torque 8 0 N m 82 kgf cm 71 in lbf c Connect the window regulator connector NOTICE Be careful not ...

Page 3209: ...nside the door panel to prevent the back win dow glass from being scratched b Connect the defogger connector 13 Power vertical type INSTALL WEATHERSTRIP INNER Install the back window glass to the window regulator assembly 14 Power vertical type INSTALL WEATHERSTRIP OUTER Install the weatherstrip as shown in the illustration 15 Power vertical type INSTALL SERVICE HOLE COVER a Install the cover with...

Page 3210: ...Access cab Standard body type Access cab Wide body type INSTALL REAR PART OF ROOF HEADLINING a Standard cab Install the rear part of the roof headlining with the 2 clips b Access cab Install the rear part of the roof headlining with the 3 clips 18 Double cab INSTALL QUARTER TRIMS UPPER See page BO 138 19 Double cab INSTALL QUARTER TRIMS LOWER See page BO 138 20 INSTALL QUARTER TRIMS See page BO 13...

Page 3211: ...CCESS DOOR SCUFF PLATES See page BO 130 29 Standard cab INSTALL FRONT DOOR SCUFF PLATES See page BO 130 30 Access cab Standard body type Access cab Wide body type INSTALL REAR SEAT See page BO 21 1 31 Double cab UNFOLD REAR SEAT CAUTION When returning the seat make sure the seat is securely locked by pushing forward and rearward on the top of the seatback or by trying to pull up the edge of the bo...

Page 3212: ...ion time of the slid ing roof Operation time Approx 6 secs b Check for abnormal noise or binding during operation c With the sliding roof fully closed check for water leakage d Check for a difference in level between the sliding roof weatherstrip and roof panel Front end 0 2 0 mm 0 0 079 in 0 1 0 mm 0 0 039 in Side end 0 1 5 mm 0 0 059 in Rear end 0 1 0 mm 0 0 039 in 0 2 0 mm 0 0 079 in ...

Page 3213: ...ar Mounting Bracket Sliding Roof Panel Stopper Sunshade Trim Sliding Roof Sunshade Stopper No 3 Sliding Roof Housing Side Mounting Bracket Sliding Roof Rail Rear Frame Sliding Roof Housing Rear Mounting Bracket No 3 Sliding Roof Housing Side Mounting Bracket 5 5 56 49 in lbf N m kgf cm ft lbf Specified Torque 5 5 56 49 in lbf 5 5 56 49 in lbf 5 5 56 49 in lbf BODY SLIDING ROOF BO 99 4870 Author Da...

Page 3214: ...x wrench remove the 4 screws b Pull the glass upward to remove it 3 REMOVE DRIVE GEAR NOTICE Remove the drive gear with the sliding roof fully closed a Disconnect the connector b Remove the 2 bolts and drive gear c Remove the 2 screws and drive gear bracket 4 REMOVE SLIDING ROOF HOUSING a Disconnect the 4 drain hoses from the housing b Disengage the wire harness clamps c Remove the 8 bolts 2 nuts ...

Page 3215: ...TOPPER a Remove the screw and stopper b Perform the same procedure on the other side 4 REMOVE SUNSHADE TRIM 5 REMOVE REAR ROOF DRIP CHANNEL Remove the 2 screws and rear roof drip channel as shown in the illustration 6 REMOVE REAR FRAME Remove the 4 screws and rear frame 7 REMOVE DRIVE CABLE a Remove the screw and sliding roof panel stopper b Slide the drive cable rearward then remove it c Perform ...

Page 3216: ...ble forward or backward to align the 2 marks as shown in the illustration Slide the cable to the forefront with your hand 8 REMOVE ROOF WIND DEFLECTOR PANEL 9 REMOVE GUIDE BLOCK a Remove the 2 screws and guide block b Perform the same procedure on the other side 10 REMOVE SLIDING ROOF HOUSING Remove the 6 screws and sliding roof housing 11 REMOVE CABLE GUIDE CASING Remove the 2 screws and cable gu...

Page 3217: ...ont or rear left or right alignment is not correct remove the drive gear and sliding roof glass then adjust the drive cable NOTICE Remove the drive gear with the sliding roof fully closed b Adjust by sliding the cable forward or rearward or rear ward to align the 2 marks as shown c Install the driving ear and sliding roof glass ...

Page 3218: ...BO4QC 02 BO 104 BODY SLIDING ROOF 4875 Author Date REASSEMBLY Reassembly is in the reverse order of disassembly see page BO 101 ...

Page 3219: ...BO4QD 02 BODY SLIDING ROOF BO 105 4876 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 100 ...

Page 3220: ...anel D D Heater Control Assembly Front Door Scuff Plate Cowl Side Trim B B Lower Finish Panel A A A A Steering Column Upper Cover Combination Switch Steering Wheel Control Knob Steering Wheel Pad Steering Column Lower Cover N m kgf cm ft lbf Specified torque Door Control Receiver H Cowl Side Trim 5 0 51 44 in lbf B B D D D D D F F F Assist Grip Integration Control Panel Front Door Scuff Plate Cons...

Page 3221: ...fied torque C C G G C G G G G C C C C D D D D A A A A A A A A F F F D D D B B 5 0 51 44 in lbf 20 204 15 A A 8 8 90 78 in lbf Lower No 2 Cover Lower No 3 Cover A A A A w Rear seat entertainment w Rear seat entertainment Disc Player Cover Disc Player w Rear seat audio or rear seat entertainment Steering Wheel Upper Steering Column Cover Front Door Scuff Plate Side Panel Cowl Side Trim Board 5 0 51 ...

Page 3222: ...H20694 Access Cab Large Type Console Box Shifting Hole Cover Console Rear End Panel No 2 Console Panel Upper Front Console Box Assembly A A A A A A BO 108 BODY INSTRUMENT PANEL 4879 Author Date ...

Page 3223: ...nstrument Panel No 3 Heater to Register Duct No 1 Register Center Bracket Center Stay No 5 Heater to Register Duct No 2 Register E E E E E E E E E E E E E E Standard Cab Access Cab Double Cab BODY INSTRUMENT PANEL BO 109 4880 Author Date ...

Page 3224: ... in Code ø 8 0 31 L 22 0 87 ø 6 0 24 L 25 0 98 ø 5 0 20 L 16 0 63 ø 5 0 20 L 16 0 63 Code Code BO 1 10 BODY INSTRUMENT PANEL 4881 Author Date The shapes and sizes of the screws bolts and nuts are indicated in the table below The codes A H corre spond to those indicated in COMPONENTS on the previous pages ...

Page 3225: ... and the cable is disconnected from the negative battery terminal The SRS is equipped with a back up power source If work is started within 90 seconds of disconnecting the cable from the negative battery terminal the SRS may deploy 2 REMOVE FRONT DOOR SCUFF PLATE a Standard cab Remove the 5 screws and front door scuff plate b Access cab standard and wide body type Remove the 4 screws and front doo...

Page 3226: ...2 as sist grips Torx driver T30 Part No 09041 00030 or locally manufactured tool d Double cab Passenger side Using a torx driver remove the 2 torx screws and assist grips Torx driver T30 Part No 09041 00030 or locally manufactured tool 7 REMOVE FRONT PILLAR GARNISH a Using a screwdriver remove the front pillar garnish HINT Tape the screwdriver tip before use b Use the same procedures described abo...

Page 3227: ...UCT 15 REMOVE STEERING COLUMN See page SR 18 SR 33 16 REMOVE CLUSTER FINISH PANEL Remove the 2 screws and cluster finish panel 17 REMOVE COMBINATION METER a Remove the 4 screws b Remove the combination meter and disconnect the 4 connectors 18 REMOVE INTEGRATION CONTROL PANEL a Remove the 3 control knobs b Remove the 5 screws c Remove the integration control panel by pulling at the positions indica...

Page 3228: ...MPARTMENT DOOR Remove the 2 screws and glove compartment door 23 REMOVE LOWER NO 2 FINISH PANEL Remove the 3 screws and lower No 2 finish panel 24 Standard cab Access cab w o Large type console box Double cab Split type seat REMOVE LOWER CENTER COVER a Remove the 2 clips and lower center cover b Disconnect the connectors 25 Access cab w Large type console box REMOVE FRONT CONSOLE BOX ASSEMBLY a Re...

Page 3229: ...t heater Using a screwdriver remove the seat heater switches then disconnect the connectors HINT Tape the screwdriver tip before use b Using a screwdriver remove the power mirror control switch then disconnect the connector HINT Tape the screwdriver tip before use c Using a screwdriver disengage the 6 clips and remove the upper console panel HINT Tape the screwdriver tip before use 28 Double cab R...

Page 3230: ...sconnect the connectors and remove the console box pocket 30 REMOVE FRONT CONSOLE BOX Remove the 2 bolts 2 clips and front console box 31 REMOVE LOWER INSTRUMENT COVER a Remove the 4 bolts and screw b Using a screwdriver disengage the clips and remove the lower instrument cover HINT Tape the screwdriver tip before use 32 REMOVE PASSENGER AIRBAG ASSEMBLY a Remove the 2 bolts which hold the passenge...

Page 3231: ...bolts and rear console box 34 REMOVE NO 4 HEATER TO REGISTER DUCT 35 REMOVE INSTRUMENT PANEL a Remove the nut b Disconnect the connectors and remove the instrument panel 36 REMOVE CENTER HEATER TO REGISTER DUCT 37 REMOVE INSTRUMENT PANEL REINFORCEMENT a Disconnect the connectors b Remove the bolt and door control receiver c Remove the 3 bolts nut and No 1 brace d Remove the bolt nut and No 2 brace...

Page 3232: ... duct 2 REMOVE NO 1 REGISTER Remove the 2 screws and register 3 REMOVE CENTER STAY Remove the 3 screws and center stay 4 REMOVE CENTER BRACKET Remove the 3 screws and center bracket 5 REMOVE NO 5 HEATER TO REGISTER DUCT Remove the screw and duct 6 REMOVE SIDE DEFROSTER NOZZLE DUCT Remove the screw and duct 7 REMOVE NO 2 REGISTER Remove the 3 screws and register ...

Page 3233: ...BO0J5 04 BODY INSTRUMENT PANEL BO 1 19 4890 Author Date REASSEMBLY Reassembly is in the reverse order of disassembly see page BO 1 18 ...

Page 3234: ...BO2F6 04 BO 120 BODY INSTRUMENT PANEL 4891 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 1 11 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL ...

Page 3235: ... 56 49 in lbf Tail Gate Lock Tail Gate 17 173 13 Service Hole Cover x8 Tail Gate Cable 27 275 20 27 275 20 27 275 20 27 275 20 N m kgf cm ft lbf Specified torque 17 173 13 13 133 10 13 133 10 12 5 128 9 Tail Gate Protector x 6 Pin x 10 Clip Tail Gate Protector Access cab Wide Body Type Tale Gate Lock Link BODY TAIL GATE BO 121 4892 Author Date TAIL GATE COMPONENTS ...

Page 3236: ... a torx socket wrench T40 remove the 4 screws and 2 tail gate locks 4 REMOVE TAIL GATE HANDLE ASSEMBLY Remove the 2 bolts and tail gate handle assembly 5 REMOVE TAIL GATE LOCK STRIKERS Using a torx socket wrench T40 remove the 4 screws and tail gate lock strikers 6 REMOVE TAIL GATE CABLE a Remove the deck side shaft and tail gate cable from the deck b Remove the gate side shaft and tail gate cable...

Page 3237: ...7 N m 275 kgf cm 20 ft lbf c Use the same procedures described above to the other side 3 INSTALL TAIL GATE LOCK STRIKER Using a torx socket wrench T40 install the 2 tail gate lock strikers with the 4 screws Torque 13 N m 133 kgf cm 10 ft lbf 4 INSTALL TAIL GATE HANDLE ASSEMBLY Install the tail gate handle assembly with the 2 bolts Torque 5 5 N m 56 kgf cm 49 in lbf 5 INSTALL TAIL GATE LOCK a Using...

Page 3238: ...Garnish Assist Grip Quarter Trim Cap Front Seat Outer Belt Front Seat Outer Belt 42 430 31 Front Pillar Garnish Quarter Trim Belt Hole Cover Quarter Trim Front Door Scuff Plate Front Door Scuff Plate Assist Grip Quarter Trim Belt Hole Cover Standard cab Sub visor 42 430 31 42 430 31 42 430 31 Holder Holder Cap Back Panel Trim cover BO 124 BODY ROOF HEADLINING 4895 Author Date ROOF HEADLINING COMPO...

Page 3239: ...r Seat Outer Belt Rear Seat Outer Belt Quarter Trim Belt Hole Cover Access Door Scuff Plate Assist Grip Front Pillar Garnish Quarter Trim Front Door Scuff Plate Front Door Scuff Plate Front Seat Outer Belt Front Seat Outer Belt Access cab Sub visor Sub visor Room Light 42 430 31 42 430 31 42 430 31 42 430 31 N m kgf cm ft lbf 42 430 31 42 430 31 Front Door Rear Scuff Plate Front Door Rear Scuff Pl...

Page 3240: ...CUFF 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 T30 remove the 2 screws and assist grip c Passenger s side Using a torx driver T30 remove the 4 screws a...

Page 3241: ...rip 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 a Using a screwdriver remove the left side lens b Remove the 2 screws c Using a screwdriver rotate the clip by 90 and remove it d Remove the front personal l...

Page 3242: ... cap b Remove the screw and coat hook 14 Standard cab REMOVE ROOM PARTITION GARNISHES a Using a screwdriver remove the back panel trim covers HINT Tape the screwdriver tip before use b Using a screwdriver remove the room partition garnishes HINT Tape the screwdriver tip before use 15 REMOVE QUARTER TRIM a Standard cab Remove the bolt and front seat outer belt floor anchor Torque 42 N m 430 kgf cm ...

Page 3243: ...anchor Torque 42 N m 430 kgf cm 31 ft lbf f Access cab Using a screwdriver open the cap g Access cab Unfasten the bolt and remove rear seat outer belt shoul der 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 Perform the same procedure on the other side 16 REMOVE ROOF HEADLINING a Remove the 2 screws and 2 sun vi...

Page 3244: ...BO2FA 05 BO 130 BODY ROOF HEADLINING 4901 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 126 ...

Page 3245: ...l Spacer RH Rear No 2 Side Rail Spacer RH Roof Headlining Trim Retainer Rear RH Front Visor Support Pad RH Front Pillar Spacer No 1 RH Cowl Side Trim Board LH Front Door Opening Trim Weatherstrip LH Roof Headlining Trim Retainer Front LH Front Visor Support Pad LH Front Pillar Spacer No 1 LH Instrument Side Panel LH Front Door Lower Frame Bracket Garnish LH Roof Headlining Trim Retainer Rear LH Re...

Page 3246: ...ap Light Lens Map Light Lens Assist Grip Assist Grip Mirror Cover Roof Headlining Assy Roof Console Box Sun Visor RH Sun Visor LH Holder Holder Sun Visor Cover Sun Visor Cover Roof Silencer Pad Roof Silencer Pad BO 132 BODY ROOF HEADLINING Double Cab 4903 Author Date ...

Page 3247: ... the LH side 3 REMOVE COWL SIDE TRIM BOARD LH a Remove the nut 2 clips and cowl side trim board 4 REMOVE COWL SIDE TRIM BOARD RH HINT Use the same procedures described for the LH side 5 REMOVE FRONT DOOR OPENING TRIM WEATH ERSTRIP LH 6 REMOVE FRONT DOOR OPENING TRIM WEATH ERSTRIP RH 7 REMOVE FRONT PILLAR GARNISH LH a Remove the assist grip 1 Using a screwdriver remove the 2 assist grip plugs HINT ...

Page 3248: ...t outer belt floor anchor Torque 42 N m 430 kgf cm 31 ft lbf b Using a screwdriver remove the 4 clips and pillar garnish HINT Tape the screwdriver tip before use 14 REMOVE LOWER CENTER PILLAR GARNISH RH HINT Use the same procedures described for the LH side 15 REMOVE FRONT SEAT OUTER BELT SHOULDER AN CHOR a Using a screwdriver remove the anchor cap HINT Tape the screwdriver tip before use b Remove...

Page 3249: ...a Using a clip remover remove the clip labeled A clip la beled B and garnish 19 REMOVE CENTER PILLAR GARNISH UPPER RH HINT Use the same procedures described for the RH side 20 REMOVE CENTER PILLAR GARNISH LOWER LH Using a screwdriver remove the 4 clips and garnish HINT Tape the screwdriver tip before use 21 REMOVE CENTER PILLAR GARNISH LOWER RH HINT Use the same procedures described for the RH sid...

Page 3250: ...same procedures described for the RH side 26 REMOVE DOME LIGHT a Using a screwdriver remove the lens HINT Tape the screwdriver tip before use b Remove the 2 screws and dome light then disconnect the connector 27 BACK PANEL TRIM a Remove the 2 clips and bolt b Using a clip remover remove the 6 clips labeled A and 7 clips labeled B 14 clips labeled C and panel 28 REMOVE MAP LIGHT a Using a screwdriv...

Page 3251: ... SIDE RAIL SPACER LH 36 REMOVE REAR NO 2 SIDE RAIL SPACER RH 37 REMOVE FRONT PILLAR SPACER NO 1 LH 38 REMOVE FRONT PILLAR SPACER NO 1 RH 39 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 40 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH RH 41 REMOVE INSTRUMENT PANEL LH 42 REMOVE INSTRUMENT PANEL RH 43 REMOVE CENTER PILLAR GARNISH PAD NO 1 LH 44 REMOVE CENTER PILLAR GARNISH PAD NO 1 RH 45 REMOVE R...

Page 3252: ...BO4QI 02 BO 138 BODY ROOF HEADLINING Double Cab 4909 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 133 ...

Page 3253: ...IDE STEP BO 139 4910 Author Date SIDE STEP REPLACEMENT REMOVE SIDE FRONT STEP Using a screwdriver remove the side front step HINT Tape the screwdriver tip before use NOTICE Do not damage the body If the clips are damaged exchange them for new clips ...

Page 3254: ...Reclining Adjuster Inside Cover RH Seatback Shield Vertical Adjuster Bracket Inner Cover Vertical Adjuster Bracket Outer Cover LH Reclining Adjuster Inside Cover Reclining Knob Slide Knob Seat Cushion Outer Shield Lumbar Switch Power Seat Switch LH Seatback Shield Hog Ring Seat Track Cover Seat Track Cover Bushing Hog Ring Non reusable part Specified torque N m kgf cm ft lbf w Side airbag 5 5 56 4...

Page 3255: ...ted within 90 seconds from discon necting the negative terminal cable of the battery the SRS may deploy 1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 2 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 3 REMOVE FRONT SEAT a Remove the 4 bolts b Discon...

Page 3256: ... release the lumbar support through lumbar switch operation 1 REMOVE HEADREST 2 REMOVE SLIDE KNOB AND RECLINING KNOB Using a screwdriver remove the slide knob and reclining knob HINT Tape the screwdriver tip before use 3 REMOVE SEAT CUSHION LOWER SHIELD SEAT CUSHION OUTER SHIELD AND SEAT CUSHION IN NER SHIELD a Remove the screw from the seat cushion outer shield b Perform the same procedure on the...

Page 3257: ... procedure on the other side 4 REMOVE FRONT SEAT INNER BELT a Disconnect the wire harness clamps and connectors b Remove the nut and front seat inner belt 5 REMOVE LUMBAR SWITCH Remove the 2 screws and lumbar switch from the seat cushion outer shield 6 REMOVE POWER SEAT SWITCH Remove the 3 screws and power seat switch 7 REMOVE ARMREST ASSEMBLY a Using a screwdriver remove the armrest cap b Remove ...

Page 3258: ...seat frame assembly f Remove the seatback cover and pad from the seat frame assembly 9 REMOVE SEATBACK COVER a Turn up the seatback cover and remove the hog rings b Remove the 2 headrest supports c Remove the seatback cover from the seatback pad 10 w Seat heater REMOVE SEATBACK HEATER ASSEMBLY Cut off the tack pins which fasten the seat heater and then re move the seatback heater assembly from the...

Page 3259: ...and then re move the seat cushion heater assembly from the seat cushion cover 14 REMOVE LUMBAR SUPPORT ADJUSTER a Disconnect the connector b Disengage the seatback spring edge from the seat frame assembly NOTICE Be careful when releasing the seatback spring edge be cause there is a possibility that the spring may break due to tension by the lumbar support c Remove the 2 screws and lumbar support a...

Page 3260: ...LDS a Remove the 2 screws and RH seatback shield b Perform the same procedure on the other side 17 REMOVE VERTICAL ADJUSTER BRACKET INNER AND OUTER COVERS a Remove the screw and vertical adjuster bracket inner cover b Perform the same procedure on the other side 18 REMOVE SEAT POSITION SENSOR See page RS 1 18 ...

Page 3261: ...ND OUTER COVERS a Install the vertical adjuster bracket inner cover with the screw b Perform the same procedure on the other side 3 INSTALL RH AND LH SEATBACK SHIELDS a Install the RH seatback shield with the 2 screws b Perform the same procedure on the other side 4 INSTALL RH AND LH RECLINING ADJUSTER INSIDE COVERS a Connect the wire harness clamp b Install the RH reclining adjuster inside cover ...

Page 3262: ...dge with the seat frame as sembly 6 w Seat heater INSTALL SEAT CUSHION HEATER ASSEMBLY a Set the seat cushion heater assembly with the name stamp side facing the seat cushion cover b Install the seat cushion heater assembly with the 10 tack pins NOTICE Do not substitute other metal parts for tack pins 7 INSTALL SEAT CUSHION COVER Install the seat cushion cover to the seat cushion pad with the hog ...

Page 3263: ...parate Type Power Adjuster BO 149 4920 Author Date b Install the hog rings to the seat cushion cover c Install the 2 clips d Connect the wire harness clamp 9 w Seat heater INSTALL SEATBACK HEATER ASSEMBLY a Set the seatback heater assembly with the name stamp side facing the seatback cover b Install the seatback heater assembly with the 11 tack pins NOTICE Do not substitute other metal parts for t...

Page 3264: ... SEATBACK COVER AND PAD a Install the seatback cover and pad to the seat frame as sembly b Install the hog rings to the seat frame assembly c Install the hog rings to the seat frame assembly d w Side airbag Connect the seatback cover bracket to the seat frame as sembly with the nut Torque 5 5 N m 56 kgf cm 49 in lbf e Close the fastener f Install the hog rings to the seat frame assembly ...

Page 3265: ...eat cushion outer shield 15 INSTALL FRONT SEAT INNER BELT a Install the front seat inner belt with the nut Torque 42 N m 430 kgf cm 32 ft lbf b Connect the connectors and wire harness clamps 16 INSTALL SEAT CUSHION LOWER SHIELD SEAT CUSHION OUTER SHIELD AND SEAT CUSHION IN NER SHIELD a Assemble the seat cushion lower shield and seat cushion outer shield with the screw b Perform the same procedure ...

Page 3266: ...SEAT Separate Type Power Adjuster 4923 Author Date g Install the screw to the seat cushion outer shield h Perform the same procedure on the seat cushion inner shield 17 INSTALL SLIDE KNOB AND RECLINING KNOB 18 INSTALL HEADREST ...

Page 3267: ...d Slide the front seat to the rearmost position e Tighten the bolts on the front side temporarily starting from the bolt on the inner side f Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf g Slide the front seat to the foremost position h Tighten the bolts on the rear side temporarily starting from the bolt on the inner side i Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf 2...

Page 3268: ... s seat Driver s seat 37 380 27 37 380 27 37 380 27 37 380 27 42 430 32 Seatback Cover Seat Cushion Cover Seat Cushion Pad Armrest Cap Armrest Spacer Armrest Lock Plate Spacer Armrest Assembly Headrest Headrest Support Seatback Pad Seat Frame Assembly Seat Position Sensor Protector Seat Position Sensor Front Seat Inner Belt Hog Ring Seat Track Cover Seat Track Cover Hog Ring 37 380 27 Occupant Cla...

Page 3269: ...emoving installing and overhauling the passenger seat check the passenger occupant clas sification system and perform the zero point calibration see page DI 1849 HINT The procedures listed below are for the LH side 1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 2 REMOVE SEAT TRACK COVERS Using a screwdriver remove t...

Page 3270: ...outer shield b Using a screwdriver remove the seat cushion outer shield HINT Tape the screwdriver tip before use 3 REMOVE RECLINING ADJUSTER RELEASE HANDLE 4 REMOVE VERTICAL ADJUSTER HANDLE a Using a screwdriver remove the vertical adjuster handle cap HINT Tape the screwdriver tip before use b Remove the 2 screws and the vertical adjuster handle 5 REMOVE SEAT CUSHION INNER SHIELD a Remove the scre...

Page 3271: ...Remove the spacer from the armrest assembly 8 REMOVE SEATBACK COVER AND PAD a Remove the hog rings from the seat frame assembly b Open the fastener c w Side airbag Remove the nut and disconnect the seatback cover bracket from the seat frame assembly d Remove the hog rings shown in the illustration from the seat frame assembly e Remove the hog rings shown in the illustration from the seat frame ass...

Page 3272: ...VER AND PAD a Remove the clip b Perform the same procedure on the other side c Remove the hog rings from the seat cushion cover d Unlatch the seat cushion cover hooks then remove the seat cushion cover with seat cushion pad 11 REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad 12 REMOVE RH AND LH UPPER RECLINING ADJUSTER INSIDE COVERS a Remove the screw...

Page 3273: ...H lower reclining adjuster inside cover b Perform the same procedure on the other side 14 REMOVE RH AND LH SEAT CUSHION LOWER SHIELDS a Using a screwdriver disengage the claw and remove the LH seat cushion lower shield HINT Tape the screwdriver tip before use b Perform the same procedure on the other side 15 Driver s seat REMOVE SEAT POSITION SENSOR See page RS 1 18 ...

Page 3274: ...S 3 INSTALL RH AND LH LOWER RECLINING ADJUSTER INSIDE COVERS a Install the LH lower reclining adjuster inside cover with the screw b Perform the same procedure on the other side 4 INSTALL RH AND LH UPPER RECLINING ADJUSTER INSIDE COVERS a Install the LH upper reclining adjuster inside cover with the screw b Perform the same procedure on the other side 5 INSTALL SEAT CUSHION COVER Install the seat ...

Page 3275: ...m the same procedure on the other side 7 INSTALL SEATBACK COVER a Install the seatback cover to the seatback pad b Install the 2 headrest supports c Turn up the seatback cover and install the hog rings 8 INSTALL SEATBACK COVER AND PAD a Install the seatback cover and pad to the seat frame as sembly b Install the hog rings to the seat frame assembly c Install the hog rings to the seat frame assembl...

Page 3276: ...EST ASSEMBLY a Install the spacer to the armrest assembly b Install the armrest assembly armrest lock plate and arm rest spacer with the bolt Torque 37 N m 380 kgf cm 27 ft lbf HINT Install the armrest lock plate as shown in the illustration c Install the armrest cap 10 INSTALL FRONT SEAT INNER BELT a Install the front seat inner belt with the nut Torque 42 N m 430 kgf cm 32 ft lbf b Connect the c...

Page 3277: ...te 12 INSTALL VERTICAL ADJUSTER HANDLE a Install the vertical adjuster handle with the 2 screws b Install the vertical adjuster handle cap 13 INSTALL RECLINING ADJUSTER RELEASE HANDLE 14 INSTALL SEAT CUSHION OUTER SHIELD Install the seat cushion outer shield with the screw 15 INSTALL HEADREST ...

Page 3278: ...he rearmost position e Tighten the bolts on the front side temporarily starting from the bolt on the inner side f Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf g Slide the front seat to the foremost position h Tighten the bolts on the rear side temporarily starting from the bolt on the inner side i Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf 2 INSTALL SEAT TRACK COVERS ...

Page 3279: ... Hog Ring Seat Cushion Frame Seat Cushion Pad RH Outer Track Assembly 20 204 15 20 204 15 37 380 27 37 380 27 Seat Position Sensor 20 204 15 Seat Position Sensor Protector Seat Track Handle LH 20 204 15 20 204 15 37 380 27 Seat Track Handle RH Seat Track Control cable 20 204 15 LH Outer Track Assembly 37 380 27 Seat Track Lower Rear Bracket Wire Harness Non reusable part Specified torque N m kgf c...

Page 3280: ...O 03 BO 166 BODY FRONT SEAT Bench Type 4937 Author Date REMOVAL 1 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c Remove the front seat NOTICE Be careful not to damage the vehicle body ...

Page 3281: ...E SEAT HINGE COVER LH Remove the 2 screws and seat hinge cover LH 3 REMOVE SEAT HINGE COVER RH Remove the 2 screws and seat hinge cover RH 4 REMOVE SEATBACK ASSEMBLY Remove the 4 bolts and seatback assembly 5 REMOVE CENTER ARMREST ASSEMBLY a Remove the hog rings and turn the seatback cover over b Remove the 2 nuts and center armrest assembly from the seatback frame 6 REMOVE SEATBACK FRAME a Remove...

Page 3282: ... the adjusting nuts HINT When loosening the nuts hold one and loosen the other g Perform the same procedure on the other side h Remove the reclining adjusting cables 7 REMOVE SEATBACK COVER Remove the hog rings and seatback cover 8 REMOVE SEAT POSITION SENSOR See page RS 1 18 9 REMOVE 2 SEAT TRACK LOWER REAR BRACKETS a Remove the 2 nuts and seat track lower rear bracket b Perform the same procedur...

Page 3283: ...outer track assembly rear side c Slide the LH outer track assembly until the torx screws on the front side can be seen d Using a torx socket wrench remove the 2 torx screws from the LH outer track assembly front side and remove the LH outer track assembly 11 REMOVE RH OUTER TRACK ASSEMBLY HINT Perform the same procedure on the other side 12 REMOVE SEAT TRACK HANDLE LH a Disconnect the seat track c...

Page 3284: ...track control cable c Remove the spring d Remove the nut and seat track handle RH 14 REMOVE SEAT CUSHION FRAME Remove the hog rings and seat cushion frame from the seat cushion pad and cover 15 REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad 16 REMOVE BELT WARNING OCCUPANT DETECTION SENSOR Detach the belt warning occupant detection sensor from the se...

Page 3285: ... marking on the pad surface as shown in the illustration 2 INSTALL SEAT CUSHION COVER Install the seat cushion cover with the hog rings HINT When installing the hog rings take as much care as possible to prevent wrinkles 3 INSTALL SEAT CUSHION FRAME Install the seat cushion frame to the seat cushion pad and cover with the hog rings HINT When installing the hog rings take as much care as possible t...

Page 3286: ...CK ASSEMBLY a Slide the LH outer track assembly until the torx screws on the front side can be seen b Using a torx socket wrench install the 2 torx screws to the LH outer track assembly front side Torque 20 N m 204 kgf cm 15 ft lbf c Slide the LH outer track assembly until the torx screws on the rear side can be seen d Using a torx socket wrench install the 2 torx screws to the LH outer track asse...

Page 3287: ...ure on the other side 9 INSTALL SEAT POSITION SENSOR See page RS 122 10 INSTALL SEATBACK COVER Install the seatback cover with the hog rings HINT When installing the hog rings take as much care as possible to prevent wrinkles 11 INSTALL SEATBACK FRAME a Temporarily install the reclining adjusting cables b Tighten the adjusting nuts HINT When tightening the nuts hold one and tighten the other c Per...

Page 3288: ...T ASSEMBLY a Install the center armrest assembly to the seatback frame with the 2 nuts Torque 18 N m 185 kgf cm 13 ft lbf b Install the hog rings to the seatback cover HINT When installing the hog rings take as much care as possible to prevent wrinkles 13 INSTALL SEATBACK ASSEMBLY Install the seatback assembly with the 4 bolts Torque 42 N m 430 kgf cm 32 ft lbf 14 INSTALL SEAT HINGE COVER LH Insta...

Page 3289: ... Type BO 175 4946 Author Date INSTALLATION 1 INSTALL FRONT SEAT a Mount the front seat to the vehicle NOTICE Be careful not to damage the vehicle body b Connect the connectors c Install the 4 bolts Torque 37 N m 380 kgf cm 27 ft lbf ...

Page 3290: ...at Cushion Lower Shield Vertical Adjuster Handle Non reusable part Specified torque N m kgf cm ft lbf 37 380 27 37 380 27 37 380 27 42 430 32 Seatback Cover Seat Cushion Cover Seat Cushion Pad Headrest Headrest Support Seatback Pad Seat Frame Assembly Seat Position Sensor Protector Seat Position Sensor Front Seat Inner Belt Hog Ring Seat Track Cover Seat Track Cover Hog Ring 37 380 27 w Side airba...

Page 3291: ...thin 90 seconds from discon necting the negative terminal cable of the battery the SRS may deploy 1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 2 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 3 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect t...

Page 3292: ...sing it to remove the parts 1 REMOVE HEADREST 2 REMOVE SEAT CUSHION OUTER SHIELD a Remove the screw from the seat cushion outer shield b Using a screwdriver remove the seat cushion outer shield HINT Tape the screwdriver tip before use 3 REMOVE RECLINING ADJUSTER RELEASE HANDLE 4 REMOVE VERTICAL ADJUSTER HANDLE a Using a screwdriver remove the vertical adjuster handle cap HINT Tape the screwdriver ...

Page 3293: ...rness clamp from the seat cushion inner shield d Using a screwdriver remove the seat cushion inner shield HINT Tape the screwdriver tip before use e Disconnect the connectors and clamps and remove the front seat inner belt 6 REMOVE SEATBACK COVER AND PAD a Remove the hog rings from the seat frame assembly b Open the fastener c w Side airbag Remove the nut and disconnect the seatback cover bracket ...

Page 3294: ...Turn up the seatback cover and remove the hog rings b Remove the 2 headrest supports c Remove the seatback cover from the seatback pad 8 REMOVE SEAT CUSHION COVER AND PAD a Remove the clip b Perform the same procedure on the other side c Remove the hog rings from the seat cushion cover d Unlatch the seat cushion cover hooks then remove the seat cushion cover with seat cushion pad 9 REMOVE SEAT CUS...

Page 3295: ...ther side 11 REMOVE RH AND LH LOWER RECLINING ADJUSTER INSIDE COVERS a Remove the screw and LH lower reclining adjuster inside cover b Perform the same procedure on the other side 12 REMOVE RH AND LH SEAT CUSHION LOWER SHIELDS a Using a screwdriver disengage the claw and remove the LH seat cushion lower shield HINT Tape the screwdriver tip before use b Perform the same procedure on the other side ...

Page 3296: ...ING ADJUSTER INSIDE COVERS a Install the LH lower reclining adjuster inside cover with the screw b Perform the same procedure on the other side 4 INSTALL RH AND LH UPPER RECLINING ADJUSTER INSIDE COVERS a Install the LH upper reclining adjuster inside cover with the screw b Perform the same procedure on the other side 5 INSTALL SEAT CUSHION COVER Install the seat cushion cover to the seat cushion ...

Page 3297: ...the same procedure on the other side 7 INSTALL SEATBACK COVER a Install the seatback cover to the seatback pad b Install the 2 headrest supports c Turn up the seatback cover and install the hog rings 8 INSTALL SEATBACK COVER AND PAD a Install the seatback cover and pad to the seat frame as sembly b Install the hog rings to the seat frame assembly c Install the hog rings to the seat frame assembly ...

Page 3298: ...AT CUSHION INNER SHIELD a Connect the front seat inner belt connectors and clamps b Install the seat cushion inner shield c Connect the front seat inner belt wire harness clamp to the seat cushion inner shield d Install the screw to the seat cushion inner shield e Install the front seat inner belt with the bolt Torque 42 N m 430 kgf cm 32 ft lbf 10 INSTALL VERTICAL ADJUSTER HANDLE a Install the ve...

Page 3299: ...H24331 Claws Clip BODY FRONT SEAT Split Type Driver s Side BO 185 4956 Author Date 12 INSTALL SEAT CUSHION OUTER SHIELD Install the seat cushion outer shield with the screw 13 INSTALL HEADREST ...

Page 3300: ...Slide the front seat to the rearmost position e Tighten the bolts on the front side temporarily starting from the bolt on the inner side f Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf g Slide the front seat to the foremost position h Tighten the bolts on the rear side temporarily starting from the bolt on the inner side i Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf 2 I...

Page 3301: ...nge Cover Seat Hinge Cover Seat Cushion Lower Shield Seat Leg Inner Cover Outer Seat Track Lower Rear Bracket Inner Seat Track Lower Rear Bracket Inner Seat Track Inner Seat Track Lower Front Bracket Outer Seat Track Outer Seat Track Lower Front Bracket LH Seat Track Handle Sub assembly Seat Track Adjusting Handle RH Seat Track Handle Sub assembly Reclining Adjusting Cable Seat Cushion Cover Seat ...

Page 3302: ...within 90 seconds from discon necting the negative terminal cable of the battery the SRS may deploy 1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working 2 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 3 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect...

Page 3303: ...leg inner cover 2 REMOVE HEADRESTS 3 REMOVE RECLINING ADJUSTER RELEASE HANDLE Using a screwdriver remove the reclining adjuster release han dle HINT Tape the screwdriver tip before use 4 REMOVE RH SEAT CUSHION SHIELD Disengage the claws and remove the RH seat cushion shield 5 REMOVE SEAT CUSHION LOWER SHIELD Remove the 2 screws and seat cushion lower shield 6 REMOVE SEATBACK ASSEMBLY a Remove the ...

Page 3304: ...and disconnect the seatback cover bracket from the seatback frame h Remove the hog rings from the seat cushion cover i Remove the bolt and disconnect the front seat center belt from the seat cushion assembly j Remove the screw and RH seat cushion lower shield k Remove the 2 screws and RH reclining adjuster inside cover l Remove the 3 nuts and disconnect the front seat center belt ...

Page 3305: ...SEATBACK FRAME a Remove the 4 headrest supports from the seatback as sembly b Remove the seatback lock upper bezel c Remove the seatback frame from the seatback pad 8 REMOVE SEATBACK COVER Remove the hog rings and seatback cover from the seatback pad 9 REMOVE SHOULDER BELT COVER 10 REMOVE FRONT SEAT CENTER BELT a Disconnect the clamps b Remove the bolt nut and front seat center belt 11 REMOVE RH C...

Page 3306: ...over 14 REMOVE OUTER SEAT TRACK LOWER FRONT AND REAR BRACKET a Remove the 2 nuts and outer seat track lower front brack et b Remove the 2 nuts and outer seat track lower rear brack et 15 REMOVE INNER SEAT TRACK LOWER FRONT AND REAR BRACKET a Remove the 2 nuts and inner seat track lower front brack et b Remove the 2 nuts and inner seat track lower rear brack et HINT When removing the inner seat tra...

Page 3307: ...e procedure on the inner seat track 18 REMOVE SEAT CUSHION FRAME Remove the hog rings and seat cushion frame from the seat cushion pad 19 REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad 20 REMOVE BELT WARNING OCCUPANT DETECTION SENSOR Detach the belt warning occupant detection sensor from the seat cushion pad 21 REMOVE FRONT SEAT INNER BELT a Disconn...

Page 3308: ... Perform the same procedure on the other side c Remove the seat track adjusting handle 23 REMOVE RH AND LH SEAT TRACK HANDLE SUB ASSEMBLY a Remove the nut and RH seat track handle sub assembly b Perform the same procedure on the other side 24 REMOVE RECLINING ADJUSTING CABLE a Disconnect the clamp b Loosen the adjusting nuts HINT When loosening the nuts hold one and loosen the other c Remove the r...

Page 3309: ...b Tighten the adjusting nuts HINT When tighten the nuts hold one and tighten the other c Connect the clamp 2 INSTALL RH AND LH SEAT TRACK HANDLE SUB AS SEMBLY a Install the RH seat track handle sub assembly with the nut Torque 10 N m 102 kgf cm 7 ft lbf HINT Apply MP grease to the sliding part of the seat track handle sub assembly b Perform the same procedure on the other side 3 INSTALL SEAT TRACK...

Page 3310: ...Peel the coated paper off the back of the new sensor Attach the sensor along with the marking on the pad surface as shown in the illustration 6 INSTALL SEAT CUSHION COVER Install the seat cushion cover to the seat cushion pad with the hog rings HINT When installing the hog rings take as much care as possible to prevent wrinkles 7 INSTALL SEAT CUSHION FRAME a Install the seat cushion frame to the s...

Page 3311: ...CKET HINT When installing the inner seat track lower rear bracket slide the inner seat track as shown in the illustration a Install the inner seat track lower rear bracket with the 2 nuts Torque 32 N m 326 kgf cm 24 ft lbf b Install the inner seat track lower front bracket with the 2 nuts Torque 32 N m 326 kgf cm 24 ft lbf 11 INSTALL OUTER SEAT TRACK LOWER FRONT AND REAR BRACKET a Install the oute...

Page 3312: ...cm 32 ft lbf HINT Check that the seatback frame claws are securely engaged 16 INSTALL SHOULDER BELT COVER 17 INSTALL SEATBACK COVER Install the seatback cover to the seatback pad with the hog rings HINT When installing the hog rings take as much care as possible to prevent wrinkles 18 INSTALL SEATBACK FRAME a Install the seatback frame to the seatback pad b Install the seatback lock upper bezel c ...

Page 3313: ...seat center belt with the 3 nuts Torque 5 5 N m 56 kgf cm 49 in lbf e Install the RH reclining adjuster inside cover with the 2 screws f Install the RH seat cushion lower shield with the screw g Connect the front seat center belt with the bolt to the seat cushion assembly Torque 42 N m 430 kgf cm 32 ft lbf h Install the hog rings to the seat cushion cover HINT When installing the hog rings take as...

Page 3314: ...l the center armrest assembly with the bolt Torque 20 N m 204 kgf cm 15 ft lbf m Close the fastener n Install the hog rings to the seatback cover HINT When installing the hog rings take as much care as possible to prevent wrinkles o Install the hog rings to the seatback cover belt 20 INSTALL SEAT CUSHION LOWER SHIELD Install the seat cushion lower shield with the 2 screws 21 INSTALL RH SEAT CUSHIO...

Page 3315: ... Slide the front seat to the rearmost position e Tighten the bolts on the front side temporarily starting from the bolt on the inner side f Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf g Slide the front seat to the foremost position h Tighten the bolts on the rear side temporarily starting from the bolt on the inner side i Tighten them completely Torque 37 N m 380 kgf cm 27 ft lbf 2 ...

Page 3316: ...e Cover Seat Cushion Hinge Plate Center Armrest Hinge Cup Holder Center Armrest Hinge Cover Center Armrest N m kgf cm ft lbf Specified torque Non reusable part 5 0 51 44 in lbf LH Headrest Support Seat Lock Cover Seatback Lock Seatback Lock 21 215 16 Hog Ring 19 195 14 9 0 92 80 in lbf 21 215 16 19 195 14 9 0 92 80 in lbf RH Headrest Support 21 215 16 Seatback Cover Seat Lock Handle 21 215 16 CRS ...

Page 3317: ...3 H24386 H24387 BODY REAR SEAT Bench Type BO 203 4974 Author Date REMOVAL REMOVE REAR SEAT a Release the rear seat lock and swing the seat cushions up b Remove the 4 bolts c Lift up the rear seat and remove it ...

Page 3318: ...river remove the rear seat lock handle HINT Tape the screwdriver tip before use b Perform the same procedure on the other side 3 REMOVE REAR SEAT LOCK COVER a Remove the screw and rear seat lock cover b Perform the same procedure on the other side 4 REMOVE REAR SEAT CUSHION COVER a Remove the screw and rear seat cushion cover b Perform the same procedure on the other side 5 REMOVE SEAT CUSHION ASS...

Page 3319: ...screwdriver tip before use 8 REMOVE SEAT CUSHION COVER a Open the fastener b Remove the hog rings and seat cushion cover c Perform the same procedure on the other side 9 REMOVE SEAT CUSHION SIDE COVER Remove the screw and seat cushion side cover 10 REMOVE SEAT CUSHION HINGE PLATE Remove the 2 nuts and seat cushion hinge plate from the seat back frame 11 REMOVE SEATBACK ASSEMBLY Remove the 4 bolts ...

Page 3320: ...cup holder from the center armrest 15 REMOVE CENTER ARMREST HINGE a Using a screwdriver remove the center armrest hinge cover HINT Tape the screwdriver tip before use b Perform the same procedure on the other side c Remove the 2 bolts and center armrest hinge 16 REMOVE HEADREST SUPPORTS 17 REMOVE SEATBACK COVER a Remove the hog rings from the rear side of the seatback assembly b Remove the hog rin...

Page 3321: ...TALL SEATBACK COVER a Install the seatback cover with new hog rings HINT When installing the hog rings take as much care as possible to prevent wrinkles b Install the new hog rings to the rear side of the seatback assembly HINT When installing the hog rings take as much care as possible to prevent wrinkles 2 INSTALL HEADREST SUPPORTS HINT Ensure that the button of the 3 LH headrest supports is ins...

Page 3322: ...bracket with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf b Perform the same procedure on the other CRS tether an chors 7 INSTALL SEATBACK ASSEMBLY Install the seatback assembly with the 4 bolts Torque 21 N m 215 kgf cm 16 ft lbf 8 INSTALL SEAT CUSHION HINGE PLATE Install the seat cushion hinge plate with the 2 nuts to the seat back frame Torque 21 N m 215 kgf cm 16 ft lbf 9 INSTALL SEAT CUSHION SI...

Page 3323: ...ON ASSEMBLY a Install the seat cushion assembly to the seat cushion hinge plate b Install the seat cushion assembly to the seatback lock with the 2 bolts Torque 21 N m 215 kgf cm 16 ft lbf c Perform the same procedure on the other side 14 INSTALL REAR SEAT CUSHION COVER a Install the rear seat cushion cover with the screw b Perform the same procedure on the other side 15 INSTALL REAR SEAT LOCK COV...

Page 3324: ...H11236 BO 210 BODY REAR SEAT Bench Type 4981 Author Date 16 INSTALL REAR SEAT LOCK HANDLE a Install the rear seat lock handle b Perform the same procedure on the other side 17 INSTALL HEADRESTS ...

Page 3325: ...ecification is shown in the standard bolt chart see page SS 2 INSTALL REAR SEAT a Hook the rear seat to the body panel b Install the 4 bolts Torque 19 N m 195 kgf cm 14 ft lbf c Release the rear seat lock and swing down the seat cush ions HINT Before swinging down the seat cushion store the inner belts in the rear seat ...

Page 3326: ... LH Cushion Seat Leg Cover LH Rear Seat Cushion Hinge LH Rear Seat Stay Rear Seat Cushion Hinge RH Rear No 1 Seat Inner Belt Seat Adjuster Control Cable Hinge Cover RH Hinge Cover Rear Seat Outer Belt Rear No 1 Seat Inner Adjuster Seat Inner Bracket Rear Seat Cushion Cover RH 37 380 27 37 380 27 N m kgf cm ft lbf Specified torque Non reusable part Reclining Adjuster Release Handle No 1 Reclining C...

Page 3327: ... back angle adjusting lever and fold the seatback down b Unlock the seat legs by pulling up one of the lever on the seat legs and swing the seat up and forward 2 REMOVE REAR SEAT LH a Using a screwdriver remove the 2 seat leg covers HINT Tape the screwdriver tip before use b Remove the 4 bolts and rear No 1 seat Torque 37 N m 380 kgf cm 27 ft lbf ...

Page 3328: ...s shown in the stan dard bolt chart see page SS 2 1 REMOVE HEADREST Remove the 2 headrests 2 REMOVE RECLINING ADJUSTER RELEASE HANDLE Remove the screw and release handle 3 REMOVE NO 1 RECLINING COVER LH a Unzip the seat cushion cover b Remove the screw and No 1 rear seat reclining cover 4 REMOVE NO 1 RECLINING COVER RH a Unzip the seat cushion cover b Remove the screw and No 1 rear seat reclining ...

Page 3329: ... the 10 screws and seat cushion under cover 6 REMOVE FOLD SEAT LOCK CONTROL CABLE NO 1 a Tilt the seat forward b Remove the clamp and fold seat lock control cable as shown in the illustration 7 REMOVE SEATBACK ASSEMBLY a As shown in the illustration disengage the hook and open the seatback cover b Remove the reclining connecting wire of the LH side edge ...

Page 3330: ...ws and remove the rear seat shoulder belt cover HINT Tape the screwdriver tip before use b Remove the 4 headrest supports c Disengage the hooks and remove the seatback frame from the seatback cover with pad d Remove the seatback cover from the seatback pad e Remove the hog rings and seatback cover HINT At the time of reassembly take as much care as possible to minimize wrinkles when installing hog...

Page 3331: ... rear seat shoulder belt guide Torque 43 N m 440 kgf cm 32 ft lbf b Remove the nut rear seat outer belt Torque 43 N m 440 kgf cm 32 ft lbf 13 REMOVE SEAT CUSHION COVER a Remove the seat cushion cover with pad from the seat cushion frame b Remove the seat cushion cover from the seat cushion pad HINT At the time of reassembly take as much care as possible to minimize wrinkles when installing hog rin...

Page 3332: ...r covers from the rear No 1 seat outer and inner adjusters 15 REMOVE REAR SEAT STAY Remove the 2 bolts and rear seat stay 16 REMOVE REAR SEAT CUSHION HINGE LH AND RH a Using a screwdriver remove the spring nut and E rings b Remove the 2 hinge pins 2 cushion spacers 2 cushion support springs and 2 rear seat cushion hinges 17 REMOVE LH REAR SEAT LOCK Unfasten the bolt then remove the inner belt and ...

Page 3333: ...BO4R6 02 BODY REAR SEAT LH BO 219 4990 Author Date REASSEMBLY Reassembly is in the reverse order of disassembly see page BO 214 ...

Page 3334: ...BO4R7 02 BO 220 BODY REAR SEAT LH 4991 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 213 ...

Page 3335: ... Cover RH Reclining Adjuster Release Handle LH Rear Seat Reclining Adjuster No 1 Rear Seat Reclining Cover LH 43 440 32 Reclining Connecting Pipe 42 430 31 37 380 27 37 380 27 N m kgf cm ft lbf Specified torque 43 440 32 43 440 32 43 440 32 Seat Leg Cover LH Seat Leg Cover RH Hog Ring Non reusable part Hog Ring Clip Rear Seatback Board Fold Seat Lock Control Cable No 1 Rear Seat Cushion Hinge RH x...

Page 3336: ... back angle adjusting lever and fold the seatback down b Unlock the seat legs by pulling up one of the lever on the seat legs and swing the seat up and forward 2 REMOVE REAR SEAT RH a Using a screwdriver remove the 2 seat leg covers HINT Tape the screwdriver tip before use b Remove the 4 bolts and rear No 1 seat Torque 37 N m 380 kgf cm 27 ft lbf ...

Page 3337: ...R RELEASE HANDLE a Remove the screw and release handle 3 REMOVE NO 1 REAR SEAT RECLINING COVER RH a Remove the screw and No 1 rear seat reclining cover 4 REMOVE NO 1 REAR SEAT RECLINING COVER LH a Remove the screw and No 1 rear seat reclining cover 5 REMOVE SEATBACK ASSEMBLY a Tilting the seat forward b As shown in the illustration disengage the hook and open the seatback cover c Remove the 4 bolt...

Page 3338: ... the bolt and cushion b Remove the 6 screws and rear seat cushion under cover c Remove the screw and fold seat stopper band 9 REMOVE FOLD SEAT LOCK CONTROL CABLE ASSY NO 1 Using a screwdriver remove the control cable as shown in the illustration HINT Tape the screwdriver tip before use 10 REMOVE LH REAR SEAT RECLINING ADJUSTER AND REAR SEAT LOCK a Unfasten the bolt then remove the rear No 1 seat i...

Page 3339: ... lbf 13 REMOVE SEAT CUSHION COVER a Remove the seat cushion cover with pad from the seat cushion frame b Remove the seat cushion cover from the seat cushion pad HINT At the time of reassembly take as much care as possible to minimize wrinkles when installing hog rings 14 REMOVE REAR SEAT CUSHION HINGE LH a Using a screwdriver remove the E ring b Remove the pin bushings spring collar and rear seat ...

Page 3340: ...SPECTION INSPECT RECLINING LOCK POSITION SLIPPING OFF When reclining the seat check that the RH and LH rear seat reclining adjusters are released at the same time HINT When the reclining lock position slips off disassemble the seat to adjust the position ...

Page 3341: ...BO4RB 03 BODY REAR SEAT RH BO 227 4998 Author Date REASSEMBLY Reassembly is in the reverse order of disassembly see page BO 223 ...

Page 3342: ...BO4RC 03 BO 228 BODY REAR SEAT RH 4999 Author Date INSTALLATION Installation is in the reverse order of removal see page BO 222 ...

Page 3343: ...ip 42 430 32 Standard Cab 42 430 32 42 430 32 42 430 32 8 5 87 75 in lbf N m kgf cm ft lbf Specified torque 42 430 32 CRS Tether Anchor Bracket Front Seat Center Belt CRS Tether Anchor Bracket 42 430 32 42 430 32 8 5 87 75 in lbf 20 204 15 20 204 15 Room Partition Garnish Room Partition Garnish Room Partition Garnish Back Panel Trim Cover BODY SEAT BELT BO 229 5000 Author Date SEAT BELT COMPONENTS...

Page 3344: ... Seat Outer Belt Quarter Trim Belt Hole Cover Access Door Scuff Plate Front Door Rear Scuff Plate Front Door Scuff Plate Front Seat Outer Belt Assist Grip Access Cab 42 430 32 42 430 32 42 430 32 42 430 32 42 430 32 42 430 32 8 5 87 75 in lbf BO 230 BODY SEAT BELT 5001 Author Date ...

Page 3345: ...er Belt 42 430 32 CRS Tether Anchor Bracket Rear Seat Center Belt 42 430 32 8 5 87 75 in lbf 20 204 15 42 430 32 20 204 15 CRS Tether Anchor Bracket CRS Tether Anchor Bracket 20 204 15 Shoulder Belt Cover Separate type Power adjuster Separate type Manual adjuster Front Seat Inner Belt 42 430 32 Front Seat Inner Belt 42 430 32 42 430 32 8 5 87 75 in lbf BODY SEAT BELT BO 231 5002 Author Date ...

Page 3346: ...er Pillar Garnish Rear Door Opening Trim Weatherstrip Adjustable Anchor 42 430 32 42 430 32 42 430 32 Front Seat Outer Belt 42 430 32 42 430 32 42 430 32 8 5 87 75 in lbf Double Cab 42 430 32 42 430 32 Quarter Trim Upper Quarter Trim Lower 42 430 32 42 430 32 Back Panel Trim Rear No 1 Seat Outer Belt BO 232 BODY SEAT BELT 5003 Author Date ...

Page 3347: ...42 430 32 42 430 32 Front Seat Inner Belt Front Seat Inner Belt N m kgf cm ft lbf Specified torque Front Seat Inner Belt 43 440 32 43 440 32 43 440 32 Rear Seat Inner Belt Front Seat Inner Belt 42 430 32 Front Seat Inner Belt 42 430 32 Front Seat Center Belt 42 430 32 Separate type Power adjuster Split type 42 430 32 Front Seat Inner Belt 42 430 32 21 214 15 BODY SEAT BELT BO 233 5004 Author Date ...

Page 3348: ...y verify the proper operation before installation 2 Driver 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 de grees or less and cannot be pulled out over 45 degrees If a problem is found replace the assembly 3 Except driver seat belt ALR ...

Page 3349: ...led out at over 45 de grees If a problem is found replace the assembly 4 INSPECT REAR NO 1 SEAT CENTER BELT a After extracting 300 mm 11 81 in check that the belt locks when suddenly extracted b Check that the belt can be extracted 300 mm 11 81 in without being locked when the seat is reclined as shown in the illustration c Check that the belt is locked when the belt is extracted by a certain amou...

Page 3350: ...cable CAUTION Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the cable is dis connected from the negative battery terminal The SRS is equipped with a back up power source If work is started within 90 seconds of disconnecting the cable from the negative battery terminal the SRS may deploy 2 Standard cab REMOVE FRONT SEAT OUTER BELT a Remove the...

Page 3351: ...r nishes 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 ...

Page 3352: ... 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 Usi...

Page 3353: ...e the front door scuff plate 1 Remove the 4 screws disengage the claw and front door scuff plate 2 Remove the front door opening trim weatherstrip b Remove the rear door scuff plate 1 Remove the 3 screws 2 Using a screwdriver disengage the clip and remove the rear door scuff plate HINT Tape the screwdriver tip before use c Remove the rear door opening trim weatherstrip d Remove the lower center pi...

Page 3354: ...front seat outer belt CAUTION Never disassemble the front seat outer belt NOTICE When removing the retractor of front seat outer belt take care not to pull the seat belt pretensioner wire harness 1 Using a screwdriver pull the locking button of the pretension connector to your side to release the lock HINT Tape the screwdriver tip before use 2 Disconnect the connector 3 Remove the 2 bolts and the ...

Page 3355: ...ms with the front seat outer belt removed from the vehicle Standard cab Check the quarter trim for cuts cracks or marked discoloration Access cab Check for cuts and cracks in or marked discolor ation on the front door rear scuff plate Double cab Check for cuts and cracks in or marked discolor ation on the front door rear scuff plate and front door rear scuff plate and center piller gernish lower C...

Page 3356: ...hor Date Standard cab Check for deformation of the quarter panel Access cab Check for deformation of the ELR bracket Double cab Check for deformation of the ELR bracket CAUTION For removal and installation of the front seat outer belt see page BO 236 and BO 252 Be sure to follow the correct procedure ...

Page 3357: ... Check for cuts and miute cracks in wire harness or marked discoloration on the front seat outer belt CAUTION For removal and installation of the front seat outer belt see page BO 236 and BO 252 Be sure to follow the correct procedure 2 PRETENSIONER IS ACTIVATED a Perform a diagnostic system check see page DI 1871 ...

Page 3358: ...5015 Author Date 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 har ness ...

Page 3359: ...ner The seat belt pretensioner produces a sizeable ex ploding sound when it activates so perform the op eration out of door and where it will not create a nui sance 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...

Page 3360: ...CAUTION If the LED lights up when the activation switch is not being pressed SST may be malfunctioning Definitely do not use the SST 3 Disconnect the SST from the battery b Disconnect the negative terminal cable from the bat tery CAUTION Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative terminal cable is disconnected from the battery...

Page 3361: ...heck 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 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 3 Move the SST to at least 10 m 33 ft away from the front of the vehicle 4 Close all the doors and ...

Page 3362: ...eat outer belt with seat belt pretensioner only never use the customer s ve hicle to activate the seat belt pretensioner Be sure to follow the procedure given on the next page when activating the seat belt pretensioner a Disconnected the negative terminal cable from the battery HINT Have a battery ready as the power source when activating the seat belt pretensioner NOTICE If the cable is disconnec...

Page 3363: ...lace the front seat outer belt on the ground and cover it with the disc wheel with tire NOTICE 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 NOTICE Take care not to damage the SST wire harness e Activate the seat belt pretensioner 1 Connect the SST red clip to the battery positive terminal and black clip to the battery nega...

Page 3364: ...st 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 to a front seat outer belt with acti vated 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 ...

Page 3365: ...ioner has been activated The seat belt pretensioner has been found to be faulty during troubleshooting The front seat outer belt has been found to be faulty while checking items 1 b or 2 b see page BO 241 The front seat outer belt has been dropped CAUTION For removal and installation of the seat belt pretensioner see pages BO 236 and BO 252 Be sure to follow the correct procedure ...

Page 3366: ...NTAINER OR EXPOSE IT TO OPEN FLAME 5 BE CAREFUL NOT TO DROP CONTAINER OR NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYS TEM If there is not enough refrigerant in the refrigerant system oil lu brication will be insufficient and compressor burnout may occur Necessary care should be taken to avoid this 7 DO NOT OPEN PRESSURE MANIFOLD VAL...

Page 3367: ... System such as the driver and front passenger air bags Failure to carry out service operation in the correct se quence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servic ing including removal or installation of parts inspection or re placement be sure to read the precautionary notices in the RS section ...

Page 3368: ... or too much Refer to items 3 and 4 3 No temperature difference between com pressor inlet and outlet Empty or nearly empty 1 Check for gas leakage with gas leak de tector and repair if necessary 2 Add refrigerant until bubbles disappear 4 Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately after air conditioning is turned...

Page 3369: ...due to ambient tempera ture conditions 1 Normally functioning refrigeration system Gauge reading Low pressure side 0 15 to 0 25 MPa 1 5 to 2 5 kgf cm2 High pressure side 1 37 to 1 57 MPa 14 to 16 kgf cm2 2 Moisture present in refrigeration system Symptom seen in refrigeration system Probable cause Diagnosis Remedy During operation pressure on low pressure side cycles between vac uum and normal Moi...

Page 3370: ...n sys tem Insufficient refrigerant in system Refrigerant leaking 1 Check for gas leakage with gas leak detector and repair if neces sary 2 Charge proper amount of re frigerant 3 If indicated pressure value is near 0 when connected to gauge create the vacuum after inspecting and repairing the location of the leak 4 Poor circulation of refrigerant Symptom seen in refrigeration system Probable cause ...

Page 3371: ...in expansion valve by blowing with air 3 Replace receiver 4 Evacuate air and charge new refrigerant to proper amount 5 For gas leakage from expan sion valve replace expansion valve 6 Refrigerant overcharged or insufficient cooling of condenser Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure too high on both low and high pressure sides No air bubbles seen through the s...

Page 3372: ...ssure sides The low pressure piping hot to the touch Bubbles seen in sight glass Air in refrigeration system Air present in refrigeration sys tem Insufficient vacuum purging 1 Check compressor oil to see if it is dirty or insufficient 2 Evacuate air and charge new refrigerant 8 Expansion valve malfunction Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure too high on bot...

Page 3373: ...osition A C switch ON Temperature control dial at COOL position Magnetic clutch condition Idle up speed 1GR FE Engine Magnetic clutch not engaged 700 50 rpm Magnetic clutch engaged 700 50 rpm 2UZ FE Engine Magnetic clutch not engaged 750 50 rpm Magnetic clutch engaged 800 50 rpm If idle speed is not as specified check the Idle control system 4 INSPECT FOR LEAKAGE OF REFRIGERANT a Perform under the...

Page 3374: ...hat the gas leak detector does not react to the volatile gases If such reaction is unavoidable the vehicle must be lifted up c If gas leak is not detected on the drain hose remove the blower motor linear controller from the cooling unit Then insert the gas leak detector sensor into the unit and per form the test d Disconnect the connector and leave the pressure switch for approx 20 minutes Then br...

Page 3375: ...o the service valves 4 EVACUATE AIR FROM REFRIGERATION SYSTEM a Connect the vacuum pump adapter to the vacuum pump b Connect the center hose of the manifold gauge set to the vacuum pump adapter c Open both the high and low side valves and run the vacu um pump d After 10 minutes or more check that the low pressure gauge indicates 750 mmHg 30 in Hg or more HINT If the reading is 750 mmHg 30 in Hg or...

Page 3376: ...enter hose to the charging cylinder CAUTION Do not open either the high or low side valve of the manifold gauge set c Open the valve of the charging cylinder d Press the valve core on the side of the manifold gauge and expel the air from the center hose 2 INSPECT REFRIGERATION SYSTEM FOR LEAKS a Open the high pressure side valve and charge refrigerant b When the low pressure gauge indicates 98 kPa...

Page 3377: ...NT The system is fully charged if bubbles cannot be seen through the sight glass c Partially charge the refrigeration system with refrigerant 1 Prepare the vehicle Running engine at 1 500 rpm Single A C Front blower speed control dial at HI posi tion Dual A C Front and rear blower speed set at HI posi tion Single A C Front temperature control dial at MAX COOL position Dual A C Front temperature co...

Page 3378: ...on Panel Assembly A C Amplifier A C Switch Air Inlet Selector Heater Control Assembly Heater Unit Heater Radiator Cooling Unit Blower Resistor Evaporator Expansion Valve Thermistor Blower Unit Blower Motor Air Inlet Servomotor Water Valve Access Cab Standard Cab AIR CONDITIONING AIR CONDITIONING SYSTEM AC 13 5040 Author Date LOCATION ...

Page 3379: ...Integration Panel Assembly A C Amplifier A C Switch Air Inlet Selector Heater Control Assembly Heater Unit Heater Radiator Cooling Unit Blower Resistor Evaporator Expansion Valve Thermistor Blower Unit Blower Motor Air Inlet Servomotor Water Valve AC 14 AIR CONDITIONING AIR CONDITIONING SYSTEM 5041 Author Date ...

Page 3380: ... compressor operation 1 Refrigerant volume 2 A C Fuse 3 Magnetic clutch 1GR FE 2UZ FE 4 Compressor 1GR FE 2UZ FE 5 Pressure switch 6 Heater main relay 7 Blower speed control switch 8 A C switch 9 Integration control and panel 10 Thermistor 11 Wire harness AC 3 AC 52 AC 59 AC 52 AC 59 AC 79 AC 82 AC 103 AC 92 AC 83 AC 28 Compressor operates intermittently 1 Refrigerant volume 2 Pressure switch 3 A ...

Page 3381: ...GR FE 2UZ FE 5 Condenser 6 Receiver 7 Expansion valve 8 Evaporator 9 Refrigerant lines 10 Pressure switch 11 Integration control and panel 12 Heater control assembly AC 3 AC 17 AC 52 AC 59 AC 52 AC 59 AC 70 AC 67 AC 28 AC 34 AC 23 AC 79 AC 83 AC 99 No engine idle up with A C switch ON 1 Integration control and panel 2 Idle control system 1GR FE 2UZ FE 3 Wire harness AC 83 DI 266 DI 712 2A C indica...

Page 3382: ...LT TENSIONER Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise If a malfunction exists replace the tensioner 3 2UZ FE engine INSPECT DRIVE BELT TENSION Check that the tension is within the range A on the auto tension er scale If the tension is not within the range A on the scale replace the belt with a new one HINT When replacing the drive belt with a new...

Page 3383: ...EMOVE DRIVE BELT a Remove the engine under cover b Loosen the belt tension by turning the belt tensioner counterclockwise and remove the drive belt from the belt tensioner 2 2UZ FE engine REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner counterclockwise and remove the drive belt ...

Page 3384: ... fix the belt tensioner b Install the drive belt c While turning the belt tensioner counterclockwise re move the bar d If it is hard to install the drive belt perform the following procedures 1 Wrap the drive belt around all the pulleys and idlers except for the P S pump as shown in the illustra tion 2 While releasing belt tension by turning the belt ten sioner counterclockwise wrap the drive belt...

Page 3385: ...2 AC 20 AIR CONDITIONING MANIFOLD GAUGE SET 5047 Author Date MANIFOLD GAUGE SET SET ON 1 CONNECT CHARGE HOSE TO MANIFOLD GAUGE SET Tighten the nuts by hand CAUTION Do not connect the wrong hoses 2 CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH VALVES OF MANIFOLD GAUGE SET 4 REMOVE CAPS FROM SERVICE VALVES ON RE FRIGERANT LINE ...

Page 3386: ... Hose N04392 Sleeve AIR CONDITIONING MANIFOLD GAUGE SET AC 21 5048 Author Date 5 CONNECT QUICK DISCONNECT ADAPTERS TO SER VICE VALVES HINT Push the quick disconnect adapter onto the service valve then slide Slide the sleeve of the quick disconnect adapter down ward to lock it ...

Page 3387: ...SE BOTH VALVES OF MANIFOLD GAUGE SET 2 DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT Slide the sleeve of the quick disconnect adapter upward to un lock the adapter and remove it from the service valve 3 INSTALL CAPS TO SERVICE VALVES ON REFRIGER ANT LINE ...

Page 3388: ... REFRIGERANT LINE AC 23 5050 Author Date 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 3389: ...e Hose 5 4 55 48 in lbf Liquid Tube Condenser N m kgf cm ft lbf Specified torque 1GR FE Piping Clamp 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf Piping Clamp AC 24 AIR CONDITIONING REFRIGERANT LINE 5051 Author Date LOCATION ...

Page 3390: ...e 5 4 55 48 in lbf 10 100 7 Liquid Tube Discharge Hose N m kgf cm ft lbf Specified torque Condenser Piping Clamp Piping Clamp Piping Clamp 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf AIR CONDITIONING REFRIGERANT LINE AC 25 5052 Author Date ...

Page 3391: ...ose N m kgf cm ft lbf Specified torque Suction Hose 5 4 55 48 in lbf Double Cab Condenser Piping Clamp Piping Clamp Piping Clamp 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf AC 26 AIR CONDITIONING REFRIGERANT LINE 5053 Author Date ...

Page 3392: ...t lbf Receiver x Liquid tube 5 4 55 48 in lbf Condenser x Discharge hose 5 4 55 48 in lbf Condenser x Liquid tube 5 4 100 48 in lbf Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Expansion valve x Evaporator 5 4 55 48 in lbf 4 EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount Access cab Standard cab 600 50 g 21 16 1 76 oz Double cab 5...

Page 3393: ...el k Install the lower center cover l Install the lower No 2 finish panel m Install the glove compartment door See page BO 120 2 INSPECT EXPANSION VALVE a Check quantity of gas during refrigeration cycle b Set the manifold gauge set c Run the 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 to 1 57 Mpa 14 to 16 kgm cm2 199 to 288 psi d...

Page 3394: ...te RH Lower No 2 Finish Panel Glove Compartment Door Upper Unit Case Evaporator Thermistor 5 4 55 18 in lbf Expansion Valve O Ring Grommet Liquid and Suction Tube Drain Hose Packing Blower Controller N m kgf cm ft lbf Specified torque Non reusable part Packing Insulator Grommet O Ring Lower Unit Case Access Cab Standard Cab Clamp AIR CONDITIONING COOLING UNIT AC 29 5056 Author Date COMPONENTS ...

Page 3395: ...5 4 55 48 in lbf Expansion Valve O Ring Grommet Liquid and Suction Tube Drain Hose Packing Blower Controller N m kgf cm ft lbf Specified torque Non reusable part Packing Insulator Grommet O Ring Lower Unit Case Instrument Side Panel RH Cowl Side Trim RH Console Box Assy FR Console Panel UPR Console Box Assy RR Glove Compartment Door Double Cab Clamp AC 30 AIR CONDITIONING COOLING UNIT 5057 Author ...

Page 3396: ...ccess cab Standard cab 600 50 g 21 16 1 76 oz Double cab 530 50 g 18 69 1 76 oz 2 DISCONNECT LIQUID AND SUCTION TUBE a Using SST remove the piping clamp SST 09870 00025 Liquid tube 1 Install SST to the piping clamp HINT Confirm the directions of the piping clamp claw and SST using the illustration on the caution label 2 Push down SST and release the clamp lock NOTICE Be careful not to deform the t...

Page 3397: ...me of installation refer to the following Lubricate 2 new O rings with compressor oil and install them to the tubes After connection check the claw of the piping clamp is se curely engaged 3 REMOVE GLOVE COMPARTMENT PARTS 4 REMOVE LOWER NO 2 FINISH PANEL 5 REMOVE LOWER CENTER COVER 6 REMOVE LOWER LH FINISH PANEL 7 REMOVE LOWER COVER See page BO 1 11 8 REMOVE NO 4 HEATER TO REGISTER DUCT 9 REMOVE C...

Page 3398: ...he thermistor from the evaporator 3 REMOVE EVAPORATOR FROM LOWER UNIT CASE HINT At the time of reassembly refer to the following If the evaporator is replaced add compressor oil to the com pressor Add 40 to 50 cc 1 4 to 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 tu...

Page 3399: ...ance according tor the value s in the table below Standard Tester connection Condition Specified condition 1 2 10 C 14 F 7 40 to 9 20 kΩ 1 2 5 C 23 F 5 65 to 7 00 kΩ 1 2 0 C 32 F 4 35 to 5 40 kΩ 1 2 5 C 41 F 3 40 to 4 20 kΩ 1 2 10 C 50 F 2 68 to 3 30 kΩ 1 2 15 C 59 F 2 10 to 2 60 kΩ 1 2 20 C 68 F 1 66 to 2 10 kΩ 1 2 25 C 77 F 1 32 to 1 66 kΩ 1 2 30 C 86 F 1 05 to 1 35 kΩ NOTICE Even slightly touch...

Page 3400: ... Resistance kΩ 32 F 68 F 104 F 4 0 F AIR CONDITIONING COOLING UNIT AC 35 5062 Author Date HINT As the temperature increases the resistance decreases see the graph below If the result is not as specified replace the sensor ...

Page 3401: ...AC0CI 02 AC 36 AIR CONDITIONING COOLING UNIT 5063 Author Date REASSEMBLY The reassembly procedures are the disassembly procedures in reverse order see page AC 33 ...

Page 3402: ...AC0CJ 02 AIR CONDITIONING COOLING UNIT AC 37 5064 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 31 ...

Page 3403: ...ct Brace No 1 Brace No 2 Heater to Register Duct No 1 Heater Unit Cooling Unit Heater Radiator Foot Air Duct Air Vent Duct Heater Unit Case O Ring Clamp Grommet Heater Radiator Pipe Packing Clamp Clamp Clamp Clamp Access Cab Standard Cab AC 38 AIR CONDITIONING HEATER UNIT 5065 Author Date HEATER UNIT COMPONENTS ...

Page 3404: ...t No 1 Heater Unit Cooling Unit Heater Radiator Air Vent Duct Heater Unit Case O Ring Grommet Heater Radiator Pipe Clamp Double Cab Foot Air Duct Packing Floor Heater Air No 1 LH Duct Air Duct RR No 3 Air Duct RR No 1 Air Duct RR No 2 Floor Heater Air No 1 RH Duct Air Duct RR No 4 Air Duct RR No 5 AIR CONDITIONING HEATER UNIT AC 39 5066 Author Date ...

Page 3405: ...oolant 3 DISCONNECT WATER HOSES FROM HEATER RA DIATOR PIPES a Using pliers grip the claws of clips and slide the clips along the hoses b Disconnect the water hoses HINT At the time of installation refer to the following Push the water hose onto the heater radiator pipe up to the second ridge on the pipe Install the hose clip to the position shown in the illustra tion 4 REMOVE INSTRUMENT PANEL AND ...

Page 3406: ...41 5068 Author Date DISASSEMBLY 1 REMOVE HEATER RADIATOR a Remove the 3 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 ...

Page 3407: ...AC22N 02 AC 42 AIR CONDITIONING HEATER UNIT 5069 Author Date INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air ...

Page 3408: ...AC0CN 02 AIR CONDITIONING HEATER UNIT AC 43 5070 Author Date REASSEMBLY The reassembly procedures are the disassembly procedures in reverse order see page AC 41 ...

Page 3409: ...AC0CO 02 AC 44 AIR CONDITIONING HEATER UNIT 5071 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 40 ...

Page 3410: ... Lower Center Cover Heater to Register Duct No 4 Cowl Side Trim RH Front Door Scuff Plate RH Lower No 2 Finish Panel Glove Compartment Door Blower Unit Case Air Inlet Servomotor Blower Motor Access Cab Standard Cab AIR CONDITIONING BLOWER UNIT AC 45 5072 Author Date BLOWER UNIT COMPONENTS ...

Page 3411: ...Cowl Side Trim RH Lower No 2 Finish Panel Glove Compartment Door Air Inlet Servomotor Blower Motor Double Cab Blower Unit Case Front Door Scuff Plate RH Instrument Side Panel RH Console Box Assy Console Panel UPR Console Box Assy RR Motor Cover AC 46 AIR CONDITIONING BLOWER UNIT 5073 Author Date ...

Page 3412: ... BLOWER UNIT a Double cab Remove the 2 screws and motor cover b Disconnect the connector from the blower motor c Disconnect the air inlet damper control cable from the blower unit HINT At the time of installation refer to the following After connection adjust the control cable d Remove the nut bolt and blower unit ...

Page 3413: ...ITIONING BLOWER UNIT 5075 Author Date DISASSEMBLY 1 REMOVE BLOWER MOTOR a Double cab Remove the 2 screws and motor cover b Remove the 3 screws and blower motor 2 REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and servomotor ...

Page 3414: ...ON a Connect the positive lead from the battery to terminal 5 and the negative lead to terminal 2 b Check the motor arm rotates counterclockwise and stops in the FRESH position c Connect the positive lead from the battery to terminal 5 and the negative lead to terminal 1 d Check the motor arm rotates counterclockwise and stops in the RECIRC position ...

Page 3415: ...AC0CY 03 AC 50 AIR CONDITIONING BLOWER UNIT 5077 Author Date REASSEMBLY The reassembly procedures are the disassembly procedures in reverse order see page AC 48 ...

Page 3416: ...AC0CX 02 AIR CONDITIONING BLOWER UNIT AC 51 5078 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 47 ...

Page 3417: ... 22 8 CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 9 CHECK FOR SIGNS OF OIL ON PRESSURE PLATE If necessary repair or replace the pressure plate 10 INSPECT MAGNETIC CLUTCH BEARING FOR NOISE a Start the engine b Check if abnormal noise is heard from near the compres sor when the A C switch is OFF If abnormal noise is being emitted replace the magnetic clutch 11 INSPECT MAGNETIC CLUTCH OPERATION a...

Page 3418: ...cm ft lbf Specified torque Non reusable part Magnet Clutch Assy Magnet Clutch Washer Snap Ring Cooler Compressor Assy Snap Ring 18 183 13 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH 1GR FE AC 53 5080 Author Date COMPONENTS ...

Page 3419: ...essor and magnetic clutch b Remove the O ring from the discharge hose sub assy NOTICE Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering 7 DISCONNECT SUCTION HOSE a Remove the nut and disconnect the suction hose sub assy from the compressor and magnetic clutch b Remove the O ring from the suction hose sub assy NOTICE Seal the openings ...

Page 3420: ... the compressor and magnetic clutch in a vise b Using SST remove the bolt the magnet clutch hub and the magnet clutch washer SST 09960 10010 09962 01000 09963 00500 c Using a snap ring expander remove the snap ring and the magnet clutch rotor d Remove the screw and disconnect the connector e Using a snap ring expander remove the snap ring and the magnet clutch stator ...

Page 3421: ... chamfered side facing up c Install the screw and connect the connector d Using a snap ring expander install the magnet clutch ro tor and a new snap ring with the chamfered side facing up e Install the magnet clutch washer and the magnet clutch hub NOTICE Do not change the combination of the magnet clutch wash ers used before disassembly f Using SST install the magnet clutch hub and the magnet clu...

Page 3422: ...r gradually removing the refrigerant gas from the service valve drain the following amount of oil from the new compressor and magnetic clutch before installation Standard Oil capacity inside the new compressor and magnet ic clutch 120 15 cc 4 0 0 5 fl oz Remaining oil amount in the removed compressor and magnetic clutch Oil amount to be removed when replacing NOTICE When checking the compressor oi...

Page 3423: ... 7 in lbf 3 INSTALL DISCHARGE HOSE a Remove the attached vinyl tape from the hose b Sufficiently apply compressor oil to a new O ring and the fitting surfaces of the compressor and magnetic clutch Compressor oil ND OIL 8 or equivalent c Install the O ring on the discharge hose sub assy d Install the discharge hose sub assy on the compressor and magnetic clutch with the nut Torque 10 N m 100 kgf cm...

Page 3424: ...MANIFOLD GAUGE SET See page AC 22 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 the engine b Check if abnormal noise is heard from near the compres sor when the A C switch is OFF If abnormal noise is being emitted replace the magnetic clutch 11 INSPECT MAGNETIC CLUTCH ...

Page 3425: ...0 7 Discharge Hose Cooler Bracket Compressor Drive Belt Stator Rotor Pressure Plate Shim Snap Ring Compressor N m kgf cm ft lbf Non reusable part Specified torque 25 250 18 25 250 18 13 2 135 9 AC 60 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH 2UZ FE 5087 Author Date COMPONENTS ...

Page 3426: ...NAL CABLE FROM BATTERY 4 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5 DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nuts and disconnect both hoses NOTICE Cap the openings immediately to keep moisture or dirt out of the system 6 REMOVE DRIVE BELT See page AC 18 7 REMOVE COMPRESSOR a Disconnect the connector b Remove the 4 bolts and nut c Remove the cooler bracket d Remove the compressor ...

Page 3427: ... 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 plate SST 07112 66040 c Using SST and a socket wrench remove the pressure plate SST 07112 66040 07112 76060 d Remove the shims from the pressure plate 2 REMOVE ROTOR a Using SST remove the snap ring SST 95994 10020 ...

Page 3428: ...The snap ring should be installed so that its beveled side faces up b Using a plastic hammer remove the rotor from the shaft NOTICE Be careful not to damage the pulley when tapping on the ro tor 3 REMOVE STATOR a Disconnect the stator lead wire from the compressor housing b Using SST remove the snap ring SST 95994 10020 NOTICE The snap ring should be installed so that its beveled side faces up ...

Page 3429: ...AC0951 Stator AC 64 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH 2UZ FE 5091 Author Date c Remove the stator ...

Page 3430: ...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 ro tor when connecting the negative terminal to the bat tery Standard clearance 0 5 0 15 mm 0 020 0 0059 in If the clearance is not within the standard range adjust the clearance using shims to obtain the standard clearance S...

Page 3431: ... 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 3 INSTALL AND CHECK DRIVE BELT See page AC 19 and AC 17 4 CONNECT NEGATIVE TERMINAL CABLE TO BATTERY 5 EVACUATE AIR FROM REFRIGERATION SYSTEM 6 CHARGE SYSTEM WITH REFRIGERANT Specified amount Access cab Standard cab 600 50 g 21 16 1 76 oz Double cab 530 5...

Page 3432: ...IR CONDITIONING RECEIVER AC 67 5094 Author Date RECEIVER ON VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage If there is leakage check the tightening toque at the joints ...

Page 3433: ...FROM RECEIVER Remove the 2 bolts and disconnect both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the openings immediately to keep moisture or dirt out of the system HINT At the time of the installation refer to the following Lubricate 2 new O rings with compressor oil and install them to the tubes 3 REMOVE RECEIVER a Remove the holder bolt and pull the receiver downward HINT At the time of...

Page 3434: ...AC278 02 AIR CONDITIONING RECEIVER AC 69 5096 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 68 ...

Page 3435: ... the fins are clogged wash them with water and dry with compressed air NOTICE 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 3436: ... installation refer to the following Evacuate air from the refrigeration system Charge the system with refrigerant and inspect for leak age of refrigerant Specified amount Access cab Standard cab 600 50 g 21 16 1 76 oz Double cab 530 50 g 18 69 1 76 oz 2 A T models REMOVE A T OIL COOLER 3 REMOVE HORN 4 REMOVE HOOD LOCK 5 REMOVE CENTER BRACE 6 REMOVE RECEIVER AND HOLDER See page AC 68 ...

Page 3437: ... to keep moisture or dirt out of the system HINT At the time of installation refer to the following 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 then upward HINT At the time of installation refer to the following If the condenser is re...

Page 3438: ...AC0DA 02 AIR CONDITIONING CONDENSER AC 73 5100 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 71 ...

Page 3439: ... VALVE CONTROL CABLE 3 INSPECT WATER VALVE OPERATION a Check that warm air comes out from the vent when the water valve lever is moved to the WARM posi tion b Check that cool air comes 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 3440: ...following After connection adjust the control cable See page AC 105 3 DISCONNECT WATER HOSES a Using pliers grip the claws of the hose clips and slide the hose clips along the hoses b Disconnect the water hoses HINT At the time of installation refer to the following Heater radiator pipe Push the water hose onto the heater radiator pipe up to the second ridge on the pipe Water valve Push the water ...

Page 3441: ...AC27C 02 AC 76 AIR CONDITIONING WATER VALVE 5103 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 75 ...

Page 3442: ...ct the positive lead from the battery to terminal 1 and the negative lead to terminal 2 then check that the motor op erates smoothly If operation is not as specified replace the blower motor 3 Double cab 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 op erates smoothly If operation is not as spec...

Page 3443: ...tor b Remove the 2 screws and blower resistor 8 INSPECT BLOWER RESISTOR RESISTANCE Tester connection Condition Specified condition 1 4 Constant 3 3 0 2 Ω 1 3 Constant 1 9 0 1 Ω 1 2 Constant 2 9 0 2 Ω 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 3444: ...ET See page AC 20 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 termi nal 1 and the negative lead to terminal 2 b Check continuity between terminals when refrigerant pressure is changed a...

Page 3445: ...refrigerant Specified amount Access cab Standard cab 600 50 g 21 16 1 76 oz Double cab 530 50 g 18 69 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 Being careful not to deform the tube lock the switch mounted on the tube with an open end wrench and re move the switch At the time of installation refer...

Page 3446: ...AC0E9 03 AIR CONDITIONING PRESSURE SWITCH AC 81 5108 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 80 ...

Page 3447: ...cess cab Standard cab REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK 2 Double cab REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK NO 2 3 INSPECT HEATER MAIN RELAY Marking HEATER CONTINUITY Condition Tester connection Specified condition Constant 2 4 3 5 Continuity Apply B between terminals 3 and 5 1 2 Continuity If continuity is not as specified replace the relay ...

Page 3448: ...wire harness side as shown in the chart below Test condition Turn the ignition switch to ON Tester connection Condition Specified condition A1 Ground Constant Continuity A4 G d Turn ignition switch to ON Battery positive voltage A4 Ground Turn ignition switch OFF No voltage A5 Ground Constant Battery positive voltage A13 G d Turn ignition switch to ACC Battery positive voltage A13 Ground Turn igni...

Page 3449: ... the manifold gauge set Tester connection Condition Specified condition B1 Ground Constant Continuity B8 Ground Magnetic clutch is engaged Battery positive voltage Magnetic clutch is not engaged Below 1 0 V B13 Ground Air inlet switch FRESH Below 1 0 V Air inlet switch RECIRC Battery positive voltage B15 Ground Air inlet switch RECIRC Below 1 0 V Air inlet switch FRESH Battery positive voltage B19...

Page 3450: ...n in the chart below Test condition Turn the ignition switch to ON Tester connection Condition Specified condition A10 Ground Constant Continuity A14 Ground Turn ignition switch ON Battery positive voltage Turn ignition switch OFF No voltage A15 Ground Constant Battery positive voltage A9 Ground Turn ignition switch to ACC Battery positive voltage Turn ignition switch OFF No voltage If the result ...

Page 3451: ...nection Condition Specified condition A10 Ground Constant Continuity A18 Ground Magnetic clutch is engaged Battery positive voltage Magnetic clutch is not engaged Below 1 0 V B8 Ground Air inlet switch FRESH Battery positive voltage Air inlet switch RECIRC Below 1 0 V B7 Ground Air inlet switch RECIRC Battery positive voltage Air inlet switch FRESH Below 1 0 V B12 Ground A C switch ON 9 0 V A C sw...

Page 3452: ... Connector Heater Control Housing Airbag Indicator Circuit Lens Bulb Clock Lighting Bulb Panel Lighting Integration Circuit Integration Panel Access Cab Standard Cab AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Center Cluster Integration AC 87 5114 Author Date COMPONENTS ...

Page 3453: ...enter Cluster Integration Panel Connector Heater Control Housing Lens Bulb Integration Circuit Integration Panel Double Cab AC 88 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Center Cluster Integration 5115 Author Date ...

Page 3454: ...r Cluster Integration AC 89 5116 Author Date REMOVAL REMOVE CENTER CLUSTER INTEGRATION PANEL a Remove the 3 heater control knobs b Remove the 5 screws c Remove the integration control panel by pulling the por tions indicated by arrows in the illustration d Disconnect the connector ...

Page 3455: ...ss cab Standard cab REMOVE AIRBAG INDICATOR CIRCUIT Release the 2 claws and remove the indicator circuit then dis connect the connector 2 REMOVE BULBS a Access cab standard cab Remove the 5 bulbs b Double cab Remove the 6 bulbs 3 Access cab Standard cab REMOVE HEATER CONTROL HOUSING a Remove the 5 screws b Remove the heater control housing 4 Double cab REMOVE HEATER CONTROL HOUSING a Remove the 5 ...

Page 3456: ...IR CONDITIONING CONTROL ASSEMBLY Center Cluster Integration AC 91 5118 Author Date 5 Access cab Standard cab REMOVE INTEGRATION CIRCUIT a Disconnect the 2 connectors b Remove the circuit 6 Double cab REMOVE INTEGRATION CIRCUIT a Remove the 2 screws b Remove the circuit 7 REMOVE LENS Release the 3 claws then remove the lens ...

Page 3457: ... A8 then check that the illumina tions lights up If operation is not as specified check the faulty bulb 2 Double cab INSPECT ILLUMINATION OPERATION Connect the positive lead from the battery to terminal B2 and the negative lead to terminal B11 then check that the illu minations lights up If operation is not as specified check the faulty bulb 3 INSPECT BULB Set the tester as shown in the illustrati...

Page 3458: ...s specified replace the integration circuit bulb 5 Double cab INSPECT A C SWITCH CONTINUITY Standard Switch condition Tester connection Specified condition OFF A17 A18 No continuity ON A17 A18 Continuity If operation is not as specified replace the integration circuit bulb 6 Access cab Standard cab INSPECT A C INDICATOR OPERATION a Connect the positive lead from the battery to terminal A12 and the...

Page 3459: ...ration circuit 7 Double cab INSPECT A C INDICATOR OPERATION a Connect the positive lead from the battery to terminal A17 and the negative lead to terminal A10 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 8 Access cab Standard cab INSPECT AIR INLET CONTROL SWITCH CONTINUITY Switch condition Tester connection Spe...

Page 3460: ...ERATION a Connect the positive lead from the battery to terminal A4 and the negative lead to terminal A1 b Push the air inlet button in and check that the air inlet indi cator lights up If operation is not as specified replace the integration circuit c Connect the positive lead from the battery to terminal A11 and the negative lead to terminal A10 then check that the indicator dims If operation is...

Page 3461: ... Cluster Integration 5123 Author Date REASSEMBLY 1 INSTALL LENS Install the lens 2 Access cab Standard cab INSTALL INTEGRATION CIRCUIT a Connect the 2 connectors b Install the circuit 3 Double cab INSTALL INTEGRATION CIRCUIT a Install the circuit b Install the 2 screws 4 Access cab Standard cab INSTALL HEATER CONTROL HOUSING a Connect the connector b Install the heater control housing c Install th...

Page 3462: ...Y Center Cluster Integration AC 97 5124 Author Date 5 Double cab INSTALL HEATER CONTROL HOUSING a Install the heater control housing b Install the 6 screws 6 INSTALL BULBS a Access cab standard cab Install the 5 bulbs b Double cab Install the 6 bulbs 7 Access cab Standard cab INSTALL AIRBAG INDICATOR CIRCUIT a Connect the connector b Install the circuit ...

Page 3463: ...I 02 AC 98 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Center Cluster Integration 5125 Author Date INSTALLATION The installation procedures are the removal procedures in reverse order see page AC 89 ...

Page 3464: ...E INSPECTION INSPECT HEATER CONTROL DIAL AND LEVER OPERA TION Move the control dial and lever left and right and check for stiff ness and binding through the full range of the levers If a click sound cannot be heard or recoil is felt adjust the con trol cable or check the control cable and heater control assem bly ...

Page 3465: ... Valve Control Cable Color Black Blower Speed Control Switch Air Mix Control Cable Color Black Heater Control Housing Base Def Mode Switch Heater to Register Duct No 2 Lower LH Finish Panel Heater to Register Duct No 4 Lower No 2 Finish Panel Glove Compartment Door AC 100 AIR CONDITIONING HEATER CONTROL ASSEMBLY 5127 Author Date COMPONENTS ...

Page 3466: ...the 5 screws c Remove the integration control panel by pulling the por tions 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 See page BO 1 11 7 DISCONNECT HEATER CONTROL CABLES 8 REMOVE HEATER CONTROL ASSEMBLY...

Page 3467: ...ight HINT Tape the screwdriver tip before use b Pull the cable rearward until the claws are disengaged c Remove the cable d 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 3 REMOVE DEF MODE SWITCH Release the 2 claws then remove the switch HINT Tape the screwdriver tip before use ...

Page 3468: ...ntinuity Illumination circuit 6 7 Continuity If continuity is not as specified replace the switch and check the bulb 2 INSPECT DEF MODE SWITCH a Check the continuity exists between terminals 1 and 3 of the blower switch connector when turning the mode se lector to the DEF position and F DEF position If no continuity exists proceed to the next step b Check the continuity exists between the terminal...

Page 3469: ...TALL DEF MODE SWITCH Install the switch HINT After installation check that the 2 claws are securely engaged 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 ...

Page 3470: ...ITIONING HEATER CONTROL ASSEMBLY AC 105 5132 Author Date 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 ...

Page 3471: ...n d Adjust the air mix control cable Pull the air inlet control link to the COOL position con nect the control cable and lock the clamp HINT Lock the clamp while lightly pulling the outer cable in the direc tion shown by the arrow in the illustration e Adjust the water valve control cable Pull the air inlet control link to the COOL position con nect the control cable and lock the clamp HINT Lock t...

Page 3472: ...7 5134 Author Date 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 ...

Page 3473: ...d require no welding When repairing don t cut and join areas that are not shown in this manual Only work on the specified contents to maintain body strength Body construction will sometimes differ depending on specifications and country of destination Therefore please keep in mind that the information contained herein is based on vehicles for general destinations For the repair procedures and spec...

Page 3474: ...re no welding When repairing don t cut and join areas that are not shown in this manual Only work on the specified contents to maintain body strength Body construction will sometimes differ depending on specifica tions and country of destination Therefore please keep in mind that the information contained herein is based on vehicles for general destinations For the repair procedures and specificat...

Page 3475: ......

Page 3476: ...r Views of weld panel replacement instructions Cautionary items Views of weld panel replacement instructions BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition from which bolted parts have been removed with individual supply parts Front side member replacement Quarter panel replacement BODY DIMENSIONS Body aligning measurements Dimension diagrams PAINT ...

Page 3477: ......

Page 3478: ...e 2 Before performing repair work check for fuel leaks If a leak is found be sure to close the opening totally 3 If it is necessary to use a flame in the area of the fuel tank first remove the tank and plug the fuel line c SAFETY WORK CLOTHES 1 In addition to the usual mechanic s wear cap and safety shoes the appropriate gloves head protector glasses ear plugs face protector dust prevention mask e...

Page 3479: ...nly for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents CAB Cellulose Acetate 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents EPDM Ethylene Propylene 100 212 Alcohol is harmless Gasoline is harmless if applied only for short time...

Page 3480: ...yurethane 80 176 Alcohol is harmless if applied only for very short time in small amounts e g quick wiping to remove grease Avoid dipping or immersing in alcohol gasoline solvents etc PVC Polyvinylchloride Vinyl 80 176 Alcohol and gasoline are harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid dipping or immersing in alcohol gasoline solvents etc SAN S...

Page 3481: ...PC UP Cowl Top Ventilator Louver TSOP Outer Rear View Mirror ABS AAS Front Fender Moulding TSOP Front Body Mudguard E VAC Front Door Outside Handle PC PBT PC PET Front Door Outside Moulding PPF Rear Door Outside Handle PC PBT PC PET Rear Door Outside Moulding PPF Center Stop Light PC PC PMMA Rear Combination Light PMMA ASA License Plate Light PC Quarter Wheel Opening Moulding TSOP Rear Body Mudgua...

Page 3482: ... repair A REPLACEMENT PARTS AND METHOD QUARTER PANEL CUT Replacement method ASSY Assembly replacement CUT Major cutting less than 1 2 of parts used CUT H Half cutting about 1 2 of parts used CUT P Partial cutting most of parts used Replacement Parts B PARTS LOCATION C REMOVAL DIAGRAM Describes in detail removal of the damaged parts involving repair by cutting D REMOVAL GUIDE Provides additional in...

Page 3483: ...tion of the new parts involving repair by welding and or cutting but excluding painting F INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation G SYMBOLS See page IN 4 H ILLUSTRATION OF WELD POINTS Weld method and panel position symbols See page IN 5 ...

Page 3484: ...ding Diagrams in Section RE of this manual to indicate cutting areas and the types of weld required SYMBOLS MEANING ILLUSTRATION SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD See page IN 5 CONTINUOUS MIG WELD BUTT WELD OR TACK WELD BRAZE BODY SEALER ...

Page 3485: ...nts Outside Middle Inside HINT Panel position symbols are as seen from the working posture Spot Weld Mig Plug Weld Spot MIG Weld Weld points Remove weld point and panel position Weld points Weld method and panel position 2 2 INTRODUCTION Symbols IN 5 Illustration of Weld Point Symbols EXAMPLE ...

Page 3486: ...INTRODUCTION F13890A IN 5 HOW TO USE THIS MANUAL 1 BODY PANEL REPLACEMENT THIS MANUAL ...

Page 3487: ...INTRODUCTION IN 6 ...

Page 3488: ...DISC SANDER ETC BRAZE Removal BRAZE Installation SPOT WELD OR MIG PLUG WELD See Page IN 9 BODY SEALER WELD POINTS CONTINUOUS MIG WELD BUTT WELD CONTINUOUS MIG WELD TACK WELD INTRODUCTION IN 7 2 SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required ...

Page 3489: ...INTRODUCTION F13894A SYMBOLS MEANING ILLUSTRATION Assembly Mark BODY SEALER Flat Finishing BODY SEALER No flat Finishing IN 8 ...

Page 3490: ...are as seen from the working posture Spot Weld MIG Plug Weld Spot MIG Weld Weld points Remove weld point and panel position Weld method and panel position Weld points MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION Middle Inside INTRODUCTION IN 9 3 ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE ...

Page 3491: ...tem never use a back up power supply from outside the vehicle Even in cases of a minor collision where the SRS does not deploy the passenger s airbag assembly the steering wheel pad and seat belt pretensioners should be inspected Never use SRS parts from another vehicle When replacing parts replace them with new parts Before repairs remove the airbag sensor if shocks are likely to be applied to th...

Page 3492: ...cident if the airbag inflates Never measure the resistance of the airbag squib This may cause the airbag deploy which is very dangerous Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind Store the airbag assembly where the ambient temperature remains below 93 C 200 F without high humidity and away from electrica...

Page 3493: ...air out of the TRAC system 3 DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resis tance of the vehicle After installing components in the sections listed in the table below perform alignments to ensure correct mounting angles and dimensions Particularly accurate repair of the body must also be done to ensure c...

Page 3494: ...memory system Then when work is finished reset the clock and audio systems as before When the vehicle has tilt and telescopic steering power seat and outside rear view mirror which are all equipped with memory function it is not possible to make a record of the memory contents So when the operation is finished it will be necessary to explain this fact to the customer and request the customer to ad...

Page 3495: ... necessary to use a flame in the area of the fuel tank first remove the tank and plug the fuel line HAND TOOLS Keeping your hand tools in neat order improve your work efficiency SAFETY WORK CLOTHES In addition to the usual mechanic s wear cap and safety shoes the appropriate gloves head protector glasses ear plugs face protector dust prevention mask etc should be worn as the situation demands WRON...

Page 3496: ...ge IN 4 5 REMOVAL OF ADJACENT COMPONENTS When removing adjacent components apply protective tape to the surrounding body and your tools to prevent damage HINT See Handling Precautions on Related Components on page IN 6 PRECAUTIONS FOR DRILLING OR CUTTING Check behind any area to be drilled or cut to insure that there are no hoses wires etc that may be damaged HINT See Handling Precautions on Relat...

Page 3497: ...ot be used use a puncher or drill to make holes for plug welding SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS When welding there is a danger that electrical components will be dam aged by the electrical current flow ing through the body Before starting work disconnect the negative terminal of the battery and ground the welder near the welding location of the body Less than 3 mm Overlap Air Saw Pun...

Page 3498: ...Gas welder Do not gas weld or braze panels at areas other than specified POST WELDING REFINISHING 1 Always check the welded spots to insure they are secure 2 When smoothing out the weld spots with a disc grinder be careful not to grind off too much as this would weaken the weld SPOT WELD LOCATIONS Try to avoid welding over previous spots SPOT WELDING PRECAUTIONS 1 The shape of the welding tip poin...

Page 3499: ...Parts Number Paster UC Oil Base 08836 00155 Paster UW Water Base 08836 00115 Paster Gun For thick application 08836 00091 The above SSM or equivalent Parts Name Parts Number Rustop W Aerosol 08860 00200 Rustop W 1 Milky White 08860 00210 Rustop W 18 Milky White 08860 00230 Rustop B 1 Black 08860 00220 Rustop B 18 Black 08860 00240 The above SSM or equivalent ANTI RUST TREATMENT When replacing body...

Page 3500: ...ce Small nonwaterproof rivet Magnetic adherence Small waterproof rivet Waterproof seal Large waterproof rivet Mandrel sticks out after installation RIVET REMOVAL 1 SELECTION OF CUTTING TOOL Cutting tool Note Aluminum Rivet Steel Rivet T Rivet with ø6 4 mm Drill blade Cutting can be done with drill blade or rivet cutter for an aluminum rivet with ø4 8 mm When a rivet cutter is used for an aluminum ...

Page 3501: ... a protective glasses If a drill is strongly pushed deeply into a rivet the rivet can t be cut as it spins together with the drill Prizing the hole with a drill can lead to damage to the rivet hole or the breaking of the rivet cutter Take care as the cut rivet is hot 5 Aluminum Rivet and Waterproof Rivet with ø4 8 mm Even if flange is taken off continue drilling and push out re maining fragments w...

Page 3502: ...rel NOTE Wrong selection of a nose piece may cause the rivet er to be damaged or bad tightening Reference Nose piece of Air Riveter Parts Name Parts Number Color Rivet type Nose piece No 1 09050 02020 Silver ø4 0 mm Aluminum ø4 0 mm Steel ø4 8 mm Waterproof Nose piece No 2 09050 02030 Copper ø4 8 mm Aluminum ø4 8 mm Steel Nose piece No 3 09050 02040 Black ø6 4 mm T Rivet 4 Insert the nose piece to...

Page 3503: ...t is cut and opened in this area Prizing a riveter damages the riveter showing that it is not tightened correctly and bends the mandrel Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the materi al Loose tightening also occurs when a rivet is applied be tween materials without touching T Rivet with ø6 4 mm When a mandrel of a rivet is los...

Page 3504: ...mponents or apply protective covers over the com ponents Before prying components off using a screwdriver or a scraper etc attach protective tape to the tool tip or blade to prevent damaging the components and the body paint Before removing components from the outer surface of the body attach protective tape to the body to ensure no damage to painted areas HINT Apply touch up paint to any damaged ...

Page 3505: ...olled Transmission ECU Electronic Control Unit e g Exempli Gratia for Example Ex Except FWD Front Wheel Drive Vehicles 2WD Two Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in inch LH Left hand LHD Left hand Drive MIG Metal Inert Gas M Y Model Year PPS Progressive Power Steering RH Right hand RHD Right hand Drive SRS Supplemental Restraint System SSM Special Service Materials w with w o witho...

Page 3506: ...on Transaxle ECT Electronic Controlled Transmission ECU Electronic Control Unit e g Exempli Gratia for Example Ex Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in inch LH Left hand LHD Left hand Drive MIG Metal Inert Gas M T Manual Transmission Transaxle M Y Model Year PPS Progressive Power Steering RH Right hand RHD Right hand Drive SRS Supplemental Restraint System SSM Spec...

Page 3507: ...l is coated with a zinc alloy If a body structure parts are heat repaired with an acetylene torch or other heating source the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxid...

Page 3508: ...strength steel maintains its special crystal line organization by heat treatment or alloy additives Since these parts were designed to exhibit a 100 perfor mance when they were in their original shape if they are deformed in an accident or if the deformed parts are re paired and reused they become unable to exhibit the same performance as intended in the design It is necessary to replace the door ...

Page 3509: ...r frame b CUTTING AREA 1 Always cut in a straight line and avoid reinforced area c PRECAUTIONS FOR DRILLING OR CUTTING 1 Check behind any area to be drilled or cut to insure that there are no hoses wires etc that may be dam aged HINT See Handling Precautions on Related Compo nents on page IN 15 d REMOVAL OF ADJACENT COMPONENTS 1 When removing adjacent components apply protec tive tape to the surro...

Page 3510: ...gh prim er c MAKING HOLES FOR PLUG WELDING 1 For areas where a spot welder cannot be used use a puncher or drill to make holes for plug welding REFERENCE mm in Thickness of welded portion Size of plug hole 1 0 0 04 under 5 0 20 ø over 1 0 0 04 1 5 0 06 6 4 0 25 ø over 1 5 0 06 over 8 0 31 ø over d SAFETY PRECAUTIONS FOR ELECTRICAL COM PONENTS 1 When welding there is a danger that electrical compo ...

Page 3511: ...nufacturer s spots Plug weld More than No of manufacturer s plugs 2 Plug welding should be done with a MIG Metal Inert Gas welder Do not gas weld or braze panels at areas other than specified c POST WELDING REFINISHING 1 Always check the welded spots to insure they are se cure 2 When smoothing out the weld spots with a disc grind er be careful not to grind off too much as this would weaken the wel...

Page 3512: ...ody from dam age by flying stones always apply sufficient under coat to the bottom surface of the under body and in side of the wheel housings 5 ANTI RUST TREATMENT AFTER PAINTING PROCESS a ANTI RUST AGENT WAX APPLICATION 1 To preserve impossible to paint areas from corrosion always apply sufficient anti rust agent wax to the in side of the hemming areas of the doors and hoods and around the hinge...

Page 3513: ... REFERENCE Painting prevents corrosion and protect the sheet metal from damage In this section anti chipping paint only for anti corrosion purpose is described a ANTI CHIPPING PAINT 1 To prevent corrosion and protect the body from dam age by flying stones etc apply anti chipping paint to the rocker panel wheel arch areas balance panel etc HINT Depending on the model or the application area there a...

Page 3514: ...ganic or aromatic solvents ASA Acrylonitrile Styrene Acrylate 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents CAB Cellulose Acetate 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents EP...

Page 3515: ...applied only for very short time in small amounts e g quick wiping to remove grease Avoid dipping or immersing in alcohol gasoline solvents etc PVC Polyvinylchloride Vinyl 80 176 Alcohol and gasoline are harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid dipping or immersing in alcohol gasoline solvents etc SAN Styrene Acrylonitrile 80 176 Alcohol is h...

Page 3516: ...P Cowl Top Ventirator Louver PP PE Front Fender Mudguard EVA PP Outer Rear View Mirror ABS ASA Front Door Outside Handle PC PBT PC PET Access Panel Outside Handle PC PBT Rear Body Mudguard EVA PP Center Stop Light PC Rear Combination Light PP PMMA Tail Gate Outside Handle PC PET Licence Plate Light PC PP Rear Bumper TSOP HINT Resin material differs with model Made up of 2 or more kinds of material...

Page 3517: ...l in body repair Body panels on TOYOTA models are made of two different melted galvannealed sheet steel The ordinary melted galvannealed sheet has a zinc plating over the base metal surface and when heated a zinc iron alloy plating The zinc iron double layered galvannealed sheet has an iron rich and another zinc rich layer above the sheet steel These 2 layers improve paint adhesion These two melte...

Page 3518: ...cause HSS is thinner than mild steel care should be taken to avoid warping during hammering operations 2 Removing Spot Welds Because HSS is tougher than mild steel damage will occur more easily to a regular drill There fore an HSS Spot Cutter is recommended Also use a high torque drill at low speed and supply grinding oil to the drill use 3 Panel Welding Panel welding procedures for HSS are exactl...

Page 3519: ...RADIATOR UPPER SUPPORT ASSY REMOVAL LH only RH only 2 2 10 BODY PANEL REPLACEMENT RE 2 ...

Page 3520: ...porarily install the new parts and measure each part in accordance with the body dimension diagram HINT First install the hood lock support LH only 3 RH only 3 11 2 1 BODY PANEL REPLACEMENT RE 3 INSTALLATION ...

Page 3521: ...RADIATOR SIDE SUPPORT ASSY REMOVAL With the radiator upper support removed 12 13 9 1 BODY PANEL REPLACEMENT RE 4 ...

Page 3522: ...nd measure each part in accordance with the body dimension diagram HINT First install the radiator upper support 6 2 Radiator Support to Front Fender Bracket Front End Panel No 1 Bracket 11 1 9 13 4 BODY PANEL REPLACEMENT RE 5 INSTALLATION ...

Page 3523: ...FRONT CROSSMEMBER ASSY REMOVAL 23 BODY PANEL REPLACEMENT RE 6 ...

Page 3524: ...1 Temporarily install the new parts and measure each part in accordance with the body dimension diagram 2 4 8 8 7 BODY PANEL REPLACEMENT RE 7 INSTALLATION ...

Page 3525: ...RADIATOR SUPPORT ASSY REMOVAL 12 1 1 1 BODY PANEL REPLACEMENT RE 8 ...

Page 3526: ...1 Temporarily install the new parts and measure each part in accordance with the body dimension diagram 1 4 11 1 2 2 BODY PANEL REPLACEMENT RE 9 INSTALLATION ...

Page 3527: ...COWL TOP SIDE PANEL ASSY REMOVAL 8 2 4 BODY PANEL REPLACEMENT RE 10 ...

Page 3528: ... 8 2 4 BODY PANEL REPLACEMENT RE 11 INSTALLATION ...

Page 3529: ...FRONT FENDER APRON ASSY REMOVAL With the radiator support cowl top side panel removed 4 3 2 4 2 3 RH LH M T LH A T 6 5 7 8 BODY PANEL REPLACEMENT RE 12 ...

Page 3530: ...he 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 6 3 6 2 2 3 RH LH M T LH A T 6 5 7 8 BODY PANEL REPLACEMENT RE 13 INSTALLATION ...

Page 3531: ...BODY PANEL REPLACEMENT RE 14 MEMO ...

Page 3532: ...s of the outer pillar inner pillar and roof drip channel 2 Cut and join the rocker outer panel and rocker panel reinforcement at position shifted about 50 mm 1 97 in Cut and Join Location 50 mm Cut and Join Location 50 mm 30 mm 50 mm 610 mm Cut and Join Location Cut and Join Location 2 3 5 4 1 6 11 9 1 2 4 BODY PANEL REPLACEMENT RE 15 mm in 30 50 610 1 18 1 97 24 02 ...

Page 3533: ...il lar reinforcement and rocker panel reinforcement weld the front body outer pillar with standard points 73 mm Cut Location Cut Location Cut Location for Supply Parts 124 mm Cut Location 35 mm LH RH Inner Pillar Outer Pillar Pillar Reinforcement Butt Weld Butt Weld Cowl Side Panel Reinforcemen Cowl Side Inner Panel Rocker Panel Reinforcement 1 1 8 3 4 4 3 3 5 6 3 2 2 2 2 2 3 5 2 2 4 1 4 5 1 2 6 2...

Page 3534: ...d windshield glass 4 Temporarily install the new parts and measure each part in accordance with the body dimension diagram 5 Apply foamed material to the pillar section 1 9 2 6 Butt Weld 1 2 6 10 Butt Weld RH only Roof Drip Channel 1 2 6 BODY PANEL REPLACEMENT RE 17 INSTALLATION ...

Page 3535: ...VAL 1 Cut and join the parts at the locations as shown above 2 After grinding off the hemming location remove the outer panel Hemming Location Disc Sander Cut and Join Location Cut and Join Location 3 2 2 BODY PANEL REPLACEMENT RE 18 ...

Page 3536: ...10 mm 0 39 in from the edge as shown 2 For other sealing points refer to section AR 2 Bend the flange hem about 30 with a hammer and dolly then fasten tightly with a hemming tool HINT 1 Perform hemming in three steps being careful not to warp the panel 2 If a hemming tool cannot be used hem with a hammer and dolly Body Sealer about 10 mm Do not close the drain hole Cloth Tape 30 Hemming Tool Butt ...

Page 3537: ...VAL 1 Cut and join the parts at the locations as shown above 2 After grinding off the hemming location remove the outer panel Hemming Location Disc Sander Cut and Join Location Cut and Join Location 6 1 14 BODY PANEL REPLACEMENT RE 20 ...

Page 3538: ...0 mm 0 39 in from the edge as shown 2 For other sealing points refer to section AR 2 Bend the flange hem about 30 with a hammer and dolly then fasten tightly with a hemming tool HINT 1 Perform hemming in three steps being careful not to warp the panel 2 If a hemming tool cannot be used hem with a hammer and dolly Body Sealer about 10 mm Do not close the drain hole Cloth Tape 30 Hemming Tool Butt W...

Page 3539: ...AL 1 Cut and join the parts at the locations as shown above Cut and Join Location Cut and Join Location Cut and Join Location Cut Location for Supply Parts Cut and Join Location Cut Location for Supply Parts 14 12 BODY PANEL REPLACEMENT RE 22 ...

Page 3540: ...1 Temporarily install the new parts and check the fit of the fornt door 14 12 Butt Weld Butt Weld BODY PANEL REPLACEMENT RE 23 INSTALLATION ...

Page 3541: ...L 1 Cut and join the parts at the locations as shown above Cut and Join Location Cut and Join Location Cut and Join Location Cut Location for Supply Parts Cut and Join Location Cut Location for Supply Parts 26 23 BODY PANEL REPLACEMENT RE 24 ...

Page 3542: ...1 Temporarily install the new parts and check the fit of the front door and access panel 26 23 Butt Weld Butt Weld BODY PANEL REPLACEMENT RE 25 INSTALLATION ...

Page 3543: ...ab REMOVAL 1 Cut and join the parts at the locations as shown above 50 mm Cut and Join Location Cut and Join Locations Cut and Join Location Cut Location for Supply Parts 18 7 2 12 2 1 5 BODY PANEL REPLACEMENT RE 26 mm in 50 1 97 ...

Page 3544: ...d check the fit of the front door and back window glass 2 After installing the new parts apply foamed material Butt Weld Butt Weld A A B B A A B B Foamed Material Application Areas 18 6 2 2 12 5 2 2 BODY PANEL REPLACEMENT RE 27 INSTALLATION ...

Page 3545: ... Cut and join the parts at the locations as shown above 50 mm Cut and Join Location Cut and Join Location Cut and Join Location Cut and Join Location Cut Location for Supply Parts 22 1 1 5 4 12 17 BODY PANEL REPLACEMENT RE 28 mm in 50 1 97 ...

Page 3546: ...1 Temporarily install the new parts and check the fit of the access panel and back window glass Butt Weld Butt Weld 11 1 1 9 3 4 12 17 7 BODY PANEL REPLACEMENT RE 29 INSTALLATION ...

Page 3547: ...Cut and join the parts at the location as shown above 2 Leave the quarter lock piller upper reinforcement to the vehicle Remove the quarter lock piller reinforce ment Cut and Jion Location Quarter Lock Piller Upper Reinforcement 50 mm 8 16 1 1 6 2 3 BODY PANEL REPLACEMENT RE 30 mm in 50 1 97 ...

Page 3548: ...mporarily install the quarter panel and check the fit 2 After installing the new parts apply foamed material Butt Weld A A B B A A B B Foamed Material Application Areas 8 1 1 21 4 2 2 1 1 1 1 8 BODY PANEL REPLACEMENT RE 31 INSTALLATION ...

Page 3549: ...ved 1 Cut and join the parts at the location as shown above 2 Leave the quarter panel inner reinforcement to the ve hicle Remove the quarter lock piller reinforcement Cut and Join Location Quarter Panel Inner Reinforcement 50 mm 9 19 2 5 6 9 2 BODY PANEL REPLACEMENT RE 32 mm in 50 1 97 ...

Page 3550: ...ts temporarily install the quarter panel and check the fit 2 After installing the new parts apply foamed material Butt Weld A A A A Foamed Material Application Area 9 25 4 4 5 2 4 2 2 2 12 BODY PANEL REPLACEMENT RE 33 INSTALLATION ...

Page 3551: ...BACK PANEL ASSY Regular Cab REMOVAL 15 17 15 17 24 BODY PANEL REPLACEMENT RE 34 ...

Page 3552: ...1 Temporarily install the new parts and check the fit of the back window glass BODY PANEL REPLACEMENT RE 35 INSTALLATION ...

Page 3553: ...BACK PANEL ASSY Access Cab REMOVAL 67 25 BODY PANEL REPLACEMENT RE 36 ...

Page 3554: ...1 Temporarily install the new parts and check the fit of the back window glass 19 14 14 25 2 25 2 2 2 2 BODY PANEL REPLACEMENT RE 37 INSTALLATION ...

Page 3555: ...BACK PANEL ASSY Access Cab REMOVAL 67 25 BODY PANEL REPLACEMENT RE 36 ...

Page 3556: ...1 Temporarily install the new parts and check the fit of the back window glass BODY PANEL REPLACEMENT RE 37 INSTALLATION ...

Page 3557: ...BACK PANEL ASSY Regular Cab REMOVAL 15 17 15 17 24 BODY PANEL REPLACEMENT RE 34 ...

Page 3558: ...1 Temporarily install the new parts and check the fit of the back window glass 20 17 17 20 24 8 9 2 2 2 2 2 BODY PANEL REPLACEMENT RE 35 INSTALLATION ...

Page 3559: ...ROOF PANEL ASSY Regular Cab REMOVAL 9 9 16 2 2 20 BODY PANEL REPLACEMENT RE 38 ...

Page 3560: ...ck window frame HINT 1 Apply just enough sealer for the new parts to make contact 2 For other sealing points refer to Section AR 2 After installing the new parts apply foamed material Body Sealer A A A A A A A A Foamed Material Application Areas 12 12 3 3 20 16 BODY PANEL REPLACEMENT RE 39 INSTALLATION ...

Page 3561: ...ROOF PANEL ASSY Access Cab REMOVAL 16 16 16 2 2 20 BODY PANEL REPLACEMENT RE 40 ...

Page 3562: ...ement and back window frame HINT 1 Apply just enough sealer for the new parts to make contact 2 For other sealing points refer to Section AR 2 After installing the new parts apply foamed material Body Sealer A A A A A A A A Foamed Material Application Areas 21 21 16 3 3 20 BODY PANEL REPLACEMENT RE 41 INSTALLATION ...

Page 3563: ...apply the weld through primer spot sealer to welding surfaces where the paint film has been removed HINT Apply the weld through primer spot sealer so that it does not ooze out from the joining surfaces ANTI RUST TREATMENT BEFORE PAINTING PROCESS 1 BODY SEALER APPLICATION For water proofing and anti corrosion measures always apply the body sealer to the body panel seams and hems of the doors hoods ...

Page 3564: ...side of the hem ming areas of the doors and hoods and around the hinges or the welded surfaces inside the boxed cross section structure of the side member body pillar etc REFERENCE ANTI RUST TREATMENT BY PAINTING Painting prevents corrosion and protects the sheet metal from damage In this section anti chipping paint only for anti corro sion purpose is described 1 ANTI CHIPPING PAINT To prevent cor...

Page 3565: ...aler clean the area with a rag soaked in a grease wax and silicone remover 2 If weld through primer was used first wipe off any excess and coat with anti corrosion primer before applying body seal er 3 Wipe off excess body sealer with a rag soaked in a grease wax and silicone remover 4 If body sealer is damaged by peeling cracks etc be sure to repair as necessary ALL ...

Page 3566: ...Flat Surfacing Flat Surfacing Access Cab Regular Cab ANTI RUST TREATMENT Body Panel Sealing Areas AR 5 ...

Page 3567: ...ess Cab Regular Cab Flat Surfacing Access Cab Regular Cab Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Access Cab Regular Cab Flat Surfacing ANTI RUST TREATMENT Body Panel Sealing Areas AR 6 ...

Page 3568: ...Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Regular Cab Access Cab ANTI RUST TREATMENT Body Panel Sealing Areas AR 7 ...

Page 3569: ...Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing ANTI RUST TREATMENT Body Panel Sealing Areas AR 8 ...

Page 3570: ...Flat Surfacing Flat Surfacing ANTI RUST TREATMENT Body Panel Sealing Areas AR 9 ...

Page 3571: ...d coat over the entire area 4 Do not coat parts which become hot such as the tailpipe or moving parts such as the propeller shaft 5 Besides the locations described below apply undercoating to all weld points under the body to insure corrosion preven tion 6 Be sure to seal the edge of the flange of the member and bracket with undercoating 7 If undercoat is damaged by peeling cracks etc be sure to r...

Page 3572: ...Areas AR 11 BODY PANEL ANTI RUST AGENT WAX APPLICATION AREAS HINT 1 Whenever adjusting the doors and hoods apply anti rust agent wax around the hinges 2 Even if partially repairing a part apply anti rust agent wax over the entire application area of the part 3 Wipe off the anti rust agent immediately with a rag soaked in a grease wax and silicone remover if accidently applied to other areas ALL ...

Page 3573: ...pplication Areas AR 12 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 remov er ...

Page 3574: ...BODY PANEL REPLACEMENT F16919 F16919A REMOVAL BP 1 RADIATOR UPPER SUPPORT ASSY REPLACEMENT ...

Page 3575: ...on diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the inside of the necked section structural weld spots ...

Page 3576: ...BODY PANEL REPLACEMENT F16927 435 mm 17 13 in 1 250 mm 49 21 in POINT 1 Measure the dimensions before installing headlights 2 These values are reference values BP 3 ...

Page 3577: ...BODY PANEL REPLACEMENT F16921 F16921 REMOVAL BP 4 RADIATOR SIDE SUPPORT ASSY REPLACEMENT With the radiator upper support removed ...

Page 3578: ... measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top...

Page 3579: ...BODY PANEL REPLACEMENT F16923 F16923A REMOVAL BP 6 FRONT CROSSMEMBER ASSY REPLACEMENT ...

Page 3580: ...on diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the inside of the necked section structural weld spots ...

Page 3581: ...BODY PANEL REPLACEMENT F16925 F16925A REMOVAL BP 8 RADIATOR SUPPORT ASSY REPLACEMENT ...

Page 3582: ...ordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the i...

Page 3583: ...BODY PANEL REPLACEMENT F16930 F16930A REMOVAL BP 10 FRONT FENDER APRON ASSY REPLACEMENT With the radiator side support and cowl top side panel removed ...

Page 3584: ...ordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the i...

Page 3585: ...BODY PANEL REPLACEMENT F16928 F16928A REMOVAL BP 12 COWL TOP SIDE PANEL ASSY REPLACEMENT ...

Page 3586: ...on diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the inside of the necked section structural weld spots ...

Page 3587: ...BODY PANEL REPLACEMENT F16932 50 mm 1 97 in 100 mm 3 94 in F16932A REMOVAL 60 mm 2 36 in BP 14 FRONT BODY PILLAR CUT REPLACEMENT With the cowl top side panel removed ...

Page 3588: ...BODY PANEL REPLACEMENT F16933 200 mm 7 87 in POINT 1 A is reuse PART NAME A Side Panel No 1 Retainer BP 15 ...

Page 3589: ...de No 5 Bracket I Front Pillar To Cowl Side Panel No 2 Bracket BP 16 INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the ...

Page 3590: ...BODY PANEL REPLACEMENT F16935 POINT 1 Inspect the fitting of the front door windshield glass and front fender etc before welding since this affects the appearance of the finish BP 17 ...

Page 3591: ...BODY PANEL REPLACEMENT F16936 PART NAME J Antenna Pole Mounting Bracket RH Onry K Roof Drip Channel BP 18 ...

Page 3592: ...BODY PANEL REPLACEMENT F16937 20 mm 0 79 in 30 mm 1 18 in 50 mm 1 97 in F16937A REMOVAL BP 19 CENTER BODY PILLAR CUT REPLACEMENT ...

Page 3593: ...the new parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After...

Page 3594: ...939 15 mm 0 59 in POINT 1 Inspect the fitting of the front door and rear door etc before welding since this affects the appearace of the finish 2 After welding the reinforcement to the vehicle side install the outer panel BP 21 ...

Page 3595: ...BODY PANEL REPLACEMENT F16948 POINT 1 After grinding off the hemming location remove the outer panel F16948A REMOVAL BP 22 FRONT DOOR OUTER PANEL CUT REPLACEMENT ...

Page 3596: ...l HINT 1 Perform hemming in three steps being careful not to warp the panel 2 If a hemming tool cannot be used hem with a hammer and dolly BP 23 INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects th...

Page 3597: ...BODY PANEL REPLACEMENT F16950 POINT 1 After grinding off the hemming location remove the outer panel F16950A REMOVAL BP 24 REAR DOOR OUTER PANEL CUT REPLACEMENT ...

Page 3598: ...l HINT 1 Perform hemming in three steps being careful not to warp the panel 2 If a hemming tool cannot be used hem with a hammer and dolly BP 25 INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects th...

Page 3599: ...BODY PANEL REPLACEMENT F16940 20 mm 0 79 in F16940A REMOVAL BP 26 ROCKER PANEL CUT H REPLACEMENT ...

Page 3600: ...ance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the insi...

Page 3601: ...BODY PANEL REPLACEMENT F16942 50 mm 1 97 in F16942A REMOVAL BP 28 ROCKER PANEL CUT REPLACEMENT ...

Page 3602: ... accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to t...

Page 3603: ...BODY PANEL REPLACEMENT F16952 200 mm 7 87 in F16952A REMOVAL BP 30 QUARTER PANEL CUT REPLACEMENT ...

Page 3604: ...s in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent ...

Page 3605: ...e the A to the vehicle side 2 Take care not to damage the internal reinforcement PART NAME A Quarter Lock Pillar Upper Reinforcement 75 mm 2 95 in F16954A REMOVAL BP 32 QUARTER PANEL REINFORCEMENT CUT REPLACEMENT With the quarter panel removed ...

Page 3606: ...imension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the inside of the necked sec...

Page 3607: ...BODY PANEL REPLACEMENT F16956 F16956A REMOVAL BP 34 BACK PANEL ASSY REPLACEMENT ...

Page 3608: ...ordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applying the top coat layer apply anti rust agent to the i...

Page 3609: ...BODY PANEL REPLACEMENT F16958 F16958A REMOVAL BP 36 ROOF PANEL ASSY w o sun roof REPLACEMENT ...

Page 3610: ...parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sealer and under coating to the corresponding parts After applyin...

Page 3611: ...BODY PANEL REPLACEMENT F16960 POINT 1 If reusing the roof panel reinforcement trim the hemming location using a disc sander etc F16960A REMOVAL BP 38 ROOF PANEL ASSY w sun roof REPLACEMENT ...

Page 3612: ...warp the panel BP 39 INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram See the body dimension diagram Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding apply the polyurethane foam to the corresponding parts After welding apply body sea...

Page 3613: ...F16903 4 9 mm 0 193 in 5 4 mm 0 213 in 5 5 mm 0 217 in 5 6 mm 0 220 in 5 7 mm 0 224 in 6 1 mm 0 240 in 7 7 mm 0 303 in 9 5 mm 0 374 in BODY PANEL REPLACEMENT BP 43 FIT STANDARDS ...

Page 3614: ...F16901 7 5 N m 76 5 kgf cm 66 in lbf 13 0 N m 132 6 kgf cm 10 ft lbf BODY PANEL REPLACEMENT BP 40 OUTER PANEL INSTALLATION TORQUE ...

Page 3615: ...BODY PANEL REPLACEMENT F16902 23 0 N m 234 6 kgf cm 17 ft lbf BP 41 ...

Page 3616: ...F16918 47 0 N m 479 4 kgf cm 35 ft lbf 61 0 N m 622 2 kgf cm 45 ft lbf 86 0 N m 877 2 kgf cm 63 ft lbf BODY PANEL REPLACEMENT BP 42 ...

Page 3617: ... off any excess and coat with anti corrosion primer before applying body sealer 3 Wipe off excess body sealer with a rag soaked in a grease wax and silicone remover 4 If body sealer is damaged by peeling cracks etc be sure to repair as necessary F16904 1 ENGINE COMPARTMENT Flat Finishing No Flat Finishing PAINT COATING PC 1 BODY PANEL SEALING AREAS ...

Page 3618: ...PAINT COATING F16905 2 INSIDE PC 2 ...

Page 3619: ...F16906 3 OUTSIDE PAINT COATING PC 3 ...

Page 3620: ...F15043 PAINT COATING PC 4 ...

Page 3621: ...PAINT COATING F16908 4 DOOR PARTS PC 5 ...

Page 3622: ...F16909 PAINT COATING PC 6 ...

Page 3623: ...e hot such as the tailpipe or moving parts such as the propeller shaft 5 Besides the locations described below apply undercoating to all weld points under the body to insure corro sion prevention 6 Be sure to seal the edge of the flange of the member and bracket with undercoating 7 If undercoat is damaged by peeling cracks etc be sure to repair as necessary 8 Before the undercoat apply sealer allo...

Page 3624: ...these sections or their peripheries refill with foamed materials HINT 1 Use the service holes located on the reverse side of the body panel to refill with foamed materials 2 When handling foamed material follow the directions of the material s manufacturer F16911 PAINT COATING PC 8 FOAMED MATERIAL APPLICATION AREAS ...

Page 3625: ...F16912 PAINT COATING PC 9 ...

Page 3626: ...tially repairing a part apply anti rust agent wax over the entire application area of the part 3 Wipe off the anti rust agent immediately with a rag soaked in a grease wax and silicone remover if accidently applied to other areas F16913 PAINT COATING PC 10 BODY PANEL ANTI RUST AGENT WAX APPLICATION AREAS ...

Page 3627: ...F16914 PAINT COATING PC 11 ...

Page 3628: ...F16915 1 5 mm 0 059 in 3 0 mm 0 118 in 3 7 mm 0 146 in Thickness of Silencer Sheet PAINT COATING PC 12 SILENCER SHEET INSTALLATION AREAS ...

Page 3629: ...hers 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 Rocker PVC One Component Urethane Soft Chiping Primer 1 W Side Step 2 W O Side Step PAINT COATING PC 13 BODY PANEL ANTI CHIPPING PAINT APPLICATION AREAS ...

Page 3630: ...F16917 Anti Chip Film 1 W Over Fender 2 W O Over Fender PAINT COATING PC 14 ...

Page 3631: ... There are two types of dimensions in the diagram 1 Three dimensional distance Straight line distance between the centers of two measuring points 2 Two dimensional distance Horizontal distance in forward rearward between the centers of two measuring points The height from an imaginary standard line b In cases in which only one dimension is given left and right are symmetrical c The dimensions in t...

Page 3632: ... tape measure should be used b Use only a tracking gauge that has no looseness in the body measuring plate or pointers HINT 1 The height of the left and right pointers must be equal 2 Always calibrate the tracking gauge before measuring or after adjusting the pointer height 3 Take care not to drop the tracking gauge or otherwise shock it 4 Confirm that the pointers are securely in the holes c When...

Page 3633: ...a reference 2 MEASURING a Basically all measurements are to be done with a tracking gauge For portions where it is not possible to use a tracking gauge a tape measure should be used b Use only a tracking gauge that has no looseness in the body measuring plate or pointers HINT 1 The height of the left and right pointers must be equal 2 Always calibrate the tracking gauge before measuring or after a...

Page 3634: ...0 31 nut F f F f G g H h I Front fender apron working hole Front fender apron standard hole Radiator installation hole Radiator installation hole Hood lock support installation nut 10 0 39 10 0 39 10 0 39 6 0 24 nut Three Dimensional Distance RH 13 x 10 0 51 x 0 39 LH 10 0 39 1 153 6 02 A C c B D E G g I h f a F H b d 1 533 60 35 821 32 32 1 721 67 76 1 058 41 65 835 32 87 771 30 35 837 32 95 763 ...

Page 3635: ...or support working hole Hood lock support installation nut 10 0 39 10 0 39 6 0 24 nut C E or c e 153 6 02 Vehicle Dimensions 1 533 60 35 821 32 32 1 721 67 76 771 30 35 1 520 59 84 837 32 95 1 059 41 69 1 035 40 75 1 026 40 39 1 492 58 74 553 21 77 434 17 09 763 30 04 804 31 65 776 30 55 529 20 83 404 15 91 HINT For symbols capital letters indicate right side of vehicle small letters indicate left...

Page 3636: ...y mark Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark Three Dimensional Distance E e F f G g H h I i J j K k 1 408 1 604 1 606 1 606 1 270 1 381 1 600 55 43 63 15 63 23 63 23 50 00 54 37 62 99 E f E h E j F j F k G h H i J k or or or or or or or or e F e H e J f J f K g H h I j K 1 768 1 857 1 558 2 030 1 900 1 750 1 826 1 692 69 61 73 11 61 34 79 92 74 80 68 ...

Page 3637: ...k Rear door hinge installation nut Rear door hinge installation nut 8 0 31 nut 8 0 31 nut E e F f G g H h I i J j K k 1 441 1 603 1 606 1 606 1 309 1 494 1 604 56 73 63 11 63 23 63 23 51 54 58 82 63 15 Vehicle Dimensions Left Right E f E h E j F j F k H i J k or or or or or or or e F e H e J f J f K h I j K 1 795 1 859 1 629 2 051 1 843 1 876 1 710 70 67 73 19 64 13 80 75 72 56 73 86 67 32 1 286 5...

Page 3638: ...r panel assembly mark Quarter panel assembly mark Rear door hinge installation nut front Rear door hinge installation nut front 8 0 31 nut 8 0 31 nut Tree Dimensional Distance E e F f G g H h I i J j K k L l 1 408 1 604 1 606 1 606 1 606 1 271 1 376 1 601 55 43 63 15 63 23 63 23 63 23 50 04 54 17 63 03 E f E h E k F k F l G i H j K l or or or or or or or or e F e H e K f K f L g I h J k L 1 768 1 ...

Page 3639: ... 63 94 Vehicle Dimensions Left Right G p I q N r N s O s P q R s or or or or or or or g P i Q n R n S o S p Q r S 2 111 1 410 1 721 1 861 1 776 1 890 1 691 83 11 55 51 67 76 73 27 69 92 74 41 66 57 Rear floor side member plate Rocker panel adjoining portion P p S s Rear floor side member plate Quarter panel adjoining portion 1 217 47 91 782 30 79 1 015 39 96 951 37 44 852 33 54 741 29 17 q HINT Fo...

Page 3640: ...nting installation nut Rear spring rear hanger hole inner Rear body mounting installation nut 12 0 47 nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut Three Dimensional Distance RH L H Front A B C E F G I H J K L D a b c e f g i h j k l d A a B b C c D d E e F f G g H h I i J j K k L l 1 040 40 94 1 666 65 59 1 171 46 10 1 351 53 19 1 841 72 48 1 221 48 07 213 8 39 700 27 56 770 30 31...

Page 3641: ...ar body mounting installation nut 12 0 47 nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut Two Dimensional Distance A a 342 13 46 B b 51 2 01 C c 522 20 55 D d 51 2 01 E e 206 8 11 F f 266 10 47 G g 448 17 64 H h 128 5 04 I i 448 17 64 J j 448 17 64 K k 260 10 24 L l 448 17 64 A C B D E F G H I J K L a c b d e f g h i j k l 2 248 88 50 520 20 47 574 22 60 385 15 16 385 15 16 978 38 50...

Page 3642: ... mounting installation nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut B d C e or C c or b D c E 799 1 150 1 430 31 46 45 28 56 30 Vehicle Dimensions Left Right 38 20 1 50 0 79 38 20 1 50 0 79 RH LH 1 040 40 94 1 667 65 63 770 30 31 213 8 39 770 30 31 702 27 64 1 172 46 14 1 351 53 19 2 000 78 74 2 420 95 28 1 372 54 02 1 143 45 00 1 083 42 64 1 894 74 57 1 035 40 75 1 858 73 15 1 46...

Page 3643: ...llation nut Rear spring rear hanger hole inner Rear body mounting installation nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut 38 20 1 50 0 79 38 20 1 50 0 79 Wheel base 3 569 140 51 RH LH Front 3 150 124 02 520 20 47 2 613 102 87 575 22 64 385 15 16 385 15 16 2 729 107 44 2 516 99 06 1 997 78 62 676 26 61 686 27 01 686 27 01 572 22 52 274 10 79 0 0 509 20 04 542 21 34 497 19 57 1 54...

Page 3644: ... Rear body mounting installation nut Rear spring rear hanger hole inner Rear body mounting installation nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut Tree Dimensional Distance RH L H Front A B C 213 8 39 1 040 40 94 1 666 65 59 D E F G H I J K a b c d e f g h i j k A a B b C c D d E e F f G g H h I i J j K k 770 30 31 770 30 31 700 27 56 1 171 46 10 1 351 53 19 2 245 88 39 1 772 69...

Page 3645: ...ner Rear body mounting installation nut 14 6 0 575 12 0 47 nut 12 0 47 nut 14 3 0 563 12 0 47 nut Two Dimensional Distance RH L H Front Imaginary Standard Line A B C D E F G H I J K a b c d e f g h i j k 520 20 47 2 386 93 94 2 923 115 08 1 770 69 69 0 193 7 60 1 462 57 56 1 983 78 07 2 289 90 12 2 501 98 46 0 428 16 85 1 698 66 85 Wheel Base 3 260 128 35 A a 342 13 46 B b 51 2 01 C c 522 20 55 D ...

Page 3646: ...nut 12 0 47 nut 12 7 0 47 0 28 20 15 0 79 0 59 12 7 0 47 0 28 12 7 0 47 0 28 12 7 0 47 0 28 RH LH 940 37 01 622 24 49 1 150 45 28 995 39 17 1 481 58 31 1 940 76 38 1 005 39 57 1 190 46 85 1 554 61 18 2 279 89 72 999 39 33 1 190 46 85 1 291 50 83 1 701 66 97 2 538 99 92 1 030 40 55 2 487 97 91 965 37 99 1 382 54 41 949 37 36 Front A a 345 13 58 B b 300 11 81 C c 287 11 30 D d 287 11 30 E e 470 18 5...

Page 3647: ...installation hole Rear body mounting installation nut 12 0 47 nut 12 7 0 47 0 28 20 15 0 79 0 59 12 7 0 47 0 28 12 7 0 47 0 28 12 7 0 47 0 28 Wheel base 3 569 140 51 RH LH Front 2 619 103 11 470 18 50 497 19 57 2 000 78 74 999 39 33 595 23 43 595 23 43 595 23 43 515 20 28 1 276 50 24 0 0 2 240 88 19 475 18 70 A a 345 13 58 B b 300 11 81 C c 287 11 30 D d 287 11 30 E e 470 18 50 F f 448 17 64 Imagi...

Page 3648: ... hole Rear body mounting installation nut 12 x 7 0 47 x 0 28 12 x 7 0 47 x 0 28 12 0 47 nut Three Dimensional Distance RH L H Front A a A B C D E F a b c d e f B b C c D d E e F f 940 37 01 1 150 45 28 622 24 49 995 39 17 1 481 58 31 1 940 76 38 1 005 39 57 2 292 90 24 1 190 46 85 1 546 60 87 1 039 40 91 2 265 89 17 1 100 43 31 1 420 55 91 2 155 84 84 1 029 40 51 1 382 54 41 949 37 36 965 37 99 94...

Page 3649: ...ear body mounting installation nut 12 x 7 0 47 x 0 28 12 x 7 0 47 x 0 28 12 0 47 nut Two Dimensional Distance RH L H Front Imaginary Standard Line Wheel Base 3 260 128 35 A a 345 13 58 470 18 50 1 620 63 78 0 1 966 77 40 1 001 39 41 0 1 038 40 87 2 930 115 35 B b 300 11 81 C c 287 11 30 D d 322 12 68 E e 470 18 50 F f 448 17 64 595 23 43 515 20 28 497 19 57 595 23 43 550 21 65 475 18 70 A B C D E ...

Page 3650: ...ut 11 0 43 12 0 47 nut 16 16 0 63 0 63 16 16 0 63 0 63 16 16 0 63 0 63 RH LH Front 874 34 41 580 22 83 1 072 42 20 929 36 57 985 38 78 1 436 56 54 1 861 73 27 1 175 46 26 792 31 18 1 408 55 43 2 050 80 71 1 155 45 47 743 29 25 1 375 54 13 1 928 75 91 1 159 45 63 1 628 64 09 1 296 51 02 1 777 69 96 1 197 47 13 1 045 41 14 798 31 42 1 291 50 83 986 38 82 A a 227 8 94 B b 229 9 02 C c 107 4 21 D d 10...

Page 3651: ...rame side rail working hole Towing hitch installation nut 11 0 43 8 0 31 nut 11 0 43 12 0 47 nut 16 16 0 63 0 63 16 16 0 63 0 63 16 16 0 63 0 63 Wheel base 3 569 140 51 RH LH Front 3 084 121 42 437 17 20 465 18 31 2 505 98 62 1 535 60 43 588 23 15 578 22 76 743 29 25 580 22 83 580 22 83 540 21 26 627 24 69 1 177 46 34 523 20 59 493 19 41 1 974 77 72 A a 227 8 94 B b 229 9 02 C c 107 4 21 D d 107 4...

Page 3652: ...hitch installation nut Towing hitch installation nut 8 0 31 nut 12 0 47 nut 12 0 47 nut Three Dimensional Distance RH L H Front A a B b C c D d e F f G g 874 34 41 1 861 73 27 580 22 83 1 072 42 20 929 36 57 1 436 56 54 985 38 78 1 175 46 26 2 050 80 71 1 408 55 43 1 155 45 47 2 176 85 67 1 552 61 10 2 323 91 46 1 437 56 57 1 698 66 85 1 024 40 31 1 071 42 17 986 38 82 370 14 57 979 38 54 1 077 42...

Page 3653: ...ch installation nut Towing hitch installation nut 8 0 31 nut 12 0 47 nut 12 0 47 nut Two Dimensional Distance RH L H Front Imaginary Standard Line A 437 17 20 2 341 92 17 A a 227 8 94 Wheel Base 3 260 128 35 0 1 761 69 33 B C D F G a b c d f g e 791 31 14 0 2 039 80 28 1 062 41 81 2 409 94 84 465 18 31 588 23 15 578 22 76 578 22 76 540 21 26 493 19 41 512 20 16 B b 230 9 06 C c 107 4 21 D d 107 4 ...

Page 3654: ... mm 10 0 mm 10 0 mm APPENDIX Fit Standards AP 2 FIT STANDARDS After doors and the engine hood are installed be sure to perform fit adjustment to prevent abnormal wind noise and ensure a good appearance mm in 5 0 5 2 5 3 5 5 6 1 10 0 0 197 0 205 0 209 0 217 0 240 0 394 ...

Page 3655: ... AP 3 Thickness of Asphalt Sheet 1 5 mm 0 059 in Thickness of Asphalt Sheet 1 5 mm 0 059 in 3 0 mm 0 118 in A T 1 5 mm 0 059 in M T 4 0 mm 0 157 in A T 1 5 mm 0 059 in M T 4 0 mm 0 157 in SILENCER SHEET INSTALLATION AREAS REGULAR CAB ACCESS CAB ...

Page 3656: ...PENDIX Silencer Sheet Installation Areas AP 3 Thickness of Asphalt Sheet 1 5 mm 0 059 in Thickness of Asphalt Sheet 1 5 mm 0 059 in 3 0 mm 0 118 in SILENCER SHEET INSTALLATION AREAS REGULAR CAB ACCESS CAB ...

Page 3657: ...04 01 040806 00 FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2005 TOYOTA TUNDRA Applicable models GSK30 Series UCK30 31 40 41 Series For service specifications and repair procedures of the above models other than those listed in this manual refer to the following manuals Manual Name Pub No 2005 TOYOTA TUNDRA Repair Manual 2005 TOYOTA ...

Page 3658: ...USE THIS MANUAL B 3 TROUBLESHOOTING C 12 ABBREVIATIONS D 17 GLOSSARY OF TERMS AND SYMBOLS E 18 RELAY LOCATIONS F 20 ELECTRICAL WIRING ROUTING G 52 SYSTEM CIRCUITS H 100 GROUND POINT I 534 POWER SOURCE Current Flow Chart J 546 CONNECTOR LIST K 562 PART NUMBER OF CONNECTORS L 578 OVERALL ELECTRICAL WIRING DIAGRAM M 584 ...

Page 3659: ...on is closely related to the system circuit INDEX Index of the system circuits H SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points Wiring connections and their positions are shown and classified by code according to the connection method Refer to the section How to use this manual The System Outline and Service Hints useful for troubleshooting...

Page 3660: ...ircuit see Power Source section and the ground points see Ground Point section See the System Outline to understand the circuit operation When the circuit operation is understood begin troubleshooting of the problem circuit to isolate the cause Use Relay Location and Electrical Wiring Routing sections to find each part junction block and wiring harness connectors wiring harness and wiring harness ...

Page 3661: ...S ECU S 6 Combination Meter C 7 BV1 1 W B Shielded BV1 1 I 5 G W IB 2 IB 1 IE1 14 BO 50 8 L 4 15A STOP 7 5A GAUGE From Power Source System See Page 66 Stop Light G R W B W B W B W B G B Y G R L R G R W R G W W B G W W G S D L L S D Stop Stop Rear Lights 2005 TOYOTA TUNDRA EWD611U 4 B HOW TO USE THIS MANUAL The system shown here is an EXAMPLE ONLY It is different to the actual circuit shown in the ...

Page 3662: ... 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 3C indicates that it is inside Junction Block No 3 Example H Indicates the wiring color Wire colors are indicated by an alphabetical code B Black W White BR Brown L Blue V Violet SB Sky Blue R Red G Green LG Light Green P Pink Y Yello...

Page 3663: ...the ignition SW is turned off S6 Stop Light SW 2 1 Closed with the brake pedal depressed L4 Light Failure Sensor 1 2 7 Ground Approx 12 volts with the stop light SW on 4 8 Ground Approx 12 volts with the ignition SW at ON position 11 Ground Always continuity Parts Location Code See Page Code See Page Code See Page C7 34 L4 36 R7 37 H17 36 R6 37 S6 35 Relay Blocks Code See Page Relay Blocks Relay B...

Page 3664: ...ge showing the position on the vehicle of J B and Wire Harness in the system circuit Example Connector 3C connects the Instrument Panel Wire and J B No 3 It is described on page 22 of this manual and is installed on the instrument panel left side S Indicates the reference page describing the wiring harness and wiring harness connector the female wiring harness is shown first followed by the male w...

Page 3665: ...7 10 A A A A A A Junction Connector J 1 W B W B W B W B BR W B W B W B W B W B W B I GROUND POINT FAN MAIN Relay FAN MAIN Relay A C Relay No 2 A C Relay No 3 Radiator Fan Motor Headlight Cleaner Relay Headlight LH Headlight RH Front Fog Light LH Brake Fluid Level SW Front Fog Light RH Front Turn Signal Light RH Front Clearance Light RH Front Turn Signal Light LH Front Clearance Light LH Door Lock ...

Page 3666: ...and Traction Control Cruise Control Electronically Controlled Transmission Multiplex Communication System STOP System DOME Headlight Interior Light 3 EA2 1 EA1 E 6 E 7 E 7 2 2 2 2 2 2 2 2 INJECTION Relay STARTER Relay B B B B O 1 1 2 2 3 4 3 4 W B W B B W B W E 7 E 7 B B W 1 25B FL MAIN 50A MAIN 7 5A AM2 15A HAZ RADIO 2 2 2 2 2 W W EB1 EB1 7 6 W R I 2 I 2 I 2 W W W W W 1 1 1 1 40A DOOR LOCK CB 7 5...

Page 3667: ...t terminal Junction Connector Short Terminal Same Color Junction connector in this manual 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 shor...

Page 3668: ...ator 90980 11009 Door Courtesy SW LH 90980 11097 A 8 ABS Actuator 90980 10941 Door Courtesy SW RH A 9 ABS Speed Sensor Front LH 90980 11002 Door Courtesy SW Front LH ABS Speed Sensor Front RH 90980 11856 Door Courtesy SW Front RH 90980 11156 Airbag Sensor Front LH Door Courtesy SW Rear LH Airbag Sensor Front RH Door Courtesy SW Rear RH A10 A11 A12 A13 Airbag Squib 90980 11194 Door Key Lock and Unl...

Page 3669: ...lead to the connector or component terminal This check can be done with a test light instead of a voltmeter 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 If the circuit has diodes reverse the two leads and check again When contacting the negative lead to th...

Page 3670: ... 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 m...

Page 3671: ...on the left 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 NOTICE Do not remove the terminal retainer from connector body A For Non...

Page 3672: ...nal Retainer Connector Body Black or White Gray Black or White Dark Gray Gray or White Black 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 ...

Page 3673: ...se 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 b Push the secondary locking device or terminal retainer in to the full lock position 5 CO...

Page 3674: ...ork CAN Controller Area Network DVD Digital Versatile Disc EC Electrochromic ECU Electronic Control Unit ESA Electronic Spark Advance ETCS i Electronic Throttle Control System intelligent EVAP Evaporative Emission FL Fusible Link Block IC Integrated Circuit INT Intermittent IPO Intelligent Power Outlet J B Junction Block LH Left Hand M T Manual Transmission O D Overdrive R B Relay Block RH Right H...

Page 3675: ... but blocks reverse flow only up to a specific voltage Above that potential it passes the excess voltage This acts as a simple voltage regulator LIGHT Current flow through a filament causes the filament to heat up and emit light PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light LED LIGHT EMITTING DIODE Upon current flow these diodes emit ...

Page 3676: ...ral positions which allows various circuits particularly the primary ignition circuit to become operational RESISTOR VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance Also called a potentiometer or rheostat SENSOR Thermistor A resistor which varies its resistance with temperature SWITCH WIPER PARK Automatically returns wipers to the stop position when the wiper switch...

Page 3677: ...2005 TOYOTA TUNDRA EWD611U 20 F RELAY LOCATIONS Engine Compartment Access Cab Standard Cab Instrument Panel Access Cab Standard Cab ...

Page 3678: ...2005 TOYOTA TUNDRA EWD611U 21 F Body Access Cab Standard Cab ...

Page 3679: ...2005 TOYOTA TUNDRA EWD611U 22 F RELAY LOCATIONS Seat Access Cab Captain Seat ...

Page 3680: ...2005 TOYOTA TUNDRA EWD611U 23 F 2 Engine Room R B Engine Compartment Left See Page 20 Access Cab Standard Cab ...

Page 3681: ...2005 TOYOTA TUNDRA EWD611U 24 F RELAY LOCATIONS Driver Side J B and Integration Relay Lower Finish Panel See Page 20 Access Cab Standard Cab w o Daytime Running Light ...

Page 3682: ...2005 TOYOTA TUNDRA EWD611U 25 F ...

Page 3683: ...2005 TOYOTA TUNDRA EWD611U 26 F RELAY LOCATIONS Driver Side J B and Integration Relay Inner Circuit Access Cab Standard Cab w o Daytime Running Light ...

Page 3684: ...2005 TOYOTA TUNDRA EWD611U 27 Memo ...

Page 3685: ...2005 TOYOTA TUNDRA EWD611U 28 F RELAY LOCATIONS Driver Side J B and Integration Relay Lower Finish Panel See Page 20 Access Cab Standard Cab w Daytime Running Light ...

Page 3686: ...2005 TOYOTA TUNDRA EWD611U 29 F ...

Page 3687: ...2005 TOYOTA TUNDRA EWD611U 30 F RELAY LOCATIONS Driver Side J B and Integration Relay Inner Circuit Access Cab Standard Cab w Daytime Running Light ...

Page 3688: ...2005 TOYOTA TUNDRA EWD611U 31 Memo ...

Page 3689: ...2005 TOYOTA TUNDRA EWD611U 32 F RELAY LOCATIONS Engine Compartment Double Cab Instrument Panel Double Cab ...

Page 3690: ...2005 TOYOTA TUNDRA EWD611U 33 F Body Double Cab Seat Double Cab Captain Seat ...

Page 3691: ...2005 TOYOTA TUNDRA EWD611U 34 F RELAY LOCATIONS Fusible Link Block Engine Compartment Left See Page 32 Inside Engine Room J B Double Cab ...

Page 3692: ...2005 TOYOTA TUNDRA EWD611U 35 F ...

Page 3693: ...2005 TOYOTA TUNDRA EWD611U 36 F RELAY LOCATIONS Fusible Link Block Engine Compartment Left See Page 32 Inside Engine Room J B Double Cab ...

Page 3694: ...2005 TOYOTA TUNDRA EWD611U 37 F ...

Page 3695: ...2005 TOYOTA TUNDRA EWD611U 38 F RELAY LOCATIONS 2 Engine Room R B No 2 Engine Compartment Left See Page 32 Double Cab ...

Page 3696: ...2005 TOYOTA TUNDRA EWD611U 39 F 3 Engine Room R B No 3 Engine Compartment Left See Page 32 Double Cab 5 Driver Side R B Under the Instrument Panel J B See Page 32 Double Cab ...

Page 3697: ...2005 TOYOTA TUNDRA EWD611U 40 F RELAY LOCATIONS Engine Room J B Engine Compartment Left See Page 32 Double Cab ...

Page 3698: ...2005 TOYOTA TUNDRA EWD611U 41 F ...

Page 3699: ...2005 TOYOTA TUNDRA EWD611U 42 F RELAY LOCATIONS Engine Room J B Inner Circuit Double Cab ...

Page 3700: ...2005 TOYOTA TUNDRA EWD611U 43 Memo ...

Page 3701: ...2005 TOYOTA TUNDRA EWD611U 44 F RELAY LOCATIONS Driver Side J B Lower Finish Panel See Page 32 Double Cab ...

Page 3702: ...2005 TOYOTA TUNDRA EWD611U 45 F ...

Page 3703: ...2005 TOYOTA TUNDRA EWD611U 46 F RELAY LOCATIONS Driver Side J B Inner Circuit Double Cab ...

Page 3704: ...2005 TOYOTA TUNDRA EWD611U 47 F ...

Page 3705: ...2005 TOYOTA TUNDRA EWD611U 48 F RELAY LOCATIONS Sub J B No 3 Upper the Accelerator Pedal See Page 32 Double Cab ...

Page 3706: ...2005 TOYOTA TUNDRA EWD611U 49 F Sub J B No 3 Inner Circuit Double Cab ...

Page 3707: ...2005 TOYOTA TUNDRA EWD611U 50 F RELAY LOCATIONS Sub J B No 4 Upper the Accelerator Pedal See Page 32 Double Cab ...

Page 3708: ...2005 TOYOTA TUNDRA EWD611U 51 F Sub J B No 4 Inner Circuit Double Cab ...

Page 3709: ...ke Fluid Level Warning SW C 1 Camshaft Position Sensor C 2 Crankshaft Position Sensor C19 Camshaft Timing Oil Control Valve LH C20 Camshaft Timing Oil Control Valve RH D 2 Daytime Running Light Resistor D 3 Detection SW Transfer 4WD Position D 4 Detection SW Transfer L4 Position E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp Sensor F 1 Front Fog Light LH F 2 Front Fog ...

Page 3710: ...ector No 8 J 1 Junction Connector J 2 Junction Connector J 18 Junction Connector J 63 Junction Connector K 1 Knock Sensor Bank 1 K 2 Knock Sensor Bank 2 M 1 Mass Air Flow Meter N 1 Noise Filter O 1 O D Direct Clutch Speed Sensor O 2 Oil Pressure SW P 1 Park Neutral Position SW S 1 Starter S 2 Starter S29 Skid Control ECU with Actuator S30 Skid Control ECU with Actuator T 3 Transfer Shift Actuator ...

Page 3711: ...Level Warning SW C 2 Crankshaft Position Sensor C19 Camshaft Timing Oil Control Vakve LH C20 Camshaft Timing Oil Control Vakve RH D 2 Daytime Running Light Resistor E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp Sensor F 1 Front Fog Light LH F 2 Front Fog Light RH F 3 Front Turn Signal Light and Parking Light LH F 4 Front Turn Signal Light and Parking Light RH F 5 Fuel...

Page 3712: ...on Connector J 18 Junction Connector J 63 Junction Connector K 1 Knock Sensor Bank 1 K 2 Knock Sensor Bank 2 M 1 Mass Air Flow Meter N 1 Noise Filter O 1 O D Direct Clutch Speed Sensor O 2 Oil Pressure SW P 1 Park Neutral Position SW P 2 Power Steering Oil Pressure SW S 1 Starter S 2 Starter S29 Skid Control ECU with Actuator S30 Skid Control ECU with Actuator T 10 TVIP Buzzer T 14 Throttle Contro...

Page 3713: ...llumination A20 Accelerator Pedal Position Sensor A22 ACC Cut Relay A36 Airbag Cut Off SW B 3 Back Up Light Relay B 4 Blower Motor B 5 Blower Resistor B 6 Blower SW and Defroster Mode SW C 4 Center Airbag Sensor Assembly C 5 Center Airbag Sensor Assembly C 6 Center Airbag Sensor Assembly C 7 Cigarette Lighter C 8 Cigarette Lighter Illumination C10 Clutch Start Cancel SW C11 Combination Meter C12 C...

Page 3714: ...27 Diode Step Light D28 Diode Door Lock D29 Diode TVIP D30 Diode Unlock Warning E 3 Engine Control Module E 4 Engine Control Module E 5 Engine Control Module E 6 Engine Control Module E 7 Engine Control Module F 20 4WD Control ECU F 21 4WD Control ECU G 3 Glove Box Light I 22 Ignition Key Cylinder Light I 23 Ignition SW I 24 Integration Control and Panel I 25 Integration Control and Panel ...

Page 3715: ...22 Junction Connector J 23 Junction Connector J 24 Junction Connector J 26 Junction Connector J 27 Junction Connector J 28 Junction Connector J 29 Junction Connector J 64 Junction Connector J 65 Junction Connector J 66 Junction Connector J 67 Junction Connector J 68 Junction Connector J 69 Junction Connector J 70 Junction Connector J 71 Junction Connector J 72 Junction Connector J 73 Junction Conn...

Page 3716: ...d Player with Display R26 Radio and Player with Display S 3 Step Light S 4 Stop Light SW S 8 Short Pin S 9 Short Connector TVIP S10 Security Indicator and Glass Breakage Sensor Microphone S19 Steering Sensor S31 Stop Light Relay T 5 Turn Signal Flasher T 9 Trailer Converter T 11 TVIP ECU T 12 TVIP ECU T 13 TVIP ECU T 16 Tire Pressure Monitor ECU T 17 Tire Pressure Warning Standardization SW U 1 Un...

Page 3717: ... Door Unlock Detection SW RH F 8 Front Door Speaker LH F 9 Front Door Speaker RH F 10 Fuel Pump and Sender H 10 Cargo Light High Mounted Stop Light I 26 Interior Light I 27 Inner Mirror L 1 License Plate Light LH L 2 License Plate Light RH L 4 Leak Detection Pump Assembly P 8 Personal Light P 9 Power Window Control SW Front RH P 10 Power Window Master SW P 11 Power Window Motor Front LH P 12 Power...

Page 3718: ...r Door Unlock Detection SW RH F 8 Front Door Speaker LH F 9 Front Door Speaker RH F 10 Fuel Pump Sender H 10 Cargo Light High Mounted Stop Light I 26 Interior Light I 27 Inner Mirror L 1 License Plate Light LH L 2 License Plate Light RH L 4 Leak Detection Pump Assembly P 8 Personal Light P 9 Power Window Control SW Front RH P 10 Power Window Master SW P 11 Power Window Motor Front LH P 12 Power Wi...

Page 3719: ...ccupant Classification Sensor Front LH O13 Occupant Classification Sensor Front RH O14 Occupant Classification Sensor RearLH O15 Occupant Classification Sensor RearRH P15 Power Seat Motor Driver s Seat Front Vertical Control P16 Power Seat Control SW Driver s Seat P17 Power Seat Motor Driver s Seat Rear Vertical Control P18 Power Seat Motor Driver s Seat Reclining Control P19 Power Seat Motor Driv...

Page 3720: ...YOTA TUNDRA EWD611U 63 G Position of Parts in Seat Standard Cab Bench Seat B 7 Buckle SW LH B15 Buckle SW RH Occupant Detection SW B16 Buckle SW LH O16 Occupant Detection Sensor S36 Seat Position Airbag Sensor ...

Page 3721: ...Sensor C19 Camshaft Timing Oil Control Valve LH C20 Camshaft Timing Oil Control Valve RH D 2 Daytime Running Light Resistor D 3 Detection SW Transfer 4WD Position D 4 Detection SW Transfer L4 Position E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp Sensor E 8 Engine Hood Courtesy SW F 1 Front Fog Light LH F 2 Front Fog Light RH F 3 Front Turn Signal Light and Parking Li...

Page 3722: ...ctor J 32 Junction Connector J 34 Junction Connector J 35 Junction Connector J 74 Junction Connector K 1 Knock Sensor Bank 1 K 2 Knock Sensor Bank 2 M 1 Mass Air Flow Meter N 1 Noise Filter O 1 O D Direct Clutch Speed Sensor O 2 Oil Pressure SW P 1 Park Neutral Position SW S 1 Starter S 2 Starter S29 Skid Control ECU with Actuator S30 Skid Control ECU with Actuator T 3 Transfer Shift Actuator T 14...

Page 3723: ...dal Position Sensor A22 ACC Cut Relay A29 ABS Deceleration Sensor B 4 Blower Motor B 5 Blower Resistor B 6 Blower SW and Defroster Mode SW B 8 Back Window Relay B 9 Body ECU B10 Body ECU B 11 Body ECU C 4 Center Airbag Sensor Assembly C 5 Center Airbag Sensor Assembly C 6 Center Airbag Sensor Assembly C 7 Cigarette Lighter C 8 Cigarette Lighter Illumination C11 Combination Meter C12 Combination Me...

Page 3724: ...D Player E 3 Engine Control Module E 4 Engine Control Module E 5 Engine Control Module E 6 Engine Control Module E 7 Engine Control Module F 20 4WD Control ECU F 21 4WD Control ECU G 3 Glove Box Light H11 Headphone Terminal LH H12 Headphone Terminal RH I 22 Ignition Key Cylinder Light I 23 Ignition SW I 24 Integration Control and Panel I 25 Integration Control and Panel ...

Page 3725: ... 45 Junction Connector J 46 Junction Connector J 47 Junction Connector J 48 Junction Connector J 49 Junction Connector J 50 Junction Connector J 51 Junction Connector J 52 Junction Connector J 53 Junction Connector J 54 Junction Connector J 55 Junction Connector J 56 Junction Connector J 57 Junction Connector J 58 Junction Connector J 59 Junction Connector J 64 Junction Connector J 75 Junction Con...

Page 3726: ...17 Rear Seat Entertainment ECU R18 Rear Seat Entertainment ECU R19 Rear Seat Entertainment ECU R27 Radio and Player with Display R28 Radio and Player with Display R29 Radio and Player with Display R30 Radio and Player with Display R31 Radio and Player with Display S 3 Step Light S 4 Stop Light SW S 11 Seat Heater SW Driver s Seat S12 Seat Heater SW Front Passenger s Seat S13 Short Connector S14 Sh...

Page 3727: ...Courtesy SW Rear LH D39 Door Courtesy SW Rear RH D40 Door Lock Motor Door Unlock Detection SW Rear LH D41 Door Lock Motor Door Unlock Detection SW Rear RH D42 Door Lock Motor Door Key Lock and Unlock SW Door Unlock Detection SW Front LH D43 Door Lock Motor Door Key Lock and Unlock SW Door Unlock Detection SW Front RH D44 Driver Door ECU F 8 Front Door Speaker LH F 9 Front Door Speaker RH F 10 Fuel...

Page 3728: ... RH R 6 Rear Door Speaker LH R 7 Rear Door Speaker RH R 8 Remote Control Mirror LH R 9 Remote Control Mirror RH R20 Rear Seat Audio Controller R21 Rear Seat Entertainment Display R22 Rear Window Defogger R23 Rear Window Defogger S23 Stereo Component Amplifier S24 Stereo Component Amplifier S32 Side Airbag Sensor Rear LH S33 Side Airbag Sensor Rear RH S34 Side Airbag Sensor LH S35 Side Airbag Senso...

Page 3729: ... Sensor Front RH O14 Occupant Classification Sensor RearLH O15 Occupant Classification Sensor RearRH P15 Power Seat Motor Driver s Seat Front Vertical Control P16 Power Seat Control SW Driver s Seat P17 Power Seat Motor Driver s Seat Rear Vertical Control P18 Power Seat Motor Driver s Seat Reclining Control P19 Power Seat Motor Driver s Seat Slide Control P20 Power Seat Motor Driver s Seat Lumbar ...

Page 3730: ...2005 TOYOTA TUNDRA EWD611U 73 Memo ...

Page 3731: ...2005 TOYOTA TUNDRA EWD611U 74 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Access Cab Standard Cab 2UZ FE Location of Splice Points ...

Page 3732: ... 4 3 2 1 4 5 6 EA2 EB2 EC1 EC3 ED1 Black Black Dark Gray Gray Gray Code Joining Wire Harness and Wire Harness Connector Location EA2 Cowl Wire and Engine Room Main Wire Right Fender EB2 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 EC3 Engine No 2 Wire and Engine Wire Near the Starter ED1 Engine No 2 Wire and Differential...

Page 3733: ...2005 TOYOTA TUNDRA EWD611U 76 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Access Cab Standard Cab 1GR FE Location of Splice Points ...

Page 3734: ... 4 7 3 6 2 5 8 2 5 8 3 6 1 4 7 1 2 3 4 5 6 1 2 3 4 5 6 EA2 EB2 EF2 Black Black Dark Gray Code Joining Wire Harness and Wire Harness Connector Location EA2 Cowl Wire and Engine Room Main Wire Right Fender EB2 Engine No 2 Wire and Engine Room Main Wire Under the Engine Room R B EF2 Engine Wire and Sensor Wire Over the Cylinder Head ...

Page 3735: ...2005 TOYOTA TUNDRA EWD611U 78 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Access Cab Standard Cab Location of Ground Points ...

Page 3736: ...8 9 10 5 4 3 2 1 10 9 8 7 6 2 1 7 6 5 4 3 11 10 9 8 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 1 2 3 4 5 6 IA1 IA8 IA9 IB3 IB4 IC2 Gray Yellow Gray ID2 Code Joining Wire Harness and Wire Harness Connector Location IA1 IA8 Engine Room Main Wire and Cowl Wire Left Kick Panel IA9 g IB3 Front Door LH Wire and Cowl Wire Left Kick Panel IB4 Front Door LH Wire and Cowl Wire Left Kick Panel IC2 Cowl Wire and Roo...

Page 3737: ...2005 TOYOTA TUNDRA EWD611U 80 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Access Cab Standard Cab Location of Splice Points ...

Page 3738: ...de of Instrument Panel IE4 Engine Wire and Cowl Wire Right Side of Instrument Panel IF3 Front Door RH Wire and Cowl Wire Right Kick Panel IF4 Front Door RH Wire and Cowl Wire Right Kick Panel IG1 Cowl Wire and Instrument Panel No 2 Wire Instrument Panel Brace RH IH1 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH IJ1 Cowl Wire and Cowl Wire Right Side of Instrument Panel ...

Page 3739: ...2005 TOYOTA TUNDRA EWD611U 82 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Access Cab Location of Splice Points ...

Page 3740: ...B5 BC1 Front Door RH Wire and Speaker Tweeter Wire RH Inside of Front Door RH BE2 Floor No 2 Wire and Cowl Wire Center of Left Rocker Panel BF2 Floor No 1 Wire and Cowl Wire Center of Right Rocker Panel BG2 Floor No 2 Wire and Rear Door No 2 Wire Under the Left Quarter Panel BH1 Floor No 1 Wire and Rear Door No 1 Wire Under the Right Quarter Panel BK1 Frame Wire and Frame No 3 Wire Near the Licens...

Page 3741: ...2005 TOYOTA TUNDRA EWD611U 84 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Standard Cab Location of Splice Points ...

Page 3742: ...A1 BB3 BB4 BC1 BB5 BK1 BK2 Gray Black Gray Black Code Joining Wire Harness and Wire Harness Connector Location BA1 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BB3 BB4 Frame Wire and Cowl Wire Under the Driver s Seat BB5 BC1 Front Door RH Wire and Speaker Tweeter Wire RH Inside of Front Door RH BK1 Frame Wire and Frame No 3 Wire Near the License Plate Light BK2 Frame Wire...

Page 3743: ...2005 TOYOTA TUNDRA EWD611U 86 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Access Cab Captain Seat ...

Page 3744: ...3 4 5 8 7 6 17 16 15 14 13 12 11 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 2 1 4 3 6 5 BI2 BN1 Code Joining Wire Harness and Wire Harness Connector Location BI2 Cowl Wire and Seat No 1 Wire Under the Driver s Seat BN1 Seat No 1 Wire and Cowl Wire Under the Passenger s Seat ...

Page 3745: ...2005 TOYOTA TUNDRA EWD611U 88 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Standard Cab Bench Seat ...

Page 3746: ... 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 2 1 4 3 6 5 1 2 3 4 1 2 3 4 BI2 BL1 BM1 Code Joining Wire Harness and Wire Harness Connector Location BI2 Cowl Wire and Seat No 1 Wire Under the Driver s Seat BL1 Seat No 1 Wire and Cowl Wire Under the Driver s Seat BM1 Cowl Wire and Seat No 1 Wire Under the Passenger s Seat ...

Page 3747: ...2005 TOYOTA TUNDRA EWD611U 90 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Double Cab Location of Splice Points ...

Page 3748: ...2 3 6 5 4 3 2 1 4 5 6 EB2 EC1 EC3 ED1 Black Dark Gray Gray Gray Code Joining Wire Harness and Wire Harness Connector Location EB2 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 EC3 Engine No 2 Wire and Engine Wire Near the Starter ED1 Engine No 2 Wire and Differential Wire Near the Transmission ...

Page 3749: ...2005 TOYOTA TUNDRA EWD611U 92 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Double Cab Location of Ground Points ...

Page 3750: ... Wire and Cowl Wire Left Kick Panel IA8 IB5 Front Door LH Wire and Cowl Wire Left Kick Panel IC2 Cowl Wire and Roof Wire Left Side of Instrument Panel IC3 Cowl Wire and Roof Wire Left Side of Instrument Panel ID2 Cigarette Lighter Wire and Cowl Wire Instrument Panel Brace LH IL2 Floor No 2 Wire and Cowl Wire Right Kick Panel IM1 IM3 Console Box Wire and Cowl Wire Rear Console IM4 IN1 Cowl Wire and...

Page 3751: ...2005 TOYOTA TUNDRA EWD611U 94 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Double Cab Location of Splice Points ...

Page 3752: ...wl Wire Right Side of Instrument Panel IF5 Front Door RH Wire and Cowl Wire Right Kick Panel IF6 Front Door RH Wire and Cowl Wire Right Kick Panel IJ1 IJ2 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH IJ3 g IK1 Floor Wire and Cowl Wire Right Kick Panel IK2 Floor Wire and Cowl Wire Right Kick Panel IL1 Floor No 2 Wire and Cowl Wire Instrument Panel Brace RH IL3 Floor No 2 Wire and Cowl Wir...

Page 3753: ...2005 TOYOTA TUNDRA EWD611U 96 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Location of Ground Points Double Cab Location of Splice Points ...

Page 3754: ...on BK1 Frame Wire and Frame No 3 Wire Near the License Plate Light BK2 Frame Wire and Frame No 3 Wire Near the License Plate Light BL1 Rear Door No 1 Wire LH and Floor No 2 Wire Left Side of Center Pillar BM1 Rear Door No 1 Wire RH and Floor Wire Right Side of Center Pillar BP1 BP2 Frame Wire and Floor No 2 Wire Under the Driver s Seat BP3 ...

Page 3755: ...2005 TOYOTA TUNDRA EWD611U 98 G ELECTRICAL WIRING ROUTING Location of Connector Joining Wire Harness and Wire Harness Double Cab ...

Page 3756: ...11 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 2 1 4 3 6 5 BO1 BQ2 BS1 Code Joining Wire Harness and Wire Harness Connector Location BO1 Floor Wire and Seat No 1 Wire Under the Front Passenger s Seat BQ2 Floor No 2 Wire and Seat No 2 Wire Under the Driver s Seat BS1 Seat No 1 Wire and Floor Wire Under the Front Passenger s Seat ...

Page 3757: ...4 Electronically Controlled Transmission and A T Indicator 2UZ FE 198 Engine Control 1GR FE 136 Engine Control 2UZ FE 120 Fog Light w Daytime Running Light 156 Fog Light w o Daytime Running Light 158 Headlight w Daytime Running Light 150 Headlight w o Daytime Running Light 154 Horn 282 Ignition 1GR FE 114 Ignition 2UZ FE 110 Illumination 166 Interior Light 170 Key Reminder 274 Light Auto Turn Off ...

Page 3758: ...Running Light 352 Fog Light w o Daytime Running Light 354 Garage Door Opener 476 Headlight w Daytime Running Light 346 Headlight w o Daytime Running Light 350 Horn 482 Ignition 326 Illumination 360 Interior Light 408 Key Reminder 404 Light Auto Turn Off System 400 Mirror Heater 492 Moon Roof 484 Multiplex Communication System BEAN 384 Multiplex Communication System BEAN Bus 380 Multiplex Communica...

Page 3759: ... C 2 2 2 PWR OUTLET Relay 2 HEATER Relay 5 1 3 2 2 5 1 3 2 4 2 2 5 1 3 2 2 2 2 2 2 W G L R W W R W G W L R B W G 3 G 3 R B W L B R W G W R R W Battery DIMMER Relay R B B L 1 C J 1 3 EFI Relay 4 4 3 2 5 4 1 2 10A ETCS 1 2 2 1 2 1 30A TOW TAIL 30A SUB BATT 30A TOW BRK 2 R B 3 1 2 1 2 7 5A ALT S 1 2 Short Pin 2 B 5A ECU B 2 1 10A DOME 2 1 20A RADIO 2 1 30A ABS3 1 2 30A ST3 1 2 Junction Connector IA9 ...

Page 3760: ... G L R W W R W G W L R B W G 3 G 3 W G B Y B R G B L R 10A A C I23 10A GAUGE 20A 4WD 20A WIP 5A IGN 10A H LP LH 30A POWER 7 5A OBD 5A CARGO LP 15A STOP 15A TAIL 10A HORN 10A HEAD RL 10A HEAD LL 4 w o Daytime Running Light 15A PWR OUTLET 2 1 3 G B 5A STA M T M T 1I 3 G B M T B W A T A T B W A T B W M T L R A T 1 3 2 4 L O L R A T L R M T A22 1 Towing Package 2 Except Towing Package V W G A T A T AC...

Page 3761: ...57 J1 55 1GR FE Relay Blocks Code See Page Relay Blocks Relay Block Location 2 23 Engine Room R B Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1I 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1I 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1K 24 2 Engine Room Main Wire and Driver Side J B Lower F...

Page 3762: ...2005 TOYOTA TUNDRA EWD611U 105 Memo ...

Page 3763: ...W B W R B L I23 S 1 A S 2 B Ignition SW Junction Connector Starter B 1 2 I 3 B 27 A 10 B 17 A 34 B 34 A 17 B 25 A 8 B 29 A 12 I 3 B W IF Junction Connector J 3 A 2 1 8 3 G Y W B G R G R G B G B B W G Y B W G Y G R G R G R G R SRLY ST M T M T M T M T A T A T M T A T M T M T A T M T TVIP ECU T13 Junction Connector J26 A J27 B P B W W B P P M T A T A T M T Clutch Start SW C10 IA9 8 W R 1 2 B 4 ...

Page 3764: ... A 15 B W P L R P NSW STA STSW R L IE1 15 2 2UZ FE 1 1GR FE B E A A A A J28 A J29 B E 3 A E 5 C E 6 D Engine Control Module Junction Connector Park Neutral Position SW B W P A T A T M T R L A T A T C 11 STA B E A A B M T B M T Junction Connector J28 A J29 B A T A T A T ...

Page 3765: ...e Junction Block and Wire Harness Connector Location 1F 24 2 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1I 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1I 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location EB2 74 2UZ FE Engine No 2 Wire and Engine Room Main Wire Under the Engine Room R B EB2 76 1GR FE E...

Page 3766: ...2005 TOYOTA TUNDRA EWD611U 109 Memo ...

Page 3767: ... 4 2 IGT1 L Y L B W B B R LG B 1 3 I 4 4 2 IGT2 LG B L W W B B R L 1 3 I 5 4 2 IGT3 L L W W B E 5 I 3 E 5 E 5 E 5 EC W B W R B R B R L W W B L B W B W B I23 Battery 2 E 7 8 15 11 B R 1 W B 2 N 1 E 5 B R E 5 B R Engine Control Module Igniter and Ignition Coil No 1 Igniter and Ignition Coil No 2 Igniter and Ignition Coil No 3 Ignition SW Noise Filter IA9 8 B 2 ...

Page 3768: ... L B E 7 10 13 12 24 E 5 B R Engine Control Module Igniter and Ignition Coil No 4 Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 B R P 1 3 I 9 4 2 9 14 IGT7 P L B W B B R LG 1 3 I10 4 2 IGT8 LG L W W B E 5 E 5 W B L B Igniter and Ignition Coil No 7 Igniter and Ignition Coil No 8 E 5 E 5 W B B R B R I 3 I 3 I 3 25 IGF2 L W L W L W 1 Towing Package 2 Except Towing Package ...

Page 3769: ... J B Lower Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA9 78 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel Ground Points Code See Page Ground Points Location EC 74 2UZ FE Rear ...

Page 3770: ...2005 TOYOTA TUNDRA EWD611U 113 Memo ...

Page 3771: ... 2 IGT1 B L B Y W B B R L W 1 3 I 4 4 2 IGT2 L W B Y W B B R LG 1 3 I 5 4 2 IGT3 LG B Y W B E14 E14 E14 E14 EV W B W R B R B R W B B Y W B W B I23 Battery 2 E 7 8 9 10 B R 1 W B 2 N 1 E14 B R E14 B R Engine Control Module Igniter and Ignition Coil No 1 Igniter and Ignition Coil No 2 Igniter and Ignition Coil No 3 Ignition SW Noise Filter IA9 8 E15 E15 B Y ...

Page 3772: ...L B 1 3 I 7 4 2 IGT5 L B B Y W B B R R W 1 3 I 8 4 2 IGT6 R W B Y W B IGF1 E14 E14 E15 E14 E15 B Y B R B Y W B W B B Y B Y E 7 11 12 13 24 E14 B R Engine Control Module Igniter and Ignition Coil No 4 Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 E15 B Y ...

Page 3773: ...Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA9 78 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel Ground Points Code See Page Ground Points Location EV 76 1GR FE Rear Bank of Left Cylin...

Page 3774: ...2005 TOYOTA TUNDRA EWD611U 117 Memo ...

Page 3775: ...B W B Y W B W J 2 Y G B Y Y G Y G 2 1 Y G B Y W B B O B L 3 1 1 2 2 C12 7 5A ALT S 140A ALT 3 100A ALT 4 Battery L IG B IC Regulator S Y G 1 A A A J12 Y G 1 Integration Relay 3 Towing Package 4 Except Towing Package B 3 A 20 24 8 Charge J26 A J27 B G 1 A G 2 B From Power Source System See Page 102 Combination Meter Generator Junction Connector Junction Connector Junction Connector B 4 ...

Page 3776: ...ge Junction Block and Wire Harness Connector Location 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Ha...

Page 3777: ... L O G 2 7 6 8 AM2 AM1 ACC IG1 ST1 IG2 ST2 140A ALT 1 100A ALT 2 1 2 2 W 5A ECU B Short Pin 1 40A AM1 2 A 22 B 5 5A STA From Power Source System See Page 102 J26 A J27 B ACC Cut Relay Ignition SW Junction Connector Junction Connector 3 2 5 1 C C V W Junction Connector J12 2 2 2 2 20A A F HTR From Power Source System See Page 102 2 2 1 W L Y G W L ET A 26 B 9 IE1 12 W R W R W R W B Junction Connect...

Page 3778: ...B A A J 8 EA2 8 R G 1 Towing Package 2 Except Towing Package R A 11 B 28 J 1 W L B O W L A 7 B 24 A 4 B 21 5 4 J26 A J27 B J26 A J27 B J26 A J27 B Fuel Pump Resistor Fuel Pump Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector W L B R B R W R G R L R W R G R L 2 R G E11 A 19 B 2 W L J26 A J27 B Junction Connector B B W L BB3 9 R R L O ...

Page 3779: ... CG SG IE1 25 R P B 13 TC B R GR G B O 4 B R Y W L R L R 16 4 5 BAT Y BR W B EC BR J66 A J67 B From Power Source System See Page 102 B R R G GR G B O B R G P B Y W L G R R L Data Link Connector 3 W R W L W R Junction Connector R W L CANH E 1 D 2 D L R 14 CANL 6 W B L R Junction Connector J71 D J72 E E 1 2 B W ...

Page 3780: ... B R B R GR G J66 A B O 23 IE1 B O NSW IGSW BATT MREL FPR TC STSW Y R L P B FC B O B O B R B R B R R G B R R G GR G 23 A 12 C 10 A 8 D 3 A 8 A 30 C 9 A 4 1I 6 1K 7 1J 11 1F 5A IGN L R B R GR G B R HA2A D 1 W L 3 Shielded 3 W R W R Y W R G G HA1A 2 D L G P V W L W L A1A A1A A2A A2A B2 B I 4 3 I 3 1 A 30 D 22 D 31 D 23 D A10 4 3 1 2 2 1 3 4 A30 2 A B R B R B R B R B R L R L G R 10 30 50 70 3 E 6 C 4...

Page 3781: ...2B HT2B EW BR I 3 I 3 I 3 18 E 1 E 33 D 5 D H 4 3 1 4 2 H 6 3 1 4 2 B R L W L B L B B R L W E 5 E 5 I 3 I 3 L B IGT4 G R IGT3 L 10 E 11 E 3 2 1 I 6 3 2 1 I 5 B R B R B R B R B R B R B R IGT1 IGT2 80 60 3 3 2 1 2 1 L W B R L B B R B R B R B R B R L Y LG B R W Y R B W 8 E 15 E 2 E 7 C 5 C 3 C 20 40 E 5 E 5 5 IE1 I 4 I 3 E 5 I21 1 2 I19 1 2 I17 1 2 I15 1 2 B R Engine Control Module E 3 A E 4 B E 5 C ...

Page 3782: ...24 E 5 I 3 E 5 I 3 I 3 I 3 B R L W B R L B B R L B L W 29 B R C 19 C B R B R L B L W L B L B L W 3 B R L B L W E 5 B W R B R VSV EVAP R W G 34 2 E 2 1 V 4 Camshaft Position Sensor Engine Control Module Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 Igniter and Ignition Coil No 7 Igniter and Ignition Coil No 8 B O B O BR W R G B W BR R W L R G W 33 E 1 2 I 3 W L B W I 3 R R 3 3 3 3 3...

Page 3783: ...tion Control and Panel Junction Connector Mass Air Flow Meter Throttle Control Motor and Throttle Position Sensor G B G B I 3 23 E B W 21 17 I 3 10 B O B O C 15 C 14 C 17 C 16 1 2 1 2 W L W L R R E 3 A E 4 B E 5 C E 6 D E 7 E Engine Control Module P L W R G B L Y OC2 OC2 OC1 OC1 C19 C20 B W G B G C G B G B Camshaft Timing Oil Control Valve RH Camshaft Timing Oil Control Valve LH AIV1 R B L 27 E I ...

Page 3784: ...ssembly Engine Control Module Junction Connector Junction Connector G B B W B W R B W W L B O 1 EC3 E 32 EC3 6 I 3 EC3 5 A 22 5 A 6 A BB3 10 BB3 5 BB3 7 4 BB4 IE1 19 EC I 3 IE1 18 B O BB3 8 6 BB3 B W R G B W B W B W B R W L B L W L W L B R W W L G B G B W L G B G B MPMP VPMP PPMP AIP 1 2 3 B W G B G B A34 W L Air Pressure Sensor 2 1 E 26 G Y R AIV2 VSV Air Switching Valve Bank 2 V15 1 8 3 6 L 4 9 ...

Page 3785: ... 4 A 3 A 2 A 28 B 11 A 1 EB2 4 EB2 3 EX E13 14 IE1 B 1 L E03 ME01 W B W B EW 4 3 D D E01 E02 E1 E05 W B B BR W B EC 7 E 6 E 1 6 D C D 7 W B E04 2 1 AIRP AIRV AIDI W L W B W B P G B GR B P G B GR B W B L W L B R W W W R B B R B L 5 IJ1 B 30 8 B B 1 THWO B L L W G O V G 14 L W G O V G B TACH SPD W 10 IJ1 D D Junction Connector J 5 Junction Connector J26 A J27 B Air Switching Valve A31 Air Pump A35 J...

Page 3786: ...G O J66 A B O A 18 A 25 A 23 B 24 G O V G L W B 12 W B IH A B B D W B Combination Meter Junction Connector Junction Connector B L A 32 60A AIPR From Power Source System See Page 102 2 2 1 B L L V G L A H A H Malfanction Indicator Lamp TEMP CONTROL OIL PRESS CONTROL ...

Page 3787: ...cts the throttle valve opening angle as a control signal which is input into TERMINALS VTA1 VTA2 of the engine control module 6 Vehicle speed circuit The vehicle speed sensor detects the vehicle speed and input to the speed sensor of the skid control ECU with actuator from skid control ECU to TERMINAL SPD of the engine control module via combination meter 7 Battery signal circuit Voltage is consta...

Page 3788: ...d outputs current to TERMINALS HT1B and HT2B to control the heater Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low Temp of exhaust emission is low and warms up the air fuel ratio sensor to improve detection performance of the sensor The engine control module evaluates the signals from each sensor curr...

Page 3789: ... fully closed 4 7 5 1 volts with ignition SW on and throttle valve fully open VTA1 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 VPA E1 0 3 0 9 volts with ignition SW on and throttle valve fully closed 3 2 4 8 volts with ignition SW on and throttle valve fully open VPA2 E1 1 8 2 7 volts with ignition SW on and t...

Page 3790: ...57 I21 53 2UZ FE V4 53 2UZ FE E4 B 57 I23 57 V13 53 2UZ FE E5 C 57 I24 57 V14 53 2UZ FE E6 D 57 J1 53 2UZ FE V15 53 2UZ FE E7 E 57 J3 58 V16 53 2UZ FE F5 52 2UZ FE J5 58 V17 53 2UZ FE F10 60 3 J8 58 Relay Blocks Code See Page Relay Blocks Relay Block Location 2 23 Engine Room R B Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connect...

Page 3791: ...ire and Cowl Wire Under the Driver s Seat BB4 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB4 84 4 Ground Points Code See Page Ground Points Location EA 74 2UZ FE Front Left Fender EC 74 2UZ FE Rear Bank of Left Cylinder Head ET 74 2UZ FE Front Right Fender EW 74 2UZ FE Front Left Side of Cylinder Head EX 74 2UZ FE Left Side of Cylinder Block IF 78 Left Kick Panel IH 78 Right Kick Panel ...

Page 3792: ...2005 TOYOTA TUNDRA EWD611U 135 Memo ...

Page 3793: ... B L O G 2 7 6 8 AM2 AM1 ACC IG1 ST1 IG2 ST2 100A ALT 1 2 2 W 5A ECU B Short Pin 1 40A AM1 2 A 22 B 5 5A STA From Power Source System See Page 102 J26 A J27 B ACC Cut Relay Ignition SW Junction Connector Junction Connector 3 2 5 1 C C V W Junction Connector J12 2 2 2 2 20A A F HTR From Power Source System See Page 102 2 2 1 W L Y G W L ET A 26 B 9 IE1 12 W R W R W R W B Junction Connector J26 A J2...

Page 3794: ...0 L O W R B W R G A A J 8 EA2 8 R G R A 11 B 28 J 1 W L B O W L A 7 B 24 A 4 B 21 5 4 J26 A J27 B J26 A J27 B J26 A J27 B Fuel Pump Resistor Fuel Pump Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector W L B R B R W R G R L A T R W R G R L 2 R G E11 A 19 B 2 W L J26 A J27 B Junction Connector B B W L BB3 9 R R L O L O A W B R W L W L G...

Page 3795: ... CG SG IE1 25 R P B 13 TC B R GR G B O 4 B R Y W L R L A T R 16 4 5 BAT Y BR W B EC BR J66 A J67 B From Power Source System See Page 102 B R R G GR G B O B R G P B Y W L G R R L A T Data Link Connector 3 W R W R Junction Connector R CANH E 1 D 2 D L R 14 CANL 6 W B L R Junction Connector J71 D J72 E E 1 2 B W ...

Page 3796: ...R GR G J66 A B O 23 IE1 B O IGSW BATT MREL FPR TC STSW Y R L P B FC B O B O B R B R B R R G B R R G GR G 23 A 12 C 10 A 3 A 8 A 30 C 9 A 4 1I 6 1K 7 1J 11 1F 5A IGN B R GR G B R HA2A D 1 W L 1 Shielded 1 W R W R G W R Y Y HA1A 2 D P V L G W L W L A1A A1A A2A A2A B2 B I 4 1 I 3 1 A 30 D 22 D 31 D 23 D A10 4 3 1 2 2 1 3 4 A30 2 A B R B R B R B R L G R 10 30 50 6 C 4 C 2 C I 3 I18 2 1 I16 2 1 I14 2 1...

Page 3797: ...W B W R OX1B HT1B OX2B HT2B EV BR I 3 I 3 I 3 18 E 1 E 33 D 5 D H 4 3 1 4 2 H 6 3 1 4 2 B R B Y B Y B R B Y E14 E14 E15 IGT4 V IGT3 LG 11 E 10 E 3 2 1 I 6 3 2 1 I 5 B R B R B R B R B R B R B R IGT1 IGT2 60 3 3 2 1 2 1 B Y B R B Y B R B R B R B R B L L W Y R B W 8 E 9 E 7 C 5 C 3 C 20 40 E14 E14 13 IE1 I 4 I 3 I 3 I19 2 1 I17 2 1 I15 2 1 B R Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E E E R...

Page 3798: ... G R G W B BR R R B 33 E 1 2 I 3 B W I 3 R R 1 1 1 1 E15 EF2 1 EF2 2 EF2 5 EF2 4 EF2 6 I 3 BR 6 B 1 A VCP2 A20 A B VPA2 VPA EPA VCPA VCP2 EPA2 VPA2 EPA VCPA VPA Accelerator Pedal Position Sensor EPA2 M T 3 B 18 A 19 A G R LG R R G L V R P G 21 A 27 A 26 A 20 A 2 B 3 A A T 2 A 5 B 6 A 1 B 5 A 4 B 4 A R B 32 B F PS IJ1 1 R B 22 C 5 GSW2 Center Airbag Sensor Assembly Knock Sensor Bank 1 K 1 Knock Sen...

Page 3799: ... Position Sensor G B G B R I 3 23 E B W 21 17 I 3 10 B O B O 3 C 15 C 14 C 17 C 16 I 3 1 2 1 2 R R W BB3 8 E 3 A E 4 B E 5 C E 6 D E 7 E Engine Control Module L R V W R G B OC2 OC2 OC1 OC1 C20 C19 W R G Y G B G B G B G B IE1 10 Camshaft Timing Oil Control Valve LH Camshaft Timing Oil Control Valve RH VV1 19 C VV1 29 C VVT Sensor RH V17 3 1 2 G B L Y VV2 VV2 C 18 28 C V16 VVT Sensor LH 1 2 L G C C ...

Page 3800: ...nction Connector R B W B O A 22 5 A 6 A BB3 10 BB3 5 BB3 7 4 BB4 IE1 19 B O 6 BB3 B W W B W B W B R W L B L W L W L B R W MPMP VPMP PPMP 2 B W E01 W B 7 E C D 6 1 E 6 D 7 EU W B BR B W B E05 E1 E02 E04 E03 ME01 W B W B EV 4 3 D D B L 5 IJ1 B 30 8 B B 1 THWO B L L W G O V G 14 L W G O V G B TACH SPD W 10 IJ1 D D Junction Connector J 5 1 8 3 6 9 4 Canister Closed Valve Pressure Sensor M R G B G B IE...

Page 3801: ...ccess Standard Cab B O J66 A J67 B C11 A C12 B L W G O J66 A B O A 18 A 25 A 23 B 24 G O V G L W B 12 W B IH A B B D W B Combination Meter Junction Connector Junction Connector B L A 32 B L V G A H A H Malfanction Indicator Lamp TEMP CONTROL OIL PRESS CONTROL ...

Page 3802: ...opening angle as a control signal which is input into TERMINALS VTA1 VTA2 of the engine control module 6 Vehicle speed circuit The vehicle speed sensor detects the vehicle speed and input to the speed sensor of the skid control ECU with actuator from skid control ECU to TERMINAL SPD of the engine control module via combination meter 7 Battery signal circuit Voltage is constantly applied to TERMINA...

Page 3803: ...each sensors and outputs current to TERMINALS HT1B and HT2B to control the heater Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low Temp of exhaust emission is low and warms up the air fuel ratio sensor to improve detection performance of the sensor The engine control module evaluates the signals from e...

Page 3804: ...open THA E1 0 5 3 4 volts with idling intake air temp 0 C 32 F 80 C 176 F THW E1 0 2 1 0 volts with idling engine coolant temp 60 C 140 F 120 C 248 F STA E1 6 0 volts or more with engine cranking W E1 9 0 14 0 volts with idling and malfunction indicator lamp off SPD E1 Pulse generation with vehicle moving STP E1 7 5 14 0 volts with brake pedal depressed Parts Location Code See Page Code See Page C...

Page 3805: ...r Head IA9 78 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH BB3 82 3 BB3 84 4 Frame Wire and Cowl Wire Under the Driver s Seat BB4 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB4 84 4 Ground Points Code See Page Ground Points Location EA 76 1GR FE Front L...

Page 3806: ...2005 TOYOTA TUNDRA EWD611U 149 Memo ...

Page 3807: ...G Y R R B R B P R Y B H LP Relay DIMMER Relay 10A HEAD LL 10A H LP LH 10A HEAD RL 10A H LP RH W G W G W G W G W G A C R B J 2 D 2 W B H 2 H 1 Battery J18 W G G B L 2 W B W B W B DRL NO 4 Relay 2 1 B B 13 J 5 G Y A 2 3 R B 1K 4 A V V Daytime Running Light Resistor Headlight LH Headlight RH Junction Connector Junction Connector Junction Connector V W B IJ 3 J 3 Junction Connector J 2 Junction Connec...

Page 3808: ...4 1O 3 1N 3 1N 8 1N 7 1N 13 G R LG Y B G Y R P 8 A 14 B 31 B 3 A 20 D D J 4 D R W 1 A T J26 A J27 B From Power Source System See Page 102 High Beam C12 J66 A J67 B J26 A J27 B Brake Fluid Level Warning SW Combination Meter Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector G 2 Generator R W 1 R W 1 M T BR A F B H J66 A J67 B Junction C...

Page 3809: ...P5 58 G2 54 1GR FE J5 58 H1 52 2UZ FE J12 58 Relay Blocks Code See Page Relay Blocks Relay Block Location 2 23 Engine Room R B Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1B 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1C 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wir...

Page 3810: ...2005 TOYOTA TUNDRA EWD611U 153 Ground Points Code See Page Ground Points Location EA 74 2UZ FE Front Left Fender EA 76 1GR FE Front Left Fender IF 78 Left Kick Panel IH 78 Right Kick Panel ...

Page 3811: ...R G R Y R Y R Y R G LG Battery R Y R G R G R Y R W R L R B R B LG B L H 2 H 1 J 2 1 1 2 2 2 H LP Relay Integration Relay 1L 6 1L 5 A B B D IH W B B B A 14 B 31 J26 A J27 B C12 J23 A J24 B Combination Meter Combination SW Headlight LH Headlight RH Junction Connector Junction Connector Junction Connector Junction Connector G Y Junction Connector J 5 EL H T HF HU HL 17 12 1J 4 17 B B A C Junction Con...

Page 3812: ...Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1K 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1L 25 2 Cowl Wire and Driver Side J B Lower Finish Panel Ground Points Code See Page Ground Points Location IF 78 Left ...

Page 3813: ... LG R B Battery 13 G R BR W W B P C15 FOG Relay LG J18 5 4 2 3 DIMMER Relay H LP Relay BR W Integration Relay G Y G Y 2 1 R B B L 1 B L 1 B 15 A 32 J26 A J27 B From Power Source System See Page 102 Combination SW Front Fog Light LH Front Fog Light RH Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector J 5 OFF ON Fog Light SW 10 11 H EL T LFG BFG A C B L 1...

Page 3814: ... and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1K 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1N 29 1 Cowl Wire and Driver Side J B Lower Finish Panel 1O 29 1 Cowl Wire and Driver Side J B Lower Finish Panel Ground Points Code See Page Ground Points Location EA 74 2UZ FE Fro...

Page 3815: ... 2 1 1 GR L R Y 10 A IF 16 R Y GR L R B 2 2 H LP Relay Integration Relay F 1 F 2 W B 1L 6 1L 5 B L B B J 5 J18 W B A 32 B 15 A 14 B 31 From Power Source System See Page 102 Combination SW Front Fog Light LH Front Fog Light RH Headlight LH Headlight RH Junction Connector Junction Connector Junction Connector OFF ON Fog Light SW 11 GR L R Y Junction Connector J 3 G Y A A EL H T HF HU HL LFG BFG Junc...

Page 3816: ...y Block Location 2 23 Engine Room R B Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1K 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1L 25 2 Cowl Wire and Driver Side J B Lower Finish Panel Ground Points Code See Page Ground Points Locati...

Page 3817: ...B5 9 R B R B From Power Source System See Page 102 B 1 B P 1 A J 3 Back Up Light SW Diode A T Junction Connector Junction Connector Park Neutral Position SW Rear Combination Light LH Rear Combination Light RH Back Up Back Up Back Up A 1 BB4 6 W B B D A B J 8 Junction Connector Junction Connector J28 A J29 B B F B F A H R B A T L B B Y 2UZ FE A T M T Junction Connector J28 A J29 B B F BACK UP LIGHT...

Page 3818: ...Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IH1 80 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH BB4 82 3 BB4 84 4 Frame Wire and Cowl Wire Under the Driver s Seat BB5 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB5 84 4 Ground Points Code See Page Ground Points L...

Page 3819: ...6 W B 140A ALT 1 100A ALT 2 1 Towing Package 2 Except Towing Package 3 w Daytime Running Light 4 w o Daytime Running Light 2 1L 1N 13 4 3 4 Light Control SW Combination SW Front Parking Light LH Front Parking Light RH Junction Connector Junction Connector Junction Connector Rear Combination Light LH Tail EL H T A C B A R B Junction Connector J21 A J22 B A W B G W B A A G J63 Junction Connector A A...

Page 3820: ...2005 TOYOTA TUNDRA EWD611U 163 3 2 2 1 2 1 R 5 L 2 B10 B10 B10 B10 W B W B W B W B G G G G G W B W B L 1 BL License Plate Light LH License Plate Light RH Rear Combination Light RH Tail ...

Page 3821: ... Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 1K 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1L 25 2 Cowl Wire and Driver Side J B Lower Finish Panel 1N 29 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining...

Page 3822: ...with Splice Points E11 74 2UZ FE Engine Room Main Wire B10 82 3 Frame Wire E11 76 1GR FE Engine Room Main Wire B10 84 4 Frame Wire 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Power Seat ...

Page 3823: ...A Battery R 3 W B W B W B W B W B T E L Integration Relay R B EW BR 2 1 2 140A ALT 1 100A ALT 2 B L 1 R B 1L 1N 13 4 3 4 IE1 3 Light Control SW Illumination C11 Combination Meter Junction Connector Junction Connector Rheostat I 1 EU BR 1GR FE 2UZ FE W B Junction Connector J 3 Combination SW C15 EL H T G E G BR 4 1 Steering Pad SW C16 Combination SW E A C B A Junction Connector J21 A J22 B A B 2 ...

Page 3824: ...Running Light 5 Separate Type Amplifier 6 Built in Type Amplifier IG1 10 IH1 10 D 12 5 7 C 12 5 8 G W W G W G W G 5 6 6 5 B 10 6 C 2 5 8 IH1 17 IG1 17 G G G G 5 5 6 6 I24 A I25 B R24 D Ashtray Illumination Cigarette Lighter Illumination Glove Box Light Integration Control and Panel Junction Connector Junction Connector Junction Connector Mirror Heater SW Radio and Player with Display G B 10 GND W ...

Page 3825: ...ish Panel 1L 25 2 Cowl Wire and Driver Side J B Lower Finish Panel 1N 29 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location ID2 78 Cigarette Lighter Wire and Cowl Wire Instrument Panel Brace LH IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IG1 80 Cowl Wire and In...

Page 3826: ...2005 TOYOTA TUNDRA EWD611U 169 Memo ...

Page 3827: ... L L L L Y W L L L D 9 D16 W L W L W L W L W L I22 2 2 2 L 1 C S 3 B 1 2 L Y D27 1 2 1F 4 A B B C A B A B L Y L Y L Y From Power Source System See Page 102 J23 A J24 B C11 A C12 B Combination Meter Diode Door Courtesy Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy SW Front LH Diode Step Light Ignition Key Cylinder Light Junction Connector Junction Connector Junction Connec...

Page 3828: ...2 2 2 2 2 1 2 2 2 W B D21 D20 D17 2 2 2 2 W B 2 Access Cab 1 Standard Cab 1 B 4 W B W B B W 2 C J 5 Door BE2 4 BG2 5 C B W 2 B W 2 B W 2 IC2 5 B 2 1 B B B J 4 J21 B W B B W B D29 Door Courtesy SW Front RH Door Courtesy SW Rear LH Lower Door Courtesy SW Rear LH Upper Door Courtesy SW Rear RH Lower Door Courtesy SW Rear RH Upper Diode TVIP Interior Light Junction Connector Junction Connector Junctio...

Page 3829: ...ver Side J B Lower Finish Panel 1B 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 1F 28 1 1H 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1H 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1J 24 2 1J 28 1 Connector Joining Wire Harn...

Page 3830: ... Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points B4 82 3 Roof Wire B8 82 3 Rear Door No 1 Wire LH B4 84 4 Roof Wire B9 82 3 Rear Door No 1 Wire RH 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Power Seat ...

Page 3831: ...B W B B1 I24 R 5 T 5 F 4 B IG ER EL EHW LL LR GND B10 BL W B 1 2 L W IE A A A J18 W B 1D 9 1D 6 Trailer Converter G B G Y 15A HAZ A 21 B 4 W B From Power Source System See Page 102 J26 A J27 B Turn Turn C11 A C12 B Combination SW Front Turn Signal Light LH Front Turn Signal Light RH Integration Control and Panel Junction Connector Junction Connector Rear Combination Light LH Rear Combination Light...

Page 3832: ...ire and Driver Side J B Lower Finish Panel 1H 24 2 1H 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location BB4 82 3 BB4 84 4 Frame Wire and Cowl Wire Under the Driver s Seat BB5 82 3 Frame Wire and Cowl Wire Under t...

Page 3833: ... 2 1 S 4 BL C C G W W B From Power Source System See Page 102 R 4 High Mounted Stop Light Junction Connector Rear Combination Light LH Rear Combination Light RH Stop Light SW Stop Stop J 3 Junction Connector BB5 8 B10 G W 3 2 4 5 1 5A ECU IG 1F 2 GR R 2 C G W G W 2 1 1 G Y G Y 1 1 E E GR R Junction Connector J 9 Stop Light Relay S31 Skid Control ECU with Actuator V 1 w VSC 2 w o VSC ...

Page 3834: ...ector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IC2 78 Cowl Wire and Roof Wire Left Side of Instrument Panel BB5 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB5 84 4 Frame Wire and Cowl Wire Under the Driver s Seat Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel BL 82 3 Surrounding of the Front of...

Page 3835: ... B D16 L L L L J 4 LG 1 2 2 2 1H 7 2 Access Cab 1 Standard Cab 9 1J 8 8 Integration Relay B B G Y G Y R B J 5 R B W B 1O 4 1N 3 1N 4 From Power Source System See Page 102 Door Courtesy SW Front LH Junction Connector Junction Connector OFF Tail Head Light Control SW H EL T 16 Combination SW C15 A C B A Junction Connector J21 A J22 B Junction Connector J 3 A W B B 4 3 Towing Package 4 Except Towing ...

Page 3836: ...o taillight circuit and headlight circuit As a result all lights are turned off automatically H LP Relay 5 3 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 C15 Combination SW 13 16 Closed with light control SW at HEAD position 14 16 Closed with light control SW at TAIL or HEAD position D16 Doo...

Page 3837: ...BE2 82 3 Floor No 2 Wire and Cowl Wire Center of Left Rocker Panel BG2 82 3 Floor No 2 Wire and Rear Door No 2 Wire Under the Left Quarter Panel Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Pow...

Page 3838: ...2005 TOYOTA TUNDRA EWD611U 181 Memo ...

Page 3839: ... L L L L J 4 LG 1 2 2 2 1H 7 2 Access Cab 1 Standard Cab 9 Integration Relay W B 1J 8 8 W B 1L 13 1L 5 1L 6 B B J 5 G Y G Y R B From Power Source System See Page 102 Door Courtesy SW Front LH Junction Connector Junction Connector A C B A J21 A J22 B OFF Tail Head Light Control SW H EL T 14 13 16 Combination SW C15 J21 A J22 B Junction Connector A Junction Connector J 3 B 4 3 Towing Package 4 Excep...

Page 3840: ...TERMINAL 6 and through the H LP relay coil side of the relay to taillight circuit and headlight circuit As a result all lights are turned off automatically H LP Relay 5 3 Closed with the light control SW at HEAD position or the dimmer SW at FLASH position C15 Combination 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 Cour...

Page 3841: ...n BE2 82 3 Floor No 2 Wire and Cowl Wire Center of Left Rocker Panel BG2 82 3 Floor No 2 Wire and Rear Door No 2 Wire Under the Left Quarter Panel Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o P...

Page 3842: ...2005 TOYOTA TUNDRA EWD611U 185 Memo ...

Page 3843: ...E 5 B B B Y 1 J 2 B Y 1 2 1 5 2 3 2 W B 1 2 2 A A J18 W B 1 EA SUB BATT Relay 2 2 B 1 IA9 1 BK2 1 BB5 5 B 1 L W 1 B 1 G W B 1 B 1 1 1 BR 2 BR 2 W B 1 1E 2 A A G G G J 1 W B A From Power Source System See Page 102 Junction Connector Junction Connector Junction Connector Junction Connector Option Connector Stop Light SW A A 1D 1 1D 4 Junction Connector Junction Connector J63 I 1 G W 1 Junction Conne...

Page 3844: ... R B L W L W P P R BR L B R B R BR L B G R G R Y R BR W B L G 1 B W W B W B 1 1 2 2 IG B LL LR R B 1 1 1 Y G 2 2 1 A T A T A T A T A T 1 A T A T 1 BR 2 BR 2 B F A H A 21 B 4 BB5 9 R B A T W B 1 J28 A J29 B J23 A J24 B T 6 A B From Power Source System See Page 102 J26 A J27 B Back Up Light Relay Diode A T Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector...

Page 3845: ... Finish Panel 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 1F 28 1 1G 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1G 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1J 24 2 1J 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Co...

Page 3846: ...rounding of the Front of the Fuel Tank BL 84 4 Surrounding of the Front of the Fuel Tank Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points I1 80 Cowl Wire 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Power Seat...

Page 3847: ...F J 3 A II 2 3 1A 2 1J 8 R B W B W B W B R B W R R B 5 H10 GND CAR CARS 1A 7 1L 1N 10 5 1 2 Integration Relay 2 w o Daytime Running Light 1 w Daytime Running Light From Power Source System See Page 102 I24 A I25 B Cargo Light Integration Control and Panel Junction Connector J13 Junction Connector Cargo Light SW ...

Page 3848: ... Wire and Driver Side J B Lower Finish Panel 1A 28 1 Roof Wire and Driver Side J B Lower Finish Panel 1D 24 2 1D 28 1 1H 24 2 1H 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 1L 25 2 1N 29 1 Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel II 78 Right Kick Panel 1 w Daytime Running Light 2 w o Daytime ...

Page 3849: ... BR Y 1 G Y 1 P 2 4 H L 4WD L4 F20 IND1 IND2 H L 2 4 A 20 A 19 E B Y B 13 7 6 B L DEF IE1 4 A 24 B 7 1 From Power Source System See Page 102 J26 A J27 B I24 A I25 B A 3 Dual A 1 Pressure SW A C Magnetic Clutch Air Inlet Control Servo Motor 4WD Control ECU Integration Control and Panel Junction Connector 4 6 7 5 24 C12 Combination Meter 10A GAUGE 1F 9 B 6 Defroster Mode SW J 8 Junction Connector B ...

Page 3850: ...in Type Amplifier ACC EHW 1 A 21 L B GR T 5 A B B C W R IG1 18 IH1 18 I22 ACC B 12 C 11 2 B 3 3 GR GR GR GR GR 2 2 2 2 3 3 W G 3 W G 2 W G 3 A 5 LG B CPU CSW S21 B R 2 B R12 C From Power Source System See Page 102 J23 A J24 B I24 A I25 B S29 E 4 A C Thermistor Engine Control Module Integration Control and Panel Junction Connector Junction Connector Radio and Player Skid Control ECU with Actuator S...

Page 3851: ...ifier 4 w Daytime Running Light R B R B W G W G G W 10 10 IH1 IG1 W G E J12 Integration Relay 1J 8 1A 2 W B J10 1L 1N 13 4 4 5 1L 1N 10 5 4 5 7 2 C W G 3 W G 2 IH1 17 IG1 17 G G G G G 3 2 2 3 5 w o Daytime Running Light From Power Source System See Page 102 Light Control SW C15 Combination SW Cargo Light Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector...

Page 3852: ...E4 57 J22 B 58 S29 53 2UZ FE F20 57 J23 A 58 S29 55 1GR FE H10 60 3 J24 B 58 T5 59 H10 61 4 J26 A 58 Relay Blocks Code See Page Relay Blocks Relay Block Location 2 23 Engine Room R B Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1A 24 2 Roof Wire and Driver Side J B Lower Finish Panel 1A 28 1 Roof Wire and Driver ...

Page 3853: ... Room Main Wire and Cowl Wire Left Kick Panel IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IG1 80 Cowl Wire and Instrument Panel No 2 Wire Instrument Panel Brace RH IH1 80 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel II 78 Right Kic...

Page 3854: ...2005 TOYOTA TUNDRA EWD611U 197 Memo ...

Page 3855: ...TA 15A STOP P IE1 15 D 8 L R NSW P P A A J18 W B A 9 B 26 A 4 B 21 A 23 B 6 A A A A B E From Power Source System See Page 102 J26 A J27 B J26 A J27 B J28 A J29 B TVIP ECU Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector O D Main SW Park Neutral Position SW Stop Light SW Vehicle Speed Sensor Electronically Controlled Transmission Engi...

Page 3856: ...e Coolant Temp Sensor Junction Connector Junction Connector Junction Connector Junction Connector Throttle Control Motor and Throttle Position Sensor Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E D 24 D 11 D 10 D 12 D 13 D 18 D 19 D 16 D 17 D 14 D 15 D 9 D 32 E 28 I 3 E2 TH02 SR SLU SLU SL2 SL2 SL1 SL1 SLT SLT S2 S1 TH01 2 1 9 7 13 5 11 3 12 4 14 6 15 8 10 R L L W L G W B R GR R W W B L B G ...

Page 3857: ...B W R G W P L L L B B O P L G W W R P 1 B 12 L O L Y P L G W W R LG B G R G R R A 15 W B R G O IH B B B B A D B A B A A E B C B C A C B G A G B F B F A H B D A B W B L Y G R G R LG B W R W R G W G W P L P L J28 A J29 B C11 A C12 B Combination Meter Junction Connector Park Neutral Position SW B O A B B D J66 A J67 B IJ1 7 V A 19 D N 2 R 3 P O D OFF L A T OIL TEMP Junction Connector ...

Page 3858: ...ls 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 through TERMINAL SLU of the engine control module to TERMINAL 5 of the electronically controlled tran...

Page 3859: ...olts with O 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 Park Neutral Position SW 2 6 Closed with s...

Page 3860: ...of Instrument Panel IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH Ground Points Code See Page Ground Points Location EA 74 2UZ FE Front Left Fender EC 74 2UZ FE Rear Bank of Left Cylinder Head EW 74 2UZ FE Front Left Side of Cylinder Head IF 78 Left Kick Panel IH 78 Right Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splic...

Page 3861: ...onnector Junction Connector Junction Connector O D Main SW Vehicle Speed Sensor Electronically Controlled Transmission Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E W B IF Junction Connector J 3 A D 3 D 4 EV E03 ME01 W B W B L R D 8 15A STOP C A 15 C 12 R L R L 5A STA 1F 6 1F 2 STSW STP NSW 4 5 N P P 1 G Y C G W G W J10 1 2 S 4 C 11 P STA P P P TVIP ECU 15 IE1 J28 A J29 B A A A A B E From Po...

Page 3862: ...e Coolant Temp Sensor Junction Connector Junction Connector Junction Connector Junction Connector Throttle Control Motor and Throttle Position Sensor Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E D 24 D 11 D 10 D 12 D 13 D 18 D 19 D 16 D 17 D 14 D 15 D 9 D 32 E 28 I 3 E2 TH02 SR SLU SLU SL2 SL2 SL1 SL1 SLT SLT S2 S1 TH01 R L P L W L G W B R GR R W W B L B G W G V B W B W B W V LLP 17 B IJ1 8...

Page 3863: ...B W R G W P L L L B B O P L G W W R P 1 B 12 L O L Y P L G W W R LG B G R G R R A 15 W B R G O IH B B B B A D B A B A A E B C B C A C B G A G B F B F A H B D A B W B L Y G R G R LG B W R W R G W G W P L P L J28 A J29 B C11 A C12 B Combination Meter Junction Connector Park Neutral Position SW B O A B B D J66 A J67 B IJ1 7 V A 19 D N 2 R 3 P O D OFF L A T OIL TEMP Junction Connector ...

Page 3864: ...ls 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 through TERMINAL SLU of the engine control module to TERMINAL 5 of the electronically controlled tran...

Page 3865: ...olts with O 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 Park Neutral Position SW 2 6 Closed with s...

Page 3866: ...of Instrument Panel IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH Ground Points Code See Page Ground Points Location EA 76 1GR FE Front Left Fender EU 76 1GR FE Rear Bank of Right Cylinder Head EV 76 1GR FE Rear Bank of Left Cylinder Head IF 78 Left Kick Panel IH 78 Right Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splic...

Page 3867: ...W BR V P LG L B W L R Engine Control Module E 4 Junction Connector J68 A J69 B J70 C J71 D J72 E J73 F 14 6 Data Link Connector 3 D 6 25 11 IA8 22 IA8 11 B W BR CANH CANL S29 S19 Y 1 Yaw Rate Sensor Steering Sensor Skid Control ECU with Actuator CANL CANH CANL CANH F 1 ST Plug IH B H A F BR BR Junction Connector J66 A J67 B CANL CANH CANL CANH ...

Page 3868: ...cation Code See Page Code See Page Code See Page D6 57 J69 B 58 S19 59 E4 57 J70 C 58 S29 53 2UZ FE J66 A 58 J71 D 58 S29 55 1GR FE J67 B 58 J72 E 58 Y1 60 3 J68 A 58 J73 F 58 Y1 61 4 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA8 78 Engine Room Main Wire and Cowl Wire Left Kick Panel Ground Points Code See Page Ground Poi...

Page 3869: ...el Junction Connector Junction Connector Parking Brake SW Parking Brake SW 4WD Control ECU IF 41 A LBL A A E11 W B W B W G W B 1 2 EA2 6 EA2 3 GR L R 4WD 4WD IA8 20 IA9 4 R W IA8 5 LG B 5 RL RL 6 A 20 A A 5 A 19 RR RR IA8 1 IA8 12 IA8 2 IA8 13 BB3 1 BB3 2 BB3 3 BB3 4 RH LH Y B W R R W B Y Y B W R 3 4 1 2 9 1F 10A GAUGE 6 2 L L Y P 1 2 1 3 L B B Y B Y E E 26 IE1 J 8 15A ACC 1G 11 A A J 9 GR GR D 8 ...

Page 3870: ...IA8 18 IA8 19 IA8 3 IA8 17 IA8 16 IE1 6 14 6 BR B BR B GR G B R L B L P L R L GR G B R L B L P L R L R L BR B GR G B R L B L P L R L CANH CANL SP1 WA BRL WT INFR VSCW IND 15A STOP 1F 2 A 45 STP2 G W 1 2 C C G W J10 S 4 Junction Connector Stop Light SW L From Power Source System See Page 102 3 2 4 5 1 IA8 7 G W 1D 4 1E 12 STP 7 A STPO 16 A IA8 15 G W V G Y G Y V C G W G W 3 1K 5A ECU IG BZ 30 A IA8...

Page 3871: ... L B O Combination Meter C11 A C12 B Junction Connector J66 A J67 B R L GR R GR R B W BR 5A ECU B From Power Source System See Page 102 2 2 1 A 22 B 5 V W V W Junction Connector J26 A J27 B VSC OFF VSC TRAC AUTO LSD SLIP B L ABS BRAKE SPEED CONTROL Junction Connector J66 A J67 B From Power Source System See Page 102 10 G B O B O IG2 1 B 11 1F 5A IGN CANL B O A G B 1F 11 A B O IA8 4 CANH 25 A IA8 1...

Page 3872: ... GR R GR R W B GR R GR R B W BR V P LG L B W L R W B W B V W W B L R Junction Connector J12 S19 Y 1 J23 A J24 B Engine Control Module E 4 Junction Connector J68 A J69 B J70 C J71 D J72 E J73 F BAT CANH CANL CANH CANL GND1 IG ESS IG1 CANL CANH Junction Connector Yaw Rate Sensor Steering Sensor 1 F ST Plug A F B H BR J66 A J67 B Junction Connector BR ...

Page 3873: ... power and activates the rear wheel brakes to reduce the under steering Traction control SW The traction control SW is used to stop the TRAC function After the engine is started the TRAC system is stopped turned off and the VSC OFF indicator light lights up When the traction control SW is pressed again the TRAC system enters the stand by mode If the engine is stopped and restarted the TRAC system ...

Page 3874: ...in Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1G 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1G 28 1 1K 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel Connector Joinin...

Page 3875: ... 2UZ FE Front Right Fender ET 76 1GR FE Front Right Fender IE 78 Left Kick Panel IF 78 Left Kick Panel IH 78 Right Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E11 74 2UZ FE Engine Room Main Wire E12 74 2UZ FE Engine Room Main Wire E11 76 1GR FE Engine Room Main Wire E12 76 1GR FE Engine Room Main Wire ...

Page 3876: ...2005 TOYOTA TUNDRA EWD611U 219 Memo ...

Page 3877: ...S BM WA IG D G J66 A A 5 24 GR ADD Detection SW EXI Battery 2 2 SIL P B 13 TC P B W L 20 TS 12 TS 38 L R Detection SW Transfer L4 Position EXI4 18 BR B Combination Meter SP1 A T 1F 9 B Y IH A B B D W B W B W B C12 J66 A J67 B From Power Source System See Page 102 ABS Actuator with ECU ABS Speed Sensor Front LH ABS Speed Sensor Front RH Combination Meter Data Link Connector 3 Junction Connector Jun...

Page 3878: ... 6 P 2 3 1 15A ACC 1G 11 A A E E B Y L B L B B Y B Y L L Y LG B L Y LG B A T A T A T A T A T IE1 26 P 1 D 8 J 8 J 9 From Power Source System See Page 102 J28 A J29 B From Power Source System See Page 102 ABS Actuator with ECU ABS Speed Sensor Rear ABS Deceleration Sensor Diode A T Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Park Neutral Position S...

Page 3879: ...nt the current acting on the solenoid is controlled and the hydraulic pressure is increased Holding of the hydraulic pressure is also controlled by the ECU by the same method as above by repeated pressure reduction Holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking A6 A7 ABS Speed Sensor Front LH RH 1 2 0 92 1 22 kΩ 20 C 68 F A19 ABS S...

Page 3880: ...and Engine Room Main Wire Right Fender IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel BB3 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB3 84 4 Frame Wire and Cowl Wire Under the Driver s Seat Ground Points Code See Page Ground Points Location IH 78 Right Kick Panel II 78 Right Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harne...

Page 3881: ...O G O 4 P G O A H A H B C A C P B W TC P B SIL W 13 7 G L R LG IF A IH A B B D W B W B P G O Tire Pressure W B R 2 1 Data Link Connector 3 D 6 Junction Connector J 3 Tire Pressure Monitor Receiver T18 Junction Connector J 8 Junction Connector J66 A J67 B Tire Pressure Warning Standardization SW T17 Junction Connector J66 A Combination Meter C11 A C12 B Tire Pressure Monitor ECU T16 Junction Connec...

Page 3882: ...e See Page Code See Page Code See Page C11 A 56 J8 58 T16 59 C12 B 56 J9 58 T17 59 D6 57 J66 A 58 T18 60 3 J3 58 J67 B 58 T18 61 4 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1F 24 2 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1G 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1G 28 1 Connector Joining Wire Harness a...

Page 3883: ... 2 BM BR G W B 2 CCS B Y 4 5 ON OFF RES SET CANSEL C16 2 IE1 3 S 4 J10 B 3 2 4 1 1 1 ECC CCS C G W A A J18 B IJ1 2 B Y A 9 B 26 A 23 B 6 A 1 B 18 B 21 A 4 B B J 1 W L From Power Source System See Page 102 J26 A J27 B J26 A J27 B E 3 A E 4 B E 5 C E 6 D E 7 E J26 A J27 B Cruise Control SW Combination SW Engine Control Module Junction Connector Junction Connector Junction Connector Junction Connecto...

Page 3884: ...12 A B B D W B W B T14 J28 A J29 B From Power Source System See Page 102 E 3 A E 4 B E 5 C E 6 D E 7 E C11 A C12 B J66 A J67 B Accelerator Pedal Position Sensor Combination Meter Diode A T Engine Control Module Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Park Neutral Position SW Throttle Control Motor and Throttle Position Sensor D 5A IGN L B A 26...

Page 3885: ...on Brake pedal is depressed 2 The CANCEL SW of the control SW is on 3 ON OFF SW is off 4 Gear is shifted from D position to other positions than D 5 Resume Control After canceling the cruise control Except when the ON OFF SW is off if the vehicle speed is above the minimum speed limit Approx 40km h 25mph operating the RES SW to on from off will cause the system to accelerate and resume to the vehi...

Page 3886: ...er Side J B Lower Finish Panel 1G 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH Ground Points Code See Page Ground Points Location EA 74 2UZ FE Front Left Fender EC 74 2UZ FE Rear Bank of Left ...

Page 3887: ...4 J10 B 3 2 4 1 1 1 ECC CCS C G W A A J18 IJ1 2 B Y A 9 B 26 A 23 B 6 A 1 B 18 B 21 A 4 B B J 1 W L From Power Source System See Page 102 J26 A J27 B J26 A J27 B E 3 A E 4 B E 5 C E 6 D E 7 E J26 A J27 B Cruise Control SW Combination SW Engine Control Module Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Stop Lig...

Page 3888: ...8 A J29 B From Power Source System See Page 102 E 3 A E 4 B E 5 C E 6 D E 7 E J66 A J67 B Accelerator Pedal Position Sensor Diode A T Engine Control Module Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Park Neutral Position SW Throttle Control Motor and Throttle Position Sensor D 5A IGN L B A 26 A 27 A 21 A 18 A 19 A 20 P G G R LG R R G L V R 3 E2 A...

Page 3889: ...on Brake pedal is depressed 2 The CANCEL SW of the control SW is on 3 ON OFF SW is off 4 Gear is shifted from D position to other positions than D 5 Resume Control After canceling the cruise control Except when the ON OFF SW is off if the vehicle speed is above the minimum speed limit Approx 40km h 25mph operating the RES SW to on from off will cause the system to accelerate and resume to the vehi...

Page 3890: ... Driver Side J B Lower Finish Panel 1G 28 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IJ1 80 Cowl Wire and Cowl Wire Instrument Panel Reinforcement RH Ground Points Code See Page Ground Points Location EA 76 1GR FE Front Left Fender EU 76 1GR FE Rear Bank of ...

Page 3891: ...2005 TOYOTA TUNDRA EWD611U 234 Memo ...

Page 3892: ... with memory function However it is not possible to make a record of these memory contents So when the work is finished it will be necessary to explain it to your customer and ask the customer to adjust the features and reset the memory To avoid erasing the memory in each system never use a back up power supply from outside the vehicle Before repair remove the airbag sensor if shocks are likely to...

Page 3893: ...tion Connector Pretensioner LH Pretensioner RH D2 A 8 4 Y V Y O 3 7 A D2 P2 A 1 Y GR 2 A P2 Y P 3 4 B 1 B 11 A 17 A 23 A 13 IH C 15 BM1 4 BM1 3 A 11 A 12 BL1 3 BL1 5 B 14 B 13 LG R B R LG R B R B G 1 2 1 2 DSP DSP MSW MSW A36 S36 BM1 2 O16 B15 PBE PBEW PAON P AB R W B W B R L 2 2 4 1 2 2 2 B R R R G GR 2 2 1 3 B R 2 1 Captain Seat 2 Bench Seat Airbag Cut Off SW Seat Position Airbag Sensor Buckle S...

Page 3894: ...g Sensor Front LH Airbag Sensor Front RH Center Airbag Sensor Assembly Data Link Connector 3 Junction Connector BL1 6 BL1 4 B 12 B 11 C 13 C 12 1F 11 1F 10 B Y G B 1 G R 1 B O 1 B O G R G B B Y B O A A A B Y B Y Junction Connector J 5 G R W L G R W L 1 2 DBE DBE B16 A C A C J66 A Junction Connector C W W 1 W B IJ1 1 A 22 GSW2 R B F PS 32 R B Engine Control Module E 4 1 1 1 1 Bucklw SW LH FSP FSP S...

Page 3895: ... 8 FSR W A 7 IG B O O10 A O11 B O12 O14 A 2 G R DIA A 3 W B GND IH Occupant Classification ECU Occupant Classification Sensor Front RH Occupant Classification Sensor Rear RH Occupant Classification Sensor Front LH Occupant Classification Sensor Rear LH BR BN1 2 BN1 3 BN1 5 5A ECU B From Power Source System See Page 102 2 2 1 G B 1 G R 1 B Y B O 1 B O 1 BN1 W R B 1 A C C B O G R G B V W V W B O B G...

Page 3896: ...ly expanded to soften the shock to the driver The airbag stored inside the passenger s instrument panel is instantaneously expanded to soften the shock to the passenger Front Passenger Airbag On Off Operation When the passenger airbag manual On Off SW is on the current flowing from the IGN fuse to the airbag squib Front passenger airbag assembly is same as above causing the airbag squib Front pass...

Page 3897: ...BL1 88 5 Seat No 1 Wire and Cowl Wire Under the Driver s Seat BM1 88 5 Cowl Wire and Seat No 1 Wire Under the Passenger s Seat BN1 86 6 Seat No 1 Wire and Cowl Wire Under the Passenger s Seat Ground Points Code See Page Ground Points Location IE 78 Left Kick Panel IH 78 Right Kick Panel II 78 Right Kick Panel 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench...

Page 3898: ...2005 TOYOTA TUNDRA EWD611U 241 Memo ...

Page 3899: ...J 8 D 8 GR B Y 1 2 L B L LG B W B W B G O Y B Y B BR Y BR Y J66 A J67 B LG B G O BR Y Y B Y B G O LG B LG B J 9 A G B G From Power Source System See Page 102 C11 A C12 B J28 A J29 B Combination Meter Diode A T Junction Connector Junction Connector Junction Connector Junction Connector N 2 9 Park Neutral Position SW P 1 5A IGN A B A H B F B D W B L4 4HI ...

Page 3900: ...IND1 SPD N GND L4 4WD L R 1 w VSC 2 w o VSC D 3 A 5 21 EXI4 S29 L R 1 2 EXI EXI 4WD 27 24 GR GR 2 GR 1 GR GR GR 2 1 W B From Power Source System See Page 102 E 5 I24 A ABS Actuator with ECU Detection SW Transfer 4WD Position Detection SW Transfer L4 Position Engine Control Module 4WD Control ECU Integration Control and Panel Junction Connector Junction Connector Skid Control ECU with Actuator A 5 ...

Page 3901: ... F20 A F21 B W B W B 4 A 9 IE4 5 IE4 13 IE4 1 IE4 2 IE4 7 G G 2 Y Y B R B R 3 B W B W 5 L W 6 W B W B 4 W B ADD DL1 DL2 DM1 DM2 TM1 TM2 TL3 TL1 TL2 M M T 3 H2 H4 L4 1 Detection SW GR GR 2 GR 1 EC1 4 W B B B B J10 GR 1 GR 2 2 w o VSC 1 w VSC ADD Actuator 4WD Control ECU Junction Connector Transfer Shift Actuator B 26 A 13 A 21 A 2 A 1 B 1 B 2 B 23 B 25 B 24 A F A F B H Junction Connector J28 A J29 ...

Page 3902: ...o ADD actuator TERMINAL 1 to motor to TERMINAL 5 to 4WD control ECU TERMINAL A 2 to GROUND and the ADD actuator is activated and the ADD is disconnected When the ADD is disconnected the detection SW ADD position SW is turned OFF and the 4HI indicator Light turns OFF H4 to L4 When the touch select high low SW in the integration control and panel is turned ON a signal is input into TERMINAL A 15 of ...

Page 3903: ...ith touch select 2 4 SW on A 17 Ground 2 volts or less with detection SW Transfer L4 position on and transfer shift lever at L4 position I24 A I25 B Integration Control and Panel A 5 B 1 Closed with touch select 2 4 SW on P1 Park Neutral Position SW 2 9 Closed with A T shift lever at N position Parts Location Code See Page Code See Page Code See Page A5 52 2UZ FE F20 A 57 J29 B 58 A5 54 1GR FE F21...

Page 3904: ...ound Points Code See Page Ground Points Location IH 78 Right Kick Panel II 78 Right Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points I3 80 Engine Wire I4 80 Cowl Wire ...

Page 3905: ... 1F 3 L Y 2 1 1E 6 IB4 6 R Y G B W G A A B A IE W B W B W B B B W G B W G J 7 C C J 7 L R Integration Relay 1N 19 1N 21 1N 23 1N 20 1N 6 IH D D C C C D J 4 From Power Source System See Page 102 C11 A C12 B J23 A J24 B Combination Meter Door Key Lock and Unlock SW LH Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Power Window Master...

Page 3906: ...Unlock Lock 1 3 2 13 12 8 L Y W G D25 D26 IF3 9 IF3 8 R Y G B W B W B B Y A D A D J 7 R L B E A E A E L W B Y R Y W B Integration Relay 1N 24 10 1N 9 1N 22 1N B D A F A F T13 ACT ACT B Y 2 4 J21 A J22 B J21 A J22 B Door Key Lock and Unlock SW RH Door Lock Control SW RH Door Lock Motor LH Door Unlock Detection SW LH Door Lock Motor RH Door Unlock Detection SW RH Junction Connector Junction Connecto...

Page 3907: ...1 1 B W 1 B W 1 1 L L 1 2 B W L 2 2 Standard Cab 1 Access Cab 15 14 2 1 2 1 B 9 BK B W B W W B W B D21 D20 B W 1 1 1 1 1 Integration Relay BE2 4 BG2 5 B W 1 B W 1 B W 1 C From Power Source System See Page 102 Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Lower Door Courtesy SW Rear LH Upper Door Courtesy SW Rear RH Lower Door Courtesy SW Rear RH Upper Junction Connec...

Page 3908: ... the door lock motor to TERMINAL 2 to TERMINAL 13 of the relay to TERMINAL 8 to GROUND and the door lock motor causes the door to unlock 3 Double Operation Unlock Operation When the door key lock and unlock SW LH is turned to unlock position only the front LH door is mechanically unlocked Turning the door key lock and unlock SW LH to the unlock side causes a signal to be input to the relay and if ...

Page 3909: ...th 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 Parts Location Code See Page Code See Page Code See Page C11 A 56 D23 60 3 J13 58 C12 B 56 D23 61 4 J21 A 58 D16 60 3 D24 60 3 J22 B 58 D16 61 4 D24 61 4 J23 A 58 D17 60 3 D25 60 3 ...

Page 3910: ...he Left Quarter Panel BH1 82 3 Floor No 1 Wire and Rear Door No 1 Wire Under the Right Quarter Panel Ground Points Code See Page Ground Points Location IE 78 Left Kick Panel IF 78 Left Kick Panel IH 78 Right Kick Panel II 78 Right Kick Panel BJ 82 3 Inside of Rear Door LH BK 82 3 Inside of Rear Door RH Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Spli...

Page 3911: ... L R D D C C C D C D J 4 Door Key Lock and Unlock SW LH Diode Door Lock Junction Connector Junction Connector Junction Connector Junction Connector Power Window Master SW E 10 1F 5A IGN 2 1 A 30 E 1E 23 B 24 P B E U 1 J 7 P B L L Y B O A 29 1 2 L Y 3 1F B 10A DOME 2 B 12 W B W B 6 A A B A L W B IE W B W B IH From Power Source System See Page 102 C11 A C12 B J23 A J24 B Combination Meter Junction C...

Page 3912: ...Unlock Lock 1 3 2 13 12 8 L Y R Y D25 D26 1L 8 1L 9 IF3 9 IF3 8 R Y G B J 3 W G A F B D B Y W B A A D D J 7 B E A E A E R L W B 1 2 D30 A A J 4 R W R W B Y A F 2 4 ACT ACF T13 B Y B Y J21 A J22 B J21 A J22 B Door Key Lock and Unlock SW RH Door Lock Control SW RH Door Lock Motor LH Door Unlock Detection SW LH Door Lock Motor RH Door Unlock Detection SW RH Diode Unlock Warning Junction Connector Jun...

Page 3913: ...W B D16 D19 D18 D17 1 1 1 1 1 1 1 1 B W 1 B W 1 1 L 2 B W L 2 2 Standard Cab 1 Access Cab 15 14 2 1 2 1 B 9 BK B W B W W B W B D21 D20 B W 1 1 1 1 1 BE2 4 BG2 5 B W C 1 B W 1 B W 1 IH 1L 16 BR J66 A J67 B BR Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Lower Door Courtesy SW Rear LH Upper Door Courtesy SW Rear RH Lower Door Courtesy SW Rear RH Upper Junction Connect...

Page 3914: ... the door lock motor to TERMINAL 2 to TERMINAL 13 of the relay to TERMINAL 8 to GROUND and the door lock motor causes the door to unlock 3 Double Operation Unlock Operation When the door key lock and unlock SW LH is turned to unlock position only the front LH door is mechanically unlocked Turning the door key lock and unlock SW LH to the unlock side causes a signal to be input to the relay and if ...

Page 3915: ... 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 Parts Location Code See Page Code See Page Code See Page C11 A 56 D23 61 4 J13 58 C12 B 56 D24 60 3 J21 A 58 D16 60 3 D24 61 4 J22 B 58 D16 61 4 D25 60 3 J23 A 58 D17 60 3 D25 61 4 J24 B ...

Page 3916: ...he Left Quarter Panel BH1 82 3 Floor No 1 Wire and Rear Door No 1 Wire Under the Right Quarter Panel Ground Points Code See Page Ground Points Location IE 78 Left Kick Panel IF 78 Left Kick Panel IH 78 Right Kick Panel II 78 Right Kick Panel BJ 82 3 Inside of Rear Door LH BK 82 3 Inside of Rear Door RH Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Spli...

Page 3917: ...G R R B G Y B A A B 7 6 J10 J 5 Battery H LP Relay R B Integration Relay 3 w Daytime Running Light 6 5VZ FE 4 w o Daytime Running Light 5 2UZ FE 1L 1N 5 3 3 4 1L 1O 6 4 3 4 1L 1N 13 4 3 4 1L 1N 12 12 3 4 R B 3 7 w VSC 8 w o VSC From Power Source System See Page 102 Junction Connector Junction Connector 1 1 B 2 B 2 2 Except Towing Package 1 Towing Package ...

Page 3918: ...HORN TAIL HEAD B1 B2 IG G R R B G Y V W W G 5 W G 6 V W W G W G V W W G 6 5 5 2 1 A 22 B 5 E E GR R J 9 From Power Source System See Page 102 J26 A J27 B J21 A J22 B J12 T11 A T12 B T13 C Junction Connector Junction Connector Junction Connector Junction Connector TVIP ECU C C GR R B A A C J21 A J22 B Junction Connector 2 1 ...

Page 3919: ... L W L W B V LG B V W B W B W B W B P B W G L R C B B E 1 2 3 C B E 2 4 3 1 1 T10 S10 C Shielded W B W B W B B 8 A 25 E MIC MIC LP IF A W B T11 A T12 B T13 C J26 A J27 B J23 A J24 B Door Key Lock and Unlock SW LH Junction Connector Junction Connector Glass Breakage Sensor Microphone Security Indicator TVIP Buzzer TVIP ECU Unlock Warning SW Junction Connector J 3 ET I 2 W B W G A A B A B A A S 9 Sh...

Page 3920: ...10 B 14 B 15 C 2 C 4 A F B D UL2 LSWD LSWP ACT ACT C W G W G R W 2 1 A A R W J 4 B E A E A D A D J 7 R L B Y B Y B Y J 4 1 2 A R Y 1 R W 4 D30 2 w o Daytime Running Light 1 w Daytime Running Light W B T11 A T12 B T13 C J21 A J22 B Door Key Lock and Unlock SW RH Door Lock Control SW RH Door Lock Motor LH Door Unlock Detection SW LH Door Lock Motor RH Door Unlock Detection SW RH Diode Unlock Warning...

Page 3921: ...B W 6 6 6 6 6 B 5 B 4 BE2 4 BG2 5 B W B W 6 6 B W 6 C 1 2 B G G B B W D11 CTY DSWD DMLP 6 C B W B W C 8 C 3 B 12 SRLY ST A GR G R M T P M T Park Neutral Position SW G R A T P A T Antenna Clutch Start SW M T T11 A T12 B T13 C Diode Power Window System Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Lower Door Courtesy SW Rear LH Upper Door Courtesy SW Rear RH Lower Door...

Page 3922: ...1H 1 G B B W B W L Y L Y L Y L Y L Y L Y B W B W B W B B B B J 4 D29 I26 P 8 3 2 1 1A 2 1J 8 IF 2 1 W B W B A J 3 B B W B W 6 Access Cab 5 Standard Cab J21 A J22 B From Power Source System See Page 102 Diode TVIP Interior Light Junction Connector Junction Connector Junction Connector Personal Light Door ...

Page 3923: ...ck and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1A 24 2 Roof Wire and Driver Side J B Lower Finish Panel 1A 28 1 Roof Wire and Driver Side J B Lower Finish Panel 1B 24 2 1B 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1C 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1C 28 1 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finis...

Page 3924: ...Panel BH1 82 3 Floor No 1 Wire and Rear Door No 1 Wire Under the Right Quarter Panel Ground Points Code See Page Ground Points Location ET 74 2UZ FE Front Right Fender ET 76 1GR FE Front Right Fender IE 78 Left Kick Panel IF 78 Left Kick Panel II 78 Right Kick Panel BJ 82 3 Inside of Rear Door LH BK 82 3 Inside of Rear Door RH Splice Points Code See Page Wire Harness with Splice Points Code See Pa...

Page 3925: ... 2 2 2 2 2 2 2 1 1 2 2 2 2 C J 5 E E L E J 4 B W B W B W 5 BG2 4 BE2 C 2 2 2 1 2 BF2 1 BF2 4 B C A A A A IB4 3 L R L R L R 1 P21 P22 3 6 2 UP DOWN E G B R L G B R L W B 2 L R 4 3 3 From Power Source System See Page 102 J21 A J22 B Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Lower Door Courtesy SW Rear LH Upper Door Courtesy SW Rear RH Lower Door Courtesy SW Rear RH...

Page 3926: ...p Down UP Down Window Lock SW L R 9 P10 3 4 P11 LG L Y P 9 1 Standard Cab 2 Access Cab L R Up Down Up Down IE W B 3 w Power Window Back Window 4 w o Power Window Back Window J23 A J24 B Junction Connector Power Window Control SW Front RH Power Window Master SW Power Window Motor Front LH Power Window Motor Front RH A A A A B A W B M M 2 1 1 2 ...

Page 3927: ...Auto Down AT Driver s Window When the manual SW Driver s is pushed to the up side during auto down operation a ground circuit opens in the master SW and current does not flow from TERMINAL 3 of the master SW to TERMINAL 1 so the motor stops causing auto down operation to stop If the manual SW is pushed continuously the motor rotates in the up direction in manual up operation 4 Manual Operation By ...

Page 3928: ...CK position Parts Location Code See Page Code See Page Code See Page D16 60 3 J4 58 P10 61 4 D16 61 4 J5 58 P11 60 3 D17 60 3 J21 A 58 P11 61 4 D17 61 4 J22 B 58 P12 60 3 D18 60 3 J23 A 58 P12 61 4 D19 60 3 J24 B 58 P21 58 D20 60 3 P9 60 3 P22 60 3 D21 60 3 P9 61 4 J3 58 P10 60 3 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 24 2 1C 2...

Page 3929: ...H BK 82 3 Inside of Rear Door RH Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points B8 82 3 Rear Door No 1 Wire LH B9 82 3 Rear Door No 1 Wire RH 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Power Seat ...

Page 3930: ...2005 TOYOTA TUNDRA EWD611U 273 Memo ...

Page 3931: ...L J 4 3 3 B 4 4 W B L 1 IE From Power Source System See Page 102 C11 A C12 B B 7 B 7 Combination Meter Door Courtesy SW Front LH Junction Connector Junction Connector Unlock Warning SW B B W B 3 3 1 2 2 P B IF Junction Connector J 3 A A A W B W B J23 Junction Connector Junction Connector J83 Driver s Seat Belt IH B 12 W B B A W B W B J66 A J67 B B Junction Connector D BLINK BUZZER Buckle SW LH Buc...

Page 3932: ...3 A 13 5 IH C 15 BM1 4 BM1 3 4 BM1 2 O16 B15 PBE PBEW PAON P AB R W B W B R L 2 2 GR 4 R G 4 4 R 3 B R 4 4 4 1 E Buckle SW RH Occupant Detection SW Occupant Detection Sensor PBKL PAON P AB ACC B R R L 3 B15 2 4 Buckle SW RH Occupant Detection SW 5 B R 5 4 R L W B 5 Buckle SW RH B13 2 1 C 12 C 13 8 4 9 5 BN1 3 BN1 5 L R B W G B G R 3 3 3 3 3 3 FSR FSR BSW BGND Occupant Classification ECU O10 FSP FS...

Page 3933: ...al is input to TERMINAL A 30 of the combination meter the combination meter operates current flows from TERMINAL B 23 of the combination meter to TERMINAL B 12 to GROUND and key reminder buzzer sounds B7 Buckle SW LH Captain Seat 2 3 Closed with the driver s seat belt in use B7 Buckle SW LH Separate Seat 13 3 Closed with the driver s seat belt in use B7 Buckle SW LH Bench Seat 2 1 Closed with the ...

Page 3934: ...E2 82 3 Floor No 2 Wire and Cowl Wire Center of Left Rocker Panel BG2 82 3 Floor No 2 Wire and Rear Door No 2 Wire Under the Left Quarter Panel BI2 86 6 Cowl Wire and Seat No 2 Wire Under the Driver s Seat BI2 88 5 Cowl Wire and Seat No 2 Wire Under the Driver s Seat BM1 88 5 Cowl Wire and Seat No 1 Wire Under the Passenger s Seat BN1 86 6 Seat No 1 Wire and Cowl Wire Under the Passenger s Seat Gr...

Page 3935: ... GR GR GR 1 140A ALT 1 100A ALT 2 PWR OUTLET Relay W G G G B G G B W B W B Battery 2 Except Towing Package 1 Towing Package C 7 P 6 P 7 2 1 2 1 I 2 W B W B B L 1 B L 1 A A J18 A 5 B 22 A 6 B 23 B 10 A 27 W B From Power Source System See Page 102 J26 A J27 B J26 A J27 B Cigarette Lighter Junction Connector Junction Connector Junction Connector Junction Connector Power Outlet Power Outlet ID2 2 ID2 ...

Page 3936: ...onnector Location 1G 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1G 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location ID2 78 Cigarette Lighter Wire and Cowl Wire Instrument Panel Brace LH Ground Points Code See Page Ground Points Location EA 74 2UZ FE Front Left Fend...

Page 3937: ...ccess Standard Cab 15A ACC 1G 10 10A DOME 2 1E 6 1F 4 A II J13 L Y GR L Y L Y 2 1 W B W B B ACC GND GR A B B C From Power Source System See Page 102 J23 A J24 B I25 Integration Control and Panel Junction Connector Junction Connector 10 9 15 ...

Page 3938: ...ss Connector Code See Page Junction Block and Wire Harness Connector Location 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1G 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1G 28 1 Ground Points Code See Page Ground Points Location II ...

Page 3939: ...andard Cab 10A HORN 1E 8 6 1 1 B G R 1 B C16 H 7 H 8 7 A A J10 1 w Daytime Running Light 2 w o Daytime Running Light Integration Relay 1L 1N 12 12 1 2 Horn From Power Source System See Page 102 Combination SW Horn LH Horn RH Junction Connector G R ...

Page 3940: ...ire Harness Connector Location 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1L 25 2 Cowl Wire and Driver Side J B Lower Finish Panel 1N 29 1 Cowl Wire and Driver Side J B Lower Finish Panel 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Acces...

Page 3941: ...16 2 11 3 5 2 1 4 OFF Int Low Washer High M 2 1 B S E Wiper Relay W 4 J13 A IF J 3 A 20A WIP 5A IGN B O 2 1 W 2 W 2 A 3 B 20 Wiper and Washer SW From Power Source System See Page 102 J26 A J27 B C11 A C12 B Combination Meter Junction Connector Junction Connector Junction Connector Washer Level Sensor Washer Motor Wiper Motor Combination SW C17 EA2 7 B 24 A 13 B 2 1 S B1 EW WF INT1 INT2 Washer M 4 ...

Page 3942: ...L 11 of the wiper and washer SW to TERMINAL 2 to GROUND and causes to the washer motor to run and the window washer is jetted This causes current to flow to washer continuous operation circuit in TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the wiper motor to TERMINAL 4 to GROUND and the wiper functions C17 Combination SW 2 Ground Always continuity 17 Ground Approx 12 volt...

Page 3943: ...Page Joining Wire Harness and Wire Harness Connector Location EA2 74 2UZ FE Cowl Wire and Engine Room Main Wire Right Fender EA2 76 1GR FE Cowl Wire and Engine Room Main Wire Right Fender Ground Points Code See Page Ground Points Location ET 74 2UZ FE Front Right Fender ET 76 1GR FE Front Right Fender IF 78 Left Kick Panel II 78 Right Kick Panel ...

Page 3944: ...2005 TOYOTA TUNDRA EWD611U 287 Memo ...

Page 3945: ...B L LG L B L W W B L R W B L W L L B LG L R L W B 17 8 7 16 2 11 3 5 2 1 4 M 2 1 B S E C17 C11 A C12 B W 4 J13 A IF J 3 A 20A WIP 5A IGN MIST OFF LO HIGH Washer 4 3 2 1 W 2 W 2 A 3 B 20 J26 A J27 B EA2 7 Washer Combination Meter Combination SW Junction Connector Junction Connector Junction Connector Washer Level Sensor Washer Motor Wiper Motor B 2 1 S EW WF Wiper and Washer SW B 24 A 13 M ...

Page 3946: ...uity 17 Ground Approx 12 volts with ignition SW at ON position 7 Ground Approx 12 volts with wiper and washer SW at LOW or MIST position 16 Ground Approx 12 volts with ignition SW on unless wiper motor at STOP position 8 Ground Approx 12 volts with ignition SW on and wiper and washer SW at HIGH position 11 Ground Continuity with washer SW on W4 Wiper Motor 1 2 Closed unless wiper motor at STOP pos...

Page 3947: ...U 290 Wiper and Washer without INT TIME Switch Access Standard Cab Ground Points Code See Page Ground Points Location ET 74 2UZ FE Front Right Fender ET 76 1GR FE Front Right Fender IF 78 Left Kick Panel II 78 Right Kick Panel ...

Page 3948: ...2005 TOYOTA TUNDRA EWD611U 291 Memo ...

Page 3949: ...W R W R W W B W B R W P G P G W B W B W B W B W B M 4 J13 J12 R 8 R 9 J 8 E D IG MIR HTR Relay B 1 A 18 A 31 B 14 From Power Source System See Page 102 J26 A J27 B J26 A J27 B J23 A J24 B Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Mirror Heater SW Remote Control Mirror LH Remote Control Mirror RH Heater Heater 1E 5 B Y B B J 2 ...

Page 3950: ...Connector Code See Page Junction Block and Wire Harness Connector Location 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wir...

Page 3951: ... TOYOTA TUNDRA EWD611U 294 Automatic Glare Resistant EC Mirror Access Standard Cab 7 6 IF J 3 A 1A 2 1J 8 W B W B 10A GAUGE From Power Source System See Page 102 1A 4 B Y Inner Mirror I27 Junction Connector ...

Page 3952: ...ctor Location 1A 24 2 Roof Wire and Driver Side J B Lower Finish Panel 1A 28 1 Roof Wire and Driver Side J B Lower Finish Panel 1J 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1J 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Ground Points Code See Page Ground Points Location IF 78 Left Kick Panel 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 B...

Page 3953: ...6 7 R L B P B LG R Y B W B L B P B Y B Y B Operation SW Select SW Right Down Left Up LH RH LH RH Left Right Up Down GR R10 8 J 9 1 w Mirror Heater 2 w o Mirror Heater B A A A W B B 1 2 A 5 1 B 1 2 A 5 1 B 3 A 1 B 2 A 3 B 3 A 1 B 2 A 3 From Power Source System See Page 102 J23 A J24 B R 8 A B R 9 A B Junction Connector Junction Connector Remote Control Mirror LH Remote Control Mirror RH Remote Cont...

Page 3954: ...de J B Lower Finish Panel 1G 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IB3 78 Front Door LH Wire and Cowl Wire Left Kick Panel IF3 80 Front Door RH Wire and Cowl Wire Right Kick Panel Ground Points Code See Page Ground Points Location IE 78 Left Kick Panel Splice Point...

Page 3955: ...ource System See Page 102 J23 J23 Junction Connector Junction Connector Junction Connector Lumbar Support Control SW Driver s Seat Power Seat Motor Driver s Seat Front Vertical Control Power Seat Control SW Driver s Seat Power Seat Motor Driver s Seat Rear Vertical Control Power Seat Motor Driver s Seat Reclining Control Power Seat Motor Driver s Seat Slide Control Power Seat Motor Driver s Seat L...

Page 3956: ... 7 P19 62 7 J23 58 P16 62 7 P20 62 7 J83 62 7 P17 62 7 S8 59 L3 62 7 P18 62 7 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1C 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness C...

Page 3957: ... Lock Control 1 w Door Lock Control 3 Access Cab A 2 B 19 IH1 9 R G R G IH1 18 LG L P V B Y R W I22 R G IH1 5 IH1 14 IH1 6 IH1 15 IH1 4 IH1 13 IH1 3 IH1 12 I22 GR R G GR A 11 A 1 B 7 B 8 ACC B B SW1 SW2 6 B GND GR R G IH1 8 IH1 7 IH1 16 AU1 AU2 EAU 12 11 10 L G B R L G B R C16 From Power Source System See Page 102 J26 A J27 B S20 A S21 B Steering Pad SW Combination SW Front Door Speaker LH Front D...

Page 3958: ...adio and Player with Display Stereo Component Amplifier A 9 GND 22 B 23 B 7 B 8 B 13 B A 5 A 15 B 11 B 12 TX TX IVO IVO SLD1 P L LG L TX TX IVO IVO Shielded 3 C SPD G O IH1 11 B F A H A B B D IH 12 B 25 A 24 B W B G O G O Junction Connector J66 A J67 B 5A IGN From Power Source System See Page 102 1F 10 B O Combination Meter C11 A C12 B Junction Connector J66 A J67 B 5 C REV G R Park Neutral Positi...

Page 3959: ...r Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IB4 78 Front Door LH Wire and Cowl Wire Left Kick Panel IF4 80 Front Door RH Wire and Cowl Wire Right Kick Panel IH1 80 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH BA1 82 3 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BA1 84 4 Front Door LH Wire and S...

Page 3960: ...22 80 Floor No 3 Wire B5 82 3 Speaker Tweeter Wire RH B1 82 3 Speaker Tweeter Wire LH B5 84 4 Speaker Tweeter Wire RH B1 84 4 Speaker Tweeter Wire LH 1 w Daytime Running Light 2 w o Daytime Running Light 3 Access Cab 4 Standard Cab 5 Bench Seat 6 Captain Seat 7 Access Cab Captain Seat 8 Standard Cab Bench Seat 9 Access Cab w o Power Seat ...

Page 3961: ...2 1 2 w o Door Lock Control 1 w Door Lock Control 3 Access Cab A 2 B 19 IH1 9 R G R G IH1 18 LG L P V B Y R W I22 R G IH1 5 IH1 14 IH1 6 IH1 15 IH1 4 IH1 13 IH1 3 IH1 12 I22 GR R G GR A 11 A 1 B 7 B 8 ACC B B SW1 SW2 6 B GND GR R G IH1 8 IH1 7 IH1 16 AU1 AU2 EAU 12 11 10 L G B R L G B R C16 From Power Source System See Page 102 J26 A J27 B S20 A S21 B Steering Pad SW Combination SW Front Door Spea...

Page 3962: ...0 B 1 B 3 B 5 B 2 B 4 AMP B FL FR RL RR SLD GND B R AMP F L F R R L R R G R W B I22 BR BR BR BR BR Shielded BR BR S20 A S21 B R12 A R13 B Radio and Player Stereo Component Amplifier A 9 GND 22 B 23 B 7 B 8 B 13 B A 5 A 15 B 11 B 12 TX TX IVO IVO SLD1 P L LG L TX TX IVO IVO Shielded ...

Page 3963: ...l Wire Left Kick Panel IF4 80 Front Door RH Wire and Cowl Wire Right Kick Panel IH1 80 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH BA1 82 3 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BA1 84 4 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BC1 82 3 Front Door RH Wire and Speaker Tweeter Wire RH Inside of Front Door RH BC1 84 4 Front Do...

Page 3964: ...2005 TOYOTA TUNDRA EWD611U 307 Memo ...

Page 3965: ... A 1 RR 3 BE2 BH1 2 R R R 1 2 A 3 RR 2 BE2 BH1 1 W W W R 7 3 3 3 3 3 3 3 3 3 3 3 3 IG 8 9 ACC1 ACC I25 GR GR GR GR 2 1 2 w o Door Lock Control 1 w Door Lock Control 3 Access Cab A 2 B 19 IG1 9 R G IG1 18 IG1 5 IG1 6 IG1 4 IG1 3 IG1 13 IG1 12 IG1 1 LG L P V B Y R W 3 3 3 3 IG1 15 IG1 14 BR BR BR From Power Source System See Page 102 J26 A J27 B R 1 A R 2 B Front Door Speaker LH Front Door Speaker R...

Page 3966: ...Wire Instrument Panel Brace RH BA1 82 3 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BA1 84 4 Front Door LH Wire and Speaker Tweeter Wire LH Inside of Front Door LH BC1 82 3 Front Door RH Wire and Speaker Tweeter Wire RH Inside of Front Door RH BC1 84 4 Front Door RH Wire and Speaker Tweeter Wire RH Inside of Front Door RH BE2 82 3 Floor No 2 Wire and Cowl Wire Center of ...

Page 3967: ...3 B O L Y L Y B L B W L Skid Control ECU with Acutuaor w VSC M T M T 17 IE1 A T IE1 BR B V 2 BR B R B L Y R B 3 2 1 M T M T ABS Actuator With ECU w o VSC 8 Vehicle Speed Sensor Combination Meter 10A GAUGE 1F 8 B D A B B Y M T Junction Connector J28 A J29 B B Y B Y M T M T W G B L L P B BB4 5 BB4 8 2 3 Y R BR Y R B R Fuel Sender F10 Combination Meter C11 A C12 B Ignition Key Cylinder Light Door Cou...

Page 3968: ...D 14 1 L W L W L W 3 3 Integration Control and Panel I24 Engine Control Module E 4 Junction Connector J 5 C11 A C12 B Combination Meter B F B F A H A H A H G O G O G O G O G O Engine Control Module Tire Pressure Monitor ECU 4WD Control ECU Radio and Player Junction Connector J66 A J67 B TACH TACH Buckle SW LH Tire Pressure Monitor ECU Center Airbag Sensor Assembly Skid Control ECU with Actuator 1 ...

Page 3969: ...Connector J 3 A 1N 1 1N 13 D D D D G W R W R W 6 A T Integration Relay R W R W R W R W 7 A T R W 6 A T R W R W R W 7 M T 6 R W W B W B R W Junction Connector J18 Brake Fluid Level Warning SW B 2 R W 8 A T Parking Brake SW P 5 8 8 M T 7 M T 6 M T 6 M T Parking Brake SW P 5 W B M T Skid Control ECU with Actuator IH A B B D W B W B Junction Connector J66 A J67 B V Engine Control Module C11 A C12 B Co...

Page 3970: ...n Indicator Lamp B 2 A 7 B 3 A 3 A 14 A 15 A 18 G B G Y R G R G Turn Signal Flasher 7 6 Headlight LH RH 9 Integration Relay 8 V G R L O GR B B L R L P L Engine Control Module Skid Control ECU with Actuator Combination Meter C11 A C12 B 4 w VSC 5 w o VSC 6 w Daytime Running Light 7 w o Daytime Running Light 8 w Daytime Running Light w VSC ...

Page 3971: ... Combination Meter Access Standard Cab L4 VSC OFF 4HI Washer Charge B 8 A 13 B 7 B 6 B 5 B 4 B 1 L Skid Control ECU with Actuator Y B Y B BR Y BR Y LG R Washer Level Sensor Y G Generator 4WD Control ECU Combination Meter C11 A C12 B ...

Page 3972: ...tion 1B 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1B 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1E 24 2 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1E 28 1 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel 1N 29 1 Connector Joining Wire Harness and Wire Harness Code See Page Joining ...

Page 3973: ... A J27 B Pressure SW A C Magnetic Clutch and Lock Sensor A C Thermistor Air Inlet Control Servo Motor Integration Control and Panel Junction Connector 3 E 4 Engine Control Module A 17 V W Skid Control ECU with Actuator Junction Connector J 8 E EA2 11 EA2 9 A 15 W B VER1 I 4 L R W B 2UZ FE A 21 L B A 10 R G 24 25 9 IE1 10 A 13 G W LOCK 11 IE1 W R 1 G W 2 IA8 5 LG B AC1 ACT LMS CPU 7 6 B 13 B 17 B O...

Page 3974: ...B Y L R B Y L R L B W B W B W B B Y R R B Y L R L R L B B 4 J 2 HRATER Relay Y R Y R B 6 1 2 W B L B Y R W B I 4 J13 A A A J18 A 13 B 30 From Power Source System See Page 102 J26 A J27 B Blower Motor Blower SW Junction Connector Junction Connector Junction Connector Junction Connector W B 2 1 M B 5 Blower Resistor 2 3 1 L Y L R W B W B ...

Page 3975: ...AL 1 of the blower motor to TERMINAL 2 to TERMINAL 5 of the blower SW to TERMINAL 1 to GROUND causing the blower motor to rotate at high speed 2 Operation of Air Inlet Control Servo Motor Switching from FRESH to RECIRC With the ignition SW turned on current flows from the GAUGE fuse to TERMINAL 5 of the air inlet control servo motor When the RECIRC FRESH SW is switched to the RECIRC side current f...

Page 3976: ...ngine Room Main Wire and Driver Side J B Lower Finish Panel 1F 24 2 Cowl Wire and Driver Side J B Lower Finish Panel 1F 28 1 Cowl Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location EA2 74 2UZ FE Cowl Wire and Engine Room Main Wire Right Fender EA2 76 1GR FE Cowl Wire and Engine Room Main...

Page 3977: ...0A DEFOG 30A ABS NO 2 7 5A CARGO LP 9 2 12 10 4 5 6 W L G B L B P W B B R W Battery B L W F13 1 1 1 2 2 2 40A MAIN 2 1 Body ECU Skid Control ECU with Actuator 3 ABS Actuator with ECU 4 2G 2 15A MIR HTR 2C 1 W R 20A TURN HAZ 30A DOOR NO 2 2 1 30A RAD NO 3 30A TOWING Generator 11 B 3 30A TOWING BRK 30A BATT CHARGE 30A TOWING TAIL 1 1 1 2 2 2 3 3 3 B W L W B R 30A ST 15A AC INV Skid Control ECU with ...

Page 3978: ...w o Daytime Running Light 1 w Daytime Running Light 15A DRL 1 2G 1 2 4 3 1 5 2 2 2 2 2 L L R B W W L 2 2 1 2 1 2 1 2 1 2 2 2 2 2 L G W R W R L 10A H LP RL 10A H LP LL 10A H LP RH 10A H LP LH DIMMER Relay 1 1 1 1 1 1 1 1 1 2 1 2 2 L O 7 5A RSE B B L Y L Y J31 2B 3 4 1 3 2 B O W R A22 G 3 w VSC 4 w o VSC ACC Cut Relay Ignition SW Junction Connector 7 5A STA B 2 2 1 2 1J 8 1C 5 B W B W 4 1 5 2 3 20A ...

Page 3979: ... dimmer SW at HIGH or FLASH position Parts Location Code See Page Code See Page Code See Page A22 66 I23 67 F13 34 64 J31 65 Relay Blocks Code See Page Relay Blocks Relay Block Location 2 38 Engine Room R B No 2 Engine Compartment Left 3 39 Engine Room R B No 3 Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 45 C...

Page 3980: ...2005 TOYOTA TUNDRA EWD611U 323 Memo ...

Page 3981: ...6 IE1 15 W B B M B 1 A 1 C 11 C 12 STA STSW R L P EA P N 5 4 W R W R B W B B W B B L W B P P 1 NSW D 8 L R L R A A A A B E P P IJ1 4 P P B W 30A ST 2E 3 B R A A W B J34 B W S 1 A S 2 B E 5 C E 6 D J28 A J29 B Engine Control Module Fusible Link Block Junction Connector Junction Connector Park Neutral Position SW Starter 1C 5 1J 8 7 5A STA 2 2 1 2 IJ1 8 B B W ...

Page 3982: ...Location 2 38 Engine Room R B No 2 Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1C 45 Cowl Wire and Driver Side J B Lower Finish Panel 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 2D 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2E g g g Connector Joining Wire Harne...

Page 3983: ... B L W W B B R L 1 3 I 5 4 2 IGT3 L L W W B E 2 E 2 I 1 E 2 E 2 E 2 EC W B W B W R B R B R B R L W W B L B W B W B I23 Battery 2 N 1 E 7 8 15 11 1C 3 1J 7 W R W R 2C 1 25A AM2 2D 1 B 10 12 F13 20A IGN2 1D 2 W B B R Engine Control Module Fusible Link Block Igniter and Ignition Coil No 1 Igniter and Ignition Coil No 2 Igniter and Ignition Coil No 3 Ignition SW Noise Filter ...

Page 3984: ...B B R LG 1 3 I10 4 2 IGT8 LG L W W B IGF2 IGF1 E 2 E 2 E 2 E 2 I 1 E 2 I 1 E 2 I 1 E 2 I 1 I 1 L W L B B R L B W B L W W B L B W B L W W B L B L B W B L W B R B R E 7 10 13 12 14 9 23 24 B R E 2 Engine Control Module Igniter and Ignition Coil No 4 Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 Igniter and Ignition Coil No 7 Igniter and Ignition Coil No 8 ...

Page 3985: ...r Finish Panel 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2D 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IE1 94 Engine Wire and Cowl Wire Right Side of Instrume...

Page 3986: ...2005 TOYOTA TUNDRA EWD611U 329 Memo ...

Page 3987: ... Y G B R Y G B Y W B B 12 11 7 5A ALT S Battery L IG B IC Regulator S 2F 4 2D 1 B 10 140A ALT F13 1H 5 1K 11 B R C C J31 B C A A A A B O Y G Y G Y G ALTL 18 B 9 G 1 A G 2 B 8 J55 A J56 B C12 From Power Source System See Page 320 Body ECU Combination Meter Fusible Link Block Generator Junction Connector Junction Connector CHARGE ...

Page 3988: ...31 65 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1H 45 Cowl Wire and Driver Side J B Lower Finish Panel 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2D 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2F 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left Connector Joining Wir...

Page 3989: ...ion SW 3 2 5 1 2 2 2 20A A F HTR From Power Source System See Page 320 2 2 1 W IE1 12 W R W L W L W B A F HTR Relay 6 1C 2 40A AM1 1 1 1L F13 140A ALT Battery W L W B 12 2 Fusible Link Block 10 B W R 2D 1 25A AM2 2C 1 1C 3 1J 7 W R Short Pin 1E 2 1J 3 3D 10 3C 10 4A 9 4A 19 1C 5 1J 8 7 5A STA 2 1 2 2 IJ1 8 IA8 2 2 B W W R W R B W B R W R W R B B W B B R P W R W L ...

Page 3990: ...R W B F10 W R J34 A A W B R G R B O A A B C J47 A J48 B Fuel Pump Resistor Fuel Pump Junction Connector Junction Connector B R B R W R R B R W R R B R G B R BP1 9 R W L L B W B B R W L 2H 7 2H 6 2F 1 2H 2 2H 5 2C 5 2F 3 2H 4 2B 6 2F 2 2F 5 IA8 13 IO Junction Connector J45 A From Power Source System See Page 320 IL2 1 IA4 10 IJ1 1 R G IL3 12 A A IA4 2 R 2A 2 W B B R A R L B R Y W B B R L B M 5 4 ...

Page 3991: ...25 R P B 13 TC B Y B W B O 13 B R Y B R B R 16 4 5 BAT W R BR W B EC BR From Power Source System See Page 320 B Y R G B W B O B R R P B Y B R R W L B Data Link Connector 3 W R B R W R W L B R CANH A 2 B 1 B L W L 14 CANL 6 W B L W L Junction Connector J76 A J77 B A 2 1 B W 3C 8 3B 8 3C 2 3A 2 ...

Page 3992: ... TC STSW Y R L P B FC B O B O B R B R R G B Y R G B W 23 A 12 C 10 A 8 D 3 A 8 A 30 C 9 A 2 1C 1 1J 1 1D 17 1E 20A IGN2 L R B R B W B Y HA2A D 1 B R 1 Shielded 1 W R W R Y W R G G HA1A 2 D L G P V B R B R A1A A1A A2A A2A B2 B 1 I 1 1 A 30 D 22 D 31 D 23 D A10 4 3 1 2 2 1 3 4 A30 2 A B R B R B R B R B R L R L G R 10 30 50 70 3 E 6 C 4 C 2 C E 2 I20 1 2 I18 1 2 I16 1 2 I14 1 2 Park Neutral Position ...

Page 3993: ... I 1 I 1 I 1 18 E 1 E 33 D 5 D H 4 3 1 4 2 H 6 3 1 4 2 B R L W L B L B B R L W E 2 E 2 I 1 I 1 L B IGT4 G R IGT3 L 10 E 11 E 3 2 1 I 6 3 2 1 I 5 B R B R B R B R B R B R B R IGT1 IGT2 80 60 3 3 2 1 2 1 L W B R L B B R B R B R B R B R L Y LG B R W Y R B W 8 E 15 E 2 E 7 C 5 C 3 C 20 40 E 2 E 2 5 IE1 I 4 I 3 E 2 I21 1 2 I19 1 2 I17 1 2 I15 1 2 B R Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E E...

Page 3994: ...E 2 I 1 E 2 I 1 I 1 I 1 B R L W B R L B B R L B L W 29 B R C 19 C B R B R L B L W L B L B L W 1 B R L B L W E 2 B W W L B R VSV EVAP R W G 34 2 E 2 1 V 4 Camshaft Position Sensor Engine Control Module Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 Igniter and Ignition Coil No 7 Igniter and Ignition Coil No 8 B O B O BR W R G B BR W L B R R G W 33 E 1 2 I 1 B R B W I 1 R R 1 1 1 1 1 ...

Page 3995: ...ntegration Control and Panel Junction Connector Mass Air Flow Meter Stop Light SW Throttle Control Motor and Throttle Position Sensor G B G B I 1 23 E B W 21 17 I 1 10 B O B O C 15 C 14 C 17 C 16 1 2 1 2 B R B R W L W L E 3 A E 4 B E 5 C E 6 D E 7 E Engine Control Module P L W R G B L Y OC2 OC2 OC1 OC1 C19 C20 B W G B G A B B B G B G B Camshaft Timing Oil Control Valve LH Camshaft Timing Oil Contr...

Page 3996: ... 32 EC3 6 I 1 EC3 5 A 22 5 A 6 A IL3 8 IL3 5 IL3 10 14 IL3 IE1 19 EC I 1 IE1 18 B O BP1 8 W B W B W B R W L B L W L W L B R W W L G B G B W L G B G B MPMP VPMP PPMP AIP 1 1 8 3 2 3 B W G B A34 B R IL3 11 G B BP1 10 BP1 5 BP1 7 L W L B R W IE1 24 BP1 6 B W 6 BP2 4 W B 2H 3 IA8 12 1A 10 1F 3 Air Pressure Sensor 6 IA4 B 12 G Y G Y ELS2 2 1 2 7 5A DEF I UP 2 w VSC 3 w o VSC AIP VC E2 2 1 E 26 G Y AIV2...

Page 3997: ...ME01 W B W B EY 4 3 D D E01 E02 E1 E05 W B B BR W B EC 7 E 6 E 1 6 D C D 7 W B E04 Y R B 30 8 B B 1 THWO Y R B G O V G 14 B G O V G B TACH SPD W A A Junction Connector J49 14 IE1 IA8 6 8 A 5 A EC 2 B 6 A 25 A 4 A 13 A 4 A 3 A 2 A 1 EB2 4 EB2 3 EZ E 5 B 1 A31 2 A35 1 AIRP AIRV AIDI B R P G B GR R A32 A A33 B P G B GR R BR L B R B R W W W R B B R IA8 IA8 9 IA8 10 BR W B VP VV DI SIV SIP BATT E B Air...

Page 3998: ...G O V G B B 12 W B IO W B Combination Meter Junction Connector Y R A 32 From Power Source System See Page 320 Y R L V G L Malfunction Indicator Lamp TEMP CONTROL OIL PRESS CONTROL A A 40A AIR PUMP 12 8 F13 Fusible Link Block 1D 6 1F 9 A Junction Connector J45 3E 2 3A 2 W B W B W B A ...

Page 3999: ...rottle valve opening angle as a control signal which is input into TERMINALS VTA1 VTA2 of the engine control module 6 Vehicle speed circuit The vehicle speed sensor detects the vehicle speed and input to the speed sensor of the skid control ECU with actuator from skid control ECU to TERMINAL SPD of the engine control module via combination meter 7 Battery signal circuit Voltage is constantly appli...

Page 4000: ...nd outputs current to TERMINALS HT1B and HT2B to control the heater Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low Temp of exhaust emission is low and warms up the air fuel ratio sensor to improve detection performance of the sensor The engine control module evaluates the signals from each sensor cur...

Page 4001: ...lly closed 3 2 4 8 volts with ignition SW on and throttle valve fully open VPA2 E1 1 8 2 7 volts with ignition SW on and throttle valve fully closed 4 7 5 1 volts with ignition SW on and throttle valve fully open THA E1 0 5 3 4 volts with idling intake air temp 0 C 32 F 80 C 176 F THW E1 0 2 1 0 volts with idling engine coolant temp 60 C 140 F 120 C 248 F STA E1 6 0 volts or more with engine crank...

Page 4002: ...Connector Location EB2 90 Engine No 2 Wire and Engine Room Main Wire Under the Engine Room R B EC3 90 Engine No 2 Wire and Engine Wire Near the Starter IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IA8 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 94 Engine Wire and Cowl Wire Right Side of Instrument Panel IJ1 94 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH IL2 ...

Page 4003: ... J45 W B Y R R G W L R L G Y LG R LG R W L L W R W R L HEAD HF HU HIND DIM L L L R B R B W R W R L W B W B 40A MAIN HEAD Relay HRLY H ON Y R A 18 B 12 W B IA7 13 R W R W 2 DIMMER Relay 1 P 5 C 3 PKB LG R LG R 2G 1 1D 6 1 3A 3 3A 13 A 18 CHG Y G 1K 11 1H 5 Y G Y G EB2 8 Y G 4 G 2 L B C A A From Power Source System See Page 320 B 9 A B10 B B11 C J55 A J56 B C11 A C12 B Body ECU Combination Meter Gen...

Page 4004: ... 2 2 2 3 2 1 3 2 1 2 1 A A A A A A D 2 J34 H 2 H 1 W L G W R W W L W L W B R W W L R L W B R B W R W R L W L W L W B L R L 2 2 2 2 1 1 1 1 W G W R W L R L W B J32 DRL NO 4 Relay A EA A J35 Daytime Running Light Resistor Headlight LH Headlight RH Junction Connector Junction Connector Junction Connector ...

Page 4005: ...Location Code See Page Code See Page Code See Page B9 A 66 D2 64 J35 65 B10 B 66 G2 64 J45 68 B11 C 66 H1 64 J55 A 68 C11 A 66 H2 64 J56 B 68 C12 B 66 J32 65 P5 69 C15 66 J34 65 Relay Blocks Code See Page Relay Blocks Relay Block Location 2 38 Engine Room R B No 2 Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1B 1...

Page 4006: ...2005 TOYOTA TUNDRA EWD611U 349 Memo ...

Page 4007: ...3 8 7 17 16 C15 B B 12 10 B F13 Battery 1B 7 1F 9 W B W B 15A H LP RH 2F 8 R W Y R R G H 2 15A H LP LH 2F 6 R L Y R R G H 1 B B 1B 1 1B 2 1K 2 B Y R Y R Y R J32 C C IJ2 4 R G C R G J32 W B IO A R G J45 R G Y R 2 1 3 2 1 3 Y R IA7 10 R G C 1D 6 W B R G C12 B 9 A B10 B Body ECU Combination Meter Combination SW Fusible Link Block Headlight LH Headlight RH Junction Connector Junction Connector Junctio...

Page 4008: ...h Panel 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 1G 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 2D 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2F g g g Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Locati...

Page 4009: ... 10 FOG LIGHT Relay G W G W R W P D D EA A A 1 F 2 J34 P W B W B 2 1 F 1 P W B D J31 OFF ON R W B 9 FFOG 17 11 10 2 G B C15 1 A From Power Source System See Page 320 Fog Light SW Body ECU Combination SW Front Fog Light LH Front Fog Light RH Junction Connector Junction Connector A J35 Junction Connector 2 ...

Page 4010: ...e Relay Blocks Relay Block Location 2 38 Engine Room R B No 2 Engine Compartment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1B 45 Cowl Wire and Driver Side J B Lower Finish Panel 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel Ground Points Code...

Page 4011: ...N R W Y R 17 FFOG B 9 R W G B 2F 6 R L R G Y R H 1 2F 8 R W R G Y R B B 15A H LP LH 15A H LP RH B J32 C15 3 1 5 2 Y R 1 2 3 1 2 3 H 2 10 11 A From Power Source System See Page 320 Fog Light SW Body ECU Combination SW Front Fog Light LH Front Fog Light RH Headlight LH Headlight RH Junction Connector Junction Connector Junction Connector A A J35 Junction Connector ...

Page 4012: ... 65 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1B 45 Cowl Wire and Driver Side J B Lower Finish Panel 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2F 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left Ground Points Code See Page ...

Page 4013: ...1 F 4 16 140A ALT 2 12 A A J46 LG G B 9 A B10 B Light Control SW C15 Body ECU Combination SW Fusible Link Block Junction Connector Junction Connector Junction Connector Front Parking Light RH 2 1 F12 Front Parking Light RH No 2 2 1 F11 Front Parking Light LH No 2 2 1 F 3 Front Parking Light LH 1G 8 A B G W B A 2 1 F18 B G W B A 2 1 F19 J30 Junction Connector J35 Junction Connector G Front Parking ...

Page 4014: ...1 L 2 1 2 1 2 A I B B G BP3 7 B 3 B 3 B 3 B 3 B 3 B 3 W B W B W B W B W B G G G G G W B W B G G Tail Tail License Plate Light LH License Plate Light RH Rear Combination Light LH 3 2 R 5 Rear Combination Light RH Junction Connector J38 A J39 B G G ...

Page 4015: ...d Driver Side J B Lower Finish Panel 1G 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1L 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location BP3 96 Frame Wire and Floor No 2 Wire Under the Driver s Seat Ground Points Code See Page Ground Points Loc...

Page 4016: ...2005 TOYOTA TUNDRA EWD611U 359 Memo ...

Page 4017: ... B C15 7 5A PANEL 1H 10 1M 3 1E 12 22 21 G G C12 1H 8 1E 13 W G W G W G ID2 6 G ID2 5 G ID2 3 W G ID2 4 W G G 2 1 A18 2 1 C 8 B W G B G A A J46 LG J45 G 7 8 O 8 4D 3 4D 4 4A 14 W G 4D 2 4D 1 4A 1 B 9 A B10 B Ashtray Illumination Body ECU Cigarette Lighter Illumination Combination Meter Combination SW Fusible Link Block Junction Connector Junction Connector Overhead Module 1B 4 IC2 2 W G Illuminati...

Page 4018: ... A A B B B A W G G J57 J57 4A 4 4B 4 4C 4 A 4D 10 4A 10 4A 20 W B 2 1 ILL ILL G 3 I24 C16 R 2 A R 1 B R14 C R15 D Steering PAD SW Combination SW Glove Box Light Integration Control and Panel Junction Connector Junction Connector Radio and Player Seat Heater SW Driver s Seat Seat Heater SW Front Passenger s Seat Junction Connector J58 W G W G 1 2 G M 5 Main SW 4E 4 4E 2 3 8 Speaker w o Navigation S...

Page 4019: ...d Wire Harness Connector Location 1B 1E 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 1G 1H 1L 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1M 45 Roof Wire and Driver Side J B Lower Finish Panel 4A 4B 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D 4E Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Conn...

Page 4020: ...2005 TOYOTA TUNDRA EWD611U 363 Memo ...

Page 4021: ... B B 3 W B W B From Power Source System See Page 320 J51 A J52 B Turn Signal SW J51 A J52 B J53 C J51 A J52 B J53 C J38 A J39 B J38 A J39 B J51 A J52 B Turn Turn C11 A C12 B Combination Meter Combination SW Integration Control and Panel Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Co...

Page 4022: ...J B Lower Finish Panel 1F 1H 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel BP3 96 Frame Wire and Floor No 2 Wire Under the Driver...

Page 4023: ...1 1 1 Y G W B R R W B 1 BRK G W 4 STOP J34 J45 O 5 B10 1 1 1 1 1 1 G Y W B G W 1 R B 1 1 1 1 W B 1 L 1 B R G 1 1 J46 2 G 1 W B R B L 1 1 W B B W BRK BATT B UP GND STTL STTR TAIL C C 1 J31 A B B B IA4 5 EA 3A 2 3B 2 BP3 5 BP3 2 BS A W B 1 R 1 C 6 B 6 BP3 4 BP3 1 A N B G A G B N G Y Y G BP3 10 B Y B Y B 2 2 A 3 1 A 6 1 B 4 2 A 4 A 2 A 7 B 1 B 3 A 1 A 5 W B L L R 1 1 1 From Power Source System See Pa...

Page 4024: ... 1 BP3 9 A H B F A D A D B E 1 B 30A TOWING 2B 4 20 IA4 R W R W 3 9 8 RTIN LTIN STIN G Y G B G W 2 4 6 RTOT LTOT GND Y G G W 1 IL2 2 From Power Source System See Page 320 J51 A J53 C J47 A J48 B J28 A J29 B J51 A J52 B Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Park Neutral Position SW Turn Signal Flasher Back Up T 9 Trailer Converter W R B A B A...

Page 4025: ...l 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2B 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3B 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine...

Page 4026: ...2005 TOYOTA TUNDRA EWD611U 369 Memo ...

Page 4027: ...A J45 W B W B W B 3 5 R 4 R B BS W B 3 5 R 5 R B R B 1D 7 R B A H B F BP3 9 R B B 3 B 3 W B IL2 2 From Power Source System See Page 320 J28 A J29 B Back Up Back Up Junction Connector Junction Connector Park Neutral Position SW Rear Combination Light LH Rear Combination Light RH Back Up B F 5 REV Radio and Player with Display R30 R B 1 1 w Navigation System ...

Page 4028: ...1D 1E 45 Cowl Wire and Driver Side J B Lower Finish Panel 1F Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IE1 94 Engine Wire and Cowl Wire Right Side of Instrument Panel IL2 92 Floor No 2 Wire and Cowl Wire Right Kick Panel BP3 96 Frame Wire and Floor No 2 Wire Under the Driver s Seat Ground Points Code See Page Ground Point...

Page 4029: ...urce System See Page 320 J47 A J48 B J38 A J39 B Stop Stop High Mounted Stop Light Junction Connector Junction Connector Rear Combination Light LH Rear Combination Light RH 2 w o VSC 1 w VSC 10A ECU IG 1F 4 3A 4 3D 3 4A 18 4A 8 3 2 4 5 1 D A E B Stop Light SW S 4 W R G W G W W R Stop Light Relay S31 IA8 4 S29 Skid Control ECU with Actuator 16 L B L B L B B R B R W B R 1 1 1 1 1 1 1 1 1 2 1 2 1 W S...

Page 4030: ...al 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4A 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA8 92 Engine Room Main Wire and Cowl Wire Left Kick Panel BP3 96 Frame Wire and Floor No 2 Wire Under the Driver s Seat Ground Points Code See Page Ground ...

Page 4031: ...19 11 15 8 Y B Y B P B G Y P 2 4 H L 4WD L4 F20 IND1 IND2 H L 2 4 7 B 5 B A 19 A 20 B 4 B 6 R Y B 13 7 6 B 6 W R DEF A 17 V W AC1 ACT AC1 LMS IE1 4 10A HTR 1E 4 4A 7 4D 7 R Y A 3 3 B 9 B 4 RDEF 4B 7 Y DEFOG Relay From Power Source System See Page 320 C12 B I24 A I25 B A C Magnetic Clutch and Lock Sensor Air Inlet Control Servo Motor Defroster Mode SW Combination Meter 4WD Control ECU Integration C...

Page 4032: ...R 4D 10 4B 10 W B J58 L O Skid Control ECU with Actuator I24 A I25 B From Power Source System See Page 320 Integration Control and Panel Junction Connector Turn Signal Flasher BS1 5 A 13 B B 24 B 2 A 8 16 B IK2 17 BS1 3 8 2 1 8 4 9 5 Occupant Classification ECU O10 B B G R G B G R G B R L 1 1 1 1 1 1 1 2 1 B 2 Buckle SW RH B13 FSR FSR BGND Short Connector S13 A S14 B BSW FSR FSR PBEW Center Airbag...

Page 4033: ... G B W B W W B B W W B 7 5A PANEL 1E 12 4A 1 4A 2 4B 1 4B 4 4D 10 4A 4 4A 10 IN A J58 W G W B W B G IL2 7 B W B 11 A 16 CGLP CGSW 7 5A CARGO LP F13 IA4 3 CGB 10 B P P 6 From Power Source System See Page 320 B 9 A B10 B J46 Body ECU Fusible Link Block Junction Connector Junction Connector Rheostat Cargo Light H10 B B B L E T ...

Page 4034: ...partment Left Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1E 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 1H 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3E 48 Cowl Wire an...

Page 4035: ...W H10 GND CGID CGSW 6 7 5A CARGO LP F13 IA4 3 B 10 P P P CGB A 16 CGSW W B 4B 10 4B 10 IL2 7 B W B W B W B W CGLP B 11 B 9 A B10 B I25 B From Power Source System See Page 320 J46 Body ECU Fusible Link Block Cargo Light Integration Control and Panel Junction Connector Junction Connector B B B Cargo Light SW ...

Page 4036: ... Connector Code See Page Junction Block and Wire Harness Connector Location 4B 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IL2 92 Floor No 2 Wire and Cowl Wire Right Kick Panel Ground Points Code See Page Gro...

Page 4037: ...Double Cab C 19 B 7 B MPX1 MPX2 W L IB5 3 8 20 MPX1 MPX2 D44 G B IB5 8 W L C 16 MPX3 P 1G 12 1M 9 2 MPX1 G O M 6 1 1 1 w Moon Roof 10 11 MPX2 MPX1 F17 IF6 4 IF6 8 B G B B G B G B B10 B B11 C Body ECU Driver Door ECU Front Passenger Door ECU Moon Roof Control ECU and Motor ...

Page 4038: ...ee Page B10 B 66 D44 70 M6 70 B11 C 66 F17 70 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1G 45 Cowl Wire and Driver Side J B Lower Finish Panel 1M 45 Roof Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IB5 92 Front Door ...

Page 4039: ...P LG L B W L W L Engine Control Module E 4 Junction Connector J76 A J77 B J78 C J79 D J80 E J81 F 14 6 Data Link Connector 3 D 6 25 11 IA4 24 IA4 23 R Y R G CANH CANL S29 S19 Y 1 IK2 4 IK2 13 LG L CANL CANH CANL CANH Skid Control ECU with Actuator Steering Sensor Yaw Rate Sensor CANL CANH CANL CANH ST Plug 1 F IP W B A Junction Connector J54 ...

Page 4040: ...ol Electronically Controlled Transmission and A T Indicator Engine Control VSC Parts Location Code See Page Code See Page Code See Page D6 67 J77 B 68 J81 F 68 E4 67 J78 C 68 S19 69 J54 68 J79 D 68 S29 65 J76 A 68 J80 E 68 Y1 69 Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine Room Main Wire and Cowl Wire Left Kick...

Page 4041: ... 10A H LP LH 2 10A H LP RL 2 G W 10A H LP LL 2 2 2 2 3 2 1 3 2 1 J32 2 1 From Power Source System See Page 320 A A A A D 2 H 2 H 1 LG R LG R W L G W R W W L W L W B W L L W L R B R B 2 W L 1 W L 40A MAIN HEAD Relay DIMMER Relay L R L 2 2 2 2 1 1 1 1 W 1 L R L R W 2 R L 2 R L 1 140A ALT 2 12 F13 B W Battery 15A H LP RH 2F 8 G W 1 R L 2 R L 1 1 1 Daytime Running Light Resistor Fusible Link Block Hea...

Page 4042: ... 2 1 G W 1 W B 1 1 1 1 1 R W 2 R L 1 R L 2 2 5 1 3 2 2 2 2 A A J34 R W W B R L W L W B DRL NO 4 Relay IA4 14 W 2 R G W R G 2 Y R 2 R G A R W Y R 2 H 2 R L R G 2 H 1 B B R G B J32 C C IJ2 4 R G C R G J32 2 1 3 2 1 3 2 2 2 Y R 2 B 1 w Daytime Running Light 2 w o Daytime Running Light 1 IA7 10 C 2 R G B 9 A B10 B B11 C Body ECU Headlight LH Headlight RH Junction Connector Junction Connector Junction ...

Page 4043: ... R L G Y HEAD HF HU DIM 4 LG R B HRLY W R G 2 2 R G W R W W L 14 A 14 G TAIL Y R Y R R L G G Y 1K 17 2 1 3 2 5 15A FOG From Power Source System See Page 320 1B 9 1K 7 1J 10 A 17 FFOG Fog Light SW OFF ON R G EA 2 1 2 1 D A D D F 1 F 2 P P P W B W B J31 J34 R W 10 11 R W G B G B FOG LIGHT Relay Y R Y R 2 1 1 2 15 C GND W B W B W B A B 9 A B10 B B11 C Body ECU Combination SW Front Fog Light LH Front ...

Page 4044: ...ng Light 1 w Daytime Running Light 3A 17 3C 7 W B W B A 18 CHG Y G B C A A 1H 5 1K 11 EB2 8 B 4 L Y G Y G Y G A A J34 A A 9 IA7 5 2 1 BZR LG LG W B W 5 Buzzer B 9 A B10 B B11 C J49 A J50 B G 2 B Body ECU Data Link Connector 3 Engine Hood Courtesy SW Generator Junction Connector Junction Connector Option Connector Glass Breakage Sensor Theft Deterrent Horn Wireless Door Lock Buzzer ...

Page 4045: ... 2 BM1 13 P28 W B W B R G 5 2 3 4 6 1 P26 DWN UP B E D U Up Down BQ 1 2 BL1 13 P27 W B W B R G 5 2 6 1 P25 DWN UP D U Up Down 4 3 E B C 8 1 PCTY LG B LG B D17 B E A B B I A L A C B J W B W B W B 1 C 3 PKB LG R P 5 LG R 3A 13 3A 3 IK1 12 IK1 7 IK1 8 IK1 3 B 9 A B10 B B11 C J38 A J39 B Body ECU Door Courtesy SW Front RH Junction Connector Parking Brake SW Power Window Control SW Rear LH Power Window...

Page 4046: ...R G W B K A D A E L B A A B H A K B D W B W B W B W B 2 w o Daytime Running Light 6 C 21 HORN B Y C16 L B B 4 IK1 14 IK1 13 IK1 9 B A B D A C L R L B L R L B L R L R P B L B L R L B B 9 A B10 B B11 C J38 A J39 B J38 A J39 B Horn J47 A J48 B J38 A J39 B Body ECU Combination SW Door Lock Motor Rear LH Door Unlock Detection SW Rear LH Door Lock Motor Rear RH Door Unlock Detection SW Rear RH Junction ...

Page 4047: ...2 L B R C 22 1 2 Y G Y G W B KSW U 1 IO D35 A J B C D34 4A 6 4C 6 4E 6 4D 6 R R R W R W B L R L B L R W B W B W B C 10 C 9 V R Y W B W R 3 2 5 1 PRG RDA PRG RDA E B D32 3A 1 3A 2 3A 12 A IK1 10 J45 IK2 9 4A 16 R W B B 9 A B10 B B11 C J38 A J39 B Body ECU Door Lock Control Receiver Diode Door Courtesy No 1 Diode Door Courtesy No 2 Door Courtesy Light Rear LH Door Courtesy Light Rear RH Door Courtes...

Page 4048: ... 8 R W B 1G 1 1M 7 B 1 W B W B W B B 9 A B10 B B11 C J42 A J43 B Body ECU Interior Light Junction Connector Overhead Module Step Light Vanity Light LH Vanity Light RH Personal Light B 8 ILE L B 1G 5 1M 10 W 5 1E 3 L B 1G 13 5 6 Speaker 6 Except 6 Speaker R R R L B R 2 3 R I26 1 Interior Light 7 w Vanity Light 8 w o Vanity Light B 1 7 8 W B W B 8 L B 8 13 4 7 7 W 5 L B 6 7 G R 3 B 4 7 7 L B 6 7 7 3...

Page 4049: ...L R W R R L B L R R L R L B R B W R R G 2 2 W R G W B J45 L R W B W B A W B R R B 15 1 DCTY GR R D16 A H B A GR R GR R A 30 GR R B 24 B O Door B 9 A B10 B B11 C J38 A J39 B C11 A C12 B Body ECU Combination Meter Door Courtesy SW Front LH Junction Connector Junction Connector Moon Roof Control ECU and Motor B D B D A E B 17 Junction Connector J49 A J50 B 17 C IND A 17 R G B O 2 Security 18 C HIND A...

Page 4050: ...W R W R B W R 4 B R B R W R R HR W R A 6 2F 7 1 1 8 2H L R L B R B L R W R W R LG W L R MPX1 L R R B L B L R B 7 LG TRLY B 5 W L IA7 12 B R W R 2 W R G 9 4C 4A 9 4A 19 W R W B W B W B W B 3 w Moon Roof 2 w o Daytime Running Light W R W R B MPX2 C 19 B B O 10A IGN1 1H 11 B O 1 w Daytime Running Light B 9 A B10 B B11 C From Power Source System See Page 320 Body ECU Horn LH Horn RH BP3 11 W R ...

Page 4051: ...W R L R L B R B L R W R W L R L L R R B R W R R B L B L R 1 5 2 3 2 1G TAILLIGHT Relay POWER MAIN Relay W R L W R 30A TOWING TAIL 3 3 2 5 1 3 3 3 IA4 26 A A A LG LG LG LG TOWING TAIL Relay B W B W 1 2 3 B Y W B W B 1F 9 J46 W B W R W R 3D 10 3A 10 3A 20 3D 9 W R W R B B From Power Source System See Page 320 Junction Connector ...

Page 4052: ... 7 5 6 3 2 13 4 5 D15 D43 L B R L G R L Y W R B R R Y W B LG R LG B R R W W B W B L R L Y W R B R L Y G B GND PCYL CTYB PKL PKUL LSWP LSWE LSW PDN PU BDR CPUB SIG 8 IB5 G B G B MPX2 11 4 IF6 B F17 M 3A 4 3A 14 From Power Source System See Page 320 Door Courtesy Light Front RH Door Key Lock and Unlock SW Front RH Door Lock Motor Front RH Door Unlock Detection SW Front RH Front Passenger Door ECU Po...

Page 4053: ...P GR GR P R G B W B W B W B W B W B W B W B B 5 5 IK1 4 IK1 6 6 12 IK1 L Y B 5 L Y L Y L Y Y W B R L B 4 Back Window Control Relay Power Window Control SW Back Window Power Window Motor Back Window W L B R G B L R W R R L R L W B L R W L R B R B W B W R B R G B R L B 8 Back Window Relay IK2 1 3A 11 3A 2 30A PWR NO 5 1G 15 W B W B L W 3 1 5 2 Y From Power Source System See Page 320 ...

Page 4054: ... R L B L W W B W B G R W B L R R Y W B LG R LG B R R W W B 2 1 5 3 A D42 P11 D14 2 1 D A M 4 3 6 5 1 2 B F IO 13 IB5 1 1F 25A PWR NO 1 25 3 4 1 14 24 9 10 22 5 6 13 IB5 1 W R 23 CPUB SIG W R B R From Power Source System See Page 320 J36 A J37 B Door Courtesy Light Front LH Door Key Lock and Unlock SW Front LH Door Lock Motor Front LH Door Unlock Detection SW Front LH Driver Door ECU Junction Conne...

Page 4055: ...e ignition SW at ON position 12 Ground Always approx 12 volts 20 Ground Always approx 12 volts 8 Ground Always continuity Parts Location Code See Page Code See Page Code See Page B8 66 D43 70 J47 A 68 B9 A 66 D44 70 J48 B 68 B10 B 66 E8 64 J49 A 68 B11 C 66 F1 64 J50 B 68 B12 70 F2 64 J58 68 C11 A 66 F13 34 64 M6 70 C12 B 66 F17 70 O7 69 C15 66 G2 B 64 O8 70 C16 66 H1 64 P5 69 D2 64 H2 64 P11 71 D...

Page 4056: ...ne Room Main Wire Under the Engine Room R B IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IB5 92 Front Door LH Wire and Cowl Wire Left Kick Panel IF5 94 Front Door RH Wire and Cowl Wire Right Kick Panel IF6 94 Front Door RH Wire and Cowl Wire Right Kick Panel IJ2 94 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH IK1 94...

Page 4057: ...6 A 14 TAIL A 15 HEAD 14 13 C15 G G Y 140A ALT F13 W B W 2 10 Battery 12 B 1 C 8 1 PCTY LG B LG B D17 1F 9 1B 7 1 2 C 22 IO Y G W B U 1 KSW V R Y D32 PRG RDA C 10 PRG C 9 RDA 3 2 W B A A J46 LG A 3A 2 3A 1 A J45 A W B W B W B IK1 3 B 9 A B10 B B11 C Light Control SW Body ECU Combination SW Door Courtesy SW Front RH Door Lock Control Receiver Fusible Link Block Junction Connector Junction Connector...

Page 4058: ...CY R W R W R W 16 B 2 D38 B O 1 A H B A J50 B GR R A J B C 3D 10 4A 19 C 25 W R BECU W R IK1 10 B 9 A B10 B B11 C J38 A J39 B J49 A J50 B From Power Source System See Page 320 Body ECU Door Courtesy SW Front LH Diode Door Courtesy No 1 Diode Door Courtesy No 2 Door Courtesy SW Rear LH Door Courtesy SW Rear RH Junction Connector Junction Connector Junction Connector B D B D ...

Page 4059: ... Code See Page Code See Page Code See Page B9 A 66 D34 70 J45 68 B10 B 66 D35 70 J46 68 B11 C 66 D38 70 J49 A 68 C15 66 D39 70 J50 B 68 D16 70 F13 34 64 U1 69 D17 70 J38 A 68 D32 67 J39 B 68 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1B 1E 45 Cowl Wire and Driver Side J B Lower Finish Panel 1F 45 Cowl Wire and Driver Side J B Lower Fi...

Page 4060: ...2005 TOYOTA TUNDRA EWD611U 403 Memo ...

Page 4061: ...tegration Control and Panel Junction Connector Junction Connector Front Passenger Seat Belt Warning BQ2 13 G Y BLINK Driver s Seat Belt 1D 6 1F 9 BUZZER W B GR R Y G B 13 2 A 2 1 A 3 1 B 3 2 1 1 1 1 1 W B 2 2 G Y IN A BGND FSR FSR B13 Buckle SW RH 2 B 1 2 1 1 1 1 1 1 1 L R G B G R G B G R B B O10 Occupant Classification ECU 5 9 4 8 1 2 8 3 BS1 17 IK2 B 16 8 A 2 B 24 B B 13 A 5 BS1 J58 Junction Con...

Page 4062: ...U 1 D16 GR R GR R Y G W B A H B A J49 A J50 B W B GR R 1J 3 1E 2 W R W R 3A 10 3D 10 A J45 W B 3A 2 3A 1 J38 A J39 B B10 B B11 C Body ECU Door Courtesy SW Front LH Junction Connector Junction Connector Junction Connector Unlock Warning SW A A B D B D A E 23 C KSW2 Y G GR R W B From Power Source System See Page 320 ...

Page 4063: ...ion Code See Page Code See Page Code See Page B7 72 C12 B 66 J49 A 68 B10 B 66 D16 70 J50 B 68 B11 C 66 I25 67 J58 68 B13 72 J38 A 68 J82 72 B15 70 J39 B 68 O10 72 C4 A 66 J42 A 68 S13 A 69 C5 B 66 J43 B 68 S14 B 69 C11 A 66 J45 68 U1 69 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1D 1E 45 Cowl Wire and Driver Side J B Lower Finish Pan...

Page 4064: ...2005 TOYOTA TUNDRA EWD611U 407 Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel BQ 96 Left Side of Center Pillar ...

Page 4065: ... 1 A 4 IO 10A IGN1 From Power Source System See Page 320 1H 11 B 24 B O W B L R ACTY B 9 A B10 B B11 C J38 A J39 B J38 A J39 B C11 A C12 B I22 J42 A J43 B Body ECU Combination Meter Diode Door Courtesy No 1 Diode Door Courtesy No 2 Door Courtesy Light Rear LH Door Courtesy Light Rear RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Ignition Key Cylinder Light Junction Connector Junction Connec...

Page 4066: ... 2 R L B 1 OFF ON DOOR B 1 W B W B B 1 W B 1 W B 3 1 R 3 6 BS W B R R 4 BP3 11 B 9 A B10 B B11 C Luggage Room Light Body ECU Interior Light Rear Combination Light LH Step Light Vanity Light LH Vanity Light RH Personal Light Overhead Module O 8 1G 13 W 2 2 Except 6 Speaker 1 6 Speaker I26 R 3 4 1 Interior Light 4 4 4 3 2 B 1 W B W B 3 13 G R 5 B 6 3 3 L B 4 3 3 L B 1 3 W 2 3 3 w Vanity Light 4 w o ...

Page 4067: ... 2 W R W R 10A ECU IG 1G 11 1F 4 B R B R 4A 9 4C 9 W R B R B R B R 4A 19 3D 10 3D 9 3A 10 W R W R W R 3D 3 3A 14 3A 4 From Power Source System See Page 320 W R BECU 25 C B R IG 1 B C 15 GND W B 19 C B MPX2 IO A W B J45 Junction Connector W R W R B R B R B Body ECU B 9 A B10 B B11 C ...

Page 4068: ...1 1 IB5 A D IB5 9 D14 A J45 W B R W R W B W R B R W R B R CPUB SIG CTYB DCYL GND G B 20 MPX1 D44 5 6 2 1 D15 R W R CTYB PCYL IN A J58 10 MPX1 IF6 8 B G B B J36 A J37 B Door Courtesy Light Front LH Door Courtesy Light Front RH Driver Door ECU Front Passenger Door ECU Junction Connector Junction Connector Junction Connector 4A 8 4C 8 B R B R W R W R B ...

Page 4069: ...45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1M 45 Roof Wire and Driver Side J B Lower Finish Panel 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4A 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D 50 Cowl Wire and Sub...

Page 4070: ... Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel BS 96 Surrounding of the Front of the Fuel Tank Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points B1 96 Roof Wire B6 96 Floor No 2 Wire ...

Page 4071: ...M1 2 1 IN 6 1 P25 DWN UP D U Up Down M 3 E B 2H 1 30A DOOR NO 2 B 9 BDR L W L W L W From Power Source System See Page 320 IA4 14 2 L O L Y B 4 1 B I B J A B A C B E A L L Y L Y D D A H B A J50 GR R A J58 W B IK2 1 IK1 7 IK1 8 IK1 3 B10 B B11 C J38 A J39 B J38 A J39 B Body ECU Door Courtesy SW Front LH Door Courtesy SW Front RH Fusible Link Block Junction Connector Junction Connector Junction Conne...

Page 4072: ...ECU B 2C 8 W R 4A 9 4C 9 1J 3 1E 2 W B 9 1F 16 1F 3 2 5 1 1 1L W R W R W R R L W R W L From Power Source System See Page 320 W R L POWER MAIN Relay 4A 19 C 15 GND W B 8 1F 7 1G 20A PWR NO 3 20A PWR NO 4 L Y L O L Y BM1 5 L O W B IK1 12 3D 10 3A 10 3D 9 W R W R W R MPX2 B 19 C B L O B10 B B11 C Body ECU W B L O ...

Page 4073: ...F6 3 IF6 17 1F 25A PWR NO 2 7 IF6 8 IN A PDN 2 1 M W B W B W B B R 10 IF6 8 B MPX1 W B 3D 3 3A 14 3A 4 L Y L Y L Y B 5 L Y IK1 12 6 6 IK1 4 IK1 5 B 5 PU IK2 1 W B W B W B W B W B B G R P GR GR P 6 3 2 1 3 1 2 1 4 5 8 9 11 E LS2 LS1 DOWN UP SD SU E LMTE B IGB UP DOW1 UP DOWN LMTW P21 4 P22 W B B12 W B From Power Source System See Page 320 Back Window Control Relay Front Passenger Door ECU Power Win...

Page 4074: ...O 1 1F 1 IB5 13 F B 9 A D B E A E A E 7 P11 3 5 1 2 W B L R W B R G W B 21 B L W L B L B R L B R GND DDN DU SGND PLS BDR WLSW MPX2 8 W L 3 IB5 W L G B 20 MPX1 J36 A J37 B D44 M Pulse Sensor From Power Source System See Page 320 J36 A J37 B Driver Door ECU Junction Connector Junction Connector Power Window Motor Front LH 3 1 5 2 B 8 Y Back Window Relay 3A 11 3A 2 W B KOFF ...

Page 4075: ...d Approx 12 volts with the ignition SW at ON position 23 Ground Always approx 12 volts 25 Ground Always approx 12 volts 13 Ground Always continuity F17 Front Passenger Door ECU 19 Ground Approx 12 volts with the ignition SW at ON position 12 Ground Always approx 12 volts 20 Ground Always approx 12 volts 8 Ground Always continuity Parts Location Code See Page Code See Page Code See Page B8 66 F17 7...

Page 4076: ... and Cowl Wire Right Kick Panel IK1 94 Floor Wire and Cowl Wire Right Kick Panel IK2 94 Floor Wire and Cowl Wire Right Kick Panel BL1 96 Rear Door No 1 Wire LH and Floor No 2 Wire Left Side of Center Pillar BM1 96 Rear Door No 1 Wire RH and Floor Wire Right Side of Center Pillar Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel BQ 96 Left Side of Cente...

Page 4077: ...15 1 1 PCTY DCTY LG B GR R GR R LG B D17 D16 1 1 A H B A GR R J50 U 1 Y G KSW IO 2 1 22 C W B IND 17 C W B A A J34 3A 1 3A 2 A J45 1D 6 1F 9 B O W B W B IK1 3 From Power Source System See Page 320 B 9 A B10 B B11 C J38 A J39 B Body ECU Door Courtesy SW Front LH Door Courtesy SW Front RH Engine Hood Courtesy SW Fusible Link Block Junction Connector Junction Connector Junction Connector Junction Con...

Page 4078: ...40 L B L B L R P L LSWR ACT ACT LSWL IF6 12 L R IF6 13 IB5 10 L R L B L R L R L B A A B H A K B D A D B K L R A J58 IK1 14 IK1 13 IK1 9 B A A E A C B D L R L B L R L B L R L R L B IK2 1 W B B 9 A B10 B B11 C J38 A J39 B J38 A J39 B J47 A J48 B Body ECU Door Lock Motor Rear LH Door Unlock Detection SW Rear LH Door Lock Motor Rear RH Door Unlock Detection SW Rear RH Junction Connector Junction Conne...

Page 4079: ...W R W 4 C D39 B O 1 16 B A D38 B O 1 W B H 7 10A HORN 5 2 HORN Relay 1 3 H 8 W R B B HR W R A 6 2F 7 1 1 8 2H IA7 12 IO A IK1 10 W B J45 B 9 A B10 B B11 C From Power Source System See Page 320 J38 A J39 B Body ECU Diode Door Courtesy No 1 Diode Door Courtesy No 2 Door Courtesy SW Rear LH Door Courtesy SW Rear RH Horn LH Horn RH Junction Connector Junction Connector Theft Deterrent Horn ...

Page 4080: ... W R 10A ECU IG 1G 11 1F B 1 B R IG 4 B R LG MPX1 B 7 LG TRLY B 5 W L W R W R W R B R W L 1 1L 1 5 2 3 2 1G LG TAILLIGHT Relay W L R L B L B L R L R L R R B A A J46 B R 4A 19 4C 9 3D 10 3A 10 3D 9 C 19 B MPX2 B W R W R W R B 9 A B10 B B11 C From Power Source System See Page 320 Body ECU Junction Connector ...

Page 4081: ... 2 D42 A W B LG B LG R W B R Y W B L W L B L B L R LSWD LSWE KUL KL GND BDR SIG 21 B R 9 IB5 B R G B 20 MPX1 D44 L R R B W L IB5 3 W L 8 MPX2 W R IB5 1 W R 23 CPUB J45 R B W R L R L B B R IF6 8 10 B MPX1 B From Power Source System See Page 320 J36 A J37 B Door Key Lock and Unlock SW Front LH Door Lock Motor Front LH Door Unlock Detection SW Front LH Door Key Lock and Unlock SW Front RH Door Lock M...

Page 4082: ...d Door Unlock Detection SW Front RH 6 Ground Approx 12 volts with the door lock motor at lock operate 5 Ground Approx 12 volts with the door lock motor at unlock operate 2 4 Closed with the door lock cylinder locked with key 1 4 Closed with the door lock cylinder unlocked with key Parts Location Code See Page Code See Page Code See Page B9 A 66 D41 70 J38 A 68 B10 B 66 D42 70 J39 B 68 B11 C 66 D43...

Page 4083: ...IB5 92 Front Door LH Wire and Cowl Wire Left Kick Panel IF6 94 Front Door RH Wire and Cowl Wire Right Kick Panel IK1 94 Floor Wire and Cowl Wire Right Kick Panel IK2 94 Floor Wire and Cowl Wire Right Kick Panel BL1 96 Rear Door No 1 Wire LH and Floor No 2 Wire Left Side of Center Pillar BM1 96 Rear Door No 1 Wire RH and Floor Wire Right Side of Center Pillar Ground Points Code See Page Ground Poin...

Page 4084: ...2005 TOYOTA TUNDRA EWD611U 427 Memo ...

Page 4085: ...B W 5 Buzzer RRCY RLCY 2 2 3 3 D34 D35 R W R W R W R W 4 C D39 B O 1 16 B D38 B O 1 1 A H B A D D D17 D16 GR R J50 A J B C IK1 3 A A J34 IK1 10 J38 A J39 B J38 A J39 B B 9 A B10 B B11 C Body ECU Door Courtesy SW Front LH Door Courtesy SW Front RH Diode Door Courtesy No 1 Diode Door Courtesy No 2 Door Courtesy SW Rear LH Door Courtesy SW Rear RH Fusible Link Block Junction Connector Junction Connec...

Page 4086: ... W B W B W B 1 9 9 4 D41 D40 L B L B L R P L LSWR ACT ACT LSWL IF6 12 L R IF6 13 IB5 10 L R L R L B L R A A B H A K B D B K A D L B IK1 14 IK1 13 IK1 9 IK2 1 A J58 A E A C B A B D L R B 9 A B10 B B11 C J38 A J39 B J38 A J39 B J47 A J48 B Body ECU Door Lock Motor Rear LH Door Unlock Detection SW Rear LH Door Lock Motor Rear RH Door Unlock Detection SW Rear RH Junction Connector Junction Connector J...

Page 4087: ... 1 PRG RDA KSW D32 L R L B L R IB5 2 C 14 R B R B ACTD BECU W R 25 C W L 5 B TRLY LG 7 B MPX1 IG B R 1 B E PRG RDA B 15 C W B GND W B W B A A J46 B R W R W R W R B R W L LG W 3A 12 3A 1 3A 2 A A J45 3D 10 3A 20 3D 9 3A 10 MPX2 19 C B B W R B 9 A B10 B B11 C From Power Source System See Page 320 Body ECU Door Lock Control Receiver Junction Connector Junction Connector Unlock Warning SW ...

Page 4088: ...3 4 5 D43 L B J58 R Y W B LG R LG B W B W B L R GND PKL PKUL LSWP LSWE IF6 7 25A PWR NO 2 1F 17 IF6 3 IF6 11 12 19 20 L Y W R B R L Y W R B R L Y BDR CPUB SIG MPX1 B 10 8 IF6 8 IB5 G B G B MPX2 11 4 IF6 F17 3A 14 3A 4 3D 3 B R B L R W L W R B R G B B From Power Source System See Page 320 Door Key Lock and Unlock SW Front RH Door Lock Motor Front RH Door Unlock Detection SW Front RH Front Passenger...

Page 4089: ...45 W B LG B LG R W B R Y W B W B W R B R L W L B L B W R B R L R CPUB SIG LSWD LSWE KUL KL GND BDR MPX2 8 W L 3 IB5 W L G B 20 MPX1 D44 R B R B L R G B B R W R W L From Power Source System See Page 320 J36 A J37 B Door Key Lock and Unlock SW Front LH Door Lock Motor Front LH Door Unlock Detection SW Front LH Driver Door ECU Junction Connector Junction Connector ...

Page 4090: ...ehicle after the lock signal is output from the transmitter the lock signal is output again D16 D17 D38 D39 Door Courtesy SW Front LH RH Rear LH RH 1 Ground Closed with the door open D42 Door Lock Motor Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH 2 Ground Approx 12 volts with the door lock motor at lock operate 1 Ground Approx 12 volts with the door lock motor at unlock opera...

Page 4091: ...Sub J B No 4 Upper the Accelerator Pedal 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IB5 92 Front Door LH Wire and Cowl Wire Left Kick Panel IF6 9...

Page 4092: ...2005 TOYOTA TUNDRA EWD611U 435 Memo ...

Page 4093: ...H 1K 9 4 3 IJ2 12 IO 11 16 7 8 17 2 W B R B L L A W B W 2 W 4 R B IJ2 15 L W L W L B 14 IJ2 L B L R IJ2 13 L R L IJ2 11 L L L W EM A W B J45 J30 A C B A A C L From Power Source System See Page 320 J49 A J50 B Front Wiper and Washer SW C17 Combination SW Junction Connector Junction Connector Junction Connector Washer Motor Wiper Motor M ...

Page 4094: ...s from TERMINAL 3 of the washer motor to TERMINAL 4 to TERMINAL 11 of the wiper and washer SW to TERMINAL 2 to GROUND and causes to the washer motor to run and the window washer is jetted This causes current to flow to washer continuous operation circuit in TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the wiper motor to TERMINAL 4 to GROUND and the wiper functions C17 Comb...

Page 4095: ... A J34 W B A A A A B E From Power Source System See Page 320 J28 A J29 B TVIP ECU Junction Connector Junction Connector Junction Connector O D Main SW Park Neutral Position SW Stop Light SW Vehicle Speed Sensor Electronically Controlled Transmission Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E W B IN Junction Connector J58 A D 3 D 4 EY E03 ME01 W B W B IA8 11 IA8 3 IA8 7 2H 6 2F 1 2H 2 2H 7...

Page 4096: ...emp Sensor Junction Connector Junction Connector Throttle Control Motor and Throttle Position Sensor Engine Control Module E 3 A E 4 B E 5 C E 6 D E 7 E D 11 D 10 D 12 D 13 D 18 D 19 D 16 D 17 D 14 D 15 D 32 E 28 I 1 E2 TH02 SLU SLU SL2 SL2 SL1 SL1 SLT SLT S2 S1 L W L G W B R GR R W W B L B G V B W B W B W LG R LLP 17 B LG R E 1 IPO 8 7 3B 6 3A 5 B O B B D D L B 24 D TH01 R L 9 D SR W G 2 1 9 7 13...

Page 4097: ...R G W P L L L B B O L L W W R P 1 B 12 L O L Y L L W W R LG B R B R B R L A 15 W B R L G O IO B B B B A D B A B A A E B C B C A C B G A G B F B F A H B D A B W B L Y R B R B LG B W R W R L W L W L L J28 A J29 B C11 A C12 B Combination Meter Junction Connector Park Neutral Position SW B O LG R A 19 D N 2 R 3 P O D OFF L A T OIL TEMP 1D 6 1F 9 A Junction Connector J45 ...

Page 4098: ...ls 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 through TERMINAL SLU of the engine control module to TERMINAL 5 of the electronically controlled tran...

Page 4099: ...D main SW turned on 0 3 volts with O 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 Park Neutral Posi...

Page 4100: ... and Sub J B No 3 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA8 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 94 Engine Wire and Cowl Wire Right Side of Instrument Panel IJ1 94 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH Ground Points Code See Page Ground Points Location...

Page 4101: ...S B 21 D 7 2 IE1 26 1D 7 P 1 L B L W R W R A A J34 B EPA2 VCPA VCP2 Y B A C B C B R 15A GAUGE From Power Source System See Page 320 E 3 A E 4 B E 5 C E 7 E J28 A J29 B Cruise Control SW Accelerator Pedal Position Sensor Combination SW Engine Control Module Junction Connector Junction Connector Park Neutral Position SW D L B A 26 A 27 A 21 A 18 A 19 A 20 5 3 6 2 1 4 P G G R LG R R G L V BR D 3 EM01...

Page 4102: ... M VC VTA2 VTA1 IO B 12 W B W B T14 E 3 A E 4 B E 5 C E 7 E C11 A C12 B Combination Meter Engine Control Module Junction Connector Stop Light SW Throttle Control Motor and Throttle Position Sensor 3 E2 1D 6 1F 9 A Junction Connector J45 D D B B B 3B 6 3A 5 B O Junction Connector J75 A B B B Junction Connector J47 A J48 B B O From Power Source System See Page 320 CRUISE B 18 PI B R A 3 B R S31 Stop...

Page 4103: ...edal is depressed 2 The CANCEL SW of the control SW is on 3 ON OFF SW is off 4 Gear is shifted from D position to other positions than D 5 Resume Control After canceling the cruise control Except when the ON OFF SW is off if the vehicle speed is above the minimum speed limit Approx 40km h 25mph operating the RES SW to on from off will cause the system to accelerate and resume to the vehicle speed ...

Page 4104: ...2H 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3B 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA8 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IE1 94 Engine Wire and Cowl ...

Page 4105: ...ctor Parking Brake SW 4WD Control ECU IN 41 A LBL W B Y R W B 2 1 B 2 GR L R 4WD 4WD IJ1 24 IJ1 9 LG R IJ2 5 L O 5 RL RL 6 A 20 A A 5 A 19 RR RR IJ1 25 IJ1 26 IJ1 19 IJ1 20 IL3 1 IL3 2 IL3 3 IL3 4 RH LH Y B O R R O B Y Y B O R 3 4 1 2 7 1D 15A GAUGE 6 2 L L Y P 1 L B 26 IE1 Park Neutral Position SW P A 14 IJ1 13 A B B D Junction Connector J28 A J29 B L Y L Y BS BM2 BM1 P 8 7 IPO 30A ABS NO 2 Fusib...

Page 4106: ... B P L W L P B R W G W LG B P L W L P B W L L V W R W G W L P L W L P B CANH CANL SP1 WA BRL WT INFR VSCW IND 15A STOP 1F 2 A 45 STP2 W R 1 4 G W S 4 Stop Light SW L From Power Source System See Page 320 3 2 4 5 1 IA4 19 W R STP 7 A STPO 16 A IA8 4 G W L B W W L B G W W R 4 1K 10 ECU IG BZ 30 A IA7 9 Y B Y B 1 2 Stop Light Relay S31 IG1 46 A B R B R VSC Warning Buzzer V11 3C 7 3E 7 IJ1 23 IJ1 5 IJ...

Page 4107: ... Combination Meter C11 A C12 B W L L B R B R R Y R G 7 5A ECU B From Power Source System See Page 320 W R W R VSC OFF VSC TRAC AUTO LSD SLIP P L ABS BRAKE SPEED CONTROL Junction Connector J75 From Power Source System See Page 320 11 B O B O IG2 1 B 17 1E 10A IGN1 CANL B O 1H 11 A B O IA8 5 CANH 25 A IA4 23 IA4 24 R Y R G B R 1D 6 1F 9 A Junction Connector J45 B B 3D 5 3A 5 B O 2C 8 1J 3 1E 2 3E 10...

Page 4108: ...B R B R W B B R B R R Y R G V P LG L B W L W L W B W B W R W B L W L S19 Y 1 Engine Control Module E 4 Junction Connector J76 A J77 B J78 C J79 D J80 E J81 F BK2 16 B R IK2 4 IK2 13 LG L 4D 10 4D 9 IK2 1 W B A W B IG1 ESS IG CANH CANL GND CANL CANH CANL CANH BAT Steering Sensor Yaw Rate Sensor 1 F IP W B A Junction Connector J54 ST Plug ...

Page 4109: ...er and activates the rear wheel brakes to reduce the under steering Traction control SW The traction control SW is used to stop the TRAC function After the engine is started the TRAC system is stopped turned off and the VSC OFF indicator light lights up When the traction control SW is pressed again the TRAC system enters the stand by mode If the engine is stopped and restarted the TRAC system ente...

Page 4110: ...per the Accelerator Pedal 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3E 4A 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IA8 g ...

Page 4111: ...R L 20 TS 12 TS 140A ALT 30A ABS NO 2 60A ABS NO 1 12 5 9 F13 IJ1 5 IJ1 23 3E 7 3C 7 3C 8 3A 8 1K 10 1F 15 W R L R L P B P B IJ2 16 R W IO 1F 9 1D 6 W B W B W B A J45 From Power Source System See Page 320 ABS Actuator with ECU ABS Speed Sensor Front LH ABS Speed Sensor Front RH Data Link Connector 3 Fusible Link Block Junction Connector 10A IGN1 1H 11 24 21 C C Junction Connector J31 Combination M...

Page 4112: ... IJ1 6 IJ1 15 IJ1 7 37 G VGS 8 Y GGND 4 L GL1 IJ1 11 IJ1 10 IJ1 12 IJ1 3 1 2 3 L Y G Shielded E 6 W B W B GL1 GGND VGS Shielded A29 P 1 A B B D A G B G P N 2 6 9 36 N 6 P L L Y LG B L Y LG B IJ1 13 IJ1 14 L Y LG B IE1 26 1D 7 IPO 8 7 L B G W From Power Source System See Page 320 J28 A J29 B J48 ABS Actuator with ECU ABS Speed Sensor Rear ABS Deceleration Sensor Junction Connector Junction Connecto...

Page 4113: ...ure acting on the wheel cylinder is insufficient the current acting on the solenoid is controlled and the hydraulic pressure is increased Holding of the hydraulic pressure is also controlled by the ECU by the same method as above by repeated pressure reduction Holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking A6 A7 ABS Speed Sensor Fr...

Page 4114: ...de Panel RH IJ2 94 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH IK2 94 Floor Wire and Cowl Wire Right Kick Panel IL3 94 Floor No 2 Wire and Cowl Wire Instrument Panel Brace RH BP1 96 Frame Wire and Floor No 2 Wire Under the Driver s Seat Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel Splice Points Code See Page Wire Harness with Splice Poi...

Page 4115: ... G O C11 A C12 B A H B B P B W TC P B SIL G W L R 13 LG 7 G L R LG IO A A I B C W B W B P G O Tire Pressure J42 A J43 B R J49 T16 T17 3A 4 3B 4 A B G A 3A 18 3C 8 1D 6 1F 9 3E 1 3A 2 A W B W B 3B 7 3C 7 D D Tire Pressure Monitor ECU Combination Meter GND RDA 5V Tire Pressure Warning Standardization SW Junction Connector 2 1 Junction Connector J45 Junction Connector Data Link Connector 3 D 6 Tire P...

Page 4116: ... specified value Warnings when the tire pressure is low When the tire air pressure is below a specified level the warning light in the combination meter comes on T16 Tire Pressure Monitor ECU 2 Ground Approx 12 volts with ignition SW at ON position 11 Ground Always continuity Parts Location Code See Page Code See Page Code See Page C11 A 66 J43 B 68 T17 69 C12 B 66 J45 68 T18 71 D6 67 J49 68 J42 A...

Page 4117: ...BE 4WD L4 Speedometer A G IND3 LO 2 4 7 8 IPO 1D 7 L B 4D 10 4B 10 L Y IG LG B G O Y B P B Y B F20 A F21 B W B Control Circuit From Power Source System See Page 320 C11 A C12 B I24 A I25 B J28 A J29 B Skid Control ECU 3 Combination Meter 4WD Control ECU Integration Control and Panel Junction Connector 9 2 N Park Neutral Position SW P 1 10A IGN1 E B LG B A D J49 A J50 B Junction Connector IO Juncti...

Page 4118: ... 2 1 B A A C A C Y B B D A E IN A W B W B J58 W B A W B IJ1 7 L R 2 IJ1 6 W B J55 A J56 B E 5 ABS Actuator with ECU Detection SW Transfer 4WD Position Detection SW Transfer L4 Position Engine Control Module 4WD Control ECU Junction Connector Junction Connector Skid Control ECU with Actuator A 19 A 9 A 22 A 6 B 22 B 17 13 8 IE4 6 E A G O E B A D W B G O L R 1 7 IJ1 IJ1 6 Junction Connector J55 A J5...

Page 4119: ... W B W B 4 A 9 IE4 5 13 IE4 IE4 1 IE4 2 IE4 7 G G 2 Y Y B R B R 3 B W B W 5 L W 6 W B W B 4 W B W B ADD DL1 DL2 DM1 DM2 TM1 TM2 TL3 TL1 TL2 M Detection SW M T 3 1 H2 H4 L4 GR GR GR GR 2 GR 1 EC1 4 GR B B A B GR 2 GR 1 1 w VSC 2 w o VSC ED1 6 ADD Actuator 4WD Control ECU Transfer Shift Actuator B 24 B 25 B 23 B 2 B 1 A 1 A 2 A 21 A 13 B 26 B A Junction Connector J55 A J56 B A F A F B H Junction Con...

Page 4120: ...o ADD actuator TERMINAL 1 to motor to TERMINAL 5 to 4WD control ECU TERMINAL A 2 to GROUND and the ADD actuator is activated and the ADD is disconnected When the ADD is disconnected the detection SW ADD position SW is turned OFF and the 4HI indicator Light turns OFF H4 to L4 When the touch select high low SW in the integration control and panel is turned ON a signal is input into TERMINAL A 15 of ...

Page 4121: ...nition SW at ON or ST position A 6 Ground Always continuity A 9 Ground 4 pulses with 1 rotation A 8 Ground 2 volts or less with touch select 2 4 SW on A 17 Ground 2 volts or less with detection SW Transfer L4 position on and transfer shift lever at L4 position I24 A I25 B Integration Control and Panel A 5 B 1 Closed with touch select 2 4 SW on P1 Park Neutral Position SW 2 9 Closed with A T shift ...

Page 4122: ...1U 465 Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points I1 94 Engine Wire ...

Page 4123: ...2005 TOYOTA TUNDRA EWD611U 466 Memo ...

Page 4124: ... record of these memory contents So when the work is finished it will be necessary to explain it to your customer and ask the customer to adjust the features and reset the memory To avoid erasing the memory in each system never use a back up power supply from outside the vehicle Before repair remove the airbag sensor if shocks are likely to be applied to the sensor during repair Do not expose the ...

Page 4125: ...in Airbag Cut Off SW 3C 1 3A 2 IO A Junction Connector J45 A 30 A 28 A 29 A 27 SL SL SR SR IA1 1 IA1 2 IJ3 1 IJ3 2 A 19 A 13 A 17 A 23 PBEW P AB PAON A 12 A 8 A 9 A 10 B 10 B 9 B 8 B 12 S13 A S14 B Integration Control and Panel I25 11 2 1 Airbag Squib Front Passenger Airbag Assembly A16 A 4 A 3 A 1 A 2 P P C 4 A C 5 B C 6 C Center Airbag Sensor Assembly W R B R 1 1 1 3 6 Short Connector B15 V 3 2 ...

Page 4126: ... PL PL PR PR 22 B B 20 VUPR C 1 C 2 S37 B 21 B 19 S33 C C 19 21 C 22 C 20 C 4 A C 5 B C 6 C Center Airbag Sensor Assembly 1 Captain Seat W R B R W R B R 1 1 Side Airbag Sensor RH ESR Side Airbag Sensor Rear LH Side Airbag Sensor LH Side Airbag Sensor Rear RH SFL SFL VUCR ESCR VUPL ESL ESCL VUCL Side Airbag Squib LH 2 Separate Seat 3 3 3 3 3 3 3 3 3 3 3 w Side Airbag A17 Airbag Squib Steering Wheel...

Page 4127: ...0A IGN1 W B W B 26 A B W B A Junction Connector J45 B O 1 W B B O B O F PS 6 3 5 4 B B W BR R G W R G V 1A 11 1H B 8 S38 6 B B 5 C 3 C 4 C22 18 10 1F 3 Engine Control Module E 4 W R A 25 E2 E1 1A 6 1F 9 IN IO 1 1 1 W B Curtain Shield Airbag Squib LH Buckle SW LH Seat Position Airbag Sensor Curtain Shield Airbag Squib RH Side Airbag Squib RH LBE LSP LSP LBE ICR ICR SFR SFR ICL ICL 3 3 3 3 1A 8 1G 1...

Page 4128: ...B A 20 A RMIL A 16 B B 12 A 11 Combination Meter C11 A C12 B 1A 2 1D 4 A 16 A 15 SIL TC A 14 LA 1A 2 1E 14 1A 9 1F 15 3B 6 3E 6 11 A B 3C 7 7 SIL 3A 8 3C 8 TC 13 3D 7 3A 7 3D 5 3C 5 BS1 2 BS1 3 BS1 5 7 IG FSR FSR A 2 BGND DIA BS1 4 Buckle SW RH B13 2 1 Occupant Classification ECU O10 A O11 B 1 1 1 B O B O 1 P B W P B W R W 1 Data Link Connector 3 D 6 G B 1 1 Captain Seat 2 Separate Seat Short Conn...

Page 4129: ... SGD2 SIG2 SVC2 SGD2 SIG2 SVC2 R B G B Y B SGD3 SIG3 SVC3 O14 Occupant Classification Sensor Rear LH O G V SIG1 SVC1 SIG1 SGD1 1 SVC1 1 1 1 1 1 1 1 11 B 1 W R 1 2 3 9 3E 10 3D IK2 7 BS1 1 A 1 B 3 Occupant Classification Sensor Front LH O12 3 B B 9 SIG3 SVC3 5 B Occupant Classification Sensor Rear RH B 12 O15 B 8 B 2 B 6 B 10 BS1 B 4 6 IK2 2 IP A Junction Connector J54 Occupant Classification ECU O...

Page 4130: ... mentioned circuits is activated so that current flows to the airbag squibs and causes them to operate The airbag stored inside the steering wheel pad is instantaneously expanded to soften the shock to the driver The airbag stored inside the passenger s instrument panel is instantaneously expanded to soften the shock to the passenger Parts Location Code See Page Code See Page Code See Page A11 64 ...

Page 4131: ...IA1 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IJ3 94 Engine Room Main Wire and Cowl Wire Cowl Side Panel RH IK2 94 Floor Wire and Cowl Wire Right Kick Panel BS1 98 Seat No 1 Wire and Floor Wire Under the Front Passenger s Seat Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel IO 92 Left Kick Panel IP 92 Instrument Panel Brace LH ...

Page 4132: ...2005 TOYOTA TUNDRA EWD611U 475 Memo ...

Page 4133: ... IA7 1 1 2 L R L W P L L P TEP TEP A28 6 2 A D B E G O A 24 V W ABS Actuator with ECU w o VSC B 12 W B W B From Power Source System See Page 320 C11 A C12 B J49 A J50 B Skid Control ECU with Actuator w VSC Ambient Temp Sensor Combination Meter Junction Connector Overhead Module G O J56 Junction Connector IC2 1 IO Junction Connector J45 A 1M 8 1D 5 1M 4 1D 10 1D 6 1F 9 E E SPEED CONTROL ...

Page 4134: ...ness Connector Location 1D 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 1G 45 Cowl Wire and Driver Side J B Lower Finish Panel 1H 1M 45 Roof Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IC2 92 Cowl Wire and Roof W...

Page 4135: ...6 2 2 W B P 7 1H 1 1H 7 1G 7 IN W B ID2 2 L R L R 1 2 ID2 1 P P GR W B 2 12 F13 W W Battery ACC Relay C 7 140A ALT 6 B L W W B L W W B 1H 9 W B B 2 IO A J45 W B From Power Source System See Page 320 J52 B Cigarette Lighter Fusible Link Block Junction Connector Junction Connector Power Outlet Power Outlet Power Outlet Rear 1 1 1 1 2 1 2 1 1 2 1 2 2 Except Captain Seat 1 Captain Seat 1 1 1 1 1 B 6 ...

Page 4136: ...lways continuity Parts Location Code See Page Code See Page Code See Page C7 66 J52 B 68 P24 69 F13 34 64 P6 69 J45 68 P7 69 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1E 1G 45 Cowl Wire and Driver Side J B Lower Finish Panel 1H 1L 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel Connector Joining Wire Harness and Wire ...

Page 4137: ...4 1F 4 4 1 3 7 1 4 6 4 3 IN A B R B R G B B W B LG W B W B W B LG B R B Y E AC2 AC1 B M 5 V12 P23 INVERTER Relay J58 B R B Y B Y B R IG INV E B E 3A 4 3D 4 4D 10 4E 9 4E 10 A W B W B IK2 1 W B IN1 2 IN1 1 IK2 18 LG From Power Source System See Page 320 Junction Connector Main SW Power Outlet 115V Voltage Inverter ...

Page 4138: ...Finish Panel 1G 45 Cowl Wire and Driver Side J B Lower Finish Panel 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4D 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4E 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and W...

Page 4139: ... EWD611U 482 Horn Double Cab 10A HORN 5 2 3 1 2F 7 2H 8 HORN Relay 1 1 H 7 H 8 A 6 C 21 6 C16 B Y W R W R B HR HORN B IA7 12 From Power Source System See Page 320 B 9 A B11 C Body ECU Combination SW Horn LH Horn RH Horn ...

Page 4140: ...ss Connector Code See Page Junction Block and Wire Harness Connector Location 2F 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2H 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel ...

Page 4141: ...C 16 C 8 B 15 1G 12 1M 9 1 1 MPX3 DCTY PCTY 2 LG B GR R GR R LG B P G O D16 D17 A H B A GR R J50 B E B IG MPX1 E OPN CLS DWN UP IK1 3 From Power Source System See Page 320 B10 B B11 C J49 A J50 B Body ECU Door Courtesy SW Front LH Door Courtesy SW Front RH Junction Connector Junction Connector Moon Roof Control ECU and Motor Overhead Module Moon Roof Control SW B D B D M PSW1 PSW2 Motor Position S...

Page 4142: ...n roof control SW at UP position 10 1 Closed with the moon roof control SW at DOWN position 11 1 Closed with the moon roof control SW at OPEN position 12 1 Closed with the moon roof control SW at CLOSE position 1 Ground Always continuity Parts Location Code See Page Code See Page Code See Page B10 B 66 D17 70 M6 70 B11 C 66 J49 A 68 O8 70 D16 70 J50 B 68 Junction Block and Wire Harness Connector C...

Page 4143: ...VR M M M R10 Down Right Up Left Down Right Right Right Up Left Left Left GR B A A C A C L W L W IB5 12 IB5 11 IF5 2 IF5 1 IF5 6 BR B BR R LG R LG B L W BR B BR R LG B L W W B R 9 R 8 1 2 3 3 2 1 L W LG R A J58 4D 10 4C 10 4A 5 4E 5 From Power Source System See Page 320 J36 A J37 B Junction Connector Junction Connector Remote Control Mirror LH Remote Control Mirror RH Remote Control Mirror SW ...

Page 4144: ... and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 4A 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4E Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IB5 9...

Page 4145: ... P18 Y B Y R L Y L R Y L B L W B W B L R Y G W B W B 2 A A J82 A B B B P20 J82 M M M M 1 A C B G J40 A J41 B Junction Connector Junction Connector Junction Connector Lumbar Support Control SW Driver s Seat Power Seat Motor Driver s Seat Front Vertical Control Power Seat Control SW Driver s Seat Power Seat Motor Driver s Seat Rear Vertical Control Power Seat Motor Driver s Seat Reclining Control Po...

Page 4146: ...vertical up operation 1 8 Closed with the driver s seat at rear vertical down operation 4 Ground Always continuity Parts Location Code See Page Code See Page Code See Page J40 A 68 P15 72 P19 72 J41 B 68 P16 72 P20 72 J82 72 P17 72 L3 72 P18 72 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1G 45 Cowl Wire and Driver Side J B Lower Finish...

Page 4147: ... IG L 2 3 1 5 5 5 5 5 S12 W B L R Y SEAT HEATER Relay A B B F A F B B S28 S26 G 4A 7 4E 7 IK2 11 IK2 10 C C C C J57 W B W B W B A J45 W B IK2 1 A J58 W B From Power Source System See Page 320 J36 J40 A J41 B Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Seat Heater SW Front Passenger s Seat Seat Heater Driver s Seat Seat Heater Fr...

Page 4148: ...re Harness Connector Location 1E 45 Cowl Wire and Driver Side J B Lower Finish Panel 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 4A 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4E 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IK2 94 Floor Wire a...

Page 4149: ...F13 IO A A A Y J45 J58 W B IA4 12 EA J34 E 4 4 4 6 6 R 9 R 8 2 2 2 2 IA4 7 Y Y G W B B W B B G Y IA7 3 Y A From Power Source System See Page 320 R22 A R23 B J36 A J37 B J36 A J37 B Fusible Link Block Integration Control and Panel Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Remote Control Mirror LH Remote Control Mirror RH Rear Window Defogger Rear...

Page 4150: ... Side J B Lower Finish Panel 2A 2B 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2F g g g 2G Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IA7 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IF5 94 Front Door RH Wire and Cowl Wire Righ...

Page 4151: ...2005 TOYOTA TUNDRA EWD611U 494 Automatic Glare Resistant EC Mirror Double Cab 7 6 IN 1M 7 1G 1 W B W B 10A ECU IG From Power Source System See Page 320 1M 1 B R Inner Mirror I27 ...

Page 4152: ...on Code See Page Code See Page Code See Page I27 70 Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1G 45 Cowl Wire and Driver Side J B Lower Finish Panel 1M 45 Roof Wire and Driver Side J B Lower Finish Panel Ground Points Code See Page Ground Points Location IN 92 Right Kick Panel Service Hints ...

Page 4153: ...2 A 12 GR 20A RAD NO 3 2A 3 25A RAD NO 1 A A IA4 9 A R B R B J60 L Y L Y GR GR 4A 5 4D 5 4C 5 4A 15 IL1 10 GR GR GR B 10 B 4 B 13 B 5 B 14 B 15 B 16 B 1 IL2 3 R B R B R B BR BR BR BR BR E GND2 RR RR RL RL B2 W R Y B IK1 2 IK1 1 R W B ACC From Power Source System See Page 320 S23 A S24 B Junction Connector Rear Door Speaker LH Rear Door Speaker RH Stereo Component Amplifier IL1 2 IL1 1 ...

Page 4154: ...IL1 17 IL1 18 IL1 9 IL1 8 FL FL WFL WFL WFR WFR FR FR L LG B Y W L L W G V P A 8 A 7 A 1 A 7 MUTE TX TX MUTE L R L IL1 15 IL1 16 IL1 11 IL1 5 IL1 3 IL1 6 IL1 4 IL1 7 A 23 Shielded B R G BR Y LG L L LG Y S23 A S24 B R27 A R28 B R29 C R30 D R31 E Front Door Speaker LH Woofer Front Door Speaker RH Woofer Radio and Player with Display Stereo Component Amplifier Tweeter LH Tweeter RH 13 B 11 B 12 B Shi...

Page 4155: ...MUT IM3 2 J54 GND B 29 L Y GR L Y GR 11 A 12 A 3 A GAUX AUXR AUXL LG BR BR 4 1 2 CE AUXR AUXL V10 23 A 24 A 10 A SG7 NTS4 SGN5 BR BR 3 5 6 SG6 NTS4 DGND 22 A SG6 7 SGN5 Shielded Shielded Shielded Shielded Shielded R W W B Y A AU1 EAU AU2 SEEK SEEK VOL VOL MODE IP BR R27 A R28 B R29 C R30 D R31 E C16 Steering PAD SW R17 A R18 B R19 C Combination SW Junction Connector Radio and Player with Display R...

Page 4156: ...6 ACC B GR L O L O Y LG L Y 7 A 8 A 9 A HP1R HP1L SG5 BR BR 1 2 3 HPR HPL SGND H11 19 A 20 A 21 A HP2R HP2L SG6 BR BR 1 2 3 HPR HPL SGND H12 Shielded Shielded Shielded Shielded 2 1 R17 A R18 B R19 C R27 A R28 B R29 C R30 D R31 E Headphone Terminal LH Headphone Terminal RH Radio and Player with Display Rear Seat Entertainment ECU E 4 B 21 V BR E 1 B 20 LG BR E 5 B 19 Shielded IM3 23 IM3 22 IM3 24 S...

Page 4157: ...4 14 A 15 B2 B B B IM4 13 A 16 SYN2 B B B IM4 11 A 18 VG2 5 C 11 C 12 C ACC3 B AR LG LG 19 20 6 ACC B R 2 C 3 C 4 C AR AL AL W W 7 8 9 R L L Shielded 1 C 6 C SG4 MUTE LG 5 10 SLD MUTE R21 8 BU B 7 ACC 9 TX 10 TX 12 VR 16 R 15 G 14 B 13 SYNC 11 VG Shielded Shielded Shielded W W D33 IC3 8 IC3 7 IC3 17 IC3 18 IC3 20 IC3 24 IC3 23 IC3 22 IC3 21 IC3 19 R17 A R18 B R19 C DVD Player Rear Seat Entertainme...

Page 4158: ...S2 SGN2 SG9 BR BR 3 2 1 NTSC S GND SLD Shielded 1 GND 5 L 3 R 2 SGND Shielded Shielded Shielded 15 C 13 C 14 C TX3 TX3 GND4 LG LG 17 18 16 TX TX GND LG R21 IM4 6 C 16 HPL W W W 6 L IM4 4 C 18 HPR W W W 4 R IC3 1 IC3 5 IC3 6 IC3 3 IC3 4 IC3 2 R17 A R18 B R19 C DVD Player Rear Seat Entertainment ECU Rear Seat Entertainment Display ...

Page 4159: ...ode See Page Junction Block and Wire Harness Connector Location 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2B 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3B 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4A 4C 50 Cowl W...

Page 4160: ...2005 TOYOTA TUNDRA EWD611U 503 Ground Points Code See Page Ground Points Location IP 92 Instrument Panel Brace LH BR 96 Back Panel Left ...

Page 4161: ...R 20A RAD NO 3 2A 3 25A RAD NO 1 A A IA4 9 A R B R B J60 L Y L Y GR GR 4A 5 4D 5 4C 5 4A 15 IL1 10 GR GR GR B 10 B 4 B 13 B 5 B 14 B 15 B 16 B 1 IL2 3 R B R B R B BR BR BR BR BR E GND2 RR RR RL RL B2 W R Y B IK1 2 IK1 1 R W B ACC From Power Source System See Page 320 S23 A S24 B Junction Connector Rear Door Speaker LH Rear Door Speaker RH Stereo Component Amplifier IL1 2 IL1 1 ...

Page 4162: ...GND GR V BR IL1 17 IL1 18 IL1 9 IL1 8 FL FL WFL WFL WFR WFR FR FR L LG B Y W L L W G V P A 8 A 7 A 1 A 7 MUTE TX TX MUTE L R L IL1 15 IL1 16 IL1 11 IL1 5 IL1 3 IL1 6 IL1 4 IL1 7 A 23 Shielded B R G BR Y LG L L LG Y S23 A S24 B R14 A R15 B R16 C Front Door Speaker LH Woofer Front Door Speaker RH Woofer Radio and Player Stereo Component Amplifier Tweeter LH Tweeter RH 13 B 11 B 12 B Shielded P L A 4...

Page 4163: ...L R W RSL R L B 14 B 27 IM3 17 SLD1 SG2 B 19 B 28 IM3 16 LG RMU RMUT IM3 2 J54 GND B 29 L Y GR L Y GR 11 A 12 A 3 A GAUX AUXR AUXL LG BR BR 4 1 2 CE AUXR AUXL V10 23 A 24 A 10 A SG7 NTS4 SGN5 BR BR 3 5 6 SG6 NTS4 DGND 22 A SG6 7 SGN5 Shielded Shielded Shielded Shielded Shielded R W W B Y A AU1 EAU AU2 SEEK SEEK VOL VOL MODE IP BR R14 A R15 B R16 C C16 Steering PAD SW R17 A R18 B R19 C Combination ...

Page 4164: ...R G LG MUTE LMUT L Y GR IM3 13 IM3 1 IA4 22 7 5A RSE 2 2 B 32 B 16 ACC B GR L O L O Y LG L Y 7 A 8 A 9 A HP1R HP1L SG5 BR BR 1 2 3 HPR HPL SGND H11 19 A 20 A 21 A HP2R HP2L SG6 BR BR 1 2 3 HPR HPL SGND H12 Shielded Shielded Shielded Shielded 2 1 R17 A R18 B R19 C R14 A R15 B R16 C Headphone Terminal LH Headphone Terminal RH Radio and Player Rear Seat Entertainment ECU ...

Page 4165: ...5 B2 B B B IM4 13 A 16 SYN2 B B B IM4 11 A 18 VG2 5 C 11 C 12 C ACC3 B AR LG LG 19 20 6 ACC B R 2 C 3 C 4 C AR AL AL W W 7 8 9 R L L Shielded 1 C 6 C SG4 MUTE LG 5 10 SLD MUTE R21 8 BU B 7 ACC 9 TX 10 TX 12 VR 16 R 15 G 14 B 13 SYNC 11 VG Shielded Shielded Shielded W W D33 IC3 8 IC3 7 IC3 17 IC3 18 IC3 20 IC3 24 IC3 23 IC3 22 IC3 21 IC3 19 R17 A R18 B R19 C DVD Player Rear Seat Entertainment ECU R...

Page 4166: ...S2 SGN2 SG9 BR BR 3 2 1 NTSC S GND SLD Shielded 1 GND 5 L 3 R 2 SGND Shielded Shielded Shielded 15 C 13 C 14 C TX3 TX3 GND4 LG LG 17 18 16 TX TX GND LG R21 IM4 6 C 16 HPL W W W 6 L IM4 4 C 18 HPR W W W 4 R IC3 1 IC3 5 IC3 6 IC3 3 IC3 4 IC3 2 R17 A R18 B R19 C DVD Player Rear Seat Entertainment ECU Rear Seat Entertainment Display ...

Page 4167: ... Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2B 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 4A 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D Connector Joining Wire Harness and ...

Page 4168: ...2005 TOYOTA TUNDRA EWD611U 511 Ground Points Code See Page Ground Points Location IP 92 Instrument Panel Brace LH BR 96 Back Panel Left ...

Page 4169: ...D NO 3 2A 3 25A RAD NO 1 A A IA4 9 A R B R B J60 L Y L Y GR 1 1 w Rear Seat Audio System GR 1 4A 5 4D 5 4C 5 4A 15 IL1 10 GR GR GR B 10 B 4 B 13 B 5 B 14 B 15 B 16 B 1 IL2 3 R B R B R B BR BR BR BR BR E GND2 RR RR RL RL B2 W R Y B IK1 2 IK1 1 R W B ACC IL1 2 IL1 1 1 From Power Source System See Page 320 S23 A S24 B Junction Connector Rear Door Speaker LH Rear Door Speaker RH Stereo Component Ampli...

Page 4170: ...1 GR 1 A 20 BR GND GR 1 V BR IL1 17 IL1 18 IL1 9 IL1 8 FL FL WFL WFL WFR WFR FR FR L LG B Y W L L W G V P A 8 A 7 A 1 A 7 MUTE TX TX MUTE L R L R IL1 15 IL1 16 IL1 11 IL1 5 IL1 3 IL1 6 IL1 4 IL1 7 Shielded B R G W Y LG L L LG Y J40 A J41 B R27 A R28 B R30 C S23 A S24 B Front Door Speaker LH Woofer Front Door Speaker RH Woofer Junction Connector Radio and Player with Display Stereo Component Amplif...

Page 4171: ...ded R W W B LG A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Shielded Shielded Shielded Shielded IC3 3 IC3 2 IC3 1 IM3 8 IM3 7 IM3 6 IC3 19 IC3 18 IC3 17 IM3 20 IM3 19 IM3 18 17 3 2 1 15 14 13 1 1 1 1 P L 1 1 BR BR 1 1 W B 1 1 1 1 BR BR 1 1 R20 1 1 1 w Rear Seat Audio System 8 B 6 B 7 B SW1 GND SW2 LG R GR R BR W 12 10 11 AU1 EAU AU2 MODE SEEK VOL VOL C16 22 23 9 8 7 6 11 10 24 12 IC3 21 SEEK 2 1 IC3 12 IC3 26 ...

Page 4172: ...ess Connector Location 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2B 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3B 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4A 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerato...

Page 4173: ...2005 TOYOTA TUNDRA EWD611U 516 Navigation and Audio System with 8 Speaker Double Cab Ground Points Code See Page Ground Points Location IP 92 Instrument Panel Brace LH BR 96 Back Panel Left ...

Page 4174: ...2005 TOYOTA TUNDRA EWD611U 517 Memo ...

Page 4175: ...A 3 25A RAD NO 1 A A IA4 9 A R B R B J60 L Y L Y GR 1 1 w Rear Seat Audio System GR 1 4A 5 4D 5 4C 5 4A 15 IL1 10 GR GR GR B 10 B 4 B 13 B 5 B 14 B 15 B 16 B 1 IL2 3 R B R B R B BR BR BR BR BR E GND2 RR RR RL RL B2 W R Y B IK1 2 IK1 1 R W B ACC IL1 2 IL1 1 1 From Power Source System See Page 320 S23 A S24 B Junction Connector Rear Door Speaker LH Rear Door Speaker RH Stereo Component Amplifier ...

Page 4176: ...L B R G W GR L Y L Y L Y GR 1 BU B ACC B TX TX L R L R GND R L P L Y 1 GR 1 A 20 BR GND GR 1 V BR IL1 17 IL1 18 IL1 9 IL1 8 FL FL WFL WFL WFR WFR FR FR L LG B Y W L L W G V P A 8 A 7 A 1 A 7 MUTE TX TX MUTE L R L R IL1 15 IL1 16 IL1 11 IL1 5 IL1 3 IL1 6 IL1 4 IL1 7 Shielded B R G W Y LG L L LG Y J40 A J41 B R14 A R15 B S23 A S24 B Front Door Speaker LH Woofer Front Door Speaker RH Woofer Junction ...

Page 4177: ...elded R W W B LG A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Shielded Shielded Shielded Shielded IC3 3 IC3 2 IC3 1 IM3 8 IM3 7 IM3 6 IC3 19 IC3 18 IC3 17 IM3 20 IM3 19 IM3 18 17 3 2 1 15 14 13 1 1 1 1 P L 1 1 BR BR 1 1 W B 1 1 1 1 BR BR 1 1 R20 1 1 1 w Rear Seat Audio System 8 B 6 B 7 B SW1 GND SW2 LG R GR R BR W 12 10 11 AU1 EAU AU2 MODE SEEK VOL VOL C16 22 23 9 8 7 6 11 10 24 12 IC3 21 SEEK 2 1 IC3 12 IC3 2...

Page 4178: ...nnector Location 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 2A 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2B 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 4A 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4D Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Locatio...

Page 4179: ... R A 2 RL B B BL1 12 W R 6 B 2 FL P IB5 4 P 1 2 L B 6 FL V IB5 5 V R F 8 2 4 1 3 B 1 FR LG IF6 10 LG 1 2 V B 5 FR L IF6 9 L P F 9 2 3 4 1 B 7 GND IP BR BR B A B E A E A A L Y GR 6 FL 1 FR 1F 12 T 7 T 8 4C 5 4A 5 From Power Source System See Page 320 R 1 A R 2 B J40 A J41 B Front Door Speaker LH Front Door Speaker RH Junction Connector Radio and Player Rear Door Speaker LH Rear Door Speaker RH Twee...

Page 4180: ...ne Room J B Engine Compartment Left 4A 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4C 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness Connector Location IA4 92 Engine Room Main Wire and Cowl Wire Left Kick Panel IB5 92 Front Door LH Wire and Cowl Wire Left Kick Panel IF6 94 F...

Page 4181: ... DOME From Power Source System See Page 320 2C 10A IGN1 1H 11 1J 5 1E 8 B O R R L R Skid Control ECU with Actuator 1 V W ABS Actuator With ECU 2 W G Y R GR R Y G 2 3 V BR V BR Fuel Sender F10 Combination Meter C11 A C12 B 4A 6 4E 6 R 3 Rheostat Engine Control Module Door Courtesy SW Driver s Side Body ECU Body ECU B G B J A A A C BP2 5 BP2 8 V BR Junction Connector J42 A J43 B ...

Page 4182: ...ation Meter B E B E A D A D A D G O G O G O G O Engine Control Module Tire Pressure Monitor ECU Radio and Player Junction Connector J49 A J50 B A A A A B C Junction Connector J49 A J50 B Body ECU D A 4WD Control ECU G O B E Overhead Module G O E B G O J55 A J56 B Junction Connector Buckle SW Tire Pressure Monitor ECU Skid Control ECU with Actuator Skid Control ECU with Actuator 1 ABS Actuator with...

Page 4183: ...al Position SW IO W B W B LG R Engine Control Module C11 A C12 B Combination Meter From Power Source System See Page 320 7 5A PANEL 1H 10 G 1D 6 1F 9 A Junction Connector J45 IJ1 18 A A 1 LG R A Y B 2 Y B 2 LG R 2 2 1 IJ1 24 Y B 2 4 Y B 2 3 LG R 2 3 Diode Parking Brake SW D31 3A 13 3C 3 2 1 1K 12 Brake Fluid Level Warning SW B 2 Y B 2 W B Parking Brake SW P 5 Junction Connector J59 ...

Page 4184: ...AC AUTO LSD Malfunction Indicator Lamp B 2 A 7 B 3 A 3 A 14 A 15 A 18 G B G Y R G R G Turn Signal Flasher 4 3 Headlight LH RH Body ECU V G R L L O B R P L P B W L Engine Control Module Skid Control ECU with Actuator Combination Meter C11 A C12 B 2 w o VSC 1 w VSC 3 w Daytime Running Light 4 w o Daytime Running Light ...

Page 4185: ... B 8 A 13 B 7 B 6 B 5 B 4 B 1 L R Skid Control ECU with Actuator Y B Y B P B P B R W Y G Generator Combination Meter C11 A C12 B 4WD Control ECU Integration Control and Panel 4WD Control ECU Integration Control and Panel IJ1 2 2 1 EM A Junction Connector J30 R B W B Washer Level Sensor W 2 ...

Page 4186: ...ver Side J B Lower Finish Panel 1H 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3A 3B 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3C 4A 50 Cowl Wire and Sub J B No 4 Upper the Accelerator Pedal 4E 50 Cowl Wire and Sub J B No ...

Page 4187: ...C1 L R Y ACT LMS AC1 10A IGN1 1E 17 B O 4D 7 4A 7 4B 7 R Y R Y 3 2 1 A 3 1 2 IJ1 16 LG B L B A 1 Dual E 4 I24 A I25 B From Power Source System See Page 320 Pressure SW A C Magnetic Clutch and Lock Sensor Air Inlet Control Servo Motor Defroster Mode SW Engine Control Module Integration Control and Panel IE1 11 A 13 G W IE1 10 A 12 W R 25 9 24 A 1 LG B 16 B L B IJ2 10 LG B 3D 5 3E 5 A 4 A 3 Y G B 1 ...

Page 4188: ...M1 LO M2 H1 5 3 1 R Y R Y L R L W W B W B W B R Y W R W R R Y L R L R L W LG R B 4 B 5 B 6 1 3 B E L W G W W B J58 A W B 2C 2 2G 5 A J35 4B 10 4D 10 W B A W B L R 50A HEATER F13 I24 A I25 B From Power Source System See Page 320 Blower Motor Blower Resistor Blower SW Fusible Link Block Integration Control and Panel Junction Connector Junction Connector M 2 3 L Y L R 1 W B ...

Page 4189: ...AL 2 of the blower motor to TERMINAL 1 to TERMINAL 5 of the blower SW to TERMINAL 1 to GROUND causing the blower motor to rotate at high speed 2 Operation of Air Inlet Control Servo Motor Switching from FRESH to RECIRC With the ignition SW turned on current flows from the HTR fuse to TERMINAL 5 of the air inlet control servo motor When the RECIRC FRESH SW is switched to the RECIRC side current flo...

Page 4190: ...sh Panel 1J 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 2C 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 2G 41 Engine Room Main Wire and Engine Room J B Engine Compartment Left 3D 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 3E 48 Cowl Wire and Sub J B No 3 Upper the Accelerator Pedal 4A 4B 50 Cowl Wire and Sub J B No 4 Upper the Accelerator ...

Page 4191: ...1 3 EW SG Engine Control Module W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B BR BR BR W B BR W B W B W B W B W B W B W B 5 5 2UZ FE 2UZ FE W B Front Parking Light LH No 3 A F HTR Relay J18 E11 Skid Control ECU with Actuator GND2 GND1 W B W B W B W B W B FOG Relay 2 DRL NO 4 Relay 2 W B W B A Front Turn Signal Light LH Front Turn Signal Light RH ECC Leak D...

Page 4192: ... Combination SW EW ID2 2 3 3 5 2UZ FE EX Air Switching Valve Air Pump E13 W W W Engine Control Module E01 E02 E04 E05 E1 E03 ME01 Leak Detection Pump Assembly I 3 BB4 4 IE1 19 W B W B W B W B Igniter and Ignition Coil No 2 Igniter and Ignition Coil No 3 Igniter and Ignition Coil No 4 Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 Noise Filter Data Link Connector 3 SG IE1 25 W B W B ...

Page 4193: ... License Plate Light LH License Plate Light RH Rear Combination Light LH Rear Combination Light RH B10 B10 BL W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B W B A T W B A A BRL W B Trailer Socket BK1 2 W W B Steering Sensor W B 2 1 A 12 B 29 J23 A J24 B J26 A J27 B Door Unlock Detection SW LH Security Indicator 2 Lumb...

Page 4194: ...ntegration Relay Combination Meter IH W B BR A Remote Control Mirror RH W B Integration Relay W B W B BR 1 2 24 1N IE4 6 I 4 7 Captain Seat 8 Bench Seat W B Door Unlock Detection SW RH ABS Actuator with ECU 4 Blower SW ED1 6 Engine Control Module W B IE1 20 W B W B Yaw Rate Sensor W B A B A F A B A F D B H B H B J66 A J67 B Door Courtesy SW Rear RH Upper Door Courtesy SW Rear RH Lower BH1 3 BF2 6 ...

Page 4195: ...Brace LH IE1 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IE4 80 Engine Wire and Cowl Wire Right Side of Instrument Panel IF3 80 Front Door RH Wire and Cowl Wire Right Kick Panel IG1 80 Cowl Wire and Instrument Panel No 2 Wire Instrument Panel Brace RH IH1 80 Cowl Wire and Floor No 3 Wire Instrument Panel Brace RH BB4 82 3 Frame Wire and Cowl Wire Under the Driver s Seat BB4 84 4 Fr...

Page 4196: ...rrounding of the Front of the Fuel Tank BL 84 4 Surrounding of the Front of the Fuel Tank Splice Points Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E5 74 2UZ FE Engine Wire B2 82 3 E11 74 2UZ FE Engine Room Main Wire B2 84 4 Front Door LH Wire E11 76 1GR FE Engine Room Main Wire B3 82 3 Front Door LH Wire E13 74 2UZ FE Engine No 2 Wire B3 84 4 E14 76...

Page 4197: ...W B 2 W B A F HTR Relay A Wireless Door Lock Buzzer J34 Skid Control ECU with Actuator Front Parking Light RH No 3 J35 Front Fog Light RH W B W B Front Fog Light LH A A W B Engine Control Module Combination SW E01 E1 E06 E03 ME01 Igniter and Ignition Coil No 2 Igniter and Ignition Coil No 3 Igniter and Ignition Coil No 4 Igniter and Ignition Coil No 5 Igniter and Ignition Coil No 6 Igniter and Ign...

Page 4198: ...C 1 3B 2 3B 1 3A 12 3A 11 3A 1 Trailer Converter Turn Signal Flasher Cigarette Lighter W B W B W B W B W B W B W B W B W B W B B 6 C 6 A 6 B 2 ID2 2 Seat Heater SW Front Passenger s Seat Seat Heater SW Driver s Seat SEAT HEATER Relay A D W B W B W B W B E1 GND2 Combination Meter Data Link Connector 3 A w o VSC A W B W B W B W B W B C C C C J57 W B W B W B 1 w Daytime Running Light 5 GND2 IA4 1 W B...

Page 4199: ...W B W B W B W B W B W B Detection SW Transfer L4 Position Transfer Shift Actuator Detection SW Transfer 4WD Position I 1 W B W B W B ADD Actuator W B Power Window Motor Back Window Back Window Control Relay B 4 B 4 B 4 B 4 B 4 B 5 BO1 6 IK2 1 IE4 I 1 LS2 E W B W B W B W B W B W B W B W B A W B W B 5 A 4WD Control ECU B D B D A E O D Main SW ED1 6 EC1 4 W B W B W B A W B W B W B W B A W B W B W B W...

Page 4200: ...nation Light LH Rear Combination Light RH License Plate Light LH License Plate Light RH E2 IM1 8 W B 1G 1 IM3 2 LG Y W B W B IP W B BR W B 5 4 5 4 A A J54 B 3 B 3 B 3 BS BQ Fuel Pump BP2 7 BP2 6 Power Window Control SW Rear LH BL1 13 Door Unlock Detection SW Rear LH BL1 3 E GND BR Stereo Component Amplifier W B W B BR BR W B W B W B W B W B B B B B J82 BQ2 3 W B W B W B W B W B W B W B W B W B W B...

Page 4201: ...Side R B Under the Instrument Panel J B Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness Connector Location 1A 1B 1D 45 Cowl Wire and Driver Side J B Lower Finish Panel 1F 45 Cowl Wire and Driver Side J B Lower Finish Panel 1G 1H 1K 45 Engine Room Main Wire and Driver Side J B Lower Finish Panel 1M 45 Roof Wire and Driver Side J B Lower Finish Panel 2F 41 Eng...

Page 4202: ...wl Wire Rear Console BK1 96 Frame Wire and Frame No 3 Wire Near the License Plate Light BL1 96 Rear Door No 1 Wire LH and Floor No 2 Wire Left Side of Center Pillar BM1 96 Rear Door No 1 Wire RH and Floor Wire Right Side of Center Pillar BO1 98 Floor Wire and Seat No 1 Wire Under the Front Passenger s Seat BP2 96 Frame Wire and Floor No 2 Wire Under the Driver s Seat BQ2 98 Floor No 2 Wire and Sea...

Page 4203: ...2005 TOYOTA TUNDRA EWD611U 546 J POWER SOURCE Current Flow Chart Access Cab Standard Cab ...

Page 4204: ...2005 TOYOTA TUNDRA EWD611U 547 J ...

Page 4205: ...gation System Center Cluster Integration Control System Charging Combination Mater Cruise Control 1GR FE Cruise Control 2UZ FE Door Lock Control w Daytime Running Light Door Lock Control w o Daytime Running Light Electronically Controlled Transmission and A T Indicator 1GR FE Electronically Controlled Transmission and A T Indicator 2UZ FE Engine Control 1GR FE Engine Control 2UZ FE Interior Light ...

Page 4206: ...BS Audio System Built In Type Amplifier Audio System Separate Type Amplifier w Navigation System Audio System Separate Type Amplifier w o Navigation System Back Up Light Center Cluster Integration Control System Cigarette Lighter and Power Outlet Clock Cruise Control 1GR FE Cruise Control 2UZ FE Electronically Controlled Transmission and A T Indicator 1GR FE Electronically Controlled Transmission ...

Page 4207: ... SW 284 288 20A 4WD 4WD 242 30A POWER Door Lock Control w Daytime Running Light Door Lock Control w o Daytime Running Light Power Seat Power Window TVIP and Wireless Door Lock Control 248 254 298 268 260 Engine Room R B See Page 23 Fuse System Page 5A ECU B Engine Control 1GR FE Engine Control 2UZ FE SRS TVIP and Wireless Door Lock Control VSC 136 120 236 260 212 7 5A ALT S Charging 118 10A A C Ai...

Page 4208: ... Warning Light 186 174 15A MIR HTR Mirror Heater 292 15A PWR OUTLET1 Cigarette Lighter and Power Outlet 278 15A PWR OUTLET2 Cigarette Lighter and Power Outlet 278 20A A F HTR Engine Control 1GR FE Engine Control 2UZ FE 136 120 20A EFI NO 1 Cruise Control 1GR FE Cruise Control 2UZ FE Electronically Controlled Transmission and A T Indicator 1GR FE Electronically Controlled Transmission and A T Indic...

Page 4209: ...nditioning 316 50A J B Illumination Taillight 166 162 60A AIPR Engine Control 2UZ FE 120 100A ALT Except Towing Package Charging Cigarette Lighter and Power Outlet Engine Control 1GR FE Engine Control 2UZ FE Illumination Taillight 118 278 136 120 166 162 140A ALT Towing Package Charging Cigarette Lighter and Power Outlet Engine Control 2UZ FE Illumination Taillight 118 278 120 166 162 These are th...

Page 4210: ...2005 TOYOTA TUNDRA EWD611U 553 Memo ...

Page 4211: ...2005 TOYOTA TUNDRA EWD611U 554 J POWER SOURCE Current Flow Chart Double Cab ...

Page 4212: ...2005 TOYOTA TUNDRA EWD611U 555 J ...

Page 4213: ...6 384 10A H LP RL Headlight w Daytime Running Light Multiplex Communication System BEAN 346 384 20A A F HTR Engine Control 332 Engine Room J B See Page 40 Fuse System Page 7 5A ALT S Charging 7 5A ECU B Door Lock Control and Theft Deterrent Engine Control Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off System Multiplex Communication System BEAN Power Window VSC Wireless Door ...

Page 4214: ...tem 504 496 518 512 20A TURN HAZ Trailer Towing Turn Signal and Hazard Warning Light 366 364 25A AM2 Engine Control Ignition SRS Starting 332 326 467 324 25A RAD NO 1 Audio System Rear Seat Entertainment System Audio System w Navigation and Rear Seat Entertainment System Audio System 6 Speaker Audio System 8 Speaker Audio System 8 Speaker w Navigation System 504 496 522 518 512 30A DOOR NO 2 Door ...

Page 4215: ...t EC Mirror Charging Door Lock Control and Theft Deterrent Interior Light Light Auto Turn Off System Moon Roof Multiplex Communication System BEAN Power Outlet 115V Power Window Stop Light Tire Pressure Warning System Trailer Towing VSC Wireless Door Lock Control 454 476 494 330 420 408 400 484 384 480 414 372 458 366 448 428 10A HTR Air Conditioning Center Cluster Integration Control System Rear ...

Page 4216: ...tte Lighter and Power Outlet 12V 478 15A SEAT HTR Seat Heater 490 15A STOP ABS Cruise Control Electronically Controlled Transmission and A T Indicator Engine Control Stop Light Trailer Towing VSC 454 444 438 332 372 366 448 15A TAIL Engine Control Taillight Trailer Towing 332 356 366 20A IGN2 Engine Control Ignition 332 326 20A PWR NO 3 Multiplex Communication System BEAN Power Window 384 414 20A ...

Page 4217: ...dow Defogger and Mirror Heater 492 50A HEATER Air Conditioning 530 60A ABS NO 1 ABS VSC 454 448 140A ALT ABS Charging Cigarette Lighter and Power Outlet 12V Door Lock Control and Theft Deterrent Engine Control Illumination Light Auto Turn Off System Multiplex Communication System BEAN Power Window Taillight Wireless Door Lock Control 454 330 478 420 332 360 400 384 414 356 428 Engine Room R B No 3...

Page 4218: ...05 TOYOTA TUNDRA EWD611U 561 J Fuse System Page 30A TOWING TAIL Multiplex Communication System BEAN Trailer Towing 384 366 These are the page numbers of the first page on which the related system is shown ...

Page 4219: ...A 6 1 2 w VSC A 7 1 2 w o VSC Gray A 7 1 2 3 4 5 6 Black A 9 1 2 3 4 Dark Gray A10 1 2 Yellow A11 1 2 Yellow A12 2 1 A13 5 4 3 2 1 Black A15 1 2 3 4 Yellow A16 1 2 3 4 Yellow A17 1 2 Black A18 1 2 3 4 Gray A19 1 2 3 4 5 6 A T Black A20 1 2 3 4 5 6 M T Black A20 3 5 1 2 4 Gray A22 1 2 Black A28 1 2 3 1 Black A29 1 2 3 Double Cab A29 1 2 3 4 Dark Gray A30 1 2 Black A31 1 2 3 4 5 6 Black A32 1 2 Gray...

Page 4220: ... 16 15 14 13 12 11 10 3 B 7 3 5 1 2 B 8 3 4 5 6 7 13 14 15 16 17 2 12 1 11 8 18 19 9 10 20 B 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Gray B10 2 1 3 4 5 6 7 8 9 101112 13 14 15 16171819 2021222324 25 Black B11 5 4 3 2 1 6 7 8 9 101112 B12 1 2 Gray B13 2 1 4 3 6 5 B14 1 2 4 3 Bench Seat B15 1 2 3 4 Separate Seat B15 1 2 B16 2 1 3 Gray C 1 1 2 1GR FE Black C 2 1 Access Cab Standard Cab 2 Capta...

Page 4221: ...6 9 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Double Cab Yellow C 6 1 2 C 7 1 2 Gray C 8 1 2 C10 3 1 21 23 7 27 8 28 9 29 10 30 11 31 12 32 13 33 14 34 18 38 20 40 4 24 17 37 2 22 19 39 5 25 6 26 15 35 16 36 C11 2 1 13 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 C12 1 2 4 7 8 9 10 1112131415 16 17 5 6 3 C15 12 10 9 7 6 4 1 3 5 11 2 8 Black C16 1 2 3 4 5 6 7 8 9 10 11...

Page 4222: ...16 1 D17 1 2 Gray D18 1 2 D19 1 2 Gray D20 1 2 D21 3 1 2 Gray D22 3 1 2 Gray D23 1 2 3 4 5 6 D24 1 2 3 4 Black D25 1 2 3 4 Black D26 1 2 Black D27 1 2 Black D28 1 2 D29 1 2 Black D30 1 2 Black D31 5 4 3 2 1 D32 4 5 6 7 14 15 16 17 8 18 9 19 3 13 2 12 10 20 1 11 D33 1 2 3 Orange D34 1 2 3 Gray D35 1 2 Gray D36 1 2 Gray D37 1 D38 1 D39 1 2 3 4 5 6 7 8 9 10 D40 1 Access Cab Standard Cab ...

Page 4223: ... 8 9 33 10 5 12 13 14 22 25 11 3 2 1 4 26 28 17 29 18 7 20 21 6 31 30 23 24 35 16 27 E 4 17 30 32 20 10 11 31 12 6 5 14 15 16 23 26 13 3 2 1 4 27 28 18 8 29 19 9 21 22 7 24 25 E 5 18 33 34 11 12 13 6 5 15 16 17 25 14 3 2 1 4 26 29 21 9 30 22 10 24 7 32 35 19 27 28 20 8 31 23 E 6 17 32 34 20 10 11 33 12 6 5 14 15 16 23 26 13 3 2 1 4 27 28 18 8 29 19 9 21 22 7 31 30 24 25 E 7 1 2 Black E 8 1 2 Brown...

Page 4224: ...Cab Gray F19 18 24 17 8 7 9 10 23 4 11 12 15 3 16 13 14 19 20 22 21 1 2 5 6 F20 23 22 26 18 10 7 25 13 14 16 17 19 8 20 9 11 12 15 24 21 1 2 3 4 5 6 Black F21 1 1GR FE G 1 1 2UZ FE G 1 2 1 3 4 1GR FE Green G 2 2 1 3 4 2UZ FE Black G 2 1 2 G 3 1 2 3 H 1 1 2 3 H 2 2 1 3 4 Dark Gray H 4 2 1 3 4 Dark Gray H 6 1 Black H 7 1 Black H 8 1 3 2 H10 2 3 4 1 H11 2 3 4 1 H12 1 2 3 4 Black I 3 1 2 3 4 Black I 4...

Page 4225: ... Gray I15 1 2 Gray I16 1 2 Gray I17 1 2 Gray I18 1 2 Gray I19 1 2 Gray I20 1 2 Gray I21 1 2 1 Blue I22 1 2 Double Cab Gray I22 1 2 3 4 5 6 7 8 1 I23 1 2 4 5 3 6 Double Cab I23 11 22 21 10 9 20 19 8 7 18 17 6 5 16 15 4 3 14 13 1 2 12 I24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 I25 1 2 1 I26 1 2 3 4 4 I26 1 3 2 5 I26 1 2 3 4 5 7 6 Black I27 J 1 J 2 J 3 J 4 1 Access Cab Standard Cab 4 Double Cab...

Page 4226: ... A A A A A A A A A A A A A B B C C D D E E F F A A A A A A B B B C C C A A A A A A B B B C C C A A B C C A A B B B B C C A B B C C A A B D D D C C E H H E D H H D C G G C C G F B B F F A A F E H H E D H H D C G G C C G F B B F F A A F A A A A A A J 5 J 7 J 8 J 9 J10 J12 J13 J18 J21 J22 Gray J23 Gray J24 27 26 10 9 8 25 7 24 34 33 32 31 30 29 17 16 15 14 13 12 11 28 23 22 21 20 19 6 1 5 18 4 3 2 J2...

Page 4227: ...A A A A B B C C D D D E E E A A B B C C D D D E E E A A B B C C D D D E E E A A B B C C D D D E E E L K J I H F A E G D C B H G D C B F A E H A B C D E F G I J K L M N H A B C D E F G I J K L M N H G D C B F A E L K J I H F A E G D C B A A A A A A A A B A A A B B B A A A A Black J34 Gray J35 J36 J37 J38 J39 J40 J41 J42 J43 J45 J46 Black J47 Black J48 Black J49 Black J50 1 2 3 4 5 6 J51 1 2 3 4 5 6...

Page 4228: ... D A A D J65 Blue J66 Blue J67 1 2 J68 1 2 J69 1 2 J70 1 2 J71 1 2 J72 1 J73 Gray J74 J75 1 2 J76 1 2 J77 1 2 J78 1 2 J79 1 2 J80 1 J81 Gray J82 Gray J83 1 2 Black K 1 1 2 1GR FE Black K 2 1 2 2UZ FE Gray K 2 1 2 Gray L 1 1 2 Gray L 2 1 2 3 4 5 L 3 1 2 3 4 5 6 7 8 9 10 Black L 4 5 4 3 2 1 1GR FE Black M 1 1 2 3 4 5 2UZ FE Black M 1 1 2 3 4 5 6 Black M 4 1 2 3 4 5 6 Black M 5 1 2 3 4 5 6 7 8 9 10 M...

Page 4229: ... 1 2 1 Blue P 6 2 1 6 P 6 1 2 7 P 6 1 2 8 P 7 2 1 6 P 7 1 3 2 P 8 1 2 3 4 5 P 9 1 2 3 4 5 6 7 8 9 10 P10 1 2 1 P11 1 2 3 4 5 6 Double Cab P11 1 2 P12 2 1 Access Cab Black P13 2 1 Double Cab Yellow P13 2 1 Standard Cab Yellow P13 2 1 Access Cab Black P14 2 1 Double Cab Yellow P14 2 1 Standard Cab Yellow P14 1 2 Black P15 1 2 3 4 5 6 7 8 9 10 P16 1 2 Black P17 6 Double Cab Captain seat 7 Double Cab ...

Page 4230: ...R 5 1 2 Access Cab R 6 1 2 Double Cab Gray R 6 1 2 Access Cab R 7 1 2 Double Cab Gray R 7 1 2 3 4 5 6 9 R 8 1 2 3 10 R 8 3 2 1 4 5 6 Double Cab R 8 1 2 3 4 5 6 9 R 9 1 2 3 10 R 9 3 2 1 4 5 6 Double Cab R 9 1 2 3 4 5 6 7 8 9 10 R10 5 6 7 8 9 10 11 12 13 14 3 4 2 1 15 16 17 18 19 20 R12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R13 5 6 7 8 9 10 11 12 13 14 3 4 2 1 15 16 17 18 19 20 R14 9 Ac...

Page 4231: ...1 R19 5 6 7 8 17 18 19 20 9 21 10 22 4 16 3 15 12 24 1 13 2 14 11 23 R20 9 1 10 2 12 4 13 5 14 6 15 7 11 3 8 16 R21 1 Gray R22 1 R23 5 6 7 8 9 10 11 12 13 14 3 4 2 1 15 16 17 18 19 20 R24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R25 5 4 3 2 1 Gray R26 5 6 7 8 9 10 11 12 13 14 3 4 2 1 15 16 17 18 19 20 R27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R28 12 10 9 7 6 4 1 3 5 11 2 8 R...

Page 4232: ...1 6 7 8 9 101112 S20 2 1 13 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 S21 2 1 13 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 S23 1 3 2 4 5 6 7 8 9 101112 1314 15 16 1718 19 20 S24 2 3 4 1 S26 2 3 4 1 S28 31 32 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Black S29 1 2 3 4 Black S30 3 5 1 2 Gray ...

Page 4233: ...T 7 1 2 1 T 8 4 3 2 1 Double Cab T 8 1 2 3 4 5 6 7 8 9 T 9 1 2 Gray T10 1 2 3 4 5 6 7 8 9 10 11 12 T11 1 2 3 4 5 6 7 8 9 10 11 12 13141516171819202122 T12 1 2 3 4 5 6 7 8 Black T13 1 2 3 4 5 6 Black T14 1 2 Black T15 9 1 2 3 16 4 5 8 6 7 1011 15 14 1213 T16 1 2 Black T17 5 4 3 2 1 T18 1 2 U 1 1 2 3 Black V 2 1 2 Black V 3 1 2 1GR FE Gray V 4 1 2 2UZ FE Black V 4 1 2 1 Blue V 6 13 Except Towing Pac...

Page 4234: ... 8 5 2 3 4 1 V10 1 2 Black V11 1 2 3 4 5 6 7 8 V12 1 2 Black V13 1 2 Brown V14 1 2 Brown V15 1 2 3 1GR FE Black V16 1 2 2UZ FE Dark Gray V16 1 Access Cab Standard Cab 1 2 3 1GR FE Black V17 1 2 2UZ FE Dark Gray V17 1 2 4 3 Dark Gray W 2 1 2 3 4 5 Black W 4 1 2 Black W 5 5 4 3 2 1 Black Y 1 ...

Page 4235: ...859 B 7 Buckle SW LH Captain Seat w Power Seat 90980 11950 Buckle SW LH Separate Seat Captain Seat w o Power Seat 90980 12374 B 8 Back Window Relay 82660 20340 B 9 Body ECU 90980 11974 B10 Body ECU 90980 11973 B11 Body ECU 90980 11877 B12 Back Window Control Relay 90980 10803 B13 Buckle SW RH 90980 11486 B14 Buckle SW LH 90980 12381 B14 Seat Position Airbag Sensor 90980 12381 Buckle SW RH Bench Se...

Page 4236: ...e 90980 12528 E 7 Engine Control Module 90980 12527 E 8 Engine Hood Courtesy SW 90980 11189 F 1 Front Fog Light LH 90980 11096 F 2 Front Fog Light RH 90980 11096 F 3 Front Parking Light LH F 3 Front Turn Signal Light LH 90980 11020 F 4 Front Parking Light RH 90980 11020 F 4 Front Turn Signal Light RH F 5 Fuel Pump Resistor 1GR FE 90980 10901 F 5 Fuel Pump Resistor 2UZ FE 90980 11156 F 8 Front Door...

Page 4237: ...27 Junction Connector 90980 12320 J28 Junction Connector 90980 11915 J29 Junction Connector 90980 11915 J30 Junction Connector 90980 11194 J31 Junction Connector J32 Junction Connector 90980 11542 J34 Junction Connector J35 Junction Connector 90980 11194 J36 Junction Connector 90980 11661 J37 Junction Connector 90980 11661 J38 Junction Connector 90980 12319 J39 Junction Connector 90980 12319 J40 J...

Page 4238: ...0980 11011 P12 Power Window Motor Front RH 90980 10860 Pretensioner LH Access Cab 90980 12452 P13 Pretensioner LH Double Cab 90980 12253 Pretensioner LH Standard Cab 90980 11862 Pretensioner RH Access Cab 90980 12452 P14 Pretensioner RH Double Cab 90980 12253 Pretensioner RH Standard Cab 90980 11862 P15 Power Seat Motor Driver s Seat Front Vertical Control 90980 10825 P16 Power Seat Control SW Dri...

Page 4239: ...90980 12297 S30 Skid Control ECU with Actuator 90980 12294 S31 Stop Light Relay 82660 53010 S32 Side Airbag Sensor Rear LH S33 Side Airbag Sensor Rear RH 90980 12241 S34 Side Airbag Sensor LH 90980 12241 S35 Side Airbag Sensor RH S36 Seat Position Airbag Sensor 90980 12416 S37 Side Airbag Squib LH 90980 11864 S38 Side Airbag Squib RH 90980 11864 T 3 Transfer Shift Actuator 90980 11858 T 5 Turn Sig...

Page 4240: ...L Code Part Name Part Number Code Part Name Part Number 2005 TOYOTA TUNDRA EW611U 583 ...

Page 4241: ...M OVERALL ELECTRICAL WIRING DIAGRAM 2005 TOYOTA TUNDRA EWD611U 584 ...

Page 4242: ... system for the overall wiring diagram is the same as above E Indicates a Relay Block No shading is used and only the Relay Block No is shown to distinguish it from the J B Example Indicates Relay Block No 1 F 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 3C indicates that it is i...

Page 4243: ...icator 1GR FE 15 2 Electronically Controlled Transmission and A T Indicator 2UZ FE 14 2 Engine Control 1GR FE 5 2 Engine Control 2UZ FE 4 2 Fog Light w Daytime Running Light 12 2 Fog Light w o Daytime Running Light 7 4 Headlight w Daytime Running Light 6 2 Headlight w o Daytime Running Light 7 2 Horn 27 4 Ignition 1GR FE 3 2 Ignition 2UZ FE 2 2 Illumination 9 2 Interior Light 10 2 Key Reminder 26 ...

Page 4244: ...lectronically Controlled Transmission and A T Indicator 46 2 Engine Control 37 2 Garage Door Opener 44 4 Ignition 36 2 Illumination 41 2 Mirror Heater 53 2 Moon Roof 44 2 Multiplex Communication System BEAN 38 2 Door Lock Control Fog Light Headlight Horn Interior Light Key Reminder Light Auto Turn Off System Power Window Theft Deterrent Wireless Door Lock Control Multiplex Communication System CAN...

Page 4245: ... If there is not a Toyota dealer near you or you need emergency assistance for any reason please call the following number U S OWNERS Toyota Customer Assistance Center Toll free 1 800 331 4331 CANADIAN OWNERS Toyota Canada Customer Interaction Centre Toll free 1 888 TOYOTA 8 1 888 869 6828 Please leave this Owner s Manual in this vehicle at the time of resale The next owner will need this informat...

Page 4246: ...005 TUNDRA from Sep 04 Prod OM34432U OPERATION OF INSTRUMENTS AND CONTROLS Overview of instruments and controls Instrument panel overview 2 Instrument cluster overview 11 Indicator symbols on the instrument panel 13 SECTION 1 1 ...

Page 4247: ...love box 8 Power door lock switches 9 Power window switches 10 Manual transmission gear shift lever 11 Rear console box 12 Cup holders 13 Parking brake lever 14 Tire pressure warning system reset switch 15 Lower vent 16 Hood lock release lever 17 Window lock switch 18 Power rear view mirror control switches Instrument panel overview standard and access cab models Vehicles with manual transmission ...

Page 4248: ...ry box 7 Side defroster outlet 8 Glove box 9 Power door lock switches 10 Power window switches 11 Auxiliary box 12 Rear console box 13 Cup holders 14 Passenger airbag manual on off switch 15 Tire pressure warning system reset switch 16 Lower vent 17 Hood lock release lever 18 Parking brake pedal 19 Window lock switch 20 Power rear view mirror control switches Vehicles with automatic transmission t...

Page 4249: ...ge door opener box or auxiliary box 7 Side defroster outlet 8 Glove box 9 Power door lock switches 10 Power window switches 11 Rear condole box 12 Cup holders 13 Tire pressure warning system reset switch 14 Lower vent 15 Hood lock release lever 16 Parking brake pedal 17 Window lock switch 18 Power rear view mirror control switches Vehicles with automatic transmission type B ...

Page 4250: ...ift position L switch SHIFT L switch 7 Emergency flasher switch 8 Audio system or navigation system including audio system For the navigation system see the separate Navigation System Owner s Manual 9 Air conditioning controls 10 Front passenger s occupant classification indicator light front passenger s seat belt reminder light passenger airbag on off indicator light 11 Cargo lamp switch 12 Clock...

Page 4251: ... off switch 17 Ashtray 18 Cigarette lighter 19 2WD 4HI switch transfer mode selector switch 20 AUTO LSD switch 21 Cruise control switch 22 Audio remote control switches 23 Tilt steering lock release lever 24 Toyota vehicle intrusion protection system TVIP indicator light 25 Instrument panel light control knob ...

Page 4252: ...of switches 8 Side defroster outlet 9 Glove box 10 Power door lock switches 11 Power window switches 12 Seat heater switches 13 Rear console box 14 Input terminal adapter 15 Headphone input jacks and headphone volume control dials 16 Power outlets 17 Cup holders 18 Power outlet main switch 19 Tire pressure warning system reset switch 20 Lower vent Instrument panel overview double cab models ...

Page 4253: ... 05 TUNDRA_U L O 0409 8 2005 TUNDRA from Sep 04 Prod OM34432U 21 Hood lock release lever 22 Parking brake pedal 23 Window lock switch ...

Page 4254: ...witches 7 Automatic transmission selector lever 8 Automatic transmission shift position L switch SHIFT L switch 9 Audio system or navigation system including audio system For the navigation system see the separate Navigation System Owner s Manual 10 Air conditioning controls 11 Front passenger s occupant classification indicator light front passenger s seat belt reminder light 12 Cargo lamp switch...

Page 4255: ...LO switch transfer mode selector switch 19 Cigarette lighter 20 2WD 4HI switch transfer mode selector switch 21 AUTO LSD switch 22 Emergency flasher switch 23 Cruise control switch 24 Ignition switch 25 Audio remote control switches 26 Tilt steering lock release lever ...

Page 4256: ...rom Sep 04 Prod OM34432U 1 Engine coolant temperature gauge 2 Service reminder indicators and indicator lights 3 Speedometer 4 Fuel gauge 5 Trip meter reset knob 6 Odometer and two trip meters Instrument cluster overview Without tachometer ...

Page 4257: ... 04 Prod OM34432U 1 Service reminder indicators and indicator lights 2 Oil pressure gauge 3 Tachometer 4 Speedometer 5 Fuel gauge 6 Engine coolant temperature gauge 7 Trip meter reset knob 8 Odometer and two trip meters 9 Voltmeter With tachometer ...

Page 4258: ...senger s seat belt reminder light 1 Vehicle stability control system warning light 1 Traction control system warning light 1 AUTO LSD system warning light 1 SRS warning light 1 Automatic transmission fluid temperature warning light 1 four wheel drive models Unengaged Park warning light 1 Low windshield washer fluid level warning light 1 Open door warning light 1 Low tire pressure warning light 1 E...

Page 4259: ...r light 4 Low speed four wheel drive indicator light 3 four wheel drive models High speed four wheel drive indicator light 3 four wheel drive models Automatic transmission indicator lights Overdrive off indicator light Turn signal indicator lights AUTO LSD indicator light Slip indicator light Vehicle stability control system off indicator light Headlight high beam indicator light Front passenger o...

Page 4260: ...d Doors Keys 16 Front doors 16 Side doors 18 Access doors 20 Wireless remote control 21 Power windows 31 Rear side windows 34 Back window 35 Power back window 35 Tailgate 37 Hood 38 Toyota vehicle intrusion protection system TVIP 39 Theft deterrent system 41 Fuel tank cap 42 Electric moon roof 45 SECTION 1 2 ...

Page 4261: ...on the plate Keep the plate in a safe place such as your wallet not in the vehicle If you should lose your keys or if you need additional keys duplicates can be made by a Toyota dealer using the key number We recommend writing down the key num ber and storing it in a safe place LOCKING AND UNLOCKING WITH KEY Insert the key into the keyhole and turn it To lock Turn the key forward To unlock Turn th...

Page 4262: ...on switch when closing the front doors Driver s side Passenger s side LOCKING AND UNLOCKING WITH POWER DOOR LOCK SWITCH Push the switch To lock Push the switch down on the front side To unlock Push the switch down on the rear side Both doors lock or unlock simultaneously CAUTION Before driving be sure that the doors are closed and locked especially when small children are in the ve hicle Along wit...

Page 4263: ...doors can be changed to a single key turning operation For details contact your Toyota dealer When all the doors are unlocked simulta neously using a key the interior light igni tion switch light step light come on for about 15 seconds and cargo lamp for about 20 seconds before fading out For details see Center interior and personal lights Ignition switch and step lights and Cargo lamp in Section ...

Page 4264: ... the ve hicle Doors cannot be locked when either front door is open and the key is in the igni tion Driver s side Passenger s side LOCKING AND UNLOCKING WITH POWER DOOR LOCK SWITCH Push the switch To lock Push the switch down on the front side To unlock Push the switch down on the rear side All the doors lock or unlock simultaneous ly When the front doors are locked with the inside lock knob the k...

Page 4265: ...e recommend using this feature whenever small children are in the vehicle CAUTION Before driving be sure that the doors are closed and locked especially when small children are in the ve hicle Along with the proper use of seat belts locking the doors helps prevent the driver and passengers from being thrown out from the ve hicle during an accident It also helps prevent the doors from being opened ...

Page 4266: ...ht 2 LOCK switch 3 UNLOCK switch 4 PANIC switch The wireless remote control system is designed to lock or unlock all the doors or activate the PANIC mode from a distance within approximately 1 m 3 ft of the vehicle When you operate any switch push it slowly and securely The wireless remote control transmitter is an electronic component Observe the fol lowing instructions in order not to cause dama...

Page 4267: ...he transmitter To replace the battery see Replacing battery If you lose your transmitter contact your Toyota dealer as soon as possible to avoid the possibility of theft or an acci dent See If you lose your wireless re mote control transmitter in Section 4 MODEL FCC ID BAB237131 056 CAN 2024 102 1519 ASSEMBLED IN U S A This complies with Part 15 of the FCC rules Operation is subject to the follow ...

Page 4268: ...l lights and front side marker lights will flash twice When the UNLOCK switch is pressed the interior light personal light come on The lights remain on for about 30 seconds unless any door is opened and closed For details see Interior light and Per sonal lights in Section 1 5 You have 30 seconds to open a door after using the wireless remote unlock feature If a door is not opened by then all the d...

Page 4269: ...ransmitter battery or components NOTICE When replacing the battery be care ful not to lose the components Replace only with the same or equivalent type recommended by a Toyota dealer Dispose of used batteries according to the local laws Replace the transmitter battery by follow ing these procedures 1 Using a coin or equivalent open the transmitter case 2 Remove the rubber gasket and set it aside R...

Page 4270: ...he transmitter bat tery are faced correctly Do not replace the battery with wet hands Water may cause unexpected rust Do not touch or move any compo nents inside the transmitter or it may interfere with proper operation Be careful not to bend the electrode when inserting the transmitter bat tery and that dust or oils do not adhere to the transmitter case Close the transmitter case securely After r...

Page 4271: ...icle Contact your Toyota dealer for detailed information If the wireless remote control transmitter does not actuate the doors or alarm or operate from a normal distance Check for closeness to a radio trans mitter such as a radio station or an airport which can interfere with normal operation of the transmitter The battery may have been consumed Check the battery in the transmitter To replace the ...

Page 4272: ...can be determined by turning the equipment off and on the user is en couraged to try to correct the interfer ence by one or more of the following measures Reorient or relocate the receiving an tenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced ...

Page 4273: ...p light come on for about 15 seconds and cargo lamp for about 20 seconds before fading out even if the door is not opened For details see Center interior and personal lights Igni tion switch and step lights and Cargo lamp in Section 1 5 You have 30 seconds to open a door after using the wireless remote unlock feature If a door is not opened by then all the doors will be automatically locked again ...

Page 4274: ...ignition key from the LOCK to the ON position The PANIC mode does not work when the ignition key is in the ON position This alarm function can be disabled For details contact your Toyota dealer For replacement use a CR2016 lithium battery or equivalent CAUTION Special care should be taken to pre vent small children from swallowing the removed battery or components NOTICE When replacing the transmi...

Page 4275: ...the terminals 3 Put in a new transmitter battery with positive side up Close the transmitter case securely NOTICE Make sure the positive side and negative side of the transmitter bat tery are faced correctly Do not replace the battery with wet hands Water may cause unexpected rust Do not touch or move any compo nents inside the transmitter or it may interfere with proper operation ...

Page 4276: ...ess cab models Double cab models The windows can be operated with the switch on either front door standard and access cab models each door double cab models The power windows work when the ignition switch is in the ON position Key off operation If both front doors are closed they work for 43 seconds even after the ignition switch is turned off They stop working when either front door is opened OPE...

Page 4277: ...tomatic operation to open only Push the switch completely down and then release it The window will fully open To stop the window partway lightly pull the switch up and then release it Window lock switch Driver s door switch standard and access cab models Window lock switch Driver s door switches double cab mod els ...

Page 4278: ...oor standard and access cab mod els passengers doors double cab models or the switch on the driver s door that controls each passenger s window The window moves as long as you hold the switch To open Push down the switch To close Pull up the switch If you push in the window lock switch on the driver s door the passenger s stan dard and access cab models passengers double cab models windows and pow...

Page 4279: ...ows safely When small children are in the ve hicle never let them use the power window switches without supervi sion Use the window lock switch to prevent them from making unex pected use of the switches Be sure to remove the ignition key when you leave your vehicle Never leave anyone particularly a small child alone in your vehicle especially with the ignition key still inserted Otherwise he she ...

Page 4280: ...ey off operation If both front doors are closed they work 43 seconds even after the ignition switch is turned off The pow er back window stops working when either front door is opened The back window moves as long as you hold the switch Access cab models To open Push the switch on the side To close Push the switch on the side Double cab models To open Push the switch on the side To close Push the ...

Page 4281: ...dow it could result in a serious injury When anyone closes the power back window make sure he or she operates the window safely When small children are in the ve hicle never let them use the power back window switch without super vision Be sure to remove the ignition key when you leave your vehicle Never leave anyone particularly a small child alone in your vehicle especially with the ignition key...

Page 4282: ...the tailgate try pulling and pushing it to make sure it is securely closed NOTICE Avoid driving with the tailgate open Support cable bracket REMOVAL 1 Open the tailgate to the angle where you can release the brackets on the support cables from the lugs on both sides To release the support cable bracket lift it up and slide it off 2 Tilt the tailgate to about 30 from vertical and pull up the right ...

Page 4283: ... in use NOTICE Make sure the support brackets are securely latched on both side panels when installing the tailgate LOCKING AND UNLOCKING WITH KEY Insert the key into the keyhole and turn it to lock or unlock the tailgate To lock Turn the key clockwise To unlock Turn the key counterclockwise To open the hood 1 Pull the hood lock release lever The hood will spring up slightly CAUTION Before driving...

Page 4284: ... attempts to damage or break into your vehicle the system sounds the alarm while flashing the lights SETTING THE SYSTEM You can set the system as follows 1 Remove the key from the ignition switch 2 Have all passengers get out of the vehicle 3 Close all the doors securely 4 Lock all the doors with the key or re mote keyless entry transmitter At this time the TVIP indicator light comes on The system...

Page 4285: ...lly resets the alarm af ter the alarm has stopped The alarm will activate again under the same circumstances described in Activat ing the alarm Stopping the alarm You can stop the alarm in either of the following ways Unlock any of the doors with the key or remote keyless entry transmitter Place the ignition switch in the ON position CANCELLING THE SYSTEM You can cancel the system as described in ...

Page 4286: ...cally be set after 30 seconds When the system is set the indicator light will start flashing again 4 After making sure the indicator light starts flashing you may leave the ve hicle Never leave anyone in the vehicle when you set the system because unlocking from the inside will activate the system WHEN THE SYSTEM IS SET Activating the system The system will sound the alarm under the following cond...

Page 4287: ... the system at the same time TESTING THE SYSTEM 1 Open all the windows 2 Set the system as described above The doors should be locked with the key or wireless remote control transmit ter Be sure to wait until the indicator light goes off or starts flashing 3 Unlock any door from the inside The system should activate the alarm 4 Stopping the alarm as described above 5 Repeat this operation for the ...

Page 4288: ...flames when refueling The fumes are flammable When opening the cap do not re move the cap quickly In hot weath er fuel under pressure could cause injury by spraying out of the filler neck if the cap is suddenly re moved Do not fill a fuel container on a plastic truck bed liner a rubber truck bed mat or any other insulat ing material A static electricity charge could cause a spark and fire hazard T...

Page 4289: ...ear the click the cap is fully closed If the cap is not tightened securely the malfunction indicator lamp comes on Make sure the cap is tightened securely The indicator lamp goes off after driving several times If the indicator lamp does not go off contact your Toyota dealer as soon as possible CAUTION Make sure the cap is tightened se curely to prevent fuel spillage in the event of an accident Us...

Page 4290: ...m 5 3 in from the fully opened position The sun shade will be opened together with the roof To close Push the SLIDE switch on the front side The roof will fully close To stop the roof partway push the same side or rear side briefly Tilting operation To tilt up Push the TILT switch on the UP side To lower Push the TILT switch on the opposite side of UP You may stop the moon roof at any de sired pos...

Page 4291: ... If someone s neck head or hands get caught in the closing roof it could result in a serious injury When anyone closes the moon roof first make sure it is safe to do so Be sure to remove the ignition key when you leave your vehicle Never leave anyone particularly a small child alone in your vehicle especially with the ignition key still inserted Otherwise he she could use the moon roof switches an...

Page 4292: ...r seats 53 Tumbling rear seats 54 Head restraints 56 Armrest 57 Seat heaters 58 Seat belts 59 SRS driver airbag and front passenger airbag 70 Passenger airbag manual on off switch 87 SRS side airbags and curtain shield airbags 88 Front passenger occupant classification system 98 Roll sensing of curtain shield airbags off switch 103 Child restraint 104 SECTION 1 3 ...

Page 4293: ... the risk zone for driver airbag is the first 50 75 mm 2 3 in of inflation placing yourself 250 mm 10 in from your driver airbag provides you with a clear margin of safety This distance is measured from the center of the steering wheel to your breastbone If you sit less than 250 mm 10 in away now you can change your driving position in sever al ways Move your seat to the rear as far as you can whi...

Page 4294: ...the seat does not hit a passenger or luggage After adjusting the seat position re lease the lever and try sliding the seat forward and backward to make sure it is locked in position After adjusting the seatback push your body back against the seat to make sure the seat is locked in position Do not put objects under the seats Otherwise the objects may interfere with the seat lock mechanism or unexp...

Page 4295: ...STING LEVER Pull up or push down the lever 3 SEATBACK ANGLE ADJUSTING LEVER Lean forward and pull the lever up Then lean back to the desired angle and release the lever CAUTION Avoid reclining the seatback any more than needed The seat belts pro vide maximum protection in a frontal or rear collision when the driver and the front passenger are sitting up straight and well back in the seats If you a...

Page 4296: ...ION Avoid reclining the seatback any more than needed The seat belts pro vide maximum protection in a frontal or rear collision when the driver and the front passenger are sitting up straight and well back in the seats If you are reclined the lap belt may slide past your hips and apply re straint forces directly to the abdomen or your neck may contact the shoul der belt In the event of a frontal c...

Page 4297: ...ck until it locks CAUTION After putting back the seatback try pushing the seatback forward and rearward to make sure it is secured in place Never allow anyone to rest their foot on the press pedal while the vehicle is moving Pull the seatback lock release lever and fold down the seatback Hold the lever until you have swung the seatback forward slightly Tilting passenger s seatback for rear seat en...

Page 4298: ...securely locked by pushing forward and rear ward on the top of the seatback Failure to do so will prevent the seat belt from operating properly Make sure the seat belts are not twisted or caught in the seatback and are arranged in their proper position and are ready to use 1 Stow the rear seat belt buckles as shown in the illustration This prevents the belt buckles from falling out when you swing ...

Page 4299: ...locked by trying to pull up the edge of the bottom cushion Failure to do so will prevent the seat belt from operating properly Make sure the seat belts are not twisted or caught under the bottom cushion and are arranged in their proper position and are ready to use BEFORE TUMBLING REAR SEATS Stow the rear seat belt buckles as shown in the illustration This prevents the buckles from falling out whe...

Page 4300: ...ly move it Otherwise people may be injured or luggage may be damaged if the seat hits them To avoid serious injury do not sit on the folded seatback Use the seat lock release lever on the side only when tumbling the seat 2 Take the holding strap out of its hole and hook the strap onto the assist grip Then pull the strap on the free end to secure the seat When returning the rear seat to its origina...

Page 4301: ...position observe the following pre cautions in order to prevent personal injury in a collision or sudden stop Be careful not to get your hands or feet pinched in the seat Make sure the seat is securely locked by pushing forward and rear ward on the top of the seatback or by trying to pull up the edge of the bottom cushion Failure to do so will prevent the seat belt from oper ating properly Make su...

Page 4302: ...ter position of the seats always pull up the center head restraint to the lock position The head restraint is most effective when it is close to your head Therefore using a cushion on the seatback is not recom mended CAUTION Adjust the center of the head re straint so that it is closest to the top of your ears After adjusting the head restraint make sure it is locked in position Do not drive with ...

Page 4303: ...he follow ing positions HI High heating temperature LO Low heating temperature The key must be in the ON position to operate seat heaters Pushing lightly on the opposite side will turn it off CAUTION Occupants must use caution when op erating the seat heater because it may make them feel too hot or cause burns at low temperatures erythema varicella Use extra caution for Babies small children elder...

Page 4304: ...children to stand up or kneel on either rear or front seats An unrestrained child could suffer serious in jury or death during emergency braking or a collision Also do not let the child sit on your lap Holding a child in your arms does not provide sufficient restraint Pregnant woman Toyota recommends the use of a seat belt Ask your doctor for specific recommendations The lap belt should be worn se...

Page 4305: ...tically adjusts to your size and the seat position The retractor will lock the belt during a sudden stop or on impact It also may lock if you lean forward too quickly A slow easy motion will allow the belt to extend and you can move around freely When a passenger s shoulder belt is com pletely extended and is then retracted even slightly the belt is locked in that position and cannot be extended T...

Page 4306: ...n your waist then ad just it to a snug fit by pulling the shoulder portion upward through the latch plate CAUTION Both high positioned lap belts and loose fitting belts could cause seri ous injuries due to sliding under the lap belt during a collision or other unintended event Keep the lap belt positioned as low on hips as possible Do not place the shoulder belt un der your arm Standard and double...

Page 4307: ...kept away from your neck but not falling off your shoulder Failure to do so could reduce the amount of protection in an accident and cause severe injuries in a collision To release the belt press the buckle release button and allow the belt to retract If the belt does not retract smoothly pull it out and check for kinks or twists Then make sure it remains untwisted as it re tracts FRONT CENTER SEA...

Page 4308: ...ith colors of the buckle re lease button Also the 2 tabs have differ ent shape for its end so that the belt is not buckled in the wrong place Buckle 1 with light gray buckle re lease button Properly matches with concave end tab Buckle 2 with red buckle release but ton Properly matches with round end tab CAUTION Make sure the both buckles are cor rectly located and securely latched Failure to prope...

Page 4309: ...UTION Do not use the center seat belt with either buckle released Fastening only the shoulder belt or lap belt may cause severe personal injury in case of sudden braking or a collision The rear seat belt buckles can be stowed when not in use Seat belt buckles must be stowed before you swing up the bottom cushion See Swing up rear seats in this Section Stowing the rear seat belt buckles access cab ...

Page 4310: ... observe the following precautions Failure to follow these instructions could reduce the effectiveness of the seat belt restraint system in case of an accident increasing the chance of personal injury Remember that the extender pro vided for you may not be safe when used on a different vehicle for another person or at a different seating position than the one origi nally intended If the seat belt ...

Page 4311: ...ar the seat belt with out the seat belt extender if you can fasten the seat belt without the extender Do not use the seat belt extender when installing a child restraint system on the front or rear passen ger seat If installing a child re straint system with the seat belt extender connected to the seat belt the seat belt will not securely hold the child restraint system which could cause death or ...

Page 4312: ...assenger seat belt pretensioners are designed to be activated in response to a severe fron tal impact On vehicles equipped with curtain shield airbags the pretensioners are also activated during vehicle rol lover When the sensor detects a severe frontal impact or a vehicle rollover the front seat belts are quickly drawn back by the re tractors so that the belts snugly restrain the occupants Vehicl...

Page 4313: ...y 7 SRS warning light The seat belt pretensioners are controlled by the airbag sensor assembly The airbag sensor assembly consists of a safing sen sor and airbag sensor When the seat belt pretensioners are acti vated an operating noise may be heard and a small amount of non toxic gas may be released This does not indicate that a fire is occurring This gas is normally harmless Once the seat belt pr...

Page 4314: ...ned to the ON position It goes off after about 6 seconds This means the seat belt pretensioners are operating properly This warning light system monitors the airbag sensor assembly front airbag sen sors side and curtain shield airbag sen sors curtain shield airbag sensors driv er s seat position sensor driver s seat belt buckle switch front passenger occupant classification system and indicator li...

Page 4315: ...t severe enough to cause the seat belt pretensioners to operate Either seat belt pretensioner assembly or surrounding area is scratched cracked or otherwise damaged The SRS Supplemental Restraint Sys tem airbags are designed to provide further protection for the driver and right front passenger in addition to the primary safety protection provided by the seat belts Vehicles with bench seat The SRS...

Page 4316: ...ystems The driver and front passenger can be killed or seriously injured by the inflating airbags if they do not wear the available seat belts properly During sudden braking just before a collision an unrestrained driver or front passenger can move for ward into direct contact with or close proximity to the airbag which may then deploy during the colli sion To ensure maximum protection in an accid...

Page 4317: ...move the key The indi cator light on the passenger airbag manual on off switch will come on when the passenger airbag system has been disabled See Passenger airbag manual on off switch in this Section for detail CAUTION Do not turn off the passenger air bag manual on off switch except when a member of a passenger risk group identified in TABLE 1 is oc cupying the right front passenger seating posi...

Page 4318: ...e in the front seat because Vehicle has no rear seat Vehicle has a rear seat too small to accommodate a rear facing infant seat or The infant has a medical condition which according to the infant s physician makes it necessary for the infant to ride in the front seat so that the driver can constantly monitor the child s condition Child age 1 to 12 A child age 1 to 12 must ride in the front seat be...

Page 4319: ... surface Falling into or jumping over a deep hole Landing hard or vehicle falling The SRS airbags may also deploy if a serious impact occurs to the underside of your vehicle Some examples are shown in the illustration The SRS airbag system consists mainly of the following components and their loca tions are shown in the illustration 1 Front airbag sensors 2 Front passenger occupant classification ...

Page 4320: ...use some minor irritation to the eyes skin or breathing Be sure to wash off any residue as soon as possible to prevent any potential skin irritation with soap and water If you can safely exit from the vehicle you should do so imme diately Deployment of the airbags happens in a fraction of a second so the airbags must inflate with considerable force While the system is designed to reduce serious in...

Page 4321: ...tructions and precautions con cerning the seating position see Front seat precautions in this Section CAUTION A member of a passenger risk group should never sit or be occupied in the front outside passenger seat with airbag manual on off switch in the ON or AUTO position For de tails see SRS driver airbag and front passenger airbag in this Sec tion Do not sit on the edge of the seat or lean again...

Page 4322: ...be killed or seriously injured Do not hold a child on your lap or in your arms Use a child restraint system in the rear seat For instruc tions concerning the installation of a child restraint system see Child restraint in this Section Do not put anything or any part of your body on or in front of the dashboard or steering wheel pad that houses the airbag system They might restrict inflation or cau...

Page 4323: ...ication If you wish to modify your vehicle for a person with physical disability con sult your Toyota dealer It may dan gerously interfere with the SRS front airbags operation NOTICE Do not perform any of the following changes without consulting your Toyota dealer Such changes can interfere with proper operation of the SRS airbag system in some cases Installation of electronic devices such as a mo...

Page 4324: ... following conditions occurs this indicates a malfunction of the airbags or seat belt pretensioners Contact your Toyota dealer as soon as possible The light does not come on when the ignition key is turned to the ON posi tion or remains on for more than 6 seconds The light comes on while driving Vehicles with separate seat The SRS warning light will come on and front pas senger occupant classifica...

Page 4325: ...resence of an oc cupant in the seat As for the front pas senger occupant classification system see Front passenger occupant classification system in this Section Always wear your seat belt properly CAUTION The SRS front airbag system is de signed only as a supplement to the primary protection of the driver and front passenger seat belt systems The driver and front passenger can be killed or seriou...

Page 4326: ... to an approximate 25 km h 15 mph collision when the vehicle has the impact straight into a fixed barrier that does not move or deform However this threshold velocity will be considerably higher if the vehicle strikes an object such as a parked vehicle or sign pole which can move or deform on impact or if the vehicle is involved in an underride collision e g a collision in which the front of the v...

Page 4327: ...nt passenger occupant classification system ECU and sensors 5 Front passenger s seat belt buckle switch 6 Driver s seat belt buckle switch 7 Driver s seat position sensor 8 Airbag sensor assembly 9 Airbag module for driver airbag and inflator 10 SRS warning light The airbag sensor assembly consists of a safing sensor and airbag sensor The front airbag sensors constantly moni tor the forward decele...

Page 4328: ...d is in close proximity to the airbag module at the time of deployment This is why it is important for the occupant to avoid placing any object or part of the body between the occupant and the airbag module sit straight and well back into the seat wear the available seat belt properly and sit as far as possible from the airbag module while still maintaining control of the ve hicle Parts of the air...

Page 4329: ...use your seat belt properly Toyota strongly recommends that all infants and children be placed in the rear seat of the vehicle and be properly restrained Vehicles with split bench seat Do not allow a child to stand up or kneel on the front passenger seat since the front passenger airbag could inflate with considerable speed and force Otherwise the child may be killed or seriously in jured Do not h...

Page 4330: ...isable the sys tem which could result in death or serious injury Failure to follow these instructions can result in death or serious injury Consult your Toyota dealer about any repair and modification If you wish to modify your vehicle for a person with physical disability con sult your Toyota dealer It may dan gerously interfere with the SRS front airbags operation NOTICE Do not perform any of th...

Page 4331: ...6 If either of the following conditions occurs this indicates a malfunction of the airbags or seat belt pretensioners Contact your Toyota dealer as soon as possible The light does not come on when the ignition key is turned to the ON posi tion or remains on for more than 6 seconds The light comes on while driving Vehicles with separate seat The SRS warning light will come on and front pas senger o...

Page 4332: ...ws Insert key into the keyhole To turn passenger airbag on Except for separate seat with automatic transmission Turn the key clockwise to the ON position At this time the ON indicator light comes on For separate seat with automatic transmis sion Turn the key clockwise to the AUTO position At this time the indicator light condition varies depending on the oc cupant in the right front seat For detai...

Page 4333: ...g position When the passenger airbag manual on off switch is turned off the pas senger airbag will not inflate in a collision and turning off the pas senger airbag can reduce the occu pant protection which your vehicle safety systems can provide to you in certain accidents and increase the likelihood of serious personal injuries For details see SRS driver airbag and front passenger airbag in this ...

Page 4334: ...on both sides work with the seat belts to help reduce injury by inflating The curtain shield airbags help reduce injuries mainly to the driver s or front passenger s head and help pre vent them from being thrown out of the vehicle This function can be turned off if inflation is not desired See Roll sens ing of curtain shield airbags off switch in this Section The SRS curtain shield airbag on the p...

Page 4335: ...roperly secured using a child restraint system Toyota strongly recommends that all in fants and children be placed in the rear seats of the vehicle and prop erly restrained The rear seats are the safest for infants and children For instructions concerning the installation of a child restraint sys tem see Child restraint in this Section The SRS side airbag and curtain shield airbag system may not a...

Page 4336: ...he angle of vehicle tip up is manual Skidding vehicle hitting a curb stone The curtain shield airbags may inflate if the angle of vehicle tip up is margin al or if the skidding vehicle s tires hit a curb stone laterally as shown in the illustration Collision from the front Collision from the rear Pitch end over end The curtain shield airbags are not gen erally designed to inflate if the vehicle is...

Page 4337: ...de airbag modules airbag and inflator 6 Curtain shield airbag sensors 7 Side and curtain shield airbag sensors 8 Front passenger s seat belt buckle switch 9 Airbag sensor assembly The SRS side airbag and curtain shield airbag system is controlled by the airbag sensor assembly The airbag sensor as sembly consists of a safing sensor and airbag sensor In a severe side impact the side and curtain shie...

Page 4338: ...e rail may be hot for several minutes but the airbags themselves will not be hot The airbags are designed to inflate only once CAUTION SRS side airbags and curtain shield airbags inflate with considerable force To reduce the possibility of death or serious injury when they in flate the driver front passenger and rear outside passengers must Wear their seat belts properly Remain properly seated wit...

Page 4339: ...he area where the side airbag and curtain shield air bag inflate since these airbags could inflate with considerable speed and force Otherwise he she may be killed or seriously injured Special care should be taken espe cially when you have a small child in the vehicle Do not allow anyone to kneel on the passenger seat facing the pas senger s side door since the side airbag and curtain shield airba...

Page 4340: ...r any other device or object will be thrown with great force or the side airbag may not activate correctly resulting in death or serious injury Likewise the driver and front passenger should not hold objects in their arms or on their knees Do not attach a microphone or any other device or object around the area where the curtain shield airbag activates such as on the windshield glass side door gla...

Page 4341: ...he system or cause the curtain shield airbags to inflate accidental ly resulting in death or serious in jury Do not use tires or wheels other than the manufacturer s recom mended size Such a use may cause the curtain shield airbags to inflate accidentally which could result in death or serious injury For details see Checking and replacing tires in Section 7 2 Failure to follow these instructions c...

Page 4342: ...belt buckle switch seat belt pretensioner assemblies inflat ors warning light RSCA OFF indicator light interconnecting wiring and power sources For details see Service remind er indicators and warning buzzers in Sec tion 1 6 If either of the following conditions occurs this indicates a malfunction of the airbags or seat belt pretensioners Contact your Toyota dealer as soon as possible The light do...

Page 4343: ... these conditions activates or deactivates front passenger airbags The system moni tors the weight and load on the front passenger seat and the seat belt buckle switch to determine conditions 1 4 In order for the system to detect the conditions correctly do not do any of the following Put a heavy load on the front passen ger seat Attach a seatback table to the front passenger seatback Put weight o...

Page 4344: ...l back in the seat and with the seat belt worn correctly If the OFF indicator still remains illuminated either ask the passenger to move to the rear seat or if that is not possible move the front passenger seat fully rearward The front passenger occupant classifi cation indicator light will indicate ON and OFF when the ignition key is turned to the ON position After about four seconds it will go o...

Page 4345: ...Activated 3 Unoccupied AUTO Not illuminated Off Off Deactivated 3 Unoccupied OFF OFF Off Off Deactivated 4 There is a malfunction in the AUTO OFF On Off Deactivated Activated malfunction in the system OFF OFF On Off Deactivated Activated 1 The system judges a person of adult size as an adult When a smaller adult sits in the front passenger seat the system may recognize him her as a child depending...

Page 4346: ...Unoccupied Not illuminated Off Off Deactivated Activated Deactivated 4 There is a malfunction in the system OFF On Off Deactivated Activated 1 The system judges a person of adult size as an adult When a smaller adult sits in the front passenger seat the system may recognize him her as a child depending on his her physique and posture 2 When a larger child who has outgrown a child restraint system ...

Page 4347: ...where it does not touches the rear seat Keep the front passenger seatback as upright as possible when the ve hicle is moving Reclining the seat back excessively may lessen the ef fectiveness of the seat belt system If an adult sits in the front passen ger seat the occupant classification indicator light should indicate ON If the OFF indicator is illumina ted ask the passenger to sit up straight we...

Page 4348: ... bags off switch RSCA OFF switch can turn off the curtain shield airbags and seat belt pretensioners in a vehicle rollover This switch should only be used if inflation is not desired such as extreme off road driving When you push the RSCA OFF switch for a few seconds with the ignition switch on the RSCA OFF indicator light comes on and the roll sensing function is turned off When you push the swit...

Page 4349: ...aint system the child should sit in the rear seat and must be restrained using the vehicle s seat belt See Seat belts in this Section for details CAUTION For effective protection in automo bile accidents and sudden stops a child must be properly restrained using a seat belt or child restraint system depending on the age and size of the child Holding a child in your arms is not a substitute for a c...

Page 4350: ...lt will not securely hold the child restraint system which could cause death or serious injury to the child or other passengers in the event of collision Make sure you have complied with all installation instructions provided by the child restraint manufacturer and that the system is properly se cured If it is not secured properly it may cause death or serious injury to the child in the event of a...

Page 4351: ...d cause death or serious injury to the child or other passengers in the event of collision Make sure you have complied with all installation instructions provided by the child restraint manufacturer and that the system is properly se cured If it is not secured properly it may cause death or serious injury to the child in the event of a sud den stop or accident A child restraint system for a small ...

Page 4352: ... the instructions provided by its manufac turer Your vehicle has anchor brackets for se curing the top strap of a child restraint system For instructions about how to use the an chor bracket see Using a top strap in this Section The child restraint lower anchorages ap proved for your vehicle may also be used See Installation with child restraint low er anchorages in this Section A Infant seat B Co...

Page 4353: ...mission CAUTION Never install a rear facing child re straint system on the front seat with the passenger airbag manual on off switch in the ON or AUTO posi tion In the event of an accident the force of the rapid inflation of the front passenger airbag can cause death or serious injury to the child if the rear facing child system is installed on the front passenger seat Installation with seat belt ...

Page 4354: ...The indicator light comes on when the system is off CAUTION If you must install a rear facing child restraint system on the right front seat make sure that the passenger airbag manual on off switch is in the OFF position with the key removed and that the indicator light is on CAUTION Do not install a child restraint sys tem on the rear seat if it interferes with the lock mechanism of the front sea...

Page 4355: ...ns of the belt are not twisted Do not insert coins clips etc in the buckle as this may prevent your child from properly latching the tab and buckle If the seat belt does not function normally it cannot protect your child from death or serious injury Contact your Toyota dealer immedi ately Do not install the child restraint system on the seat until the seat belt is fixed 2 Fully extend the shoulder...

Page 4356: ...to hold the infant seat secure ly CAUTION Push and pull the child restraint sys tem in different directions to be sure it is secure Follow all the installation instructions provided by its manufac turer 4 To remove the infant seat press the buckle release button and allow the belt to retract completely The belt will move freely again and be ready to work for an adult or older child passen ger ...

Page 4357: ...installing the child restraint system Except for separate seat with automatic transmission For separate seat with automatic trans mission CAUTION Rear facing child restraint system Never install a rear facing child re straint system on the front seat with the passenger airbag manual on off switch in the ON or AUTO posi tion In the event of an accident the force of the rapid inflation of the front ...

Page 4358: ...e system is off CAUTION If you must install a rear facing child restraint system on the right front seat make sure that the passenger airbag manual on off switch is in the OFF position with the key removed and that the indicator light is on CAUTION Forward facing child restraint system A forward facing child restraint sys tem which belongs to a passenger risk group should never be installed on the...

Page 4359: ...t through or around the convertible seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt Keep the lap portion of the belt tight CAUTION After inserting the tab make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted Do not insert coins clips etc in the buckle as this may ...

Page 4360: ...ecurely make sure the belt is in the lock mode before letting the belt retract 3 While pressing the convertible seat firmly against the seat cushion and seatback let the shoulder belt retract as far as it will go to hold the convert ible seat securely CAUTION Push and pull the child restraint sys tem in different directions to be sure it is secure Follow all the installation instructions provided ...

Page 4361: ...ION A booster seat must be used in for ward facing position only CAUTION A forward facing child restraint sys tem which belongs to a passenger risk group should never be installed on the front outside passenger seat with the passenger airbag manual on off switch in the ON or AUTO position because the force of the de ploying airbag could cause death or serious injury to the child in forward seating...

Page 4362: ... Otherwise the child may be killed or seriously injured in case of sud den braking or a collision Both high positioned lap belts and loose fitting belts could cause death or serious injuries due to sliding under the lap belt during a collision or other unintended event Keep the lap belt positioned as low on a child s hips as possible For child s safety do not place the shoulder belt under child s ...

Page 4363: ...d in rear facing position only CAUTION Vehicles with split bench seat Nev er install a rear facing child re straint system on the front passen ger seat In the event of an acci dent the force of the rapid inflation of the front passenger airbag can cause death or serious injury to the child if the rear facing child re straint system is installed on the front passenger seat Installation with seat be...

Page 4364: ...talled on the front passenger seat Do not install a child restraint sys tem on the rear seat if it interferes with the lock mechanism of the front seats Otherwise the child or front seat occupants may be killed or seriously injured in case of sud den braking or a collision If the driver s seat position does not allow sufficient space for safe installation install the child re straint system on the...

Page 4365: ...nnot protect your child from death or serious injury Contact your Toyota dealer immedi ately Do not install the child restraint system on the seat until the seat belt is fixed 2 Fully extend the shoulder belt to put it in the lock mode When the belt is then retracted even slightly it cannot be extended To hold the infant seat securely make sure the belt is in the lock mode before letting the belt ...

Page 4366: ... buckle release button and allow the belt to retract completely The belt will move freely again and be ready to work for an adult or older child passen ger B CONVERTIBLE SEAT INSTALLATION A convertible seat must be used in for ward facing or rear facing position de pending on the age and size of the child When installing follow the manufacturer s instructions about the applicable age and size of t...

Page 4367: ...st the seat cushion and seatback let the shoulder belt retract as far as it will go to hold the convert ible seat securely CAUTION Push and pull the child restraint sys tem in different directions to be sure it is secure Follow all the installation instructions provided by its manufac turer 7 Put a child on the child restraint sys tem and secure the child complying with the instructions provided b...

Page 4368: ...senger air bag and side airbag on the front passenger seat could deploy Vehicles with split bench seat Nev er install a rear facing child re straint system on the front passen ger seat In the event of an acci dent the force of the rapid inflation of the front passenger airbag can cause death or serious injury to the child if the rear facing child re straint system is installed on the front passeng...

Page 4369: ...bag could inflate with considerable speed and force Otherwise the child may be killed or seriously injured On vehicles with side airbags and curtain shield airbags do not allow the child to lean his her head or any part of his her body against the door or the area of the seat front or rear pillar or roof side rail from which the side airbags or curtain shield airbags deploy even if the child is se...

Page 4370: ...ions of the belt are not twisted Do not insert coins clips etc in the buckle as this may prevent your child from properly latching the tab and buckle If the seat belt does not function normally it cannot protect your child from death or serious injury Contact your Toyota dealer immedi ately Do not install the child restraint system on the seat until the seat belt is fixed 2 Fully extend the should...

Page 4371: ...hold the convert ible seat securely CAUTION Push and pull the child restraint sys tem in different directions to be sure it is secure Follow all the installation instructions provided by its manufac turer 4 To remove the convertible seat press the buckle release button and allow the belt to retract completely The belt will move freely again and be ready to work for an adult or older child passen g...

Page 4372: ... allowed to be installed on the front passenger seat only when it is unavoidable Always move the seat as far back as pos sible even if the front passenger occupant classification indicator light indicates OFF because the front passenger airbag could inflate with considerable speed and force Otherwise the child may be killed or seriously injured On vehicles with side airbags and curtain shield airb...

Page 4373: ... Otherwise the child may be killed or seriously injured in case of sud den braking or a collision Both high positioned lap belts and loose fitting belts could cause death or serious injuries due to sliding under the lap belt during a collision or other unintended event Keep the lap belt positioned as low on a child s hips as possible For child s safety do not place the shoulder belt under child s ...

Page 4374: ... to retract Follow the procedure below for a child restraint system that requires the use of a top strap Anchor brackets Use the anchor bracket on the back panel to attach the top strap Anchor brackets are installed for each passenger seating position This symbol indicates the locations of user ready anchor brackets Using a top strap standard cab models ...

Page 4375: ...Fix the child restraint system with the seat belt Latch the hook onto the anchor bracket and tighten the top strap For instructions to install the child re straint system see Child restraint in this Section CAUTION Make sure the top strap is securely latched and check that the child re straint system is secure by pushing and pulling it in different directions Follow all the installation instructio...

Page 4376: ...traint Store any removed covers in a safe place such as the glove box Be sure to replace all covers when the anchor bracket is not in use Outside position Center position Follow the procedure below for a child restraint system that requires the use of a top strap Using a top strap access cab models ...

Page 4377: ...on the side floor to attach the top strap Anchor brackets are installed for each rear seating position This symbol indicates the locations of user ready anchor brackets TO USE THE ANCHOR BRACKET Outside position 1 Remove the head restraint Routing device 2 Route the top strap through the routing device as shown in the il lustration CAUTION Make sure the top strap is not twisted ...

Page 4378: ...r and tighten the top strap For instructions to install the child re straint system see Child restraint in this Section CAUTION Make sure the top strap is securely latched and check that the child re straint system is secure by pushing and pulling it in different directions Follow all the installation instructions provided by its manufacturer 4 Replace the head restraint ...

Page 4379: ...t 2 Fold down the cup holder unfasten the Velcro that attaches the anchor bracket cover and lift the cover 3 Route the top strap through the slot on top of the seat pass the strap through the seat then latch the hook onto the anchor bracket Close the cover and return the cup holder to the original position ...

Page 4380: ... top strap CAUTION Make sure the top strap is securely latched and check that the child re straint system is secure by pushing and pulling it in different directions Follow all the installation instructions provided by its manufacturer 5 Replace the head restraint Follow the procedure below for a child restraint system that requires the use of a top strap Using a top strap double cab models ...

Page 4381: ...ackets Use one anchor bracket on the back of rear seats and two anchor brackets on the floor as shown above to attach the top strap Anchor brackets are installed for each rear seating position TO USE THE ANCHORAGES 1 Remove the head restraint Outside position Center position ...

Page 4382: ... installation instructions provided by its manufacturer 3 Replace the head restraint Lower anchorages for the child restraint systems complying with the FMVSS225 or CMVSS210 2 specifications are installed in the front seat The anchorages are installed in the gap between the seat cushion and seatback of the right side of the seat as shown in the illustration Child restraint systems complying with t...

Page 4383: ...NSTALLATION Type A 1 Widen the gap between the seat cushion and seatback slightly and confirm the position of the lower an chorages near the button on the seatback 2 Latch the hooks of lower straps onto the anchorages and tighten the lower straps Type B 1 Widen the gap between the seat cushion and seatback slightly and confirm the position of the lower an chorages near the button on the seatback 2...

Page 4384: ...e sure it is secure Follow all the installation instructions provided by its manufacturer After securing the child restraint system never slide or recline the seat Lower anchorages for the child restraint systems complying with the FMVSS225 or CMVSS210 2 specifications are installed in the rear seat The anchorages are installed in the gap between the seat cushion and seatback of the outsides of th...

Page 4385: ...child restraint system has a top strap it should be anchored For the installation of the top strap see Using a top strap in this Section For installation details refer to the instruc tion manual equipped with each product CAUTION When using the lower anchorages for the child restraint system be sure that there are no irregular ob jects around the anchorages or that the seat belt is not caught Push...

Page 4386: ...ar seats The anchorages are installed in the gap between the seat cushion and seatback for center and left positions of rear seats Child restraint systems complying with the FMVSS213 or CMVSS213 specification can be fixed to these anchorages In this case it is not necessary to fix the child restraint system with a seat belt on the vehicle Cap Covers Canada only Type A Installation with child restr...

Page 4387: ...below the button and cap in the seat cushion 3 Latch the hooks of lower straps onto the anchorages and tighten the lower straps Type B 1 Turn up the covers for left lower anchorage on the center position of the seats and for anchorages on the left side position of the seat and remove the cap for the right lower anchorage of the center position of the seat as shown in the illustration 2 Widen the c...

Page 4388: ...l the child restraint system in different directions to be sure it is secure Follow all the installation instructions provided by its manufacturer After securing the child restraint system never recline the seat Do not install a child restraint sys tem on the rear seat if it interferes with the lock mechanism of the front seats Otherwise the child or front seat occupant s may be killed or seriousl...

Page 4389: ... 05 TUNDRA_U L O 0409 144 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4390: ...p 04 Prod OM34432U OPERATION OF INSTRUMENTS AND CONTROLS Steering wheel and Mirrors Tilt steering wheel 146 Outside rear view mirrors 146 Anti glare inside rear view mirror 148 Auto anti glare inside rear view mirror 149 Sun visors 150 SECTION 1 4 ...

Page 4391: ... Doing so may cause the driver to mishan dle the vehicle and an accident may occur resulting in death or serious injuries After adjusting the steering wheel try moving it up and down to make sure it is locked in position Adjust the mirror so that you can just see the side of your vehicle in the mir ror Be careful when judging the size or dis tance of any object seen in the outside rear view mirror...

Page 4392: ...dle the vehicle and an accident may occur resulting in death or serious inju ries On some models since the mirror surfaces can get hot do not touch them when the outside rear view mirror heater or defogger switch is on Standard and access cab models Double cab models To adjust a mirror use the switches 1 Master switch To select the mirror to be adjusted Push the switch to L left or R right 2 Contr...

Page 4393: ...vehicle in the mir ror To reduce glare from the headlights of the vehicle behind you during night driving operate the lever on the lower edge of the mirror Daylight driving Lever at position 1 The reflection in the mirror has greater clarity at this position Night driving Lever at position 2 Remember that by reducing glare you also lose some rear view clarity CAUTION Do not adjust the mirror while...

Page 4394: ...ind you the mirror surface darkens slightly to reduce the reflected light To turn off the automatic function push the OFF switch To turn on the automatic function again push the AUTO switch Adjust it before driving so that the rear view is in the best condition When the inside air temperature is low it may take a little longer for the mirror to darken in response to the detection of headlights CAU...

Page 4395: ...To block out glare from the front Swing down the sun visor position 1 To block out glare from the side Swing down the sun visor remove it from the hook and swing it to the lateral side posi tion 2 If glare comes from obliquely behind you extend the plate at the end of the visor to position 3 Standard and access cab models Double cab models Sun visors ...

Page 4396: ...the sub vi sor CAUTION Do not extend the plate at the end of the sun visor when the visor is in the position 1 It can cover the anti glare inside rear view mirror and obstruct the rear view Standard and access cab models Double cab models To use the vanity mirrors swing down the sun visor and open the cover The vanity light s comes on when you open the cover Vanity mirrors ...

Page 4397: ... 05 TUNDRA_U L O 0409 152 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4398: ...154 Emergency flashers 155 Instrument panel light control 156 Front fog lights 156 Interior light 157 Personal lights 157 Center interior and personal lights 158 Ignition switch and step lights 159 Cargo lamp 160 Windshield wipers and washer 161 Outside rear view mirror heaters 162 Back window and outside rear view mirror defoggers 163 SECTION 1 5 ...

Page 4399: ...e headlights turn on at reduced intensi ty when the parking brake is released with the engine started even with the light switch in the OFF position They will not go off until the ignition switch is turned off To turn on the other exterior lights and instrument panel lights twist the knob to the position 1 Twist the knob to the position 2 to turn the headlights to full intensity for driving at nig...

Page 4400: ...en lights on the instrument panel flash faster than normal a front or rear turn signal bulb is burned out To turn on the emergency flashers push the switch All the turn signal lights will flash To turn them off push the switch once again Turn on the emergency flashers to warn other drivers if your vehicle must be stopped where it might be a traffic hazard Always pull as far off the road as pos sib...

Page 4401: ...ab models Double cab models To adjust the brightness of the instru ment panel lights turn the knob To turn on the front fog lights twist the band of the headlight turn signal lever They will come on only when the headlights are on low beam Instrument panel light control Front fog lights ...

Page 4402: ...on when any door is opened The light goes off when all the doors are closed Standard cab and access cab models only with wireless remote control When the switch is in the DOOR position and all the door are unlocked using the wireless remote control transmitter simultaneously the lights will come on and remain for about 30 seconds unless any door is opened or closed Standard and access cab models D...

Page 4403: ... on the personal light push the switch To turn the light off push the switch once again Turn the light on when any door is opened The light goes off when all the doors are closed Type A Type B CENTER INTERIOR LIGHT Type A To turn on the interior light slide the switch The interior light switch has the following positions ON Keeps the light on all the time OFF Turns the light off DOOR Turns the lig...

Page 4404: ...contact your Toyota dealer Cancelling the door key or wireless re mote control transmitter linked opera tion Changing the timing for the light turn ing off To prevent the battery being discharged the light will automatically turn off when the key is removed and the door is left opened with the switch at DOOR position for 20 minutes or more CENTER PERSONAL LIGHTS To turn on the center personal ligh...

Page 4405: ...ls contact your Toyota dealer Cancelling the door key or wireless re mote control transmitter linked opera tion Changing the timing for the light turn ing off The cargo lamp is designed to light up the rear deck of your vehicle CARGO LAMP OPERATION By pushing the CARGO LAMP switch To turn on Push the CARGO LAMP switch once At this time the indicator light on the instrument panel will come on To tu...

Page 4406: ...N position Lever position Speed setting Position 1 Intermittent Position 2 Slow Position 3 Fast The INT band lets you adjust the wiping time interval when the wiper lever is in the intermittent position position 1 Twist the band upward to increase the time be tween sweeps and downward to decrease it To squirt washer fluid pull the lever toward you and release it If the windshield wipers are off th...

Page 4407: ...efore using the washer This will help prevent the washer fluid from freezing on your windshield which can block your vision NOTICE Do not operate the wipers if the wind shield is dry It may scratch the glass To defog or defrost the outside rear view mirrors push the switch The key must be in the ON position The heater panels in the outside rear view mirrors will quickly clear the mirror sur faces ...

Page 4408: ...the inside of the back window will quickly clear the surface An indicator light will illuminate to indicate the defogger is operating Heater panels in the outside rear view mirrors will also quickly clear the sur faces Push the switch once again to turn the defogger off The system will automatically shut off af ter the defoggers have operated about 15 minutes Make sure you turn the defoggers off w...

Page 4409: ... 05 TUNDRA_U L O 0409 164 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4410: ... OF INSTRUMENTS AND CONTROLS Gauges Meters and Service reminder indicators Fuel gauge 166 Engine coolant temperature gauge 166 Oil pressure gauge 167 Voltmeter 168 Tachometer 168 Odometer and two trip meters 169 Service reminder indicators and warning buzzers 170 SECTION 1 6 ...

Page 4411: ... tank If the fuel level approaches E or the low fuel level warning light comes on fill the fuel tank as soon as possible On inclines or curves due to the move ment of fuel in the tank the fuel gauge needle may fluctuate or the low fuel level warning light may come on earlier than usual If the fuel tank is completely empty the malfunction indicator lamp comes on Fill the fuel tank immediately The i...

Page 4412: ...he engine cooling system as this may cause the engine to overheat The thermostat is designed to con trol the flow of coolant to keep the temperature of the engine within the specified operating range Do not continue driving with an overheated engine See If your ve hicle overheats in Section 4 Idling Normal driving The oil pressure gauge indicates engine oil pressure when the ignition switch is on ...

Page 4413: ...g it indicates the charging system needs im mediate repair However it is normal for the needle to drop below the normal range during en gine starting The tachometer indicates engine speed in thousands of rpm revolutions per minute Use it while driving to select correct shift points and to prevent en gine lugging and over revving Driving with the engine running too fast causes excessive engine wear...

Page 4414: ... on each trip All trip meter data is cancelled if the elec trical power source is disconnected 3 Trip meter reset knob Resets the two trip meters to zero and also change the meter display To change the meter display quickly push and release the knob The meter display changes in the order from the odometer to trip meter A to trip meter B then back to the odometer each time you push To reset the tri...

Page 4415: ...arking brake is off stop immediately and contact Toyota dealer For vehicles with the vehicle stability control system only b indicator and buzzer Fasten driver s seat belt c Fasten front passenger s seat belt d Stop and check e Stop and check f Take vehicle to Toyota dealer g Fill up tank Service reminder indicators and warning buzzers ...

Page 4416: ...es on Do this h or Take vehicle to Toyota dealer i Take vehicle to Toyota dealer j Close all doors k Take vehicle to Toyota dealer immediately l Adjust tire inflation pressure including spare tire If the light blinks contact Toyota dealer m Stop and check n Add washer fluid o Replace engine oil ...

Page 4417: ...DRA_U L O 0409 172 2005 TUNDRA from Sep 04 Prod OM34432U If the indicator or buzzer comes on Do this p Key reminder buzzer Remove key q Four wheel drive system warning buzzer Shift the transfer mode correctly ...

Page 4418: ...with the park ing brake released A warning light turning on briefly during operation does not indicate a problem CAUTION Without the vehicle stability control system If the light does not turn off even after the parking brake is released while the engine is running immedi ately stop your vehicle at a safe place and contact your Toyota dealer In this case the brakes may not work properly and your s...

Page 4419: ...as a reminder to have the front passenger buckle up the seat belt Vehicles with bench seat Once the ignition key is turned to ON or START the reminder light flash if a pas senger sits in the front passenger seat and does not fasten the seat belt Howev er if a front passenger uses an additional seat cushion the light may not flash even when the seat belt is not buckled up If luggage or other load i...

Page 4420: ...check the followings Empty fuel tank If the fuel tank is empty refuel immedi ately Loose fuel tank cap If the fuel tank cap is loose securely tighten it These cases are temporary malfunctions The malfunction indicator lamp will go off after taking several driving trips If the lamp does not go off even after several trips contact your Toyota dealer as soon as possible If the fuel tank is not empty ...

Page 4421: ...few seconds There after if the system malfunctions the light comes on again When the ABS warning light is on and the brake system warning light is off the anti lock brake system does not operate but the brake system still operates con ventionally When the ABS warning light is on and the brake system warning light is off the anti lock brake system does not operate so that the wheels could lock up d...

Page 4422: ...In this case not only the anti lock brake system will fail but also the vehicle will become extremely unsta ble during braking Either of the following conditions may occur but do not indicate a malfunc tion The light may stay on for about 60 seconds after the ignition key is turned to the ON position It is normal if it turns off after a while Depressing the brake pedal repeatedly may turn on the l...

Page 4423: ...comes on while driving l Low Tire Pressure Warning Light This light warns that the tire pressure of one or more of your tires including the spare tire is low The light comes on when the ignition key is turned to the ON position It goes off after a few sec onds This indicates that the tire pressure warning system is functioning properly If the warning light comes on stop your vehicle in a safe plac...

Page 4424: ...ng on the driving and road conditions If the light comes on replace it as soon as possible The system must be reset after the en gine oil replacement Reset the system by the following procedure 1 Turn the ignition key to the ACC or LOCK position with the odometer reading shown For details see Odometer and two trip meters in this Section 2 Turn the ignition key to the ON posi tion while holding dow...

Page 4425: ...S warning light VSC TRAC warning light Low tire pressure warning light Engine oil replacement reminder light Roll sensing of curtain shield airbag off indicator light AUTO LSD indicator light VSC OFF indicator light four wheel drive models Slip indicator light The SRS warning light goes off after about 6 seconds There may be the case that the ABS warning light brake assist system warning light VSC...

Page 4426: ...h Transmission and Parking brake Ignition switch with steering lock 182 Automatic transmission 183 Manual transmission 187 Four wheel drive system 188 Traction control system 191 AUTO LSD system 193 Vehicle stability control system 197 Tire pressure warning system 200 Parking brake 205 Cruise control 206 SECTION 1 7 ...

Page 4427: ...he key from ACC to the LOCK position On vehicles with an automatic transmission the selector lever must be in the P posi tion before pushing the key When starting the engine the key may seem stuck at the LOCK position To free it first be sure the key is pushed all the way in and then rock the steering wheel slightly while turning the key gently Approximately five hours after the engine is turned o...

Page 4428: ...position L switch SHIFT L switch To down shift to first gear L position push this switch with the shift lever in the 2 position The L is displayed on the instrument cluster and engine braking will be maximized To shift up to the 2 position push this switch again To shift up to a position other than 2 move the selector lever to that position Automatic transmission Selector lever Overdrive switch Wi...

Page 4429: ...ion must be in P or N 2 With your foot holding down the brake pedal shift the selector lever to D When the lever is in the D position the automatic transmission system will select the most suitable gear for running condi tions such as normal cruising hill climb ing hard towing etc Always turn the overdrive on for better fuel economy and quieter driving If the engine coolant temperature is low the ...

Page 4430: ... enabled because the cruise control is not cancelled For ways to decrease the vehicle speed see Cruise control in this Section CAUTION Be careful when downshifting on a slippery surface Abrupt shifting could cause the vehicle to skid or spin f Using 3 2 and L positions The 3 2 and L positions are used for strong engine braking as described pre viously With the selector lever in 3 2 or SHIFT L swit...

Page 4431: ...ete stop 2 With the brake pedal pressed down fully depress the parking brake pedal to apply the parking brake securely 3 With the brake pedal pressed down shift the selector lever to the P posi tion CAUTION Never attempt to move the selector lever into P position under any cir cumstances while the vehicle is mov ing Serious mechanical damage and loss of vehicle control may result i Good driving pr...

Page 4432: ...r downshift at the following speeds gear km h mph 1 to 2 or 2 to 1 24 15 2 to 3 or 3 to 2 40 25 3 to 4 or 4 to 3 64 40 4 to 5 or 5 to 4 72 45 5 to 6 or 6 to 5 80 50 Downshift to the appropriate gear if accel eration is needed when you are cruising below the above downshifting speeds Upshifting too soon or downshifting too late will cause lugging and possibly ping ing Regularly revving the engine t...

Page 4433: ... the 2WD 4HI and 4LO switches to select the following transfer modes 1 2WD high speed position two wheel drive 2WD 4HI and 4LO switches left out Use this for normal driving on dry hard surfaced roads This position gives greater economy the quietest ride and least wear 2 4HI high speed position four wheel drive 2WD 4HI switch pushed in The 4HI high speed four wheel drive indicator light comes on wh...

Page 4434: ...10 miles each month This will assure that the front drive com ponents are lubricated SHIFTING BETWEEN 2WD AND 4HI To shift from 2WD to 4HI reduce the vehicle speed to less than 100 km h 62 mph and push in the 2WD 4HI switch If the 4HI high speed four wheel drive indicator light flashes when you push in the 2WD 4HI switch this reminds you that the transfer mode is not securely in 4HI mode Drive str...

Page 4435: ... securely into N and push the switch again To shift from 4LO to 4HI stop the vehicle and put the transmission into N With the brake pedal depressed push the 4LO switch If the 4LO low speed four wheel drive indicator light flashes and the buzzer sounds for three times when you push the 4LO switch this reminds you that the transfer mode is not in 4HI mode Drive forward or backward in a short distanc...

Page 4436: ...action control system automatical ly helps prevent the spinning of rear wheels two wheel drive models or 4 wheels four wheel drive models when the vehicle is started or accelerated on slippery road surfaces When the ignition key is turned to ON the system automatically turns on CAUTION Under certain slippery road condi tions full traction of the vehicle and power to the rear wheels two wheel drive...

Page 4437: ...y is turned to ON If the indicator light does not come on when the ignition is turned on contact your Toyota dealer The brake actuator temperature increases during the traction control system vehicle stability control system or AUTO LSD system operating If the brake actuator temperature becomes too high while any of the systems is operating a buzzer will start to sound intermittently to indicate t...

Page 4438: ...nds If the VSC TRAC warning light and slip indicator light comes on while driving the traction control system does not work However as the brakes operate normally when applied it is no problem to continue your driving In the following cases contact your Toyota dealer The warning light does not come on after the ignition key is turned to ON The warning light remains on after the ignition key is tur...

Page 4439: ...th the vehicle stopped The AUTO LSD is activated under the following condition At this time the AUTO LSD indicator light will come on The driving mode is set in the two wheel drive mode in the four wheel drive mode the system does not work Driving at a speed under 100 km h 62 mph To cancel the system push the AUTO LSD switch once again If the engine is turned off while the AUTO LSD indicator light...

Page 4440: ...ystem vehicle stability control system or AUTO LSD system operating If the brake actuator temperature becomes too high while any of the systems is operating a buzzer will start to sound intermittently to indicate that the AUTO LSD system can no lon ger operate In this case immediately stop your vehicle at a safe place If the system continues to operate the buzzer sound changes from intermittent to...

Page 4441: ...nds after the ignition key is turned to ON Depressing the brake pedal repeatedly may turn on the light It is normal if it goes out after a few seconds If the VSC TRAC warning light and slip indicator light comes on while driving the AUTO LSD system does not work How ever as the brakes operate normally when applied it is no problem to continue your driving In the following cases contact your Toyota...

Page 4442: ... sys tem is in the self check mode but does not indicate a malfunction CAUTION Do not rely excessively on the ve hicle stability control system Even if the vehicle stability control sys tem is operating you must always drive carefully and attentively to avoid serious injury Reckless driv ing will result in an unexpected ac cident If the slip indicator light blinks and an alarm sounds special care ...

Page 4443: ...d to ON If the indicator light does not come on when the ignition is turned on contact your Toyota dealer Four wheel drive models only Shifting the driving mode into the four wheel drive mode automatically turns the vehicle stability control system off At this time the VSC OFF indicator comes on VSC OFF indicator light comes on for a few seconds when the ignition key is turned to ON It will come o...

Page 4444: ... out after a while Depressing the brake pedal repeatedly may turn on the light It is normal if they go out after a few seconds If the light comes on while driving the vehicle stability control system does not work However as the brakes operate nor mally when applied it is no problem to continue your driving In the following cases contact your Toyota dealer The warning light does not come on after ...

Page 4445: ...es on or blinks do the following If the warning light comes on Stop your vehicle in a safe place as soon as possible and check that the inflation pressure of all tires including the spare tire is as specified on the tire and loading information label See Checking tire inflation pressure in Section 7 2 If the warning light comes on even after tire inflation pressure ad justment you may have a flat ...

Page 4446: ...ure warning system is not to be used as a substitute for regular inspections Be sure to check the air pressure in the tires on a regular basis When the tires must be replaced replace the grommets for air pres sure sensors as well If the warning light blinks The tire pressure warning system may be malfunctioning Contact your Toyota dealer SYSTEM MALFUNCTION The tire pressure warning system does not...

Page 4447: ...more of your tires is significantly un der inflated You should stop and check your tires as soon as possible and inflate them to the proper pres sure as indicated on the vehicle s tire information placard Driving on a sig nificantly under inflated tire causes the tire to overheat and can lead to tire failure Under inflation also re duces fuel efficiency and tire tread life and may affect the vehic...

Page 4448: ...However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interfer ence to radio or television reception which can be determined by turning the equipment off and on the user is en couraged to try to correct the interfer ence by one or more of the following measures Reorient or relocate the receiving an tenna Increase the separa...

Page 4449: ...chase from a Toyota dealer TIRE PRESSURE WARNING SYSTEM RESET SWITCH The tire pressure warning system need to be initialized in the following condi tions After replacing or rotating tires or wheels After replacing an air pressure sen sor When initializing the system the pres ent tire condition is stored as a stan dard To initialize the system perform the fol lowing 1 Park the vehicle at a safe pla...

Page 4450: ...em again Do not push the reset switch without ad justing the tire inflation pressure to the specified level Otherwise the low tire pressure warning light may not come on even if the tire pressure is low or it may come on when the tire inflation pressure is actually normal If you push the reset switch while the vehicle is moving initialization is not per formed If the low tire pressure warning ligh...

Page 4451: ...n with your foot off the accelerator pedal Your cruising speed can be maintained up or down grades within the limits of engine performance although a slight speed change may occur when driving up or down the grades On steeper hills a greater speed change will occur so it is better to drive without the cruise control CAUTION To help maintain maximum control of your vehicle do not use the cruise con...

Page 4452: ...he vehicle speed drops 16 km h 10 mph below the preset speed the preset speed will also automatically cancel out If the preset speed automatically cancels out other than for the above cases have your vehicle checked by your Toyota deal er at the earliest opportunity RESETTING TO A FASTER SPEED Push the lever up in the RES direction and hold it Release the lever when the desired speed is attained W...

Page 4453: ... FAILURE WARNING If the CRUISE indicator light in the instrument cluster flashes when using the cruise control press the ON OFF button to turn the system off and then press it again to turn it on If any of the following conditions then oc curs there is some trouble in the cruise control system The indicator light does not come on The indicator light flashes again The indicator light goes out after...

Page 4454: ...S Audio system Reference 210 Using your audio system 211 Audio remote controls 232 Rear seat audio system 234 Rear seat entertainment system 243 Audio video system operating hints 291 For vehicle equipped with Navigation system please refer to the separate Navigation System Owner s Manual SECTION 1 8 ...

Page 4455: ...OM34432U Type 1 AM FM radio compact disc player with compact disc changer controller Type 2 AM FM radio cassette player com pact disc player with compact disc changer controller Type 3 AM FM radio cassette player com pact disc player with changer Reference ...

Page 4456: ... your own system Tone How good an audio program sounds to you is largely determined by the mix of the treble midrange and bass levels In fact different kinds of music and vocal programs usually sound better with differ ent mixes of treble midrange and bass Balance A good balance of the left and right stereo channels and of the front and rear sound levels is also important Keep in mind that if you ...

Page 4457: ...for use with 12 cm 4 7 in discs only YOUR COMPACT DISC PLAYER WITH CHANGER type 3 When you insert a disc push the LOAD button and gently push the disc in with the label side up The player will auto matically eject a disc if the label side is down This compact disc player can store up to six discs The player will play from track 1 through the end of the disc Then it will play from track 1 of the ne...

Page 4458: ... 05 TUNDRA_U L O 0409 213 2005 TUNDRA from Sep 04 Prod OM34432U Details of specific buttons controls and features are described in the alphabetical list that follows Controls and features Type 1 ...

Page 4459: ...n Each time you push the AUDIO CONTROL knob the mode changes To adjust the tone and balance turn the knob BAS Adjusts low pitched tones The dis play ranges from 5 to 5 TRE Adjusts high pitched tones The dis play ranges from 5 to 5 FAD Adjusts the sound balance between the front and rear speakers The display ranges from F7 to R7 BAL Adjusts the sound balance between the right and left speakers The ...

Page 4460: ...azine in random order To play the tracks on one disc in random order Quickly push and release RAND preset button 1 will appear on the display and the player will perform the tracks on the disc you are listening to in random order To turn off the random fea ture push this button again With compact disc changer only To play all the tracks in the magazine in random order Push and hold RAND preset but...

Page 4461: ...istening to To stop scanning push this button again If the player scanned all the tracks on the disc it will stop scanning With compact disc changer only Scanning the first tracks of all the discs in the magazine Push the SCAN button until you hear a beep SCAN will appear on the dis play and the player will scan the first track of the next disc To stop scanning push this button again If the player...

Page 4462: ... display for the compact disc that contains text data To change the display quickly push and release the TEXT button while the com pact disc is playing The display changes in the order from the elapsed time to disc title to track title then back to the elapsed time If this button is pushed while a compact disc that does not contain text data is playing NO TITLE will appear on the display If the en...

Page 4463: ... 05 TUNDRA_U L O 0409 218 2005 TUNDRA from Sep 04 Prod OM34432U Details of specific buttons controls and features are described in the alphabetical list that follows Type 2 ...

Page 4464: ...sette was playing or fast forwarding Reverse Fast forward button Cassette player Push preset button 6 to fast for ward a cassette tape FF will appear on the display Push preset button 5 to rewind a tape REW will appear on the display To stop the tape while it is fast forward ing push or TAPE button To stop the tape while it is rewinding push or TAPE button If a tape rewinds completely the cassette...

Page 4465: ...he disc or magazine again ERROR 4 Over current Ask your Toyota dealer to inspect CD OPEN The compact disc changer lid of separate unit is open Close the compact disc changer lid If the malfunction still exists take your vehicle to your Toyota dealer DISC With compact disc changer only Use these buttons to select the disc you want to listen to Push preset button 3 or preset button 4 until the numbe...

Page 4466: ... in order for the re peat feature to work correctly Compact disc player There are two repeat features you can either replay a disc track or a whole com pact disc Repeating a track Quickly push and release RPT preset button 2 while the track is playing will appear on the display When the track ends it will automatically replay To turn off the repeat feature push this button again With compact disc ...

Page 4467: ...kip up or down to locate a song or recording You can select up to nine recordings in cluding current one A blank space of at least 3 seconds is considered to be a start of a recording When the beginning of a tape is reached the player automatically resumes play When the end of the tape is reached the player automatically reverses sides and resumes normal play In addition the feature may not work w...

Page 4468: ...order from the elapsed time to disc title to track title then back to the elapsed time If this button is pushed while a compact disc that does not contain text data is playing NO TITLE will appear on the display If the entire disc or track title does not appear on the display push and hold the button until you hear a beep The rest of the title will appear TUNE Tuning Turn the TUNE knob clockwise t...

Page 4469: ... 05 TUNDRA_U L O 0409 224 2005 TUNDRA from Sep 04 Prod OM34432U Details of specific buttons controls and features are described in the alphabetical list that follows Type 3 ...

Page 4470: ...l the number of the disc you want to eject is displayed Push and release the eject but ton To eject all discs at a time press and hold the eject button until you hear a beep The last compact disc played before pushing the button will be ejected first If the ejected disc is not removed for a long time the eject function will be cancelled Program Push preset button 4 to select the other side of a ca...

Page 4471: ... display shows the track or track and disc number currently being played Vehicles with rear seat entertainment sys tem The DISC button may also be used to operate a DVD player when a disc is loaded in the DVD player Pressing the DISC button changes between the CD player and DVD player When the DVD player is in operation AUX appears on the display Error messages If the player malfunctions your audi...

Page 4472: ...c is inserted the shutter will close after 15 seconds To load multiple compact discs push and hold the button until you hear a beep when the audio system is on then insert the first compact disc After the disc is loaded the shutter of the slot will close After a few seconds the shutter will auto matically open again so the next disc can be inserted The same process can be applied for loading the r...

Page 4473: ...replay To turn off the repeat feature push this button again There must be at least 3 seconds of blank space between tracks in order for the re peat feature to work correctly Compact disc player There are two repeat features you can either replay a disc track or a whole com pact disc Repeating a track Quickly push and release RPT preset button 2 while the track is playing will appear on the displa...

Page 4474: ...own to locate a song or recording You can select up to nine recordings in cluding current one A blank space of at least 3 seconds is considered to be a start of a recording When beginning of a tape is reached the player automatically resumes play When the end of the tape is reached the player automatically reverses sides and resumes normal play In addition the feature may not work well with some s...

Page 4475: ... the display Compact disc player This button is used to change the display for the compact disc that contains text data To change the display quickly push and release the TEXT button while the com pact disc is playing The display changes in the order from the elapsed time to disc title to track title then back to the elapsed time If this button is pushed while a compact disc that does not contain ...

Page 4476: ...n while receiving an RDS station the current pro gram type appears on the display Each time you push this button the pro gram type changes as in the following ROCK EASY LIS Easy listening CLS JAZZ Classical music and Jazz R B Rhythm and Blues INFORM Information RELIGION MISC Miscellaneous ALERT Emergency message ...

Page 4477: ...M34432U Some parts of the audio system can be adjusted using the switches on the steer ing wheel Details of the specific switches controls and features are described below 1 Volume control switch 2 switch 3 MODE switch Audio remote controls steering switches ...

Page 4478: ... push the track switch further than you wanted to push the other side of the switch The track number will be in creased or reduced The track number you select is not valid if it is higher than the number of the tracks remaining on the current side of the cassette When the tape reaches to the begin ning the player will automatically start playing that side After the tape reaches to the end the play...

Page 4479: ... disc player with changer with the rear seat audio system when a cassette tape and a compact disc are loaded in the front audio system When the same mode is selected on the front and rear audio systems at the same time the system can be operated on the front audio system If the radio mode is selected on the front and rear audio systems at the same time AM and FM modes cannot be changed on the rear...

Page 4480: ...rol dials 5 Headphone input jacks 6 Controller holder The rear seat audio system can be oper ated with the rear seat audio system con troller CAUTION Do not disassemble or modify the controller It may cause an accident fire or electric shock NOTICE Keep the controller away from direct sunlight high heat and high humidity These conditions could cause the case to deform or the battery to ex plode or...

Page 4481: ... reception portion of the rear seat audio system display The rear seat audio system controller can be operated when the ignition switch is in the ACC or ON position The controller does not operate properly when the signal reception portion of the display is exposed to direct sunlight Block the display from direct sunlight Details of specific buttons controls and features of the controller see CONT...

Page 4482: ...hooked on the back of the driv er s or front passenger s seatback CAUTION To reduce the chance of injury in case of an accident or a sudden stop while driving stow the controller in the holder when it is not in use NOTICE Do not leave the controller exposed to high temperatures such as on the instrument panel for a long time otherwise the controller may be dam aged ...

Page 4483: ...side Auto reverse feature After the cassette player reaches the end of a tape side it automatically reverses and begins to play the other side This is true whether the cassette was playing or fast forwarding Compact disc player with changer Use these buttons to select a disc you want to listen to Push the or DISC CH PROG button until the number of the disc you want to listen appears on the display...

Page 4484: ...es and resumes normal play In addition the feature may not work well with some spoken live or classical re cordings Compact disc player This button has the following features To skip up or down to a different track Push the or TUNE TRACK but ton until the number of the track you want to listen to appears on the display If you want to return to the beginning of the current track quickly push the TU...

Page 4485: ...alfunctions your audio sys tem will screen one of the four following error messages WAIT The compact disc player unit may be too hot Allow the player to cool down ERR 1 The disc may be dirty damaged or inserted incorrectly up side down Clean the disc and re insert it ERR 3 There is a problem inside the system Eject the disc Set the disc again ERR 4 Over current Ask your Toyota dealer to inspect If...

Page 4486: ...de of the controller battery is facing cor rectly Do not replace the battery with wet hands Water may cause rust Do not touch or move any compo nents inside of the controller or it may interfere with proper operation Be careful not to bend the electrode of the controller battery insertion and that dust or oil does not ad here to the transmitter case Close the battery case securely After replacing ...

Page 4487: ...urn right to increase the volume Turn left to decrease the volume The maximum volume depends on the type of headphones With some headphone generally available in the market it may be difficult to catch sound properly Toyota recommends the use of Toyota genuine headphone Please contact your Toyota dealer for fur ther details CAUTION Adjust the volume when you connect the headphones to the jack Loud...

Page 4488: ... following components 1 Front audio system 2 Rear seat entertainment system display 3 Rear seat entertainment system controller 4 DVD player 5 Headphone input jacks 6 Input terminal adapter 7 Power outlet 8 Headphone volume control dials 9 Controller holder 10 Power outlet main switch Rear seat entertainment system ...

Page 4489: ... commercial headphone See Headphone input jacks in this Section for details You can also enjoy the rear seat enter tainment system with a wireless head phone The wireless headphone can be used within rear seat If the signal be comes weak the headphone will mute For details refer to the manufacturer s instructions With some wireless headphone generally available in the market it may be difficult to...

Page 4490: ... is pushed by hand or wiped with a hard cloth the surface of the screen may be scratched To close push up the display until you hear a click The illumination of the screen is automati cally turned off when the display is closed However the rear seat entertain ment system is not turned off CAUTION To reduce the chance of injury in case of an accident or sudden stop while driving close the display w...

Page 4491: ...m can be operated with the rear seat entertain ment system controller The system can not be operated by touching the switches on the screen directly CAUTION Do not disassemble or modify the controller It may cause an accident fire or electric shock NOTICE Keep the controller away from direct sunlight high heat and high humidity These conditions could cause the case to deform or the battery to ex p...

Page 4492: ...ed to direct sunlight Block the display from direct sunlight NOTICE Observe the followings otherwise the controller may be damaged Do not drop or strongly knock the controller against hard objects Do not sit on or place heavy ob jects on the controller CONTROLLER HOLDER The controller can be stowed in the holder when it is not in use The holder can be hooked on the back of the driv er s or front p...

Page 4493: ...DRA_U L O 0409 248 2005 TUNDRA from Sep 04 Prod OM34432U NOTICE Do not leave the controller exposed to high temperatures such as on the instrument panel for a long time otherwise the controller may be dam aged ...

Page 4494: ...sc track or chapter 3 CURSOR button This button indicates the control switches on the screen when the DVD player is operated 4 Joy stick This joy stick selects a control switch mode switch on the screen or the menu for the disc 5 ENT button This button inputs the selected switch or the selected menu for the disc 6 SOURCE button This button turns on the rear seat en tertainment system and selects t...

Page 4495: ...er is oper ated 14 button This button fast forwards a screen when the DVD player is operated 15 button This button plays a screen when the DVD player is operated 16 button This button pauses a screen when the DVD player is operated 17 button This button reverse a screen when the DVD player is operated 18 TOP MENU button This button indicates the title selection screen for DVD video when the DVD pl...

Page 4496: ...s tem or the DVD player only the radio mode can be selected on the rear seat entertainment system To turn off the system push the OFF button When the front audio system is turned off the rear audio system and the DVD player will be turned off simultaneously All the modes of the front audio system can be operated on the rear seat enter tainment system When the same mode is selected on the front and...

Page 4497: ... button to enter the mode The mode display which is selected by the joy stick is colored blue When the ENT button is pushed the mode display changes to green If the mode display is gray it cannot be selected The Speaker sound on the mode display is selected on the front audio system Radio Cassette tape player and compact disc player ...

Page 4498: ... of the front audio system For instructions see Controls and features in this Section To scan the preset stations Push the or DISC CH PROG button The radio will tune in the next preset station up or down the band The station frequency will appear on the screen Cassette tape player Push the or DISC CH PROG button to select the other side of a cas sette tape The screen indicates which side is curren...

Page 4499: ...e will play the other side of the tape using the auto reverse feature To skip up or down to locate a song or recording You can select up to nine recordings in cluding current one Push the or TUNE TRACK but ton FF 1 or REW 1 will appear on the screen Next push either side of the track button until the number on the screen reaches the number of tracks you want to skip If you push the button 10 times...

Page 4500: ... battery recom mended by a Toyota dealer Dispose of used batteries according to local regulations Replace the battery by using the following procedures 1 Pull the case out while pushing the lock release button to the side 2 Remove the discharged battery 3 Put in a new battery with the positive side up Put it in the case securely NOTICE Be sure that the positive side of the controller battery is fa...

Page 4501: ...propriate discs for this player see Audio video system operating hints To access the DVD player pull up the console box lid while pushing the lock release button The DVD player works when the ignition key is in the ACC or ON position To turn on the DVD player a disc must be loaded in the player To turn off the player eject the disc Error messages If the player malfunctions your audio sys tem will ...

Page 4502: ...ush the lid backward Insert a disc and push the lid forward to close the DVD player When you insert a disc push it in gently with the label side up If the label faces down the disc cannot be played In this case DISC CHECK and disc number appear on the screen If a disc which is not playable is inserted DISC CHECK will also appear on the screen For appropriate discs for this play er see Audio video ...

Page 4503: ...hapter again after it reaches the end NOTICE Never try to disassemble or oil any part of the DVD player Do not insert anything other than a disc into the slot EJECTING THE DISC Push the lid backward to open the DVD player Push the disc eject button to eject a disc CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the console box closed while driving Selecti...

Page 4504: ... system The DVD Hint screen appears when the DVD mode is first selected after you turn the ignition key to the ACC or ON position Push the OK switch when you read the message The DVD player can be operated with the controller buttons directly 1 DVD button 2 MENU button 3 TOP MENU button 4 RETURN button 5 SET UP button 6 SEARCH button 7 ANGLE button 8 AUDIO button 9 SUB TITLE button 10 and buttons ...

Page 4505: ...button You cannot select the switches on the screen by touching them directly When the switch is selected by the joy stick the outline of the switch changes to blue Push the ENT button and the switch will be highlighted in green TURNING THE OPERATION SWITCHES ON AND OFF To turn on the operation switches push the CURSOR button on the controller Top page DVD video operation switch Second page DVD vi...

Page 4506: ...32U Top page DVD audio operation switch Second page DVD audio operation switch Top page video CD Second page video CD There are operation switches on the Top Page and Second Page screens To change the screen push the Top Page or Second Page switch on the screen ...

Page 4507: ...om Sep 04 Prod OM34432U If appears on the screen when you select a switch it indicates that the switch cannot work To turn off the switches on the screen push the CURSOR button on the control ler once again or push the Hide Keys on the screen ...

Page 4508: ...deo tracks are play ing and then activate playback When playback of a disc is completed If an audio CD is playing the first track starts If a DVD video DVD audio or video CD is playing playback will stop or the menu screen will be displayed The title chapter number and playback time display may not appear while playing back certain DVD video discs CAUTION Conversational speech on some DVDs is reco...

Page 4509: ...he screen You can also turn on the menu screen by pushing the MENU or TOP MENU switch on the controller DVD audio To turn on the menu screen for the disc push the Top Menu switch on the screen You can also turn on the menu screen by pushing the TOP MENU switch on the controller For the operation of the menu screen see the separate manual for the DVD disc To turn on the selecting switch push the sw...

Page 4510: ...h push the OFF switch on the screen To turn on the switch again push the ON switch on the screen To return to the previous screen push the Back switch on the screen DVD video DVD audio OPERATING THE AND SWITCHES BUTTONS switch button Push this switch button to pause the disc switch button Push this switch button to cancel the pause and return to normal play ing and switches buttons Push and hold t...

Page 4511: ...o skip to the predetermined screen push the Return switch The DVD player starts playing from the beginning of the predeter mined screen You can also display the screen by pushing the RETURN button on the controller For further details of the predetermined screen see the separate manual for the DVD disc DVD video DVD audio ...

Page 4512: ...lect the title number by using the and 10 switches and push the En ter switch to enter the number The play er starts playing disc for that title number The selected title number will appear on the screen Push the Back switch to return to the menu screen DVD audio Enter the group number by using the and switches The selected group number will appear on the screen Push the Enter switch The player st...

Page 4513: ...ll appear To enter the number of the group you want to play push the group number If you enter the wrong number push the Clear switch to delete the num ber Push the Enter switch on the screen The player starts playing the disc from the selected bonus group number CHANGING THE STILL PICTURE DVD audio only Push the Still Prev or Still Next switch on the screen to forward or reverse the still picture...

Page 4514: ...title language screen will appear You can also display the screen by pushing the SUB TITLE button on the controller Each time you push the Sub Title switch another language stored on the disc is selected To turn off the subtitles push the Hide switch Push the Back switch to return to the previous screen The selected subtitle language will appear on the screen ...

Page 4515: ... screen and then the changing audio language screen will appear You can also display the screen by pushing the AUDIO button on the controller Each time you push the Audio switch another language stored on the disc is selected The selected audio language will appear on the screen Push the Back switch to return to the previous screen ...

Page 4516: ...io only Push the Audio switch on the screen or the AUDIO button on the controller and the changing audio format screen will ap pear Each time you touch the Audio switch another audio format stored on the disc is selected Push the Back switch to return to the previous screen DVD video DVD audio ...

Page 4517: ...ou can also display the screen by pushing the ANGLE button on the controller The angle can be selected for discs that are multi angle compatible when the mark appears on the screen Each time you push the Angle switch the angle changes The angle number which you can select will appear on the screen Push the Back switch to return to the previous screen DVD video DVD audio ...

Page 4518: ...e setting is done the player plays from the beginning of the chapter or the track Setup Menu 1 screen Setup Menu 2 screen There are initial setting switches on the Setup Menu 1 and Setup Menu 2 screens To change the screen push the Top Page or Second Page switch on the screen After you change the initial setting push the Enter switch The initial setting switch will be turned off and return to the ...

Page 4519: ...s about the lan guage codes see the language code list If you enter a wrong number push the Clear switch to delete the number If numbers which are not on the list are entered and the Enter switch is pushed the Incorrect Code screen will appear Push the language code you want to hear again To return to the Select Audio Language screen push the Back switch CHANGING THE SUBTITLE LANGUAGE To display t...

Page 4520: ...Select DVD Language screen push the DVD Language switch on the Setup Menu 1 screen Select the language you want to read on the screen To return to the Setup Menu 1 screen push the Back switch If you cannot find a language you want to read push the Others switch The Enter DVD Language Code screen will appear To enter the code of the language you want to read push the number of the language code For...

Page 4521: ... the restriction with a password Some discs do not supply a restriction To set the level of viewer restriction push the Parental switch on the Setup Menu 1 screen The Enter Personal Code screen will appear Push the number for the password and the Enter switch The Select Restriction Level screen will appear If you enter a wrong number push the Clear switch to delete the number You cannot change the...

Page 4522: ... DISPLAY MODE Each time you push the Display Mode switch on the Setup Menu 2 screen the display mode is changed from wide mode to auto mode LANGUAGE CODE LIST Code Language 1001 Japanese 0514 English 0618 French 0405 German 0920 Italian 0519 Spanish 2608 Chinese 1412 Dutch 1620 Portuguese 1922 Swedish 1821 Russian 1115 Korean 0512 Greek 0101 Afar 0102 Abkhazian 0106 Afrikaans 0113 Amharic 0118 Ara...

Page 4523: ...Faroese 0625 Frisian 0701 Irish 0704 Scots Gaelic 0712 Galician 0714 Guarani 0721 Gujarati 0801 Hausa 0809 Hindi 0818 Croatian 0821 Hungarian 0825 Armenian 0901 Interlingua 0905 Interlingue 0911 Inupiak 0914 Indonesian 0919 Icelandic 0923 Hebrew 1009 Yiddish 1023 Javanese 1101 Georgian 1111 Kazakh 1112 Greenlandic 1113 Cambodian 1114 Kannada 1119 Kashmiri 1121 Kurdish 1125 Kirghiz 1201 Latin 1214 ...

Page 4524: ...wanda 1901 Sanskrit 1904 Sindhi 1907 Sangho 1908 Serbo Croatian 1909 Sinhalese 1911 Slovak 1912 Slovenian 1913 Samoan 1914 Shona 1915 Somali 1917 Albanian 1918 Serbian 1919 Siswati 1920 Sesotho 1921 Sundanese 1923 Swahili 2001 Tamil 2005 Telugu 2007 Tajik 2008 Thai 2009 Tigrinya 2011 Turkmen 2012 Tagalog 2014 Setswana 2015 Tonga 2018 Turkish 2019 Tsonga 2020 Tatar 2023 Twi 2111 Ukrainian 2118 Urdu...

Page 4525: ...switch Push the PICTURE switch to turn off the control screen and return to the picture previously displayed 2 RPT switch DVD audio only Push the RPT switch while the track is playing When the track ends it will automatically replay To turn off the re peat feature push this switch again 3 RAND switch DVD audio only Push the RAND switch The player will play the tracks on the disc in ran dom order T...

Page 4526: ...isc menu number search screen will appear You can also display the screen by pushing the SEARCH switch on the controller Enter the disc menu number by using the and 10 switches and push the Enter switch The player starts playing the disc from the entered disc menu num ber The entered disc menu number will appear on the screen Push the Back switch to return to the menu screen Move up and down the s...

Page 4527: ... CD plays the slow motion video replay TURNING ON THE DISC MENU video CD only Push the Return switch to turn on the menu screen for the disc You can also turn on the menu screen by pushing the RETURN button on the controller For the operation of the menu screen see the manual for the video CD CHANGING MENU PAGE OR TRACK video CD only Push the D Menu Next or D Menu Prev switch while the disc menu i...

Page 4528: ...y pushing the Main Sub switch CHANGING THE INITIAL SETTING video CD only Push the Set Up switch on the screen and then the initial setting screen will ap pear You can also display the screen by pushing the SET UP button on the con troller You can change the initial setting See CHANGING THE INITIAL SETTING in this Section for details After the setting is done the player plays from the beginning of ...

Page 4529: ...lay To turn off the re peat feature push this switch again 3 RAND switch audio CD and CD text Push the RAND switch The player will play the tracks on the disc in ran dom order To turn off the random fea ture push this switch again 4 SCAN switch audio CD and CD text Push the SCAN switch The player will scan all the tracks on the disc To stop scanning push this switch again When the player has scann...

Page 4530: ... and brightness of the screen or GREEN or RED COLOR Strengthens the green color Strengthens the red color CONTRAST Strengthens the contrast Weakens the contrast TONE Strengthens the tone Weakens the tone BRIGHTNESS Brightens Darkens After adjusting the screen push the OK switch to return to the previous screen Selecting the video mode ...

Page 4531: ...cs have a region code indicating where you can use If the DVD video disc is not labeled ALL or 1 you cannot use it in this DVD player If you attempt to play an inappropriate DVD video disc in this play er REGION CODE ERROR appears on the screen Even if the DVD video disc does not have a region code in some cases you cannot use it Marks shown on DVD video discs Indicates NTSC format of color TV Ind...

Page 4532: ... language of the subtitles and audio Region codes Region codes are provided on DVD players and DVD discs If the DVD video disc does not have the same region code as the DVD player you can not play the disc on the DVD player For region codes Audio This DVD player can play liner PCM Dolby digital dts and MPEG audio format DVD Other decoded type cannot be played Title and chapter Video and audio pro ...

Page 4533: ... when the input terminal adapter is not in use Inserting anything other than an appropriate plug that fits the adapter may cause electrical failure or short circuit This power outlet is designed for use as a power supply for the audio device con nected to the input terminal adapter The key must be in the ON position for the power outlet to be used The maximum capacity for this power out let is 115...

Page 4534: ...d when the power outlet is not in use Inserting anything other than an appropriate plug that fits the outlet may cause electrical failure or short circuit The power outlet is not designed for the following electric appliances even if their power consumption is under 115 VAC 100W These appliances may not operate properly Appliances with high initial peak watt age cathode ray tube type televisions c...

Page 4535: ...ob Turn right to increase the volume Turn left to decrease the volume The maximum volume depends on the type of headphones With some headphones generally available in the marker it may be difficult to catch sound properly Toyota recommends the use of Toyota genuine headphone Please contact your Toyota dealer for fur ther details CAUTION Adjust the volume when you connect the headphones to the jack...

Page 4536: ...les Once outside this range you may notice fading and drifting which increase with the distance from the radio transmit ter They are often accompanied by distor tion Multi path FM signals are reflective making it possible for two signals to reach your antenna at the same time If this happens the signals will cancel each oth er out causing a momentary flutter or loss of reception Static and flutter...

Page 4537: ... Store cassettes in their cases and out of direct sunlight Avoid using cassettes with a total play ing time longer than 100 minutes 50 minutes per side The tape used in these cassettes is thin and could get stuck or tangled in the cassette player CARING FOR YOUR COMPACT DISC PLAYER AND DISCS Type 2 and 3 Your compact disc play er is intended for use with 12 cm 4 7 in discs only Extremely high temp...

Page 4538: ...ble on your compact disc player Copy protected CD CD R CD Recordable CD RW CD Re writable CD ROM Audio CDs DVD video discs DVD audio discs Video CDs DVD player Use only discs marked as shown above The following products may not be playable on your DVD player SACD Copy protected CD CD R CD Recordable CD RW CD Re writable CD ROM DVD R DVD R DVD RW DVD RW DVD ROM DVD RAM ...

Page 4539: ...Transparent translucent discs Low quality discs Labeled discs NOTICE Do not use special shaped transpar ent translucent low quality or labeled discs such as those shown in the il lustrations The use of such discs may damage the player or changer or it may be impossible to eject the disc ...

Page 4540: ...player to skip or to repeat a section of a track To see a pin hole hold the disc up to the light Remove discs from the compact disc player when you are not listening to them Store them in their plastic cases away from moisture heat and direct sunlight To clean a compact disc Wipe it with a soft lint free cloth that has been damp ened with water Wipe in a straight line from the center to the edge o...

Page 4541: ... 05 TUNDRA_U L O 0409 296 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4542: ...0409 297 2005 TUNDRA from Sep 04 Prod OM34432U OPERATION OF INSTRUMENTS AND CONTROLS Air conditioning system Controls 298 Air flow selector settings 301 Operating tips 303 Instrument panel and rear vents 305 SECTION 1 9 ...

Page 4543: ... 05 TUNDRA_U L O 0409 298 2005 TUNDRA from Sep 04 Prod OM34432U 1 Fan speed selector 2 Temperature selector 3 Air flow selector 4 A C button on some models 5 Air intake selector button Controls ...

Page 4544: ...ower vent For details about this see Instrument panel vents in this Sec tion 4 Floor Windshield Air flows mainly from the floor vents and windshield vents Turning the air flow selector to the floor windshield position turns on the defogging function with the purpose of clearing the front view This position allows the air intake to select FRESH automatically This is to clean up the front view more ...

Page 4545: ...tor settings described below Air intake selector button The air intake selector button is used to switch the air intake FRESH mode that draws outside air into the system and RECIRCULATED mode that recirculates the air inside vehicle To turn the air source to RECIRCULATED mode press the button The indicator will come on To turn the air source to FRESH mode press the button again The indica tor will...

Page 4546: ... 05 TUNDRA_U L O 0409 301 2005 TUNDRA from Sep 04 Prod OM34432U Air flow selector settings Standard and access cab models without rear console box See Instrument panel vents in this Section ...

Page 4547: ... 05 TUNDRA_U L O 0409 302 2005 TUNDRA from Sep 04 Prod OM34432U Standard and access cab models with rear console box See Instrument panel vents in this Section On some models ...

Page 4548: ...of the difference in air temperature on the inside and outside of the windshield Keep the area under the front seats clear to allow air to circulate through out the vehicle On cold days set the fan speed to high for a minute to help clear the intake ducts of snow or moisture This can reduce the amount of fogging on the windows When driving on dusty roads close all windows If dust thrown up by the ...

Page 4549: ...OFF Temperature Towards COLD blue zone Air intake FRESH outside air Air flow PANEL Air conditioning ON For quick cooling move the air intake selector to recirculate for a few min utes Ventilation For best results set controls to Fan speed Any setting except OFF Temperature Towards COLD blue zone Air intake FRESH outside air Air flow PANEL Air conditioning OFF Defogging The inside of the windshield...

Page 4550: ...elector to the wind shield or floor windshield position turns on the defrosting function and fun speed may with the purpose of clearing the front view When turning the air flow selector to windshield position the air intake selects FRESH automatically This is to clean up the front view more quickly It is not possible to return to RECIRCULATE in this position Vehicles with A C button Press the A C ...

Page 4551: ...els only If air flow control is not satisfactory check the instrument panel and rear vents The instrument panel and rear vents may be opened or closed as shown For removing frost or fog it is recom mended that you close the lower vent when using the Floor Floor Windshield or Windshield mode ...

Page 4552: ...ock 318 Cigarette lighter and ashtrays 318 Power outlets 12 VDC 319 Power outlet 115 VAC 320 Glove box 322 Garage door opener box 322 Auxiliary boxes 325 Rear console box 327 Coin holder 329 Compact disc and cassette tape holder 332 Cassette tape holder 333 Cup holders 334 Note pad holder 336 Grocery bag cargo net hooks 336 Floor mat 337 SECTION 1 10 ...

Page 4553: ...DRA_U L O 0409 308 2005 TUNDRA from Sep 04 Prod OM34432U 1 E M button 2 Garage door opener buttons 3 MODE button 4 Garage door opener indicator 5 Outside temperature display 6 Compass Multi information display ...

Page 4554: ...dis play switches This is also linked to the multi information display The display vari ations are as follows Indication Outside temperature English U S Customary System E F Metric M C The initial mode will be English U S Cus tomary System units however if the unit is switched to metric and the ignition switch is off it will display metric units when the ignition switch is turned to ON MODE button...

Page 4555: ...the indi cator corresponding to the selected channel begins to flash 2 Place your hand held garage transmit ter 25 to 75 mm 1 to 3 in away from the surface of the HomeLink Keep the indicator light on the HomeLink in view while programming 3 Simultaneously press and hold the hand held garage transmitter button along with the selected HomeLink but ton 4 When the indicator light on the HomeLink chang...

Page 4556: ...ner motor should now recognize the HomeLink unit and be able activate the garage door up down 4 Repeat steps 1 through 3 for each re maining HomeLink button to program another rolling code system Programming an entrance gate program ming all devices in the Canadian market 1 Decide which of the 3 HomeLink but tons you want to program 2 Place your hand held gate device transmitter 25 to 75 mm 1 to 3...

Page 4557: ... potential harm or damage Do not use this HomeLink Univer sal Transceiver with any garage door opener that lacks the safety stop and reverse feature as re quired by federal safety standards This includes any garage door opener model manufactured before April 1 1982 A garage door open er which cannot detect an object signaling the door to stop and re verse does not meet current feder al safety stan...

Page 4558: ...played value is updated every 2 second The displayed temperature ranges from 30 C 22 F up to 50 C 122 F If an abnormality exists in the connection of the outside air temperature sensor C F will appear on the display If C F appears on the display contact your Toyota dealer There may be a case that C F appears momentarily when the ignition is quickly turned to ON It is normal if it goes out soon The...

Page 4559: ...el tower between buildings roof parking near a crossing near a large vehicle etc The vehicle is magnetized There is a magnet or a metal object on or near the roof The battery has been disconnected The compass works to calibrate the direc tion automatically while the vehicle is in motion if deviation is small For additional precision or for complete calibrating see CALIBRATING THE COMPASS below If ...

Page 4560: ...tch the display to the outside tem perature To switch to this mode see Outside temperature display in this Section 2 Push and hold both the MODE and E M buttons simultaneously for 5 sec onds until the VAR indication appears on the compass display 3 Push the E M button several times until the desired zone number appears on the compass display If the button is not pushed for 10 sec onds the display ...

Page 4561: ... OM34432U Zone numbers After calibration leaving the system for several seconds returns to the compass mode CAUTION Do not adjust the display while the vehicle is moving Be sure to adjust the display only when the vehicle is stopped Samoa 5 Guam 8 Saipan 8 ...

Page 4562: ... see Outside temperature display in this Section 2 Push and hold both the MODE and E M buttons simultaneously for 10 seconds until the CAL indication ap pears on the compass display At this time the compass display is locked in N 3 Drive the vehicle in a circle at 8 km h 5 mph or less If there is not enough space to drive in a circle drive around the block When the CAL indication goes off and the ...

Page 4563: ...ay interfere with the calibration CAUTION When doing the circling calibration be sure to secure a wide space and watch out for people and ve hicles in the neighborhood Do not violate any local traffic rules while performing circling calibration Do not adjust the display while the vehicle is moving Be sure to adjust the display only when the vehicle is stopped To reset the hour Push the H button To...

Page 4564: ...htray pull it out Rear To use the ashtray raise the lid When finished with your cigarette thor oughly extinguish it in the ashtray to pre vent other cigarette butts from catching fire After using the ashtray push it back in completely Front To remove the ashtray press down on the lock spring plate and pull out Rear To remove the ashtray pull it out CAUTION To reduce the chance of injury in case of...

Page 4565: ...ting anything other than an ap propriate plug that fits the outlet or allowing any liquid to get into the outlet may cause electrical fail ure or short circuits This power outlet 115 VAC is designed for use as a power supply for electric appliances in the vehicle The key must be in the ON position for the power outlet to be used The maximum capacity for this power out let is 115 VAC 100W If you at...

Page 4566: ...hen the power outlet is not in use Inserting anything other than an appropriate plug that fits the outlet may cause electrical failure or short circuits The power outlet is not designed for the following electric appliances even though their power consumption is un der 115 VAC 100W These appliances may not operate properly Appliances with high initial peak watt age cathode ray tube type television...

Page 4567: ...ened with the headlight switch on CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the glove box door closed while driving The box is designed to store a garage door opener transmitter Open the cover and remove the Velcro square Remove the paper strip covering the adhe sive on back side of square and adhere the square to back side of the transmitter near t...

Page 4568: ...t be removed prior to adhesion of the Velcro Place the transmitter with Velcro square facing inside of box into the box Make sure the transmitter button is located above button pins Remove spacers from the center panel Place the largest spacer on the pin that would be below transmitter button when the cover is closed Close the cover ...

Page 4569: ... to see if spacer is on the cor rect pin Attach another spacer to the top of original spacer Check operation If re quired continue to add spacers until contact is achieved If the transmitter is clattering during driv ing fill in a piece of felt or pad to prevent the transmitter from clattering CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the garage doo...

Page 4570: ...er opens and closes smoothly To use the auxiliary boxes open the lids as shown in the following illustra tions CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the auxiliary box closed while driving Type A and B only As these hold ers are designed for holding a light object such as an eyeglass do not place any heavy objects in them Heavy objects may cause ...

Page 4571: ... 05 TUNDRA_U L O 0409 326 2005 TUNDRA from Sep 04 Prod OM34432U Type A Type B Type C Type D Front Type E under the rear seat of access cab models ...

Page 4572: ...ront Type F under the rear seat of double cab models UPPER TRAY To access the upper tray raise the con sole box lid CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the upper tray closed while driving Rear console box type A ...

Page 4573: ...o reduce the chance of injury in case of an accident or a sudden stop always keep the console box closed while driving UPPER TRAY To access the upper tray raise the con sole box upper lid while pushing the lock release button CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the upper tray closed while driving Rear console box type B ...

Page 4574: ...ox lid by pulling up the lock release lever CAUTION To reduce the chance of injury in case of an accident or a sudden stop always keep the console box closed while driving The rear console box is equipped with a coin holder To use the coin holder 1 Raise the console box lid 2 Push coins down into the holder Coin holder type A ...

Page 4575: ... 04 Prod OM34432U The rear console box is equipped with a coin holder To use the coin holder 1 Raise the console box upper lid while pushing the lock release button 2 Push coins down into the holder The coin holder is detachable Coin holder type B ...

Page 4576: ...he coin holder in the console box raise the console box lid by pulling up the lock release lever The auxiliary box is equipped with a coin holder To use the coin holder 1 Raise the auxiliary box lid while push ing the lock release button 2 Push coins down into the holder The coin holder is detachable Coin holder type C ...

Page 4577: ...h compact disc and cassette tape holders To use the holders raise the console box lid and upper tray by pulling up the lock release lever The plates for the compact disc and cas sette tape holders are detachable Compact disc and cassette tape holder type A Compact disc and cassette tape holder type B ...

Page 4578: ...se the holder raise the console box lid by pulling up the lock release lever The compact disc and cassette tape hold er is detachable The auxiliary box is equipped with a cassette tape holder To use the holder raise the auxiliary box lid while pushing the lock release button The plate for the cassette tape holder is detachable Cassette tape holder ...

Page 4579: ...ink cans in the cup holder as such items may be thrown about and possibly injure people in the vehicle during sudden braking or in an accident To reduce the chance of injury in case of an accident or a sudden stop while driving keep the cup holder closed when it is not in use NOTICE Type A only As this holder is de signed for holding soft cups only do not place too heavy a cup drink can or bottle ...

Page 4580: ...O 0409 335 2005 TUNDRA from Sep 04 Prod OM34432U Type C cup holders are equipped with a detachable adapter for each holder When you remove the adapter a bigger cup can be held in the holder Type D Type E Type F Type G ...

Page 4581: ...ton CAUTION Do not write on the note pad holder while the vehicle is moving Do not place anything else on the note pad holder Such items may be thrown about in the compartment and possibly cause injury during sudden braking or an accident To reduce the chance of injury in case of an accident or a sudden stop while driving keep the console box upper lid closed when it is not in use Grocery bag hook...

Page 4582: ...ng them as grocery bag hooks To prevent damage to the hook avoid hanging things other than a cargo net on it when using them as cargo net hooks Use a floor mat of the correct size If the floor carpet and floor mat have a hole then it is designed for use with a locking clip Fix the floor mat with locking clip into the hole in the floor carpet CAUTION Make sure the floor mat is properly placed on th...

Page 4583: ... 05 TUNDRA_U L O 0409 338 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4584: ...gn countries 344 Three way catalytic converters 344 Engine exhaust cautions 345 Facts about engine oil consumption 346 Iridium tipped spark plugs 347 Brake system 347 Brake pad wear limit indicators 354 Rear step bumper 354 StepSide bed 354 Limited slip differential 355 Your Toyota s identification 355 Theft prevention labels 356 Suspension and chassis 357 Tire information 358 Vehicle load limits ...

Page 4585: ...form satisfactorily under off road conditions Therefore sharp turns at excessive speeds may cause rollover CAUTION Always observe the following precau tions to minimize the risk of serious personal injury or damage to your ve hicle In a rollover crash an unbelted per son is significantly more likely to die than a person wearing a seat belt Therefore the driver and all passengers should fasten thei...

Page 4586: ...le Avoid full throttle acceleration when starting and driving Avoid racing the engine Try to avoid hard stops during the first 300 km 200 miles Do not drive slowly with the manual transmission in a high gear Do not drive for a long time at any single speed either fast or slow Do not tow a trailer during the first 800 km 500 miles FUEL TYPE Your new vehicle must use only un leaded gasoline To help ...

Page 4587: ...ine deposits However all gasoline sold in the U S contains detergent additives to keep clean and or clean intake systems QUALITY GASOLINE Automotive manufacturers in the U S Europe and Japan have developed a specification for quality fuel named World Wide Fuel Charter WWFC that is expected to be applied world wide The WWFC consists of four categories that depend on required emission lev els In the...

Page 4588: ...blem then consult your Toyota dealer NOTICE Do not use gasohol other than stated above It will cause fuel sys tem damage or vehicle performance problems If driveability problems occur poor hot starting vaporizing engine knock etc discontinue the use Take care not to spill gasohol dur ing refueling Gasohol may cause paint damage FUEL TANK CAPACITY 100 L 26 4 gal 22 0 Imp gal The fuel pump shut off ...

Page 4589: ...ne 2UZ FE engine The three way catalytic converter is an emission control device installed in the exhaust system The purpose is to reduce pollutants in the exhaust gas CAUTION Keep people and combustible mate rials away from the exhaust pipe while the engine is running The exhaust gas is very hot Do not idle or park your vehicle over anything that might burn easi ly such as grass leaves paper or r...

Page 4590: ... Remember your Toyota dealer knows your vehicle and its three way catalytic converter sys tem best To ensure that the three way cata lytic converter and the entire emis sion control system operate proper ly your vehicle must receive the periodic inspections required by the Toyota Maintenance Schedule For scheduled maintenance information refer to the Scheduled Maintenance Guide or Owner s Manual S...

Page 4591: ...e is decelerating sucks some of this oil into the combustion chamber This oil as well as some part of the oil film left on the cylinder wall is burned by the high temperature combustion gases during the combustion process Oil is also used to lubricate the stems of the intake valves Some of this oil is sucked into the combustion chamber together with the intake air and is burned along with the fuel...

Page 4592: ...s for your en gine performance and smooth drive ability Without the vehicle stability control system The tandem master cylinder brake system is a hydraulic system with two separate sub systems If either sub system should fail the other will still work However the pedal will be harder to press and your stopping distance will increase Also the brake system warning light may come on CAUTION Do not dr...

Page 4593: ...ght comes on immediately stop your vehicle and contact your Toyota deal er The brake system warning light may stay on for about 60 seconds after the ignition key is turned to the ON position It is normal if the light turns off after a while Depressing the brake pedal repeatedly may turn on the brake system warning light and buzzer It is normal if the light turns off and the buzzer stops sounding a...

Page 4594: ...e vehicle begins to move This means that the anti lock brake system is in the self check mode and does not indicate a malfunction When the anti lock brake system is ac tivated the following conditions may occur They do not indicate a malfunc tion of the system You may hear the anti lock brake sys tem operating and feel the brake pedal pulsating and the vibrations of the ve hicle body and steering ...

Page 4595: ...e turning speed resulting in a longer stopping dis tance Type A Type B ABS Warning light The light comes on when the ignition key is turned to the ON position If the anti lock brake system works properly the light turns off after a few seconds There after if the system malfunctions the light comes on again When the ABS warning light is on and the brake system warning light is off the anti lock bra...

Page 4596: ... a bridge etc on a rainy day tends to activate the anti lock brake sys tem You may hear a click or motor sound in the engine compartment for a few seconds when the engine is started or just after the vehicle begins to move This means that the anti lock brake system is in the self check mode and does not indicate a malfunction When the anti lock brake system is ac tivated the following conditions m...

Page 4597: ...etect the accurate turning speed resulting in a longer stopping dis tance Type A Type B ABS warning light The light comes on when the ignition key is turned to the ON position If the anti lock brake system and the brake assist system work properly the light turns off after a few seconds Thereafter if the systems malfunctions the light comes on again When the ABS warning light is on and the brake s...

Page 4598: ... a malfunc tion The light may stay on for about 60 seconds after the ignition key is turned to the ON position It is normal if it turns off after a while Depressing the brake pedal repeatedly may turn on the light It is normal if it turns off after about a few seconds BRAKE ASSIST SYSTEM with the ve hicle stability control system When you slam the brakes on the brake assist system judges as an eme...

Page 4599: ...bumper is for rear end protection and easier step up loading CAUTION Do not allow more than one person to get on the rear step bumper at a time It is designed for only one person Never drive the vehicle with anyone on the rear step bumper The side step is for easier step up loading CAUTION For models equipped with a StepSide bed Do not allow more than one person to get on the side step Do not exce...

Page 4600: ...could pose a danger or re sult in serious injury NOTICE Use only a spare tire of the same size construction and load capacity as the original tires on your Toyota because damage to the limited slip differential could possibly occur with another tire type The vehicle identification number VIN is the legal identifier for your vehicle This number is on the left top of the instrument panel and can be ...

Page 4601: ... the incidence of vehicle thefts by facilitat ing the tracing and recovery of parts from stolen vehicles The label is designed so that once it is applied to a surface any attempt to remove it will result in destroy ing the integrity of the label Transferring these labels intact from one part to anoth er will be impossible NOTICE You should not attempt to remove the theft prevention labels as it ma...

Page 4602: ... 357 2005 TUNDRA from Sep 04 Prod OM34432U CAUTION Do not modify the suspension chassis with lift kits spacers springs etc It can cause dangerous handling charac teristics resulting in loss of control Suspension and chassis ...

Page 4603: ...iform tire quality grading For details see Uniform tire quali ty grading that follows 4 The location of the tread wear indicators For details see Checking and replacing tires in Section 7 2 5 Tire ply composition and mate rials Plies mean a layer of rub ber coated parallel cords Cords mean the strands forming the plies in the tire 6 Radial tires or bias ply tires A radial tire has RADIAL on the si...

Page 4604: ...in flated For details about recom mended cold tire inflation pressure see Tires in Section 8 10 Summer tire or all season tire An all season tire has M S on the sidewall The tire not marked with M S is a summer tire For details see Types of tires in this Section This illustration indicates typical DOT and Tire Identification Number TIN 1 DOT symbol 2 Tire Identification Number TIN 3 Tire manufactu...

Page 4605: ...t ratio tire height to section width 4 Tire construction code R Radial D Diagonal 5 Wheel diameter in inches 6 Load index 2 digits or 3 digits 7 Speed symbol alphabet with one letter 1 Section width 2 Tire height 3 Wheel diameter 1 Bead 2 Sidewall 3 Shoulder 4 Tread 5 Belt 6 Inner liner 7 Reinforcing rubber 8 Carcass 9 Rim lines 10 Bead wires 11 Chafer Tire size Name of each section of tire ...

Page 4606: ... is a comparative rating based on the wear rate of the tire when tested un der controlled conditions on a speci fied government test course For ex ample a tire graded 150 would wear one and a half 1 1 2 times as well on the government course as a tire graded 100 The relative performance of tires depends upon the actual conditions of their use however and may depart significantly from the norm due ...

Page 4607: ...reduce tire life and excessive temperature can lead to sudden tire failure The grade C cor responds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No 109 Grades B and A represent higher levels of per formance on the laboratory test wheel than the minimum required by law Warning The temperature grades for this tire are established f...

Page 4608: ...ed air conditioning and additional weight optional engine Intended outboard sidewall A the sidewall that contains a whitewall bears white lettering or bears manufacturer brand and or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or Intended outboard sidewall deeper than the same molding on the other sidewall of the tire or B the outward facing ...

Page 4609: ...of rack heavy duty battery and special trim Recommended inflation pressure cold tire inflation pressure recommended by a manufacturer Rim a metal support for a tire or a tire and tube assembly upon which the tire beads are seated Rim diameter Wheel diameter nominal diameter of the bead seat Rim size designation rim diameter and width Rim type designation the industry of manufacturer s designation ...

Page 4610: ... weight distributed in accordance with Table 1 that follows and dividing by two Weather side the surface area of the rim not covered by the inflated tire Table 1 Occupant loading and distribution for vehicle normal load for various designated seating capacities Designated seating capacity number of occupants Vehicle normal load number of occupants Occupant distribution in a normally loaded vehicle...

Page 4611: ...hose estimated average weight is 68 kg 150 lb per person Depending on the weight of each person the seat ing capacity given may exceed the total load capacity NOTICE Even if the number of occupants are within the seating capacity do not exceed the total load ca pacity Towing capacity Towing capacity means the maximum gross trailer weight trailer weight plus its cargo weight that your vehicle is ab...

Page 4612: ...raking or a collision Do not drive with objects left on top of the instrument panel They may interfere with the driver s field of view Or they may move during sharp vehicle acceleration or turning and im pair the driver s control of the vehicle In an accident they may injure the vehicle occu pants Cargo capacity depends on the to tal weight of the occupants Cargo capacity Total load capac ity Tota...

Page 4613: ...e C kg lb as follows B kg lb A kg lb C kg lb From this condition if 3 more passen gers with the combined weight of D kg lb get on the available cargo and luggage load will be reduced E kg lb as follows C kg lb D kg lb E kg lb As shown in the above example if the number of occupants increases the cargo and luggage load equaling the combined weight of occupants who got on later must be reduced In ot...

Page 4614: ...to pro vide better traction in snow and to be adequate for driving in most winter conditions as well as for use all year round All season tires however do not have adequate traction performance compared with snow tires in heavy or loose snow Also all season tires fall short in acceleration and handling performance compared with summer tires in highway driving The details about how to distinguish s...

Page 4615: ... 05 TUNDRA_U L O 0409 370 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4616: ...NG Starting and driving Before starting the engine 372 How to start the engine 372 Tips for driving in various conditions 373 Off road driving precautions 375 Winter driving tips 376 Dinghy towing 377 Trailer towing 378 How to save fuel and make your vehicle last longer 389 SECTION 3 ...

Page 4617: ...function will keep cranking for about 30 seconds maximum 1 Apply the parking brake firmly 2 Turn off unnecessary lights and acces sories 3 Manual transmission Press the clutch pedal to the floor and shift the trans mission into neutral Hold the clutch pedal to the floor until the engine is started A starter safety device will pre vent the starter from operating if the clutch pedal is not fully dep...

Page 4618: ...ect proce dure given in normal starting If the engine will not start See If your vehicle will not start in Sec tion 4 NOTICE With manual transmission only Do not crank for more than 30 seconds at a time This may overheat the starter and wiring systems Do not race a cold engine If the engine becomes difficult to start or stalls frequently have the engine checked immediately Always slow down in gust...

Page 4619: ... the parking brake reminder light is off Do not leave your vehicle unat tended while the engine is running Do not rest your foot on the brake pedal while driving It can cause dangerous overheating needless wear and poor fuel economy To drive down a long or steep hill reduce your speed and downshift Remember if you ride the brakes excessively they may overheat and not work properly Be careful when ...

Page 4620: ...jury or damage to your ve hicle Drive carefully when off the road Do not take unnecessary risks by driving in dangerous places Do not grip the steering wheel spokes when driving off road A bad bump could jerk the wheel and injure your hands Keep both hands and especially your thumbs on the outside of the rim Always check your brakes for effec tiveness immediately after driving in sand mud water or...

Page 4621: ...after each day of off road driving that has taken you through rough terrain sand mud or water For scheduled maintenance in formation refer to the Scheduled Maintenance Guide or Owner s Manual Supplement Make sure your coolant is properly pro tected against freezing Only use Toyota Super Long Life Coolant or similar high quality ethylene glycol based non silicate non amine non nitrite and non borat...

Page 4622: ...and most auto parts stores Follow the manufacturer s directions for how much to mix with water NOTICE Do not use engine antifreeze or any other substitute because it may dam age your vehicle s paint Do not use your parking brake when there is a possibility it could freeze When parking put the transmission into P automatic or into first or reverse manual and block the front wheels Do not use the pa...

Page 4623: ...on additional requirements such as a towing kit etc WEIGHT LIMITS Before towing make sure the total trail er weight gross combination weight gross vehicle weight gross axle weight and trailer tongue load are all within the limits The total trailer weight and tongue load can be measured with platform scales found at highway weighing stations build ing supply companies trucking companies junk yards ...

Page 4624: ...le cargo must never exceed a total of the following 1GR FE engine 4173 kg 9200 lb 2UZ FE engine Without towing package 4536 kg 10000 lb With towing package 5352 kg 11800 lb Exceeding the maximum weight of the trailer the vehicle or the ve hicle and trailer combination can cause an accident resulting in seri ous personal injuries Trailer hitch assemblies have differ ent weight capacities establishe...

Page 4625: ...weight on both axles must not exceed the Gross Axle Weight Rating GAWR listed on the Certification Label 100 9 to 11 Total trailer weight Tongue load Tongue load Total trailer weight The trailer cargo load should be distributed so that the tongue load is 9 to 11 of the total trailer weight not exceeding the maximum load of the following Weight carrying hitch or distributing hitch 1GR FE engine Sta...

Page 4626: ...han in the front About 60 of the trailer load should be in the front half of the trailer and the remaining 40 in the rear HITCHES If you wish to install a trailer hitch you should consult with your Toyota dealer Use only a hitch recommended by the hitch manufacturer and the one which conforms to the total trailer weight requirement The hitch must be bolted securely to the vehicle frame and install...

Page 4627: ...p plication 1 Determine the correct trailer ball size for the trailer coupler Most couplers are stamped with the required trailer ball size The sizes you will most likely find stamped on the coupler are Trailer class Typical trailer ball size IV 2 5 16 in II and III 2 in I 1 7 8 in 2 Select the appropriate trailer ball to match or exceed the gross trailer weight rating of the trailer The trailer b...

Page 4628: ...ar bumper of your vehicle is equipped with a hole to install a trailer ball The maximum gross trailer weight is 2268 kg 5000 lb CAUTION The maximum gross trailer weight trailer weight plus cargo weight when towing with the bumper must never exceed 2268 kg 5000 lb FIFTH WHEEL TRAILER NOTICE When towing a fifth wheel trailer be careful not to hit the cabin or deck by the trailer while making a sharp...

Page 4629: ...e and the trailer Leave sufficient slack in the chain for turns The chain should cross under the trailer tongue to prevent the tongue from dropping to the ground in case it becomes dam aged or separated For correct safety chain procedures follow the hitch or trailer manufacturer s recommenda tions CAUTION If the total trailer weight exceeds 453 kg 1000 lb trailer brakes are required Never tap into...

Page 4630: ...etailed ex planation of the sub wire harness circuit is packed together with the sub wire har ness Be sure to position the trailer brake con troller where it does not prevent the driver from operating the pedal Toyota recommends that the sub wire har ness be stored in the glove box when it is not in use TIRES Ensure that your vehicle s tires are properly inflated See Section 7 2 and Section 8 for ...

Page 4631: ...ue to the additional load For this informa tion please refer to the scheduled maintenance information in the Sched uled Maintenance Guide or Owner s Manual Supplement Retighten all fixing bolts of the towing ball and bracket after approximately 1000 km 600 miles of trailer driving PRE TOWING SAFETY CHECK Check that your vehicle remains level when a loaded or unloaded trailer is hitched Do not driv...

Page 4632: ...y of sudden braking Remember that when making a turn the trailer wheels will be closer than the vehicle wheels to the inside of the turn Therefore compensate for this by making a larger than normal turning radius with your vehicle Crosswinds and rough roads will ad versely affect handling of your vehicle and trailer causing sway Pay attention to the rear from time to time to pre pare yourself for ...

Page 4633: ... on a slope 1 With the transmission in P position automatic or the clutch pedal de pressed manual start the engine With an automatic transmission be sure to keep the brake pedal de pressed 2 Shift into gear 3 Release the parking brake also foot brake on automatic transmission ve hicles and slowly pull or back away from the wheel blocks Stop and apply your brakes 4 Have someone retrieve the blocks ...

Page 4634: ...g Maintain a steady pace Try to time the traffic signals so you only need to stop as little as possible or take advantage of through streets to avoid traffic lights Keep a proper dis tance from other vehicles to avoid sud den braking This will also reduce wear on your brakes Avoid heavy traffic or traffic jams whenever possible Do not rest your foot on the clutch or brake pedal This causes prematu...

Page 4635: ... Sep 04 Prod OM34432U CAUTION Never turn off the engine to coast down hills Your power steering and brake booster will not function with out the engine running Also the emission control system operates properly only when the engine is run ning ...

Page 4636: ...cle will not start 392 If your engine stalls while driving 396 If you cannot increase engine speed 396 If your vehicle overheats 396 If you have a flat tire 397 If your vehicle becomes stuck 409 If your vehicle needs to be towed 410 If you lose your keys 415 If you lose your wireless remote control transmitter 416 SECTION 4 ...

Page 4637: ...urns over at its normal speed but will not start 1 Turn the ignition key to ACC or LOCK and try starting the engine again 2 If the engine will not start the engine may be flooded because of repeated cranking See b Starting a flooded engine for further instructions 3 If the engine still will not start it needs adjustment or repair Call a Toyota dealer or qualified repair shop If the engine will not...

Page 4638: ... must be followed precisely If you are unsure about how to follow this procedure we strongly recommend that you seek the help of a competent me chanic or towing service CAUTION Batteries contain sulfuric acid which is poisonous and corrosive Wear protective safety glasses when jump starting and avoid spilling acid on your skin clothing or ve hicle If you should accidentally get acid on yourself or...

Page 4639: ...t it run for a few minutes During jump starting run the engine at about 2000 rpm with the accelerator pedal lightly depressed Discharged battery Booster battery Positive terminal mark Jumper cable Positive terminal mark 4 Make the cable connections in the or der a b c d a Connect the clamp of the positive red jumper cable to the positive terminal on the discharged battery b Connect the clamp at th...

Page 4640: ...tly depressed 6 Start your engine in the normal way After starting run it at about 2000 rpm for several minutes with the accelerator pedal lightly depressed 7 Carefully disconnect the cables in the exact reverse order the negative cable and then the positive cable 8 Carefully dispose of the battery cover cloths they may now contain sulfuric acid 9 If removed replace all the battery vent plugs If t...

Page 4641: ...onic throttle control system is corrected during low speed driving the system may not be recovered until the engine is stopped and the ignition key is turned to ACC or LOCK position CAUTION Be especially careful to prevent erro neous pedal operation If your engine coolant temperature gauge indicates overheating if you ex perience a loss of power or if you hear a loud knocking or pinging noise the ...

Page 4642: ...s running Fill it about half full For the coolant type see Coolant type selection in Section 7 2 CAUTION Do not attempt to remove the radiator cap when the engine and radiator are hot Serious injury could result from scalding hot fluid and steam blown out under pressure 7 After the engine coolant temperature has cooled to normal again check the coolant level in the reservoir If neces sary bring it...

Page 4643: ... onally opposite to the one be ing changed if necessary Make sure to set the jack prop erly in the jack point Raising the vehicle with jack improper ly positioned will damage the vehicle or may allow the ve hicle to fall off the jack and cause personal injury Never get under the vehicle when the vehicle is supported by the jack alone Use the jack only for lifting your vehicle during wheel changing...

Page 4644: ...ction 2 until the jack is firmly secured to pre vent it flying forward during a collision or sudden braking To remove the spare tire 1 Insert the end of the jack handle into the lowering screw and turn it counterclockwise 2 After the tire is lowered completely to the ground remove the holding bracket When storing the spare tire put it in place with the outer side of the wheel facing up Then secure...

Page 4645: ...mergency you should familiarize yourself with the use of the jack each of the tools and their storage locations Turn the jack joint by hand To remove Turn the joint in direction 1 until the jack is free To store Turn the joint in direction 2 until the jack is firmly secured to pre vent it flying forward during a collision or sudden braking Required tools and spare tire access and double cab models...

Page 4646: ...ckwise with the handle 3 After the tire is lowered completely to the ground remove the holding bracket When storing the spare tire put it in place with the outer side of the wheel facing up Then secure the tire taking care that the tire goes straight up without catching on any other part to prevent it from flying forward during a collision or sudden braking 2 Block the wheel diagonally op posite t...

Page 4647: ...pe A Type B Type C Type D Type E 3 Remove the wheel ornament Pry off the wheel ornament using the beveled end of the wheel nut wrench as shown Type B only To protect the wheel surface place sufficient paper or cloth between the wheel and wrench Removing wheel ornament ...

Page 4648: ...eel nuts counterclockwise to loosen To get maximum leverage fit the wrench to the nut so that the handle is on the right side as shown above Grab the wrench near the end of the handle and pull up on the han dle Be careful that the wrench does not slip off the nut Do not remove the nuts yet just un screw them about one half turn CAUTION Never use oil or grease on the bolts or nuts The nuts may loos...

Page 4649: ...TS Front Under the frame side rail Rear Under the rear axle housing Access and double cab models Put a jack handle jack handle extension and jack handle end together as shown in the illustration 1 Jack handle end 2 Jack handle extension 3 Jack handle CAUTION Make sure they are each securely fixed with screws Standard cab models Access and double cab models Positioning the jack Raising your vehicle...

Page 4650: ...uble cab models To raise the vehicle insert the jack handle extension into the jack it is a loose fit and turn it clockwise with the handle making sure the handle remains firmly fitted onto the jack handle extension As the jack touches the vehicle and begins to lift double check that it is properly positioned CAUTION Never get under the vehicle when the vehicle is supported by the jack alone 7 Rem...

Page 4651: ...to come off while driving 8 Reinstall all the wheel nuts fin ger tight Reinstall the wheel nuts tapered end inward and tighten them as much as you can by hand Press back on the tire back and see if you can tighten them more CAUTION Never use oil or grease on the bolts or nuts Doing so may lead to overtightening the nuts and damaging the bolts The nuts may loose and the wheels may fall off which co...

Page 4652: ...ols or any addition al leverage other than your hands such as a hammer pipe or your foot Make sure the wrench is securely en gaged over the nut Tighten each nut a little at a time in the order shown Repeat the process until all the nuts are tight CAUTION When lowering the vehicle make sure all portions of your body and all other persons around will not be injured as the vehicle is lowered to the g...

Page 4653: ...nament 1 Put the wheel ornament in posi tion Type A Align the cutout of the wheel ornament with the valve stem as shown 2 Then firmly tap the outer edge of the wheel cap with the side or heel of your hand to snap it into place CAUTION Take due care in handling the or nament to avoid unexpected per sonal injury ...

Page 4654: ... nuts to the torque specified in Section 8 with a torque wrench Have a technician re pair the flat tire and replace the spare tire with it CAUTION Before driving make sure all the tools jack and flat tire are se curely in place in their storage location to reduce the possibility of personal injury during a colli sion or sudden braking Initial adjustment of the tire pres sure warning system is nece...

Page 4655: ... the transmission is com pletely shifted to forward or reverse gear Do not race the engine and avoid spinning the wheels If your vehicle remains stuck after rocking the vehicle several times consider other ways such as tow ing a Towing with wheel lift type truck From front From rear b Using flat bed truck Two wheel drive models b Using flat bed truck a Towing with wheel lift type truck From front ...

Page 4656: ...G PRECAUTIONS Use a safety chain system for all towing and abide by the state provincial and local laws The wheels and axle on the ground must be in good condition If they are damaged use a towing dolly Two wheel drive models a Towing with wheel lift type truck From front Manual transmission We recommend using a towing dolly under the rear wheels If you do not use a tow ing dolly release the parki...

Page 4657: ...the rear without a towing dolly The steering lock mechanism is not strong enough to hold the front wheels straight b Using flat bed truck c Towing with sling type truck All models c Towing with sling type truck NOTICE Do not tow with sling type truck ei ther from the front or rear This may cause body damage If towing is necessary we recommend you to have it done by your Toyota dealer or a commerci...

Page 4658: ... Securely fasten the cable or chain to the towing eyelet provided Before towing release the parking brake and put the transmission in neutral manu al or N automatic The key must be in ACC engine off or ON engine run ning CAUTION If the engine is not running the pow er assist for the brakes and steering will not work so steering and braking will be much harder than usual If towing is necessary we r...

Page 4659: ...le or chain specifically intended for use in towing vehicles Securely fasten the cable or chain to the towing hook provided Before towing release the parking brake put the transmission in neutral manual or N automatic and set the transfer in 2WD mode The key must be in ACC engine off or ON engine running CAUTION If the engine is not running the pow er assist for the brakes and steering will not wo...

Page 4660: ...ods are effective to use when your vehicle is stuck in the mud sand or other condition from which the vehicle cannot be driven out under its own power Use extreme cau tion when towing the vehicle In addi tion keep away from the vehicles and towing cable or chain when towing Remove the sand and soil in the front and the back of the tires Place stones or wood under the tires You can purchase a new k...

Page 4661: ... your Toyota dealer as soon as possible to avoid the possibility of theft or an accident Then have the identification number of your new transmitter registered At the same time you must bring all of the remaining transmitters to have them registered again as well You can use the wireless remote control system with the new transmitter Contact your Toyota dealer for detailed information If you lose ...

Page 4662: ...05 TUNDRA from Sep 04 Prod OM34432U CORROSION PREVENTION AND APPEARANCE CARE Corrosion prevention and appearance care Protecting your Toyota from corrosion 418 Washing and waxing your Toyota 419 Cleaning the interior 420 SECTION 5 ...

Page 4663: ...r ventilation The above signifies the necessity to keep your vehicle particularly the underside as clean as possible and to repair any dam age to paint or protective coatings as soon as possible To help prevent corrosion on your Toyota follow these guidelines Wash your vehicle frequently It is of course necessary to keep your vehicle clean by regular washing but to prevent corrosion the following ...

Page 4664: ...corrosion to the body and parts Wash your vehicle as soon as pos sible When driving in a coastal area When driving on a road sprinkled with antifreeze When exposed to coal tar tree sap bird droppings and carcass of an insect When driving in areas where there is a lot of smoke soot dust iron dust or chemical substances When the vehicle becomes remarkably dirty with dust and mud Hand washing your To...

Page 4665: ... even if you are using a combined cleaner and wax 2 Use a good quality polish and wax If the finish has become extremely weath ered use a car cleaning polish fol lowed by a separate wax Carefully fol low the manufacturer s instructions and precautions Be sure to polish and wax the chrome trim as well as the paint 3 Wax the vehicle again when water does not bead but remains on the sur face in large...

Page 4666: ...brush to apply the foam Rub in overlapping circles Do not apply water the best results are obtained by keeping the carpet as dry as possible Read the shampoo instructions and follow them closely Seat belts The seat belts may be cleaned with mild soap and water or with lukewarm water Use a cloth or sponge As you are clean ing check the belts for excessive wear fraying or cuts NOTICE Do not use dye ...

Page 4667: ...contain an organic solvent Never use organic substances such as benzine alcohol or gasoline or alkaline or acid solutions for clean ing the leather as these could cause discoloring Use of a nylon brush or synthetic fiber cloth etc may scratch the fine grained surface of the leather Mildew may develop on soiled leath er upholstery Be especially careful to avoid oil spots Try to keep your upholstery...

Page 4668: ...hicle maintenance and care Maintenance requirements 424 General maintenance 425 Does your vehicle need repairing 427 Emissions Inspection and Maintenance I M programs 428 For scheduled maintenance information please refer to the Scheduled Mainte nance Guide or Owner s Manual Supplement SECTION 6 ...

Page 4669: ... Guide or Owner s Manual Supplement It is recommended that any replacement parts used for maintenance or for the repair of the emission control system be Toyota supplied The owner may elect to use non Toyota supplied parts for replacement pur poses without invalidating the emission control system warranty However use of replacement parts which are not of equivalent quality may impair the effec tiv...

Page 4670: ...ought to the attention of your dealer or the qualified service shop for their advice CAUTION Make these checks only with ade quate ventilation if you run the en gine IN THE ENGINE COMPARTMENT Items listed below should be checked from time to time e g each time when refueling Washer fluid Make sure there is sufficient fluid in the tank See Section 7 3 for additional in formation Engine coolant leve...

Page 4671: ...n For folding down seatback check that the latches lock securely Seat belts Check that the seat belt system such as buckles retractors and anchors operate properly and smoothly Make sure the belt webbing is not cut frayed worn or dam aged Accelerator pedal Check the pedal for smooth operation and uneven pedal effort or catching Clutch pedal Check the pedal for smooth operation Brake pedal Check th...

Page 4672: ...ds and visual tip offs that indicate service is needed Some impor tant clues are as follows Engine missing stumbling or pinging Appreciable loss of power Strange engine noises A leak under the vehicle however wa ter dripping from the air conditioning after use is normal Change in exhaust sound This may indicate a dangerous carbon monoxide leak Drive with the windows open and have the exhaust syste...

Page 4673: ...ess codes have not been set in the OBD system Readiness codes are automatically set during ordinary driving However when the battery is disconnected or run down the codes are erased Also depending on your driving habits the codes may not be completely set Also if the malfunction indicator lamp had come on recently due to temporary mal function such as a loose fuel tank cap your vehicle may not pas...

Page 4674: ... L O 0409 429 2005 TUNDRA from Sep 04 Prod OM34432U DO IT YOURSELF MAINTENANCE Introduction Engine compartment overview 430 Fuse locations 432 Do it yourself service precautions 433 Parts and tools 435 SECTION 7 1 ...

Page 4675: ...432U 1 Power steering fluid reservoir 2 Engine oil level dipstick 3 Engine oil filler cap 4 Brake fluid reservoir 5 Fuse block 6 Battery 7 Engine coolant reservoir 8 Radiator 9 Condenser 10 Windshield washer fluid tank Engine compartment overview 1GR FE engine ...

Page 4676: ...p 04 Prod OM34432U 1 Power steering fluid reservoir 2 Engine oil level dipstick 3 Engine oil filler cap 4 Brake fluid reservoir 5 Fuse blocks 6 Battery 7 Engine coolant reservoir 8 Radiator 9 Condenser 10 Windshield washer fluid tank 2UZ FE engine ...

Page 4677: ... 05 TUNDRA_U L O 0409 432 2005 TUNDRA from Sep 04 Prod OM34432U Standard and access cab models Double cab models Spare fuses Fuse locations ...

Page 4678: ...he separate Toyota Warranty statement for details and suggestions This Section gives instructions only for those items that are relatively easy for an owner to perform As explained in Section 6 there are still a number of items that must be done by a qualified technician with special tools For information on tools and parts for do it yourself maintenance see Parts and tools Utmost care should be t...

Page 4679: ...n or skin cancer so care should be taken to avoid prolonged and repeated contact with it To re move used engine oil from your skin wash thoroughly with soap and water Do not leave used oil within the reach of children Dispose of used oil and filter only in a safe and acceptable manner Do not dispose of used oil and fil ter in household trash in sewers or onto the ground Call your dealer or a servi...

Page 4680: ... ENGINE OIL LEVEL Parts if level is low Toyota Genuine Motor Oil or equiva lent See Section 7 2 for details about en gine oil selection Tools Rag or paper towel Funnel only for adding oil CHECKING THE ENGINE COOLANT LEVEL Parts if level is low Toyota Super Long Life Coolant or similar high quality ethylene glycol based non silicate non amine non ni trite and non borate coolant with long life hybri...

Page 4681: ...ent is necessary Fuse with same amperage rating as original ADDING WASHER FLUID Parts Water Washer fluid containing antifreeze for winter use Tools Funnel REPLACING LIGHT BULBS Parts Bulb with same number and wattage rating as original See charts in Re placing light bulbs in Section 7 3 Tools Screwdriver Wrench ...

Page 4682: ...level 438 Checking the engine coolant level 440 Checking the radiator and condenser 441 Checking brake fluid 442 Checking power steering fluid 444 Checking tire inflation pressure 444 Checking and replacing tires 447 Rotating tires 449 Installing snow tires and chains 450 Replacing wheels 452 Aluminum wheel precautions 452 SECTION 7 2 ...

Page 4683: ...under the end CAUTION Be careful not to touch the hot ex haust manifold NOTICE Be careful not to drop engine oil on the vehicle components If the oil level is below or only slightly above the low level add engine oil of the same type as already in the engine Remove the oil filler cap and add engine oil in small quantities at a time checking the dipstick We recommend that you use a funnel when addi...

Page 4684: ...fy the following grade and viscosity Oil grade API grade SL Energy Conserving or ILSAC multigrade engine oil Recommended viscosity SAE 5W 30 Outside temperature SAE 5W 30 is the best choice for good fuel economy and good starting in cold weather If SAE 5W 30 is not available SAE 10W 30 may be used However it should be replaced with SAE 5W 30 at the next oil change API service symbol ILSAC certific...

Page 4685: ...available which has been specifically tested and approved for all Toyota engines Please contact your Toyota dealer for fur ther details about Toyota Genuine Motor Oil Look at the see through coolant reser voir when the engine is cold The cool ant level is satisfactory if it is between the F and L lines on the reservoir If the level is low add the coolant For the coolant type see Coolant type selec...

Page 4686: ... water This coolant pro vides protection down to about 42 C 44 F NOTICE Do not use plain water alone Toyota recommends Toyota Super Long Life Coolant which has been tested to ensure that it will not cause corrosion nor result in malfunction of your engine coolant system with proper usage Toyota Super Long Life Coolant is formulated with long life hybrid organic acid technology and has been specifi...

Page 4687: ... brake fluid to the dotted line This brings the fluid to the correct level when you put the cap back on Use only newly opened brake fluid Once opened brake fluid absorbs moisture from the air and excess moisture can cause a dangerous loss of braking When the brake fluid must be replaced contact your Toyota dealer CAUTION Take care when filling the reservoir because brake fluid can harm your hands ...

Page 4688: ...20 times until the brake pedal resistance decreases and pedal travel increases 3 Remove the reservoir cover by hand Add brake fluid up to the MAX line If you do not follow the procedure above the reservoir may overflow Use only newly opened brake fluid Once opened brake fluid absorbs moisture from the air and excess moisture can cause a dangerous loss of braking CAUTION Take care when filling the ...

Page 4689: ... the res ervoir tank and look at the fluid level If the fluid is cold the level should be in the COLD range Similarly if it is hot the fluid level should be in the HOT range If the level is at the low side of either range add automatic transmission fluid DEXRON II or III to bring the level within the range To remove the reservoir cap turn it coun terclockwise and lift up To reinstall it turn it cl...

Page 4690: ...e cold If your vehicle has been parked for at least 3 hours and has not been driven for more than 1 5 km or 1 mile since you will get an accurate cold tire inflation pres sure reading If you cannot adjust the tire pressure when the tires are cold add 20 to 30 kPa more to the front tires and rear tires than the cold tire pressure but never exceed the maximum cold tire pressure molded on the tire si...

Page 4691: ... have your vehicle checked by your Toyota dealer CAUTION Be sure to reinstall the tire valve caps Without the valve caps dirt or moisture could get into the valve core and cause air leakage If the caps have been lost have new ones put on as soon as pos sible Incorrect tire inflation pressure may waste fuel reduce the comfort of driv ing reduce tire life and make your ve hicle less safe to drive If...

Page 4692: ... know when the tires need replace ment When the tread depth wears to 1 6 mm 0 06 in or less the indica tors will appear If you can see the indicators in two or more adjacent grooves the tire should be replaced The lower the tread the higher the risk of skidding The effectiveness of snow tires is lost if the tread wears down below 4 mm 0 16 in If you have tire damage such as cuts splits cracks deep...

Page 4693: ... or snow chains Check that the maximum load of the replaced tire is greater than 1 2 of the Gross Axle Weight Ratings GAWR of either the front axle or the rear axle whichever is greater As for the maximum load of the tire see the load limit at maximum cold tire inflation pressure mentioned on the sidewall of the tire and as for the Gross Axle Weight Ratings GAWR see the Cer tification Label For de...

Page 4694: ...ee If you have a flat tire in Section 4 for tire change procedure When a tire is replaced the wheel should always be balanced An unbalanced wheel may affect ve hicle handling and tire life Wheels can get out of balance with regular use and should therefore be balanced occasionally When replacing a tubeless tire the air valve should also be replaced with a new one Initial adjustment of the tire pre...

Page 4695: ...ly caused by incorrect tire pres sure improper wheel alignment out of balance wheels or severe braking Initial adjustment of the tire pres sure warning system is necessary after you have rotated your tires See Tire pressure warning sys tem in Section 1 7 WHEN TO USE SNOW TIRES OR CHAINS Snow tires or chains are recommended when driving on snow or ice On wet or dry roads conventional tires provide ...

Page 4696: ...h the snow tires incorrectly inflated Never drive over 120 km h 75 mph with any type of snow tires TIRE CHAIN SELECTION Use the tire chains of correct size Regulations regarding the use of tire chains vary according to location or type of road so always check local reg ulations before installing chains CHAIN INSTALLATION Install the chains on the rear tires as tightly as possible Do not use tire c...

Page 4697: ...structural damage and therefore should not be used Never use an inner tube in a leaking wheel which is designed for a tubeless tire CAUTION Observe the following instructions Otherwise an accident may occur re sulting in death or serious injuries Do not use wheels other than the manufacturer s recommended size as this may cause dangerous han dling characteristics resulting in loss of control Four ...

Page 4698: ...A from Sep 04 Prod OM34432U DO IT YOURSELF MAINTENANCE Electrical components Checking battery condition 454 Battery recharging precautions 455 Checking and replacing fuses 456 Adding washer fluid 457 Replacing light bulbs 458 SECTION 7 3 ...

Page 4699: ...n or burning get medi cal attention immediately If electrolyte gets on your clothes there is a possibility of its soaking through to your skin so immediate ly take off the exposed clothing and follow the procedure above if nec essary If you accidentally swallow electro lyte drink a large quantity of water or milk Follow with milk of magne sia beaten raw egg or vegetable oil Then go immediately for...

Page 4700: ...oyota deal er Clear or Light Yellow Red Have battery checked by your Toyota dealer During recharging the battery is pro ducing hydrogen gas Therefore before recharging 1 If recharging with the battery installed on the vehicle be sure to disconnect the ground cable 2 Be sure the power switch on the re charger is off when connecting the charger cables to the battery and when disconnecting them CAUTI...

Page 4701: ...NDRA_U L O 0409 456 2005 TUNDRA from Sep 04 Prod OM34432U Good Blown Type A Good Blown Type B Good Blown Type C Good Blown Type D Standard and access cab models Double cab models Checking and replacing fuses ...

Page 4702: ...f its amper age rating is the same If you cannot use one of the same amper age use one that is lower but as close to the rating as possible If the amperage is lower than that specified the fuse might blow out again but this does not indicate anything wrong Be sure to get the correct fuse as soon as possible and return the substitute to its original clip It is a good idea to purchase a set of spare...

Page 4703: ...such as headlights may temporarily fog up when the lens becomes wet in the rain or in a car wash This is not a problem because the fogging is caused by the temperature difference between the outside and inside of the lens just like the windshield fogs up in the rain However if there is a large drop of water on the inside of the lens or if there is water pooled inside the light contact your Toyota ...

Page 4704: ...n bulbs B HB4 halogen bulbs C Wedge base bulbs amber D Wedge base bulbs clear E Double end bulbs 1 Open the hood Unplug the connec tor Remove the rubber cover If the connector is tight wiggle it 2 Release the bulb retaining spring and remove the bulb Install a new bulb and the bulb retaining spring To install a bulb align the tabs of the bulb with the cutouts of the mounting hole Headlights ...

Page 4705: ... the mounting body Aiming is not necessary after replacing the bulb When aiming adjustment is nec essary contact your Toyota dealer If either the left or right front fog lights burns out contact your Toyota dealer NOTICE Do not try to replace the front fog light bulbs by yourself You may dam age the vehicle LEFT SIDE PARKING LIGHT Loosen the bolt and remove the engine coolant reser voir Front fog ...

Page 4706: ...NDRA from Sep 04 Prod OM34432U Use a Phillips head screwdriver Remove and install the clip as shown in the fol lowing illustrations Removing clip Installing clip Front turn signal front side marker lights standard and access cab models ...

Page 4707: ...005 TUNDRA from Sep 04 Prod OM34432U Use a Phillips head screwdriver Remove and install the clip as shown in the fol lowing illustrations Removing clip Installing clip Front side marker front turn signal lights double cab models ...

Page 4708: ... L O 0409 463 2005 TUNDRA from Sep 04 Prod OM34432U Remove the bolts a Back up light b Rear turn signal light c Stop tail rear side marker light Rear turn signal stop tail rear side marker and back up lights type A ...

Page 4709: ... 05 TUNDRA_U L O 0409 464 2005 TUNDRA from Sep 04 Prod OM34432U Remove the bolts Rear turn signal stop tail rear side marker and back up lights type B ...

Page 4710: ...il rear side marker light c Back up light Remove the bolts a Back up light b Rear turn signal light c Stop tail rear side marker light Remove the bulb of the back up light at first when removing that of the rear turn signal light Rear turn signal stop tail rear side marker and back up lights type C ...

Page 4711: ... L O 0409 466 2005 TUNDRA from Sep 04 Prod OM34432U Use a Phillips head screwdriver Use a Phillips head screwdriver a High mounted stoplight b Cargo lamps License plate lights High mounted stoplight and cargo lamps ...

Page 4712: ...RA_U L O 0409 467 2005 TUNDRA from Sep 04 Prod OM34432U SPECIFICATIONS Specifications Dimensions 468 Payload 470 Towing capacity 473 Engine 474 Fuel 474 Service specifications 474 Tires 478 Fuses 479 SECTION 8 ...

Page 4713: ...dth 1910 75 2 1910 75 2 1945 76 6 3 2015 79 3 4 2015 79 3 2015 79 3 3 2025 79 7 4 Overall height 5 1795 70 7 1790 70 5 6 1800 70 9 7 or 8 1790 70 5 1880 74 0 6 1890 74 4 7 1895 74 6 8 Wheelbase 3260 128 3 3260 128 3 3260 128 3 3570 140 5 Front tread 1680 66 1 1680 66 1 1680 66 1 1680 66 1 Rear tread 1648 64 9 1648 64 9 1648 64 9 1710 67 3 1 With steel bumper 2 With plastic bumper 3 With wheel arch...

Page 4714: ...5 2 1945 76 6 3 1910 75 2 1945 76 6 3 2015 79 3 4 2015 79 3 2015 79 3 3 2025 79 7 4 Overall height 5 1805 71 1 6 1815 71 5 7 or 8 1810 71 3 6 1820 71 7 7 or 8 1810 71 3 1890 74 4 6 1900 74 8 7 1905 75 0 8 Wheelbase 3260 128 3 3260 128 3 3260 128 3 3570 140 5 Front tread 1675 65 9 1675 65 9 1675 65 9 1675 65 9 Rear tread 1648 64 9 1648 64 9 1648 64 9 1710 67 3 1 With steel bumper 2 With plastic bum...

Page 4715: ...ssion Standard bed Standard 853 1882 832 1836 1 900 1985 3 2UZ FE Four wheel drive Automatic transmission Standard bed Standard 728 1607 708 1561 1 1GR FE Two wheel drive Manual transmission Standard bed SR5 630 1391 1GR FE Two wheel drive Automatic transmission Standard bed SR5 608 1342 Standard bed SR5 734 1620 713 1574 1 Access cab models 2UZ FE Two wheel drive Automatic transmission Standard b...

Page 4716: ...Automatic transmission StepSide bed SR5 486 1073 465 1027 1 Automatic transmission StepSide bed Limited 533 1177 513 1131 1 Two wheel drive Automatic transmission Standard bed SR5 772 1702 753 1661 1 or 2 734 1620 1 2 Double cab 2UZ FE Two wheel drive Automatic transmission Standard bed Limited 761 1678 742 1637 1 or 2 723 1596 1 2 Double cab models 2UZ FE Four wheel Automatic transmission Standar...

Page 4717: ... xi in the beginning of this manual if you are not sure of which model your vehicle is 5 Maximum payload including weight of driver passengers optional equipment and cargo 6 Installing accessories in addition to those installed at the factory increases the weight of the vehicle thereby reducing payload Contact your Toyota dealer about the weight of accessory parts ...

Page 4718: ...heel drive models Without towing package 2268 5000 Two wheel drive models Without towing package 2494 5500 Access cab models 2UZ FE engine Two wheel drive models With towing package 3311 7300 2UZ FE engine Four wheel drive models Without towing package 2358 5200 Four wheel drive models With towing package 3175 7000 Two wheel drive models Without towing package 2358 5200 Double cab models 2UZ FE en...

Page 4719: ...r higher For improved vehicle perfor mance the use of premium unleaded gasoline with an Octane Rating of 91 Research Octane Number 96 or higher is recommended 2UZ FE engine Unleaded gasoline Octane Rating 87 Research Octane Number 91 or higher Fuel tank capacity L gal Imp gal 100 26 4 22 0 ENGINE Valve clearance engine cold mm in 1GR FE engine Intake 0 15 0 25 0 006 0 010 Exhaust 0 29 0 39 0 011 0...

Page 4720: ... With automatic transmission 1GR FE engine 10 3 10 9 9 1 2UZ FE engine Standard and access cab models 12 6 13 0 11 1 Double cab models 12 8 13 5 11 3 Coolant type Toyota Super Long Life Coolant is used in your Toyota vehicle at factory fill In order to avoid technical problems only use Toyota Super Long Life Coolant or similar high quality ethylene glycol based non silicate non amine non nitrite a...

Page 4721: ...in assuring optimum transmission performance Notice Using automatic transmission fluid other than Toyota Genuine ATF WS may cause deterioration in shift quality locking up of your transmission accompanied by vibration and ultimate ly damage the automatic transmission of your vehicle Please contact your Toyota dealer for fur ther details TRANSFER Oil capacity L qt Imp qt 1 0 1 1 0 9 Oil type Gear o...

Page 4722: ...sulfide lithium base chassis grease NLGI No 2 BRAKES Minimum pedal clearance when depressed with the force of 490 N 50 kgf 110 lbf with the engine running mm in Without vehicle stability control system 95 3 7 With vehicle stability control system 80 3 1 Pedal free play mm in 1 6 0 04 0 24 Pad wear limit mm in 1 0 0 04 Lining wear limit mm in 1 0 0 04 Parking brake adjustment Pedal type when depres...

Page 4723: ...thout off road package 2 Vehicles with off road package Double cab models Tire size Tire inflation pressure kPa kgf cm2 or bar psi Wheel size Tire size Front Rear Spare tire Wheel size P245 70R16 106S 220 2 2 32 240 2 4 35 240 2 4 35 7J or 7JJ 16 P265 70R16 111S 200 2 0 29 1 220 2 2 32 2 220 2 2 32 1 230 2 3 33 2 220 2 2 32 1 230 2 3 33 2 7J or 7JJ 16 P265 65R17 110S 200 2 0 29 220 2 2 32 220 2 2 ...

Page 4724: ...front passenger occupant clas sification system 12 H LP RH 10 A Right hand headlight high beam 13 PWR OUTLET 2 15 A Power outlet 14 DOME 10 A Interior light personal lights vanity light ignition switch light step light door courtesy lights open door warning light 15 H LP LH 10 A Left hand headlight high beam 16 EFI NO 2 10 A Multiport fuel injection system sequential multiport fuel injec tion syst...

Page 4725: ...sequential multi port fuel injection system discharge warning light ignition system vehicle stability control system front passenger occupant classification system 35 CARGO LP 5 A Cargo lamp 36 TAIL 15 A Tail lights turn signal lights license plate lights instrument panel lights parking lights glove box light 37 OBD 7 5 A On board diagnosis sys tem 38 HORN 10 A Horns 39 STA 5 A Multiport fuel inje...

Page 4726: ...system Right hand headlight low beam 7 STA 7 5 A Multiport fuel injection sys tem sequential multiport fuel injection system 8 H LP LH 10 A with daytime running light system Left hand headlight high beam 9 H LP RH 10 A with daytime running light system Right hand headlight high beam 10 TOWING TAIL 30 A Trailer lights tail lights Engine compartment 11 BATT CHARGE 30 A Trailer sub bat tery 12 TOWING...

Page 4727: ...d front pas senger door lock system gauges and meters wireless door lock system 31 MIR HTR 15 A Outside rear view mir ror heaters 32 RAD NO 1 20 A Audio system rear seat entertainment system 33 TAIL 15 A Tail lights trailer lights tail lights parking lights multiport fuel in jection system sequential multiport fuel injection system license plate lights 34 ECU IG 10 A Charging system stop lights an...

Page 4728: ...stems electric cooling fan back window de fogger seat heaters 52 FOG 15 A Front fog lights 53 GAUGE 15 A Back up lights gauge and meters emergency flashers slip indicator light vehicle stability control system four wheel drive system trailer lights back up lights multiport fuel injection system sequential multiport fuel injection system shift position indi cator lights 54 PWR OUTLET 15 A Power out...

Page 4729: ... 05 TUNDRA_U L O 0409 484 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4730: ...UNDRA from Sep 04 Prod OM34432U REPORTING SAFETY DEFECTS FOR U S OWNERS AND CAMPER INFORMATION Reporting safety defects for U S owners and camper information Reporting safety defects for U S owners 486 Camper information 486 SECTION 9 ...

Page 4731: ...between you your dealer or Toyota Motor Sales U S A Inc To contact NHTSA you may ei ther call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hot line This information has been prepared in ac cordance with regulatio...

Page 4732: ...ess cab models StepSide bed Recommended location for cargo center of gravity for cargo weight rating Rear end of truck bed Double cab models The figures given in the illustration indi cate the recommended center of gravity zone Standard cab models A 1186 mm 46 7 in B 1058 mm 41 7 in Access cab models Standard bed A 1186 mm 46 7 in B 1058 mm 41 7 in StepSide bed A 1158 mm 45 6 in B 1030 mm 40 6 in ...

Page 4733: ... kg 850 lb 5 people V8 4WD 272 kg 600 lb When the truck is used to carry a slide in camper the total cargo load of the truck consists of the manufacturer s camper weight figure the weight of installed addi tional camper equipment not included in the manufacturer s camper weight figure the weight of camper cargo and the weight of passengers in the camper The total cargo load should not exceed the t...

Page 4734: ...ion 2 for the Certification Label location If weight ratings are exceeded move or remove items to bring all weights below the ratings Gross vehicle weight rating Not exceed GVWR GAWR Front 1588 kg 3500 lb Rear Standard and access cab models V6 1615 kg 3560 lb V8 Standard bed 1656 kg 3650 lb StepSide bed 1615 kg 3560 lb Double cab models 1706 kg 3760 lb GVWR Two wheel drive models Standard cab mode...

Page 4735: ... 05 TUNDRA_U L O 0409 490 2005 TUNDRA from Sep 04 Prod OM34432U ...

Page 4736: ...5 Complete index NO TAG Gas station information Fuel type 1GR FE engine UNLEADED gasoline Octane Rating 87 Research Octane Number 91 or higher For improved vehicle performance the use of premium unleaded gasoline with an Octane Rating of 91 Research Octane Number 96 or higher is recommended 2UZ FE engine UNLEADED gasoline Octane Rating 87 Research Octane Number 91 or higher See page 341 for detail...

Page 4737: ...ows CAUTION This is a warning against anything which may cause injury to people if the warning is ignored You are informed about what you must or must not do in order to reduce the risk of injury to yourself and others NOTICE This is a warning against anything which may cause damage to the vehicle or its equipment if the warning is ignored You are informed about what you must or must not do in ord...

Page 4738: ...nt which these systems can provide when used together That is why it is important for you and your family to understand the purpose and proper use of each of these systems and how they relate to each other The purpose of all occupant restraint systems is to help reduce the possibility of death or serious injury in the event of a collision None of these systems either individ ually or together can ...

Page 4739: ...provisions in Section 1 3 carefully and refer to them as needed during your time of ownership of this vehicle Event data recorder Your vehicle has computers that monitor and control cer tain aspects of your vehicle These computers assist in driving and maintaining optimal vehicle performance Be sides storing data useful for troubleshooting there is a system to record data in a crash or a near car ...

Page 4740: ... by the police or other authorities Used as a defense for Toyota in a law suit Ordered by the court However if necessary Toyota will Use the data for research on Toyota vehicle safety performance Disclose the data to a third party for research pur poses without disclosing details of the vehicle owner and only when it is deemed necessary Disclose summarized data cleared of vehicle identifi cation i...

Page 4741: ... Engine exhaust some of its constitu ents and a wide variety of automobile compo nents contain or emit chemicals known to the State of California to cause cancer and birth de fects and other reproductive harm In addition oils fuels and fluids contained in vehicles as well as waste produced by component wear con tain or emit chemicals known to the State of California to cause cancer and birth defec...

Page 4742: ... for any damage they may cause to or adverse effect they may have on your Toyota vehicle This vehicle should not be modified with non genuine Toyota products Modification with non genuine Toyota products could affect its performance safety or durability and may even violate governmental regulations In addi tion damage or performance problems resulting from the modification may not be covered under...

Page 4743: ...stem SRS airbag system Seat belt pretensioner system Anti lock brake system Traction control system AUTO LSD system Vehicle stability control system Cruise control system Tire pressure warning system Tires and loading on your Toyota Underinflated or overinflated tire pressure and the excess load may result in the deterioration of steering ability and braking ability leading to an accident Check th...

Page 4744: ...icle On pavement and off road driving tips This vehicle will handle and maneuver differently from an ordinary passenger car because it is designed for off road use also It has a significantly higher rollover rate than other types of vehicles In addition this vehicle has a higher ground clearance and center of gravity than that of an ordinary passenger car This vehicle design feature causes this ty...

Page 4745: ...U Leak detection pump This pump performs fuel evaporation leakage check This check is done approximately five hours after the engine is turned off So you may hear sound coming from under neath the rear deck for several minutes It does not indi cate a malfunction ...

Page 4746: ... the Certification Label with the heading MODEL See Your Toyota s identification in Section 2 for the Certification Label location Grade D Standard grade S SR5 grade L Limited grade Engine type GSK 1GR FE en gine UCK 2UZ FE engine Driving system 30 31 Two wheel drive 40 41 Four wheel drive Deck type R Standard bed S StepSide bed Cab type T Standard cab A Access cab P Double cab ...

Page 4747: ...pair Manual tells you how to maintain your vehicle and enables you to correctly perform your own maintenance The best way to keep your new vehicle in top running order is to maintain it properly from the moment you drive it off the showroom floor The Toyota authorized Repair Manual is packed with literally everything you need to know to perform your own maintenance in virtually every area of your ...

Page 4748: ...e at 1 800 622 2033 Maintenance procedures for the engine chassis body electrical system and more are clearly explained and illustrated Periodic maintenance and tune up Periodic maintenance and tune up helps to pre vent smallproblems fromgrowing intolarger oneslat er on The repair manual outlines exactly what main tenance is required and clearly explains how to do the work yourself step by step Ar...

Page 4749: ...m Sep 04 Prod OM34432U WE REALLY CARE ABOUT YOU PLEASE BUCKLE UP Toyota has made a special effort to encourage use of seat belts Toyota belts are Comfortable Easy to use Convenient We encourage you to use your belts every time you drive U ...

Page 4750: ...isplay operation 2 Touch switch operation 2 Inputting letters and numbers 3 Current position display 5 Screen scroll operation one touch scroll 5 Map scale 9 Orientation of the map 9 Limitations of the navigation system 10 Map database information and updates 12 SECTION I ...

Page 4751: ...ions the display may react slowly or operation sound may become louder Touch switch operation This system is operated mainly by the switches on the screen To prevent dam age to the screen lightly touch switches on the screen with your finger When you touch a switch on the screen a beep sounds Do not use objects other than your finger to touch the screen INFORMATION If the system does not respond t...

Page 4752: ...etters To input numerals and symbols To display the number keys and symbol keys touch the 0 9 switch Enter numerals and symbols by touching the number keys and symbol keys directly Touching this switch erases one let ter Holding this switch will continue to erase letters Touching this switch displays other symbols To display the list To search for an address or a name touch the List switch Matchin...

Page 4753: ...operation When a list is displayed you can scroll or page through the list by using the appropriate switch To shift to the next or previous page To scroll up or down one item at a time This expresses a displayed screen position If appears to the right of the item name the complete name is too long for the display Touch to scroll to the end of the name Touch to scroll to the beginning of the name ...

Page 4754: ...m If your current position is not correct it is automatically cor rected after your vehicle receives signals from the GPS INFORMATION After the battery disconnection or on a new vehicle the current position may not be correct As soon as the system receives signals from the GPS the correct current position is displayed To correct the current position manu ally see page 77 Screen scroll operation on...

Page 4755: ...vehicle position map location display To set the cursor position as a destina tion You can set a specific point on the map as a destination using the one touch scroll func tion Touch the Enter switch The screen changes and displays the map location of the selected destination and the route preference See Entering destination on page 38 If there is already a preset destination touch the Add to swit...

Page 4756: ... on a POI icon the name and Info switch are displayed on the top of the screen Touch the Info switch Information such as the name address and phone number are displayed If you touch the Enter switch the posi tion of cursor is set as a destination If there is already a preset destination the Add to switch and the Replace switch are displayed When there is already a preset destination using the Add ...

Page 4757: ... switch Information such as the name location and phone number are displayed If you touch the Enter switch the posi tion of cursor is set as a destination If there is already a set destination the Add to switch and the Replace switch are displayed When there is already a preset destination using the Add to switch to set an addi tional destination will set the new one as the first point of arrival ...

Page 4758: ...ange the scale of the map display by touching the scale bar directly It is not available during driving The map scale is displayed under the north up symbol or heading up symbol at the top left of the screen INFORMATION When the map scale is at the maximum range of 250 miles 400 km is not shown When the map scale is at the minimum range of 150 feet 50 m is not shown However in the area where the f...

Page 4759: ... using 3 to 4 satellites The GPS sys tem has a certain level of inaccuracy While the navigation system will compensate for this most of the time occasional positioning errors up to 300 feet 100 m can and should be expected Generally position errors will be corrected within a few seconds When your vehicle is receiving signals from the satellites the GPS mark appears at the top left of the screen Th...

Page 4760: ...n a long route is searched during high speed driving When driving without setting the current position calibration correctly After repeating a change of direction by going forward and backward or turning on a turntable in the parking lot When leaving a covered parking lot or parking garage When a roof carrier is installed When driving with tire chains installed When the tires are worn After replac...

Page 4761: ... or season or other rea son The road and map data stored in your nav igation system may not be complete or may not be the latest version After replacing the tire implement the op eration described in the Tire change calibration For details see page 78 This navigation system uses the tire turning data and is designed to work with factory specified tires for your vehicle Installing tires that are la...

Page 4762: ...e merchantability fitness for a particular purpose or non infringement GDT does not warrant that the DATABASE is or will be error free No oral or written information or advice provided by GDT your supplier or any other person shall create a warranty LIMITATION OF LIABILITY The price of the DATABASE does not include any consideration for assumption of risk of consequential indirect or unlimited dir...

Page 4763: ...censed with limited rights Utilization of the DATABASE is subject to the restrictions specified in the Rights in Technical Data and Computer Database clause at DFARS 252 227 7013 or the equivalent clause for non defense agencies Manufacturer of the DATABASE for North America is Geographic Data Technology Inc at 11 Lafayette Street Lebanon New Hampshire 03766 USA END USER NOTICE PLEASE READ THIS NO...

Page 4764: ... any form for any purpose Without limiting the foregoing you may not use this information with any products systems or applications installed or otherwise connected to or in communication with vehicles capable of vehicle navigation positioning dispatch real time route guidance fleet management or similar applications No Warranty This information is provided to you as is and you agree to use it at ...

Page 4765: ...g out of or in connection with any use or possession by you of this information END USER NOTICE The marks of companies displayed by this product to indicate business locations are the marks of their respective owners The use of such marks in this product does not imply any sponsorship approval or endorsement by such companies of this product There are two types of areas available for route guidanc...

Page 4766: ... and disc coverage area 1 Push the MENU button 2 Touch the Map DVD switch Make sure the version of the database on this screen The database version on the screen above may be different from the actual screen To display the disc coverage area touch the Covered Area switch Confirm the covered area on the screen Contact your dealer to find out if there is a more recent update released ...

Page 4767: ...tment and possi bly injure people in the vehicle during sudden braking or in an accident To reduce the chance of injury in the case of an accident or sudden stop ping while driving keep the display closed Take care not to jam your hand while the display is moving Otherwise you could be injured NOTICE Do not obstruct the display while it is moving It could damage your naviga tion system INFORMATION...

Page 4768: ...y 32 Destination input by Memory 33 Destination input by Previous 34 Destination input by Map 34 Destination input by Intersection 35 Destination input by Freeway Ent Exit 36 Destination input by Coordinates 37 Destination input by Phone 37 Starting route guidance 38 Entering destination 38 Route guidance screen 40 Typical voice guidance prompts 40 Setting and deleting destination 42 Setting and d...

Page 4769: ...matically Set the destination again To select an Address POI Name Freeway Ent Exit Intersection or Phone in a different area it is necessary to change the search area If you enter a destination the road nearest to the point you selected is set as the destination CAUTION While you are driving be sure to obey traffic regulations and keep the road conditions in mind If a traffic sign on the road has ...

Page 4770: ...homa Texas US6 Illinois Indiana Kentucky Michigan Ohio Wisconsin US7 Arkansas Alabama Louisiana Mississippi Tennessee US8 Connecticut Massachusetts Maine New Hampshire New Jersey New York Rhode Island Vermont US9 Washington D C Delaware Maryland New Jersey Pennsylvania Virginia West Virginia US10 Florida Georgia North Carolina South Carolina Canada Switch Provinces and regions included in the sear...

Page 4771: ...switch even while driving Destination input by Quick access Touch any of the quick access switches on the Destination screen The screen changes and displays the map location of the quick access point and the route preference See Entering des tination on page 38 To use this function it is necessary to set the Attribute for each memory point To regis ter the Quick Access see page 70 INFORMATION Guid...

Page 4772: ...e It is possible to input a street name first Touch the Street switch to display the screen for inputting a street name Input the street name When you find your desired street name touch the corresponding switch The screen changes and displays the map location of the selected destination and the route preference See Entering destination on page 38 If the same address exists in more than one city t...

Page 4773: ...hanges You can then input the house num ber If the above screen appears you can select an address range on the screen b Selecting a city to search Touch the City switch To search by city the following three methods are possible 1 Selecting from the last 5 cities 2 Selecting from the nearest 5 cities 3 Inputting the city name INFORMATION To cancel the city setting touch the Any City switch ...

Page 4774: ...current screen changes to the screen for inputting a house number or a street name See page 23 SELECTING FROM THE NEAREST 5 CITIES Touch the Nearest 5 Cities switch Touch the switch of the desired city name from the displayed list The current screen changes to the screen for inputting a house number or a street name See page 23 INPUTTING THE CITY NAME Touch the Input City Name switch Input a city ...

Page 4775: ... number or a street name See page 23 Destination input by POI Name Touch the POI Name switch on the Destination screen Input the name of Point of Interest Touch the switch of the desired destina tion The screen changes and displays the map location of the selected destination and the route preference See Enter ing destination on page 38 If you input the name of a specific Point of In terest and th...

Page 4776: ... See a Selecting a city to search and b Select ing from the categories INFORMATION The desired Point of Interest can be dis played on the map screen For details see page 49 a Selecting a city to search Touch the City switch To search by city the following three methods are possible 1 Selecting from the last 5 cities 2 Selecting from the nearest 5 cities 3 Inputting the city name INFORMATION To can...

Page 4777: ...ING FROM THE NEAREST 5 CITIES Touch the Nearest 5 Cities switch Touch the switch of the desired city name INPUTTING THE CITY NAME Touch the Input City Name switch Input the city name Touch the switch of the desired city name from the displayed list ...

Page 4778: ...led list of the POI category If the desired POI category is not on the screen touch the List All Catego ries switch to list all POI categories When you touch the desired category the POI name list screen appears Destination input by POI Category The destination can be set by selecting the POI category and the search point Touch the POI Category switch on the Destination screen ...

Page 4779: ...r category touch the OK switch to return the previous screen If you wish to select a destination from the category displayed by the icon touch the List switch b Setting a search point It is possible to display the names of POIs lo cated within approximately 20 miles 30 km from the selected search point Touch the Search Point switch To set search points the following four meth ods are possible 1 In...

Page 4780: ...INT Touch the Current Position switch When you touch an arrow facing the desired point the map scrolls in that direction When you release your finger scrolling stops To set the position of the cursor touch the Enter switch SETTING THE SEARCH POINT VIA THE MAP SCREEN Touch the Map switch When you touch an arrow facing the desired point the map scrolls in that direction When you release your finger ...

Page 4781: ...rence See Enter ing destination on page 38 Dist To sort in the order of distance from your current location Icon To sort in the order of the POI icons Name To sort in alphabetical order by name On Route When the indicator is illumi nated by touching this switch the list of the items searched along the route is displayed Destination input by Emergency By touching the Emergency switch on the Destina...

Page 4782: ...unavail able See page 12 Destination input by Memory Touching the Memory switch on the Destination screen displays your list of registered memory points See page 66 for registering and editing memory points When you touch the switch of your de sired memory point the screen changes and displays the map location of the se lected destination and the route prefer ence See Entering destination on page ...

Page 4783: ...the previous destinations in or der of registered date Name To list the previous destinations in alphabetical order INFORMATION You can delete the list of previous des tinations while your vehicle is stopped if you no longer need them See page 91 Destination input by Map Touch the Map switch on the Destina tion screen The screen changes and displays the map location that was previously displayed j...

Page 4784: ... After inputting the two intersecting streets the screen changes and displays the map location of the selected destination and the route preference See Entering destination on page 38 If the same two streets cross at more than one intersection the screen changes and dis plays the menu to select the city name where the streets intersect Select the city and the map location of the selected destinati...

Page 4785: ...8 Select the desired freeway by touching the switch You can then select either a freeway En trance or Exit Touch the switch of the desired entrance or exit name The screen changes and dis plays the map location of the selected des tination and the route preference See Entering destination on page 38 Dist Sort In the order of distance from your current position The distance from your current positi...

Page 4786: ...Phone Touch the Phone switch on the Destination screen Input a telephone number After inputting a telephone number touch the OK switch and the screen changes and displays the map location of the se lected destination and the road prefer ence See Entering destination on page 38 If there is more than one site having the same number the following screen appears INFORMATION If there is no match for th...

Page 4787: ...ion is already set the Add to switch and the Replace switch are displayed Add to To add a destination Replace To delete the existing destina tions and set a new one Change To change the route preference See page 39 Info If this switch is displayed on the top of the screen touch the switch to see name address and phone number etc SCREEN B 3 To start guidance touch the Guide switch 3 Routes To selec...

Page 4788: ...including a freeway in some cases If the calculated route includes a trip by ferry the route guidance shows a sea route After you travel by ferry the current vehicle position may be incorrect Upon reception of GPS sig nals it is automatically corrected 3 ROUTES SELECTION To select the desired route from three routes touch the 3 Routes switch on SCREEN B Touch the Quick1 Quick2 or Short switch to s...

Page 4789: ...he vehicle approaches a guidance point such as an intersection or a freeway the screen automatically divides in two to display the guidance screen For details see page 53 The current street name will be displayed at the bottom of the screen In some areas the roads have not been com pletely digitized in our database yet For this reason the route guidance may guide the road that is not allowed to pa...

Page 4790: ...bout 4 miles to the traf fic circle 2 In a quarter of a mile traffic circle ahead and then 3rd exit ahead 3 The 3rd exit ahead 4 The exit ahead 5 Beep sound only One way road One way road The system indicates a U turn if the dis tance between two one way roads of oppo site directions is less than 50 feet 15 m in residential areas or 164 feet 50 m in non residential areas 1 In half of a mile make a...

Page 4791: ...ine the current vehicle position correctly in cases of poor GPS signal reception the voice guidance may be made ear ly or delayed If you did not hear the voice guidance command touch the MAP VOICE button to hear it again To adjust the voice guidance volume see page 63 Setting and deleting destination a Adding destinations You can add destinations and search again for the routes 1 Touch the Route s...

Page 4792: ...r of the destinations 1 Touch the Route switch 2 Touch the Reorder switch of Des tination 3 Select the destination in the order of arrival by touching the switch of destina tions Reordered number of arrival is displayed on the right side of the screen When you finish selecting the destinations touch the OK switch The system searches for the guidance route again and displays the entire route Even i...

Page 4793: ...message appears to confirm your re quest to delete To delete the destina tion s touch the Yes switch If you touch the Yes switch the data can not be recovered If you touch the No switch the previous screen will return 5 If more than one destination is set touch the OK switch after deleting the destinations The system searches for the guidance route again and displays the en tire route Setting and ...

Page 4794: ...t switch to use another road 5 If more than one destination is set the Add Preferred Road screen appears Touch the Add switch where you wish to add a preferred road b Deleting preferred road You can delete a set preferred road 1 Touch the Route switch 2 Touch the Delete switch of Pre ferred road 3 When more than one preferred road is set a list will appear on the screen Touch the switch of the pre...

Page 4795: ...preferred road is set touch the OK switch after deleting the preferred road The system searches for the guidance route again and displays en tire route c Search condition You can designate the route conditions of the route to the destination 1 Touch the Route switch 2 Touch the Search Condition switch The Search Condition screen appears 3 Touch the Quick Quick1 Quick2 or Short switch and touch the...

Page 4796: ...ng the sys tem returns to the original guidance route Whole Route If you touch this switch the system will calculate an entire new route to the destination This picture shows an example of how the system would guide you around a delay caused by a traffic jam 1 This position indicates the location of a traffic jam caused by road repairs or an accident 2 This route indicates the detour sug gested by...

Page 4797: ...n the indicator on or off by touching the switch When searching for a route the system avoids routes where the indicator is dimmed as much as possible After choosing the conditions touch the OK switch f Starting route from adjacent road You can start the route guidance from the adjacent road ex When the route guidance guides the route on the freeway but you drive on the par allel way along a freew...

Page 4798: ...reen with a limited choice of Points of In terest will be displayed To change the dis played POI see page 90 When you touch the desired Point of Interest category sym bols will appear on the map screen indicating where the POI addresses are located To turn off the symbols of the Points of In terest on the map screen touch the POI Off switch More If you cannot find your desired Point of Interest on...

Page 4799: ... in alphabetical order by name On Route When the indicator is illumi nated by touching this switch the list of the items searched along the route is displayed To set a POI as a destination You can select one of the Points of Interest icons on the map screen as a destination and use it as route guidance Directly touch the Point of Interest icon that you wish to set as a destination The map will shi...

Page 4800: ...n displays the list of the roads up to your destination You can scroll through the list of roads by touching or However not all road names in the route may appear on the list If a road changes its name without requiring a turn such as on a street that runs through two or more cities the name change will not ap pear on the list The street name closest to the starting point will be displayed with a ...

Page 4801: ...e Route Preview switch To indicate the next destination To preview the route to the next des tination To preview the route to the next des tination in fast forward mode To stop the preview To review the route to the previous destination or starting point To review the route to the previous destination or starting point in fast forward mode To indicate the previous destination or starting point ...

Page 4802: ...the conditions it may not be possible to select certain screen configura tion switches To display single map screen See page 53 To display dual map screen See page 54 To display compass mode screen See page 54 To display turn list screen See page 55 To display arrow screen See page 55 To display freeway information screen See page 55 To display intersection guidance screen or guidance screen on fr...

Page 4803: ...p Touch the OK switch when you complete editing The screen returns to the dual map screen c Compass mode Information about the destination and current position as well as a compass is displayed on the screen The destination mark is displayed in the direc tion of the destination When driving refer to the longitude and latitude coordinates and the compass to make sure that your vehicle is headed in ...

Page 4804: ...corner f Freeway information screen This screen displays the distance to the next junction and exit or POIs in the vicinity of the freeway exit Map To display the selected map of the exit vicinity On the left side of the Map switch up to five POIs around the selected exit are dis played To scroll for farther junctions or exits To scroll for closer junctions or exits To scroll for the closest three...

Page 4805: ...e screen disappears and the map screen appears When touching the switch or pushing the MAP VOICE button the intersec tion guidance screen reappears INFORMATION Intersection guidance can be turned on or off See page 85 Guidance screen on freeway This screen automatically appears when the vehicle approaches a junction or exit on a freeway The distance to the junction or exit is shown at the bottom o...

Page 4806: ... to display the follow ing screen 2 Touch the number switch of the des tination you wish to display The distance and the estimated travel time from the current position to the selected des tination are displayed Displayed while driving along the guidance route Displayed while driving off the guidance route The destination direction is indicated by an arrow INFORMATION When the vehicle is on the gu...

Page 4807: ...int map display Touch the switch INFORMATION If the map or the current position is moved to the area which is not cov ered by the foot print map the screen scale automatically changes to 150 feet 50 m On the foot print map a one way street is displayed by It is not possible to perform scrolling on the foot print map one touch scroll while driving To display building information Information is avai...

Page 4808: ...ove the cursor to the position of the building you wish to display information 3 Touch the Building Info switch 4 Details of POIs in some buildings may be displayed If you wish to see detailed POI information touch the building name You can see the detail of the selected POIs ...

Page 4809: ...DESTINATION INPUT AND ROUTE GUIDANCE 60 ...

Page 4810: ...7 Distance unit 79 Estimated travel time 79 Auto reroute 81 Adjusting time zone 81 Auto voice guidance 82 Voice guidance in all modes 83 Notifying traffic restriction 84 Intersection guidance 85 Guidance screen on freeway 86 Street name on scroll map 87 Display of building shape 88 Screen layout function Function 89 POI category change Show POI Icons 90 Delete previous point 91 Map color 92 Screen...

Page 4811: ...tch INFORMATION When you do not have route guidance the Suspend Guidance switch cannot be used The screen will return to the current posi tion map without route guidance To resume guidance You can resume the suspended route guidance Push the MENU button to display the Menu screen and touch the Resume Guidance switch The screen will change to the current posi tion map with route guidance ...

Page 4812: ... green INFORMATION During route guidance the voice guid ance continues even if the navigation screen is changed to other screens Adaptive Volume Control If you turn the Adaptive Volume Control on the volume is turned up automatically when the vehicle speed exceeds 50 mph 80 km h To turn the Adaptive Volume Control system on touch the switch The indicator will be highlighted User selection The syst...

Page 4813: ...er The confirmation screen will appear To register touch the Yes switch To re turn to the previous screen touch the No or Back switch When you touch the switch already regis tered this screen appears To replace touch the Yes switch To cancel the re placement touch the No or Back switch ...

Page 4814: ...button to display the Menu screen Then touch the Select User switch Touch the User number switch you wish to change The above message appears then the map screen will be displayed To delete user Touch the Delete switch of User num ber you wish to delete ...

Page 4815: ...e previous screen touch the No or Back switch My places You can register and keep your own memory points like restaurants sports fa cilities etc and use the memory points to input a destination a Registering memory points 1 Push the MENU button to display the Menu screen and touch the My Places switch ...

Page 4816: ...ed point in the same way as inputting a destination See page 20 When you finish memory point registration the memory point data screen will appear You can set the icon attribute name location and phone number Touch your desired switch you want to set For details see b Editing memory points INFORMATION Up to 106 memory points can be regis tered ...

Page 4817: ...screen lists the memory points Date Touch this switch to list the memory points in order of the registered date Icon Touch this switch to list the memory points in order of the icon type Name Touch this switch to list the memory points in alphabetical order Attribute Touch this switch to list the memory points in order of the home and quick access number Touch the desired memory point switch to di...

Page 4818: ... icons When your vehicle approaches the memory point the sound which you chose will sound Touch the desired sound icon The next screen appears when you touch the Bell with direction switch Touch the direction switches and adjust the direction Touch the Enter switch The bell sounds only when your vehicle ap proaches this point in the direction that you set ...

Page 4819: ... ute of the memory points as Home or Quick access 1 to 5 Touch the desired attribute It is possible to replace a registered attribute To replace the attribute touch the Yes switch To return to the previous screen touch the No or Back switch To delete the attribute touch the Del switch ...

Page 4820: ... completed touch the OK switch on the screen The previous screen will be displayed Show Name You can set the name of a memory point to be displayed or not on the map To show the name touch the On switch Not to show it touch the Off switch To change Location Touch the eight direction switch to move the cursor to the desired point on the map Touch the Enter switch and the previous screen will be dis...

Page 4821: ...oints 1 Push the MENU button to display the Menu screen and touch the My Places switch 2 Touch the Delete switch of the Memory Points 3 Touch the corresponding switch To delete all memory points touch the De lete All switch For efficient memory point search memory points can be sorted by the Date Icon Name or Attribute switch To delete touch the Yes switch To cancel the deletion touch the No switc...

Page 4822: ...he area to avoid a route passing through the area to avoid may be shown a Registering area to avoid 1 Touch the Register switch of the Areas to avoid 2 Enter the location in the same way as inputting a destination or display the map of the area you wish to avoid See page 20 INFORMATION Up to 10 locations can be registered as point area to avoid If there are 10 loca tions already registered the mes...

Page 4823: ...he size of the area to avoid b Editing area to avoid 1 Touch the Edit switch of the Areas to Avoid to display the Edit Area to Avoid screen 2 To edit an area to avoid touch the cor responding switch 3 Touch the Name Location or Area Size switch on this screen ...

Page 4824: ...a name can be set to be dis played or not on the map To show the name touch the On switch Not to show it touch the Off switch To change Location Set the cursor to the desired location then touch the Enter switch The previous screen will be displayed To change Area size Touch either or switch to change the size of area you want to avoid and touch the OK switch The previous screen will be displayed ...

Page 4825: ...h the Setup switch Touch the items you wish to set 3 Touch the OK switch on the screen and then the previous screen will be dis played Default This switch initializes all of the set tings Calibration You can adjust the current ve hicle position mark manually Distance You can select km or miles as the distance unit Estimated Travel Time You can set the system to display the travel time to the des t...

Page 4826: ... the map screen Show POI Icons You can choose 6 icons displayed on Show POI Icons top screen Previous Point You can delete the pre vious destination Map Color Day You can select the de sired map color Map Color Night You can select the de sired map color Screen Animation You can set some screen displays to be animated Current position calibration When driving the current vehicle position mark will...

Page 4827: ...ge calibration function will be used when replacing the tires This func tion will adjust the mis calculation caused by the circumference difference between the old tires and new ones If this proce dure is not performed when tires are re placed the current vehicle position mark may be incorrectly displayed To perform a distance calibration procedure touch the Tire Change switch on the Calibration s...

Page 4828: ...up switch 3 Touch the km or miles switch of Distance to choose the distance unit The selected switch is highlighted in green 4 Touch the OK switch Estimated travel time You can set the speed that is used for the calculation of the estimated travel time 1 Push the MENU button ...

Page 4829: ...you finish setting the desired speeds touch the OK switch INFORMATION The displayed time to the destination is the approximate driving time that is calculated based on the speeds you selected and your actual position along the guidance route The time shown on the screen may vary greatly depending on your prog ress along the route which may be af fected by road conditions such as traffic jams const...

Page 4830: ...lable To turn the Auto Reroute mode on 1 Push the MENU button 2 Touch the Setup switch 3 Touch the On switch of Auto Reroute The selected switch is highlighted in green INFORMATION If your vehicle strays from the guidance route the system searches for a new route to the destination The new route may or may not take you back to the pre vious route depending on how far you are off the original guida...

Page 4831: ...the Setup screen will be displayed Auto voice guidance When the Auto Voice Guidance feature is turned on the voice guidance can be heard automatically When the Auto Voice Guidance feature is turned off the voice guidance can be heard only if you push the MAP VOICE button To turn the Auto Voice Guidance mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch to display page 2 of t...

Page 4832: ...uidance in All Modes feature is turned on you can hear the voice guidance in all modes When the Voice Guidance in All Modes feature is turned off voice guidance can not be heard when you using the audio system To turn the Voice Guidance in All Modes on 1 Push the MENU button 2 Touch the Setup switch Then touch switch to display page 2 of the Setup screen ...

Page 4833: ...h Notifying traffic restriction When the Notify Traffic Restriction fea ture is turned on the system notifies you of traffic or seasonal restriction To turn the Notify Traffic Restriction mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch to display page 2 of the Setup screen ...

Page 4834: ...section guidance When the Intersection Guidance feature is turned on the system will display the in tersection guidance screen if you drive with route guidance To turn the Intersection Guidance mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch to display page 2 of the Setup screen ...

Page 4835: ... freeway When the Guidance Screen on Freeway feature is turned on the system will dis play the lane guidance screen if you drive on a freeway with route guidance To turn the Guidance Screen on Free way mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch to display page 2 of the Setup screen ...

Page 4836: ...croll map When the Street Name on Scroll Map feature is turned on the system will dis play the name of a street where the cursor is positioned on the scroll map To turn the Street Name on Scroll Map mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch twice to display page 3 of the Setup screen ...

Page 4837: ...ape When the Display Building Shape fea ture is turned on the system will display the building shape on the map screen us ing a scale of 150 feet 50 m to 300 feet 100 m To turn the Display Building Shape mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch twice to display page 3 of the Setup screen ...

Page 4838: ...nction You can set display or hide each switch and current street name on the map screen 1 Push the MENU button 2 Touch the Setup switch Then touch switch twice to display page 3 of the Setup screen 3 Touch the Change switch of the Function 4 Touch the switch corresponding to the desired setting Then touch the OK switch ...

Page 4839: ...e Show POI Icons top screen so that you can easily set which icons to display on the map screen 1 Push the MENU button 2 Touch the Setup switch Then touch switch twice to display page 3 of the Setup screen 3 Touch the Change switch of Show POI Icons 4 Touch the category switch you wish to change ...

Page 4840: ...e desired category Then touch the OK switch Delete previous point You can delete your previous destination 1 Push the MENU button 2 Touch the Setup switch Then touch switch twice to display page 3 of the Setup screen 3 Touch the Delete switch of Pre vious Point ...

Page 4841: ... point search pre vious points can be sorted by the Date or Name switch 5 To delete the point touch the Yes switch To cancel the deletion touch the No switch Map color 1 Push the MENU button 2 Touch the Setup switch Then touch switch three times to display page 4 of the Setup screen ...

Page 4842: ...lt map color Screen animation When the Screen Animation feature is turned on some switches and screens be come animated e g change map guid ance on the map screen To turn the Screen Animation mode on 1 Push the MENU button 2 Touch the Setup switch Then touch switch three times to display page 4 of the Setup screen 3 Touch the On switch of Screen Animation and touch the OK switch ...

Page 4843: ...ADVANCED FUNCTIONS 94 ...

Page 4844: ...OTHER FUNCTIONS 95 OTHER FUNCTIONS Other functions Maintenance information 96 Calendar with memo 101 Screen adjustment 108 Screen setting 110 SECTION IV ...

Page 4845: ...comes or the driving distance reaches the Information screen will be displayed This screen will appear every time the system is turned on until you touch the Do not display this mes sage again switch To prevent this information screen from being displayed again touch the Do not dis play this message again switch 1 Push the INFO button to display the Information Menu screen Touch the Maintenance sw...

Page 4846: ...ll To cancel all conditions which have been inputted Reset All To reset the item which has sat isfied a condition Touch the Off switch at the top of the Maintenance screen to turn off the informa tion screen When your vehicle needs to be serviced the icon color will change to orange INFORMATION For scheduled maintenance informa tion please refer to the Scheduled Maintenance Guide or Owner s Manual...

Page 4847: ...eduled maintenance Replace air filter Personal event a Register dealer You can register the dealer name staff location and phone number 1 Touch the Set Dealer switch on the Maintenance screen 2 Enter the location of the dealer in the same way as for destination input See page 20 ...

Page 4848: ...dealer If it is OK touch the Enter switch The screen changes to Edit Dealer screen See b Edit dealer b Edit dealer You can edit the dealer name staff loca tion and phone number 1 Touch the Set Dealer switch on the Maintenance screen The Edit Dealer screen appears 2 To edit touch the corresponding switch ...

Page 4849: ... letters After inputting touch the OK switch at the bottom right of the screen The previous screen will be displayed To edit Location Set the cursor to the desired point and touch the Enter switch on the screen To edit Phone telephone number Touch numeral keys After inputting touch the OK switch The previous screen will be displayed ...

Page 4850: ...er screen The screen changes and displays the map location of the registered dealer and the Route Preference See Entering destination on page 38 Calendar with memo This system informs you of the memo entry At the specified date the memo in formation will be displayed when the navi gation system is in operation The memo information screen will appear every time the system is turned on To disable th...

Page 4851: ...ouch the Calendar switch The current date is circled in yellow If the cur rent date is not displayed on the screen touch the Today switch to display the current month calendar a Inputting a memo 1 Touch the day you want to add a memo 2 To display the Memo screen touch the Add Memo switch ...

Page 4852: ... 24 letters After entering the text touch the OK switch at the bottom right of the screen Location Touch the Location switch to set loca tion A screen similar to the destination input screen appears Input the same way as in putting a destination See page 20 You can add the memos up to 100 until December 31 2022 ...

Page 4853: ...UNCTIONS 104 The date inputted is marked as shown above You can choose the desired mark and or date color Mark color Touch the Mark switch Touch your desired color for the mark Date color Touch the Date switch ...

Page 4854: ... OK switch to display the previous screen b Adding a memo To add a memo touch the corresponding date The Memo screen appears on the dis play Touch the Add Memo switch See page 102 for inputting a memo You can add the memo up to 100 c Deleting a memo Touch the corresponding date Touch the corresponding memo switch and then touch the Delete switch on the screen A message appears on the display To de...

Page 4855: ...TIONS 106 d Editing a memo To edit the memo touch the correspond ing date and then touch the memo you wish to edit Touch the Memo or Location switch e Memo list 1 To list the memos you added touch the List switch ...

Page 4856: ...the number keys After setting the period touch the OK switch The Memo list screen will be dis played You can set a period from January 1 2003 through December 31 2022 for searching To delete and or edit the memo touch the desired memo switch To delete all memos touch the Delete All switch A message appears on the display To delete touch the Yes switch To cancel the deletion touch the No switch ...

Page 4857: ...he Display screen push the DISPLAY button Contrast and brightness adjustment CONTRAST Strengthens the contrast of the screen CONTRAST Weakens the contrast of the screen BRIGHTNESS Brightens the screen BRIGHTNESS Darkens the screen After adjusting the screen touch the OK switch The screen goes off when you touch the SCREEN OFF switch To turn the dis play screen back on push any button such as INFO ...

Page 4858: ...ar OFF The screen turns off when you touch SCREEN OFF To turn the screen back on push any button such as INFO etc The selected screen appears INFORMATION When you do not touch any switch on the screen for 20 seconds the Display screen goes off Depending on the position of the headlight switch the screen changes to the day mode or night mode To display the screen in the day mode even with the headl...

Page 4859: ...t enables au tomatic return to the navigation screen from the audio screen Select ON or OFF and then touch the OK switch ON The navigation screen automatically returns from the audio screen 20 seconds after the end of audio op eration OFF The audio screen remains on b Background color You can select a background color Select the desired background color and then touch the OK switch ...

Page 4860: ...AUDIO SYSTEM 111 AUDIO SYSTEM Audio system Quick reference 112 Using your audio system 113 Audio system operating hints 140 V SECTION V ...

Page 4861: ... tion For details see pages 114 and 116 4 FM button Push this button to choose a FM station For details see pages 114 and 116 5 DISC button Push this button to turn the compact disc player and DVD player on For details see pages 114 121 and 125 6 SCAN button Push this button to scan radio stations or the tracks on discs For details see pages 117 122 and 126 7 OPEN button Push this button to open t...

Page 4862: ...c fea tures of your audio system Some information may not pertain to your system Your audio system works when the ignition switch is in the ACC or ON position NOTICE To prevent the battery from being dis charged do not leave the audio system on longer than necessary when the en gine is not running a Turning the system on and off PWR VOL Push this knob to turn the audio system on and off Turn this ...

Page 4863: ...om pact disc If the another function was pre viously playing it will come on again The switches for radio compact disc play er and DVD player with rear seat enter tainment system operation are displayed on the function switch display screen when the audio control mode is selected Touch them lightly and directly on the screen The selected switch is highlighted in green or yellow INFORMATION If the ...

Page 4864: ... the sound control mode Ad just the tone and balance as follows To adjust the tone touch the or switch on the screen To adjust the bal ance between the front and rear speakers touch the FRONT or REAR switch on the screen and to adjust the balance be tween the left and right touch the L or R switch on the screen BASS Adjusts low pitched tones MID Adjusts mid pitched tones TREB Adjusts high pitched ...

Page 4865: ...ppears on the screen Turn the knob clockwise to step up the sta tion band or counterclockwise to step down Your radio automatically changes to stereo reception when a stereo broadcast is re ceived ST appears on the screen If the signal becomes weak the radio reduces the amount of channel separation to prevent the weak signal from creating noise If the signal becomes extremely weak the radio switch...

Page 4866: ...ons will be searched automatically one after another To scan all the frequencies Touch the SCAN switch on the screen or push the SCAN button briefly SCAN appears on the screen The radio will find the next station and stay there for a few seconds and then scan again To select a station touch the SCAN switch or push the SCAN button again To scan the preset stations Touch the SCAN switch on the scree...

Page 4867: ...tation in the relevant pro gram type If any type program station is not found NOTHING appears on the display MSG MESSAGE switch If the system receives a radio text from RDS station MSG appears on the display Touch the MSG switch and a text message is dis played on the screen In case a text message is not accepted in a screen you can touch the MSG switch and hold it to display the rest of the messa...

Page 4868: ...e compact disc player is be hind the display To insert a compact disc push the OPEN button to lower the display Put the compact disc in the slot with the label side up The player will automatically start when you insert the compact disc At this time CD ap pears on the screen If the label faces down the disc cannot be played In this case CD CHECK appears on the screen CAUTION Do not place anything ...

Page 4869: ...le it is moving It could damage your audio system INFORMATION Under extremely cold conditions the display may react slowly or operation sound may become louder To stop and eject the compact disc push the OPEN button to lower the display Push the DISC button ...

Page 4870: ...ss to a desired track Push either side of the SEEK TRACK but ton and hold it until the desired track number appears on the screen As you release the button the player will start playing the se lected track from the beginning Vehicles with rear entertainment system While the DVD player is in operation the chapter or track can be changed by pushing either side of the SEEK TRACK button Fast forward T...

Page 4871: ...ack to the beginning of the track and play the track again To cancel it touch the switch once again RAND switch Use it for automatic and random selection When the switch is touched the system se lects a track in the disc To cancel it touch the switch once again If a CD TEXT disc is inserted the title of the disc and track will be displayed Up to 29 let ters can be displayed e If the player malfunc...

Page 4872: ... CD text dts CD or DVD au dio only when a disc is loaded in the DVD player Refer to Rear seat entertainment system for details For appropriate discs for this player see Audio system operating hints on page 140 a Inserting the disc 1 Pull up the console box lid while push ing the lock release button 2 Slide the lid backward V ...

Page 4873: ... appear on the screen For appropriate discs for this player see Audio system operating hints on page 140 An adapter must be used for 8 cm 3 in discs which are loaded in the same manner as for 12 cm 4 7 in discs 4 Slide the lid forward to close the DVD player The indicator light turns on while the disc is loaded NOTICE Never try to disassemble or oil any part of the DVD player Do not insert any thi...

Page 4874: ...the console box closed while driving c Playing a disc Push the DISC button if a disc is already loaded in the player DVD appears on the screen If the CD play er is turned on push the DISC button again to switch to the DVD player d Operating an audio CD PLAYING AN AUDIO CD CD text only The disc title and track title will appear on the screen when pushing the DISC button Push the AUDIO button to dis...

Page 4875: ...xt track for 10 seconds then scan again To select a track touch the SCAN switch on the screen or push the SCAN button a second time If the player reaches the end of the disc it will continue scanning at track 1 After all the tracks are scanned in one pass normal play resumes OTHER FUNCTIONS RPT switch Use it for automatic repeat of the track you are currently listening to Touch the switch while th...

Page 4876: ... playback of a disc is completed If an audio CD is playing the first track starts If a DVD video or video CD is playing playback will stop or the menu screen will be displayed The title chapter number and playback time display may not appear while playing back certain DVD video discs CAUTION Conversational speech on some DVDs is recorded at a low volume to empha size the impact of sound effects If...

Page 4877: ...topped and the parking brake is applied the video screen returns DVD video DVD audio DISPLAYING DVD CONTROLS If you touch a part of the screen where con trols are not located while you are watching video DVD controls will appear Second Page Touching this will display on the second page of DVD controls Top Page Touching this will display the top page of DVD controls ...

Page 4878: ...ng this will display the pre determined scene and start playing from there Audio The audio changing screen ap pears See page 132 Sub Title The subtitle changing screen appears See page 131 Angle The angle selection screen ap pears See page 132 Top page of DVD audio controls Top Menu If you touch this switch the menu screen for DVD audio appears For operation refer to the DVD audio disc manual that...

Page 4879: ...evious screen returns DVD video SEARCHING BY TITLE Enter the title number using and 10 and touch Enter The player starts playing video for that title number When you push either side of the SEEK TRACK button you can select a chap ter When you touch Back the previous screen returns DVD audio SEARCHING BY GROUP Enter the group number by using the and switches The selected group number will appear on...

Page 4880: ...ear switch to delete the number Touch the Enter switch on the screen The player starts playing the disc from the se lected bonus group number CHANGING THE STILL PICTURE DVD audio only Touch the Still Prev or Still Next switch on the screen to forward or reverse the still pic tures CHANGING THE SUBTITLE LANGUAGE Each time you touch Sub Title the lan guage is selected from the ones stored in the dis...

Page 4881: ...returns CHANGING THE AUDIO FORMAT DVD audio only Each time you touch Audio another au dio format stored on the disc is selected When you touch Back the previous screen returns CHANGING THE ANGLE The angle can be selected for discs that are multi angle compatible when the angle mark appears on the screen Each time you touch Angle the angle changes When you touch Back and the previous screen returns...

Page 4882: ...an change the subtitle language 1 Touch Subtitle Lang 2 Touch a language you want to read on the Select Subtitle Lang screen If you cannot find the language you want to read on this screen touch Others and enter a language code For the entry of language code see the following ENTER LANGUAGE CODE To return to the Setup Menu 1 screen touch the Back switch DVD language You can change the language on ...

Page 4883: ...rom wide mode to auto mode ENTER LANGUAGE CODE If you touch Others on the Select Audio Lang screen Select Subtitle Lang screen or Select DVD language screen you can select the language you want to hear or read by entering a language code 1 Enter the 4 digit language code If you enter the wrong numbers touch Clear to delete the numbers 2 Touch Enter Code Language 1001 Japanese 0514 English 0618 Fre...

Page 4884: ...Hindi 0818 Croatian 0821 Hungarian 0825 Armenian 0901 Interlingua 0905 Interlingue 0911 Inupiak 0914 Indonesian 0919 Icelandic 0923 Hebrew 1009 Yiddish 1023 Javanese 1101 Georgian 1111 Kazakh 1112 Greenlandic 1113 Cambodian 1114 Kannada 1119 Kashmiri 1121 Kurdish 1125 Kirghiz 1201 Latin 1214 Lingala 1215 Laothian 1220 Lithuanian 1222 Latvian 1307 Malagasy 1309 Maori 1311 Macedonian 1312 Malayalam ...

Page 4885: ...n 1909 Sinhalese 1911 Slovak 1912 Slovenian 1913 Samoan 1914 Shona 1915 Somali 1917 Albanian 1918 Serbian 1919 Siswati 1920 Sesotho 1921 Sundanese 1923 Swahili 2001 Tamil 2005 Telugu 2007 Tajik 2008 Thai 2009 Tigrinya 2011 Turkmen 2012 Tagalog 2014 Setswana 2015 Tonga 2018 Turkish 2019 Tsonga 2020 Tatar 2023 Twi 2111 Ukrainian 2118 Urdu 2126 Uzbek 2209 Vietnamese 2215 Volapük 2315 Wolof 2408 Xhosa...

Page 4886: ...itches from the display If appears on the display when you touch the switch the operation is not permitted DESCRIPTION OF EACH SWITCH Switches on top page Sel Number switch The track or number search screen appears See SEARCHING BY TRACK on page 138 D Menu Prev switch When you touch this switch while the disc menu is displayed the previous page appears on the screen If you touch this switch while ...

Page 4887: ...is not play able is inserted DISC CHECK will also ap pear on the screen For appropriate discs for this player see Audio system operating hints on page 140 If REGION CODE ERROR appears on the display It indicates that the DVD region code is not set properly If DVD ERROR appears on the display It indicates that the inside of the player unit may be too hot due to the very high ambient temperature Rem...

Page 4888: ...ideo disc Some DVD video discs cannot be played at all or violent scenes are skipped or replaced with other scenes Level 1 DVD video discs for children can be played Level 2 7 DVD video discs for children and G rated movie can be played Level 8 All types of the DVD video discs can be played Multi angle feature You can enjoy the same scene at different angles Multi language feature You can select a...

Page 4889: ...ON Usually a problem with radio reception does not mean there is a problem with your radio it is just the normal result of conditions outside the vehicle For example nearby buildings and terrain can interfere with FM reception Power lines or telephone wires can interfere with AM sig nals And of course radio signals have a lim ited range The farther you are from a station the weaker its signal will...

Page 4890: ... electrical mo tors This results in static CARING FOR YOUR COMPACT DISC PLAYER DVD PLAYER AND DISCS Your compact disc player is intended for use with 12 cm 4 7 in discs only Extremely high temperatures can keep your compact disc player and DVD player from working On hot days use the air conditioning to cool the vehicle interior be fore you use the players Bumpy roads or other vibrations may make y...

Page 4891: ...y discs marked as shown above The following products may not be play able on your DVD player SACD Copy protected CD CD R CD Recordable CD R W CD Re writable CD ROM DVD R DVD R DVD R W DVD RW DVD ROM DVD RAM Special shaped discs Transparent translucent discs Low quality discs Labeled discs ...

Page 4892: ...arly on the shiny side Dirt scratches warping pin holes or oth er disc damage could cause the player to skip or to repeat a section of a track To see a pin hole hold the disc up to the light Remove discs from the players when you are not using them Store them in their plastic cases away from moisture heat and direct sunlight To clean a compact disc Wipe it with a soft lint free cloth that has been...

Page 4893: ...AUDIO SYSTEM 144 ...

Page 4894: ...ngested Your own personal local knowledge or short cut may at times be faster than the calcu lated routes The navigation system s database includes about 75 Point of Interest categories to allow you to easily select destinations such as restaurants and banks If a destination is not in the database you can enter the street address or a major intersection close to it and the system will guide you th...

Page 4895: ...t or must not do in order to avoid or reduce the risk of damage to your vehicle and its equipment INFORMATION This provides additional information Initial screen When you start the engine or turn the ignition switch to the ACC position the initial screen appears and the system begins operating CAUTION When the vehicle is stopped with the engine running always apply the park ing brake for safety Af...

Page 4896: ...nd become thoroughly familiar with it Read the entire Navigation System Owner s Manual to make sure you under stand the system Do not allow others to use this system until they have read and under stood the instructions in this manual For your safety some functions may become inoperable when you start driving Unavail able switches are dimmed You can input your destination and select your route onl...

Page 4897: ...restrictions no left turns street closures etc frequently change Therefore before you follow any instruction from the system look to see whether you can comply with the instruction safely and legally This system cannot warn you about such things as the safety of an area condition of streets and availability of emergency servi ces If you are unsure about the safety of an area do not drive into it U...

Page 4898: ...v ...

Page 4899: ...ale 9 3 INFO button Push this button to display the Information Menu screen ii 96 101 110 4 Zoom out switch Touch this switch to reduce the map scale 9 5 Mark switch Touch this switch to register the cursor posi tion as a memory point 6 6 Route switch Touch this switch to change the route 42 44 7 DISPLAY button Push this button to display the Display screen 108 Your navigation system Quick referen...

Page 4900: ...y the foot print map and the building information 58 12 MAP VOICE button Push this button to repeat a voice guidance cancel one touch scroll start guidance and display the current position 5 6 42 13 DEST button Push this button to display the Destination screen x 20 14 Screen configuration switch Touch this switch to change the screen mode 53 15 MENU button Push this button to display the Menu scr...

Page 4901: ... 3 POI Category switch You can select a destination from the POI category 29 4 Previous switch You can select a destination from any of the last 99 previously set destinations and from the previous starting point 34 5 Memory switch You can select the location from those regis tered as the Memory points To register memory points see page 66 33 6 Emergency switch You can select one of the three cate...

Page 4902: ... can enter a destination by the telephone number 37 11 Coordinates switch You can set a destination using latitude and longitude coordinates 37 12 Quick access switch You can select one of 5 preset destinations directly To use this function it is necessary to set the Attribute for each memory point To register the Quick Access see page 70 22 13 Home switch You can select your own home without en t...

Page 4903: ...ch Enables recall of up to three memorized user setting patterns 63 3 Setup switch Enables various settings for the navigation system 76 4 My Places switch Enables changes to Memory points and Areas to avoid 66 5 Suspend Guidance and Resume Guidance switch Suspends or resumes the guidance 62 6 Volume switch Sets the volume of the voice guidance 63 Menu screen ...

Page 4904: ... can be confident of the quality that is going on your vehicle as well as the qualifications of the person under the hood Documenting Your Investment To help you verify that you ve invested in proper maintenance each mainte nance checklist includes space for your Toyota dealership to certify that you obtained Genuine Toyota Service for your vehicle The dealership will mark the dealer service verif...

Page 4905: ...aintenance Providers Maintenance and repair services may be performed by you or by any automotive service provider you choose Toyota will not deny a warranty claim solely because you used a service provider other than a Toyota dealership for maintenance and repairs However damage or failures caused by improper maintenance or repairs are not covered under warranty Dealer Recommended Maintenance You...

Page 4906: ...ormation for your vehicle is also available at www toyota com From the site s home page select the Owners link then select Service Maintenance This will bring you to the screen shown below where you will select your vehicle s model name year and current mileage time interval After you click Submit you ll be able to view your vehicle s recommended mainte nance for that interval Online Information 2...

Page 4907: ...Vehicle Identification 2 Model In service date Selling dealership Key number Body style Mileage at delivery Selling dealership phone number Vehicle Identification Number ...

Page 4908: ...aintenance when recommended If you are a low mileage driver mark your calendar to remind yourself to obtain maintenance every six months Special Operating Conditions In addition to standard maintenance items the maintenance log indicates services that should be performed on vehicles that are driven under especially demanding conditions These special operating conditions and their required maintena...

Page 4909: ...ts on chassis Driving while towing Tighten nuts and bolts on chassis 10 000 Miles or 12 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive shaft boots Inspect engine air fi...

Page 4910: ...s __ Drive shaft boots __ Engine coolant3 __ Exhaust pipes and mountings Note Driving in heavy traffic on dirt roads or in urban dusty or desert areas may shorten the life of the cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur A...

Page 4911: ...rolla Matrix Tighten nuts and bolts on chassis Driving while towing Tighten nuts and bolts on chassis 25 000 Miles or 30 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive ...

Page 4912: ...gs ECHO 3 Tighten drive shaft bolt Corolla and Corolla Matrix Inspect the following __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings drums and brake pads discs4 __ Differential oil5 __ Drive shaft boots __ Engine coolant6 __ Exhaust pipes and mountings __ Fuel lines and connections fuel tank band and fuel tank vapor vent system hoses Additional Maintenance Items for Special...

Page 4913: ...ing Tighten nuts and bolts on chassis 40 000 Miles or 48 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Replace cabin air filter Corolla and Corolla Matrix if equipped Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive ...

Page 4914: ...s __ Drive shaft boots __ Engine coolant3 __ Exhaust pipes and mountings Note Driving in heavy traffic on dirt roads or in urban dusty or desert areas may shorten the life of the cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur A...

Page 4915: ...ts on chassis Driving while towing Tighten nuts and bolts on chassis 55 000 Miles or 66 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive shaft boots Inspect engine air fi...

Page 4916: ...uipped Replace engine air filter Replace spark plugs ECHO 3 Tighten drive shaft bolt Corolla and Corolla Matrix Inspect the following __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings drums and brake pads discs4 __ Differential oil5 __ Drive belts6 __ Drive shaft boots __ Engine coolant7 __ Engine valve clearance __ Exhaust pipes and mountings Additional Maintenance Items fo...

Page 4917: ...ts on chassis Driving while towing Tighten nuts and bolts on chassis 70 000 Miles or 84 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive shaft boots Inspect engine air fi...

Page 4918: ...ve belts __ Drive shaft boots __ Engine coolant3 Note Driving in heavy traffic on dirt roads or in urban dusty or desert areas may shorten the life of the cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur Additional Maintenance It...

Page 4919: ...olla Matrix Tighten nuts and bolts on chassis Driving while towing Tighten nuts and bolts on chassis 85 000 Miles or 102 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Inspect drive ...

Page 4920: ...lt Camry with 1MZ FE or 3MZ FE Camry Solara with 3MZ FE Sienna Tighten drive shaft bolt Corolla and Corolla Matrix Inspect the following __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings drums and brake pads discs4 __ Differential oil5 __ Drive belts __ Drive shaft boots __ Engine coolant6 __ Exhaust pipes and mountings Additional Maintenance Items for Special Operating Cond...

Page 4921: ...uts and bolts on chassis 100 000 Miles or 120 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Replace cabin air filter Corolla and Corolla Matrix if equipped Replace engine coolant3 Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers I...

Page 4922: ...llowing __ Ball joints and dust covers __ Brake lines and hoses __ Drive belts __ Drive shaft boots __ Engine coolant4 Note Driving in heavy traffic on dirt roads or in urban dusty or desert areas may shorten the life of the cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult ...

Page 4923: ...ts on chassis Driving while towing Tighten nuts and bolts on chassis Dealer Service Verification Date Mileage 115 000 Miles or 138 Months Replace engine oil and oil filter1 Rotate tires except MR2 Spyder Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect ball joints and dust covers Insp...

Page 4924: ...r Replace cabin air filter if equipped Replace engine air filter Replace spark plugs3 Tighten drive shaft bolt Corolla and Corolla Matrix Inspect the following __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings drums and brake pads discs4 __ Differential oil5 __ Drive belts __ Drive shaft boots __ Engine coolant6 __ Engine valve clearance __ Exhaust pipes and mountings Additi...

Page 4925: ...ft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 10 000 Miles or 12 Months Replace engine oil and oil filter1 Rotate tires Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Ope...

Page 4926: ...r filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect engine air filter Tighten nuts and bolts on chassis Driving while towing Replace f...

Page 4927: ...d bolts on chassis Driving on salted roads Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 25 000 Miles or 30 Months Replace engine oil and oil filter1 Rotate tires Visually inspect brake linings drums...

Page 4928: ...cs7 __ Drive shaft boots3 __ Engine coolant8 __ Exhaust pipes and mountings __ Front differential oil 4WD models Highlander and RAV4 __ Fuel lines and connections fuel tank band and fuel tank vapor vent system hoses Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Tighten nuts and bolts on chassis Driving while towing Replace front differential oil ...

Page 4929: ...aft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 40 000 Miles or 48 Months Replace engine oil and oil filter1 Rotate tires Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Op...

Page 4930: ...r filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect engine air filter Tighten nuts and bolts on chassis Driving while towing Replace f...

Page 4931: ...er shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis Driving on salted roads Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 55 000 Miles or 66 Months Replace engine oi...

Page 4932: ...ms and brake pads discs7 __ Charcoal canister8 __ Drive belts9 __ Drive shaft boots3 __ Engine coolant10 __ Engine valve clearance except Tacoma with 2TR FE __ Front differential oil 4WD models Highlander RAV4 Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Tighten nuts and bolts on chassis Driving while towing Replace automatic transmission fluid ...

Page 4933: ...aft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 70 000 Miles or 84 Months Replace engine oil and oil filter1 Rotate tires Visually inspect brake linings drums and brake pads discs Additional Maintenance Items for Special Op...

Page 4934: ...cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect engine air filter Tighten nuts and bolts on chassis Driving while towing R...

Page 4935: ...ve shaft bolt 4WD RAV4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis Driving on salted roads Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 85 ...

Page 4936: ... and RAV4 Inspect the following __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings drums and brake pads discs8 __ Drive belts __ Drive shaft boots3 __ Engine coolant9 __ Exhaust pipes and mountings __ Front differential oil 4WD models Highlander and RAV4 Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt...

Page 4937: ...bricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 100 000 Miles or 120 Months Replace engine oil and oil filter1 Rotate tires Replace engine coolant5 Visually inspect brake linings drums and brake pads dis...

Page 4938: ...rt areas may shorten the life of the cabin air filter Replacement may be needed if you notice reduced air flow from the air conditioner and heater or if the windows fog easily when you use the Fresh mode Consult your dealer if any of these conditions occur Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Inspect engine air filter Tighten nuts and bo...

Page 4939: ...d bolts on chassis Driving on salted roads Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Driving while towing Lubricate propeller shaft4 Re torque propeller shaft bolt all models except Highlander and RAV4 Tighten nuts and bolts on chassis 115 000 Miles or 138 Months Replace engine oil and oil filter1 Rotate tires Visually inspect brake linings dru...

Page 4940: ...ke pads discs7 __ Charcoal canister8 __ Drive belts __ Drive shaft boots3 __ Engine coolant9 __ Engine valve clearance except Tacoma with 2TR FE __ Front differential oil 4WD models Highlander RAV4 Additional Maintenance Items for Special Operating Conditions2 Driving in desert or on dirt roads Tighten nuts and bolts on chassis Driving while towing Replace automatic transmission fluid Replace fron...

Page 4941: ...and damage Check all dust covers for deterioration and damage Replace any deteriorated or damaged parts A qualified technician should perform these operations Brake Lines and Hoses Visually inspect for proper installation Check for chafing cracks deterioration and signs of leakage Replace any deteriorated or damaged parts A qualified technician should perform these operations Brake Linings Drums a...

Page 4942: ...and refill with an ethylene glycol type coolant Inspect the radiator condenser and or intercooler for leaves dirt and insects and clean if necessary Inspect hoses and connections for corrosion and leaks Tighten connections and replace parts as necessary A qualified technician should perform these operations For further details refer to Radiator Condenser and Hoses in the Vehicle Maintenance and Ca...

Page 4943: ...or cracks deterioration and damage and replace if necessary Nuts and Bolts on Chassis and Body Re tighten the seat mounting bolts and front rear suspension member retaining bolts to specified torque Propeller Shaft Lubricate the propeller shaft spiders and slide yokes with lithium base chassis grease and the double cardan joint with molybdenum disulfide lithium base chassis grease and re torque th...

Page 4944: ... Rotation Tires should be rotated at specified intervals according to the instructions in the Owner s Manual When rotating tires check for damage and uneven wear Replace if necessary Transfer Case Oil Inspect or replace at specified intervals When performing inspections check for signs of leakage If you discover any leakage have it repaired by a qualified tech nician immediately Wheel Bearing and ...

Page 4945: ...Notes 40 ...

Page 4946: ...Notes 41 ...

Page 4947: ...Notes 42 ...

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Toyota 2006 Tundra, Service - Repair - Maintenance

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