ELECTRICAL
EL006-06

Title
BACK DOOR FUNCTIONS

Models
'03 - '05 4Runner

May 23, 2006

Introduction

Some 2003 - 2005 model year 4Runner vehicles may experience a condition where certain back door functions (auto power window, etc.) are inoperative. A new back door ECU has been developed to address this condition.

Applicable Vehicles

^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Parts Information







Warranty Information

Applicable Warranty**:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

**Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Required SSTs

Repair Procedure







1. Remove the back door trim board.

A. Remove the assist strap hole cover.

B. Remove the screw and assist strap.

C. Using the plastic pry tool, remove the 10 clips and the back door trim cover.

D. Remove the inner weatherstrip.









2. Remove and replace the back door ECU.

3. Install the back door trim board.

A. Install the inner weatherstrip.

B. Clip into place the back door trim cover.

C. Install the assist strap and hole cover.









4. Re-initialize the power back window.

A. Turn ignition switch to the ~ON" position.

B. Push the back door power window switch to the "DOWN" side to open the window.

C. Push and hold the back door power window switch to the "UP" side until the window closes. Continue holding it for approximately 1 second.

D. Check for proper operation of the "one-touch open/close" functions by pushing the switch briefly to the "DOWN" and "UP" position.


NOTE :Jam protection function becomes effective through the above initialization procedure.

5. Verify proper operation of all back door functions.

ENGINE
EG029-06

May 1, 2006

Title:
"NO START" IN SUB-FREEZING AMBIENT AIR TEMPERATURES

Models:
'03 - '05 4Runner (1GR-FE)

TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. EG043-05. TSB No. EG043-05 is now obsolete.

Introduction

Some customers may experience a "no start" condition and/or M.I.L. "ON" with DTCs P0300, P0171, and P0174 after the vehicle has cold soaked in sub-freezing ambient air temperatures. To correct this condition a new fuel pump sub-tank assembly is now available. Follow the repair procedure to replace the fuel pump sub-tank assembly.

Applicable Vehicles:^ 2003 - 2005 model year 4Runner vehicles equipped with the 1GR-FE engine produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Parts Information







Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. For California specification vehicles sold, registered, and operated in California, Maine, Massachusetts, and Vermont, this repair is covered under the California Emission Warranty, which is 36 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Required Tools & Material







Required SSTs

NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335.

Repair Procedure

If the customer experiences a "no start" and/or M.I.L. "ON" condition with DTCs P0300, P0171, and P0174 after a cold soak in sub-freezing ambient air temperatures, replace the fuel pump sub-tank assembly.

Refer to the Technical Information System (TIS), 2003 - 2005 model year 4Runner Repair Manual:

^ Fuel: Fuel Tank Assy (1GR-FE): Removal & Installation And Disassembly & Reassembly

^ Fuel: Fuel Pump Assy (1GR-FE): Removal & Installation And Disassembly & Reassembly

ENGINE
EG043-05
REVISED

September 28, 2005

Title:
"NO START" IN SUB-FREEZING AMBIENT AIR TEMPERATURES

Models:
Applicable 4Runner, Highlander, Sequoia, Sienna, Tacoma, & Tundra

TSB REVISION NOTICE:
May 1, 2006: This TSB no longer applies to 2003 - 2005 model year 4Runner, and 2005 model year Sequoia and Tundra vehicles. For 4Runner see TSB No. EG028-06 or EG029-06, for Sequoia and Tundra see TSB No. EG030-06. Previous versions of this TSB should be discarded.

Introduction

Some customers may experience a "no start" condition and/or M.I.L. "ON" with DTCs P0300, P0171, and P0174 after the vehicle has cold soaked in sub-freezing ambient air temperatures. To correct this condition a new fuel pump sub-tank assembly is now available. Follow the repair procedure to replace the fuel pump sub-tank assembly.

Applicable Vehicles^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown in this TSB.

^ 2004 - 2005 model year Highlander and Sienna vehicles produced BEFORE the Production Change Effective VINs shown in this TSB.

^ 2005 model year Sequoia, Tacoma, and Tundra vehicles produced BEFORE the Production Change Effective VINs shown in this TSB.








Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. For California specification vehicles sold, registered, and operated in California, Maine, Massachusetts, and Vermont, this repair is covered under the California Emission Warranty, which is 36 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Production Change Information







Parts Information







Required Tools & Material







Required SSTs

NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335.

Repair Procedure







If the customer experiences a "no start" and/or M.I.L. "ON" condition with DTCs P0300, P0171, and P0174 after a cold soak in sub-freezing ambient air temperatures, refer to the following sections in the Toyota Technical Information System (TIS) to replace the fuel pump sub-tank assembly.

BODY
BO017-03
REVISED

Title:
TRIM GARNISH LOOSE

Models:
'91 - '07 All Models

September 9, 2003

TSB REVISION NOTICE :

^ April 24, 2006: Model year applicability has been defined to 1991 - 2007.
The Inspection/Replacement Procedure has been updated with parts information for applicable model year Avalon, Camry, and Solara vehicles.

^ March 3, 2004: The TSB has been changed to include new inspection and replacement instructions.


Previous versions of this TSB should be discarded.

Introduction

Customers may experience an interior trim panel either loose or fitting poorly due to a deformed or missing panel attachment clips. When a trim garnish (A, B, C, or D pillar garnish, door trim panel, etc.) is removed and reinstalled using the old clips, there is a possibility that the garnish may exhibit a loose condition. To prevent this condition from occurring, please use the following procedures.

Applicable Vehicles

1991 - 2007 model year Toyota vehicles.







Warranty Information

Inspection/Replacement Procedure

All Models:

All trim panel attachment clips must be inspected prior to reassembly and replaced if any damage or wear is detected. If NO damage is visible, the clip may be reused. Always check to make sure that the garnish is properly attached after reinstallation of all interior trim panels.







2005 - 2006 model year Avalon, 2002 - 2007 model year Camry, and 2004 - 2006 model year Solara:

When removing the A-pillar garnish panels, replace the plastic attachment clips. Refer to the table below for appropriate part numbers.

BRAKES
BR004-06

March 17, 2006

Title:
INCONSISTENT OR UNUSUAL BRAKE FEELING

Models:
'03 - '05 4Runner

Introduction







Some customers may experience a slightly lower brake pedal feel intermittently. A new brake pad anti-squeal shim service part has been developed to address this concern.

Applicable Vehicles^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs in this TSB.








Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Production Change Information







Parts Information

Repair Procedure

1. Remove the front wheels.

2. Remove the front disc brake anti-rattle pins.

3. Remove the front disc brake pads.








4. Remove the anti-squeal shims.

5. Install the NEW anti-squeal shims.

NOTE: There should be NO oil or grease on the friction surfaces of the brake pads and the front disc.

6. Install the front disc brake pad with shims.








7. Install the front disc brake anti-rattle pins.

NOTE: When installing the pin hole clip, be sure to install the pin hole clip with the handle facing to the vehicle center.

8. Check the fluid level in the reservoir.

9. Check for any brake fluid leakage.

10. Install the front wheels.

Torque: 112 N.m (1142 kgf.cm, 83 ft.-lbf)

ELECTRICAL
EL006-05
REVISED

April 18, 2005

Title:
CHARGE WARNING LIGHT "ON"

Models:
'03 - '05 4Runner (V6)

TSB REVISION NOTICE:^ January 31, 2006: T1 and T2 codes have been updated in Warranty Information. Previous versions of this TSB should be discarded.


Introduction







A limited number of customers that drive in areas where road salt is used during the winter may notice an illuminated charge warning light. Vehicles driven in these conditions may be affected by salt water residue getting inside the alternator. Performing the following repair will correct a "no charging" condition that may result.

Applicable Vehicles^ 2003 - 2005 model year 4Runner vehicles equipped with the 1GR-FE V6 engine produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Parts Information

Repair Procedure







1. Remove and replace the alternator with the updated part.








2. Remove and replace the oil baffle plate (found on the driver's side bolted to the engine intake brace) with the updated part.








3. Apply the foam strip to the engine cover as shown.

NOTE: Throughly clean the engine cover mounting surface before application

BODY
BO022-04
REVISED

Title:
SEAT BELT EXTENDER

Models:
'03 - '05 Toyota & '04 - '05 Scion

December 9, 2004

TSB REVISION NOTICE :^ December 9, 2005: Series QSS has been updated to R-7. In the "Rear Seat Belt Extender Applications" section, series Q-4 for the 2005 model year Sequoia and Tundra has been updated to Q-5, and the Tundra D-Cab has been added.
Previous versions of this TSB should be discarded.

Introduction







Toyota and Scion customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer.

^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths.

^ The extender is available only in black.

^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle.


The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place an order through Dealer Daily.

The dealership service department should complete the affixed Seat Belt Extender Customer Information Label on the part and review the Owner Instructions" with the customer. The dealership should give a copy of the completed worksheet and Owner Instructions to the customer and keep the originals in the customer's file.

To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue.

It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers.

This bulletin contains the following information:

Procedure and Sample Label

Application Charts

Part Number Information

Owner Instructions







Seat Belt Extender Worksheet

Applicable Vehicles

^ 2003 - 2005 model year Toyota vehicles.

^ 2004 - 2005 model year Scion vehicles.








Warranty Information

Procedure

1. Customer requests a Seat Belt Extender from dealer.

2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet.

3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places an order for the part through Dealer Daily.

4. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part.

5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet.








6. Dealer places copy of the completed Worksheet in the customer's records.








Sample Seat Belt Extender Customer Information Label







Sienna Front Seat Belt Extender Applications







Sienna Rear Seat Belt Extender Applications







Front Seat Belt Extender Applications







Rear Seat Belt Extender Applications







Part Number Information

Owner Instructions

Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury.

If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge.

Please visit your local Toyota dealer so that the dealer can order the proper required length extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer.

When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use.

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are both facing outward as shown.

You will hear a click when the tab locks into the buckle.

When not in use, remove the extender and store in the vehicle for future use.

CAUTION :On vehicles equipped with SRS - Occupant Classification System (OCS)*, it is critical that the extender tab be buckled into the buckle AFTER the occupant sits down in the seat.

Leaving extender installed in the buckle before sitting down will cause the OCS to be in the "airbag off" or disarmed state.

* OCS will enable or disable the passenger front and side airbags based on passenger weight and seat belt latch position classifying the passenger as a child or adult.

CAUTION :When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury.

^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.

^ The Seat Belt Extender must never be used with any child safety seats.

^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for.

NOTE: This bulletin has three sub bulletins.

Body - Sunroof Components and Service Procedures
Information
Body - Sunroof Components and Service Procedures
Repair Procedure: Removal
Repair Procedure: Reassembly

#1
BODY
BO001-05
REVISED

Title:
MOON ROOF REPLACEMENT PARTS

Models:
'03 - '05 4Runner

January 12, 2005

TSB REVISION NOTICE :

^ November 30, 2005: The note in step 9 of the "Repair Procedure: Removal" section has been updated. In the "Repair Procedure: Reassembly" section, the illustration in step 19 has been clarified, and a note has been added to step 20.


Previous versions of this TSB should be discarded.

Introduction

A complete moon roof (sliding roof) assembly is no longer available as a service part. The moon roof (sliding roof) assembly has been separated into three serviceable parts. This bulletin provides information on the three serviceable parts and replacement procedures.

Applicable Vehicles

2003 - 2005 model year 4Runner vehicles.







Parts Information







Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Components


#2
Moon Roof (Sliding Roof) Housing Sub-assembly

Refer to the Technical Information System (TIS), 2003 to 2005 model year 4Runner

Repair Manual for moon roof housing sub-assembly removal and installation procedures:

Sliding Roof/convertible: Sliding Roof: Replacement

1. Remove roof headlining assembly. Please refer to TIS, applicable model year 4Runner Repair Manual: Exterior/Interior Trim: Headlining Assy: Replacement.

2. Remove sliding roof guide rail cover LH.

Using a taped screwdriver, pry out the rail cover.

3. Remove sliding roof guide rail cover LH.

4. Remove sliding roof guide rail cover RH.

5. Remove sliding roof side garnish LH.

6. Remove sliding roof side garnish RH.








7. Remove sliding roof glass sub-assembly.

A. Using a Torx wrench (T25), remove the 4 screws.

B. Pull the glass upward to remove it.









8. Remove sliding roof
housing sub-assembly.

A. Disconnect the 4 drain hoses from the housing.

B. Remove the 8 bolts and 4 brackets.

C. Remove the 6 nuts and housing sub-assembly.


9. Remove white end caps from the rear of the housing assembly.

NOTE :

^ Make sure NOT to lose or damage the foam tape on the end caps. This tape is used to prevent waterleaks. Also, make note of the correct position of the end cap to aid in reassembly.









10. Remove rear drip bar.








11. While holding slide, move cable shoe rearwards to end of travel. Then push slide rearwards approximately 6 inches.








12. Remove wind deflector retaining clip (both sides).

Push down on tab, pull up on rear.

NOTE :To prevent breakage of the guide block release lever when the outside temperature is below 40°F (4°C), use a heat gun to raise the temperature of the guide block and surrounding aluminum housing to a temperature of at least 65°F (18°C). Be careful NOT to damage components or paint with the heat gun.








13. Remove wind deflector.








14. Move slides to most forward position and then while holding slides, move cable shoes forward so roof is in full tilt-up position.








NOTE :Keep slide tab in the middle of the cut-out in the moon roof assembly for ease.







15. Move front of slide bracket rearwards until Phillips screws are exposed 2 screws on each side.








16. Remove the 2 Phillips screws from each side.












17. Remove front drip pan/drip rail. Unhook cable overflow housings from frame. Pull up on frame to remove drip rail. Cables will slide out of housings.








18. Release wind deflector actuator rod from front clip.

19. Remove front wind deflector actuator clip.








20. Grab shoe and push it out the front of the moon roof housing.








21. Remove actuator rod clips (both sides).








22. Remove actuator rod (both sides).








23. Remove garnish slide (both sides).








24. Remove end plug (both sides).

#3

NOTE uring reassembly, lubricate all moving components and track with Body Grease W.







1. Install end plugs.

2. Install garnish slides.

3. Install actuator rods.








4. Install actuator rod clips.

NOTE :Make sure actuator rod and actuator rod clips are fully seated.












5. Slide bracket assembly and cable assembly into front of housing.

NOTE :Sliding bracket assembly and cable assembly must be installed at the same time.








6. Push back far enough to allow access to the screw holes. Brackets should be in the full tilt-up position.








7. Reinstall wind deflector actuator shoe.

8. Slide actuator rod into shoe.

NOTE :Make sure rod is fully seated.








9. Slide cables into metal cable housing.

NOTE :Make sure metal cable housing clips into frame sub-assembly before attaching drip rail.

10. Install front drip rail.








11. Install 2 Phillips screws on each side.








12. Align tab in the cut-out in the housing assembly.








13. While holding slide, move cable shoe rearwards to end of travel.

14. Push the front of the sliding bracket back to clear the front wind deflector shoe.

15. If previously removed, install wind deflector springs onto wind deflector.

16. Install wind deflector and wind deflector clips.

NOTE :Install front tab first, then slide back and snap into position.








17. Holding wind deflector down, move cable shoe forward to timing marks.

18. Install rear drip bar.








19. Install white end caps onto rear of housing assembly.

20. Install moon roof housing sub-assembly into vehicle.

Refer to TIS, 2003 to 2005 model year 4Runner Repair Manual for moon roof housing sub-assembly removal and installation procedures: Sliding Roof/convertible: Sliding Roof: Replacement.


NOTE :

^ Make sure foam tape is added between the end cap and housing assembly.

^ Also ensure the end cap is positioned correctly to prevent over travel of the sun shade

SPECIAL SERVICE TOOLS
SS003-05

Title:
CD SKIP VERIFICATION USING
TOYOTA MASTER CD

Models:
'01 - '06 All Toyota & '04 - '06 All Scion

November 28, 2005

Introduction

Toyota has developed a master CD to be used for customer complaints of the CD player skipping or CD player cannot read disc. This disc has been specially manufactured to test the performance of the Toyota CD players. Using this master CD will confirm that the radio exceeds Toyota's specification for CD player performance.

Applicable Vehicles

^ 2001 - 2006 model year Toyota vehicles.

^ 2004 - 2006 model year Scion vehicles.








Test Disc Specifications







Warranty Information







Required SSTs

Repair Procedure

1. Make sure the vehicle is stationary during the test.

2. Insert a compact disc (NOT the Toyota Master CD) to make sure the radio can accept and eject the disc without damaging it.

3. Check the Toyota Master CD for any unintended scratches or dirt. Wipe away dirt using a glass cleaning cloth. If the disc is damaged, order a replacement master CD.

4. Insert the Toyota Master CD and change to track number 9.

5. Play the track for one minute.

A. If skips are heard, replace the CD player.

B. If NO skips are heard, the CD player is working normally. Check the customer's CDs for scratches or other damage to the discs. Confirm that the customer is using a pre-recorded CD, NOT CD-Rs or CD-RWs as they may NOT have been burned properly.


NOTE :

^ Tracks 1 - 8 and 11 - 14 are reference tracks. They can be used, but the conditions are less severe than track 9. Do NOT use tracks 10 and 15.

^ Track 9 (0.8 mm scratch) is much more severe than the Toyota engineering specification in order to ensure customer satisfaction. If the customer's radio passes this test, a replacement radio will NOT improve the performance.

^ This disc has been specially manufactured with a physical defect for the purposes of testing the CD player's performance. It is NOT possible to make copies of this disc that can be used to test the CD player's performance.

ENGINE
EG012-03
REVISED

Title:
ACCESSORY DRIVE BELT NOISE

Models:
'03 4Runner (1GR-FE)

July 3, 2003

TSB REVISION NOTICE :

^ November 18, 2005: Applicable Warranty has been changed from Powertrain to the Toyota Basic Warranty.


Previous versions of this TSB should be discarded.

Introduction

On some 2003 model year 4Runner vehicles equipped with the 1GR-FE V6 engine, under certain conditions, the accessory drive belt may make a "squealing" or "chirping" sound when the engine is first started. An improved auto tensioner assembly, flange bolt, V-rib belt, and service procedure have been developed to correct the condition.

Applicable Vehicles

^ 2003 model year 4Runner vehicles equipped with the 1GR-FE engine.


VIN Information







With 4Runner vehicles BEFORE the engine number and BEFORE the VINs shown below, proceed to step 1.







With 4Runner vehicles AFTER the engine number and AFTER the VINs shown below, proceed to step 7.







Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Parts Information







Required Tools & Material

Repair Procedure

1. Check the engine number. If the engine number is higher than 1GR-0053092, go to step 7 (refer to the VIN Information table in this TSB). Otherwise, continue with step 2.

2. Remove the accessory drive belt and remove the alternator from the vehicle.

3. Remove the A/C compressor from the auto tensioner assembly and carefully move the A/C compressor to the side to allow access to the 5 bolts holding the auto tensioner assembly to the engine block. Pay close attention to all wire harnesses, connectors, and A/C lines. It is NOT necessary to disconnect ANY A/C lines to perform this procedure.

4. Remove the five bolts holding the auto tensioner assembly to the engine block and remove the auto tensioner assembly from the engine.








5. Install the NEW auto tensioner with the NEW flange bolt in Position 1 and one of the previously removed bolts in Position 2 as shown in Figure 1 below. Install the two bolts finger-tight. Then first torque the flange bolt in Position 1 to 27 ft.lbs and then torque the bolt in Position 2 to 27 ft.lbs. Lastly, tighten the other three bolts to 27 ft.lbs.

Torque: 36 N.m (373 kgf.cm, 27 ft.lbs)








6. Reinstall the A/C compressor and alternator, and then install the NEW V-rib belt ensuring that the belt is properly installed by using the diagram in Figure 2.

7. If the VIN in the VIN Information table refers to step 7, replace the V-rib belt before continuing on with step 8.

8. Start the engine and allow it to run for at least 10 seconds under the following conditions:

^ A/C switch in the OFF position and do NOT turn the steering wheel to prevent load on the power steering pump.

^ Engine temperature should be warm and engine speed should be kept below 1,000 rpm.


9. Using the diagram below, with the engine OFF, hold a straightedge flat against the face of the crank pulley. Next, take the metric ruler and measure the distance from the straightedge to the side of the V-rib belt. The target specification is 8.5 - 10.5 mm. If the measurement is within the target, go to step 11. If the measurement is less than the target measurement, go to step 10.








10. Remove the V-rib belt and auto tensioner pulley and insert a 0.5 mm shim in the location indicated in Figure 3 below.

NOTE :The pulley bolt is a LEFT HAND threaded bolt.

HINT:

^ Only 1 shim should be inserted at a time.

^ Total thickness of the shim inserted must be 2.0 mm or less.


Reinstall the pulley and torque the pulley bolt to 40 ft.lbs. Reinstall the V-rib belt and perform steps 8 and 9 again.

Torque: 54 N.m (553 kgf.cm, 40 ft.lbs)

If the measurement value is less than the target specification, replace the shim in the following order: 0.5 mm --> 1.0 mm --> 1.5 mm 2.0 mm.

11. Start the engine and let the engine idle for 10 minutes to confirm the repair effectiveness.

BODY
BO014-05

Title:
SEAT COVER REPLACEMENT FOR SIDE
AIRBAG EQUIPPED VEHICLES

Models:
'98 - '06 All Models

November 10, 2005

TSB UPDATE NOTICE :The information contained in this TSB supercedes TSB No. B0025-97.
TSB No. B0025-97 is now obsolete and should be discarded.

Introduction

Beginning in 1998, Toyota introduced side airbags as optional equipment.

Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following:

^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident.

^ Modifications that negatively affect side airbag performance can result in severe occupant injuries.

^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system.

^ The design of the seat is complex, integrating safety and strength with comfort and luxury.

*NOTE :Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance.

Toyota strongly discourages modifying original equipment seats that have optional side airbags.

Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident.

Applicable Vehicles

^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags.








Warranty Information

PAINT
PA002-02
REVISED

May 31, 2002

Title
PAINT STAINS UNDER RAPGARD

Models
All '02 - '06 Toyota & All '04 - '06 Scion

TSB REVISION NOTICE: ^ October 17, 2005: Applicable Vehicles updated to include 2006 model year Toyota vehicles and 2004 - 2006 model year Scion vehicles.
^ September 9, 2004: Applicable Vehicles now includes 2004 - 2005 model year vehicles.
All previous versions of this TSB should be discarded.

Introduction
On some vehicles when RapgardTM is removed the paint may have a stained appearance. These stains appear to be under the clear coat and should not be considered a defect in the paint (clear coat or color coat). The stain patterns are usually under wrinkles in the RapgardTM. These wrinkles sometimes trap water and cause the paint to stain from the trapped moisture especially on horizontal surfaces such as the hood roof and trunk. Stains can be removed by heating the stained surface to remove the trapped moisture.






Applicable Vehicles
^ 2002 - 2006 model year Toyota vehicles all models.
^ 2004 - 2006 model year Scion vehicles all models.

Warranty Information






Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customers specific complaint.

Required Tools & Material






Repair Procedure1. Use the aluminum foil or damp cloth to cover plastic/rubber parts that are near the stain.

2. Apply heat to the stain using an infrared lamp or heat gun.

Note: Apply heat for 5 - 10 minutes at 158°F - 176°F (70°C - 80°C). Do NOT allow the surface to become hotter than 176°F (80°C). Measure the temperature with a thermometer.

3. After applying heat for 5 minutes examine the area to determine if the stain has been removed. If the stain still exists continue to apply heat and re-examine the stain 5 minutes later.

HEATING & AIR CONDITIONING
AC004-05
REVISED

Title:
BLOWER MOTOR
ABNORMAL OPERATION

Models:
'03 - '05 4Runner

August 3, 2005

TSB REVISION NOTICE :^ September 12, 2005: The "Parts Identification" section has been updated. Previous versions of this TSB should be discarded.


Introduction

Some 2003 - 2005 model year 4Runner vehicles may experience a condition where the blower motor speed does not match the HVAC display indication. The blower motor controller has been modified to resolve this condition. Follow the repair procedure described in this TSB.

Applicable Vehicles

^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown.








Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Production Change Information







Parts Information

Parts Identification







Countermeasure service parts are identified by the 4-digit date code printed on the side of the blower motor controller cooling fins. Date code is 2 G 17 or later.







Components

Repair Procedure

1. Remove the negative (-) battery terminal.

NOTE :Failure to complete step "1" above may result in internal damage to the transfer case shifting mechanism.







2. Remove the instrument panel under cover sub-assembly No. 2.

A. Remove the screw.

B. Disengage the 3 clips.









C. Disconnect the wire harness from the 4WD computer.

D. Remove the instrument panel under cover sub-assembly No. 2.

3. Remove the blower motor controller.

A. Disconnect the wire harness connector.

B. Remove the two retaining screws.

C. Remove the blower motor controller from the HVAC module.


4. Install the NEW blower motor controller.

A. Insert the blower motor controller into the HVAC module.

B. Install the two retaining screws.

C. Connect the wire harness.


5. Reconnect the 4WD computer.

6. Install the instrument panel under cover sub-assembly No. 2.

7. Reconnect the negative (-) battery terminal.

8. Confirm proper blower motor operation and speed control.

9. Re-initialize all power systems per TSB No. PD008-05, "Power System Initialization During PDS."

NOTE: This bulletin has 5 sub bulletins and goes three replies long

Steering - Highway Speed Steering 'Flutter'
Information
Steering - Highway Speed Steering 'Flutter'
Diagnostic Procedure
Dunlop Tire Flat Spotting Diagnosis/Tire Balance Procedure
Steering Rack Guide Preload Spring Installation Procedure
Increased Mass Steering Wheel Installation Procedure

#1

STEERING
ST001-05
REVISED

July 28, 2005

Title:
STEERING FLUTTER FIELD - FIX PROCEDURE

Models:
'03 - '05 4Runner

TSB REVISION NOTICE:

^ September 8, 2005: The contact information in the "Obtaining Replacement Tires" section of the "Dunlop Tire Flat Spotting Diagnosis" procedure has been updated. Previous versions of this TSB should be discarded.


Introduction

Some customers may experience a steering flutter condition while driving at highway speeds. In most cases, this concern is caused by flat spots that can normally develop in the tires after sitting for long periods of time. To minimize the effects of flat spotting and other minor tire irregularities, a new repair procedure has been developed that includes installing improved components to help reduce steering flutter complaints.

Applicable Vehicles^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown.








Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Production Change Information







Parts Information







Required Tools & Material







Required SSTs

#2

Steering - Highway Speed Steering 'Flutter'
Notes





Notes










#3

Notes







The following instructions apply only to black sidewall P265/65R17 110S Dunlop AT20 original equipment tires produced in Japan before the production week 0905. Tires produced on or after production week 0905 do NOT qualify for this program. The last four digits of the tire DOT number represent the production week. This procedures does NOT apply to vehicles equipped with Dunlop AT20 original equipment tires produced in the U.S.A.

After the tires have been warmed up for a minimum 10 minutes at 65 mph (104.6 km/h), the vehicle should be immediately raised on the hoist. The tires may be checked with a dial indicator placed at the center rib of the tread design.







If the tires are flat spotted, there will be a short duration dip in the runout gauge reading equal to the approximate size of the tire's footprint, or approximately 3 - 7 inches (7.6 - 17.8 cm) of the tread circumference. The dip in the reading on the runout gauge will go in and out the same amount; it is not just a short duration but an abrupt change in the reading. Flat spotting will NOT be visible by eye and requires the use of a dial indicator. Flat spotting should NOT be confused with any external abrasion on the tire (such as a panic stop) that causes the tread depth in the tire's footprint area.







If the runout between A and B exceeds 0.020 - 0.040 inches (0.051 - 0.102 cm) over 3 - 7 inches (7.6 - 17.8 cm) of the tread circumference, this may cause a ride complaint depending on the vehicle sensitivity.

If the tires are not flat spotted but the assembly runout is greater than desired, then standard match mounting and balancing procedures should be followed.

Obtaining Replacement Tires:

Tires with 9/32 or greater tread depths that are flat spotted based on the above criteria may be exchanged at no charge through a Dunlop dealer. It is recommended that all four tires be exchanged when flat spotting has occurred. For dealers participating in the Toyota Tire Center Program, please contact Program Headquarters for instructions. For dealers not participating in the Toyota Tire Center Program, your local Dunlop dealer must call the Goodyear/Dunlop Customer Assistance Center at 1-800-321-2136 for authorization to return the tires through the Goodyear/Dunlop warranty system.

Tire Balance Procedure







Mount the tire/wheel assembly to the tire balancer as illustrated. When balancing the tire, ensure that the Road Force function of the balancer is turned ON and the "Haweka" type balancing adapter MUST be used when balancing these tires. (Refer to your balancer owner's manual for further information about Road Force variation measurements on tire and wheel assemblies.) This is necessary to ensure that the wheels and tires are match mounted (heavy portion of tire is matched with light side of wheel or visa-versa).

Remount the tire and wheel assembly to the vehicle. Torque all wheels.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.lbf)

#4

PRECAUTION:

^ The 4Runner is equipped with SRS, which consists of a driver airbag, front passenger airbag, side airbag, and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection. or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.

^ Wait at least 90 seconds AFTER the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)

^ Do not expose the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor directly to hot air or flames.

NOTE: ^ Malfunction symptoms of the SRS are difficult to confirm, so the DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.

^ Even in cases of a minor collision when the SRS does not deploy, the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, and seat position airbag sensor should be inspected.

^ Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation.

^ Never use SRS parts from another vehicle. When replacing parts, replace them with new ones.

^ Never disassemble and repair the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor in order to reuse them.

^ If the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor has been dropped, or if there are any cracks, dents, or other defects in the case, bracket, or connector, replace it with a new one.

^ Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting the electrical circuits.

^ Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.

^ After work on the SRS is completed, perform the SRS warning light check.

^ When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be cancelled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio system as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle.

^ If the vehicle is equipped with a mobile communication system, refer to the preceding Precaution.

1. Place the front wheels facing straight ahead with the engine running.

2. Record the radio presets.

3. Turn the key to the OFF position and remove the keys from the ignition.

4. Disconnect the negative (-) battery terminal.

5. Remove the front wheels.

6. Remove the 6 bolts and the engine under cover assembly rear.

7. Remove the 4 bolts and the engine under cover sub-assembly No. 1.

8. Remove the 2 nuts and the front stabilizer link assembly LH.

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








9. Remove the 2 nuts and the front stabilizer link assembly RH.








10. Remove the 2 bolts and the front stabilizer bracket No. 1 LH.

11. Remove the 2 bolts and the front stabilizer bracket No. 1 RH.

12. Remove the 2 front stabilizer bar bushings No. 1.

13. Remove the front stabilizer bar.

14. Separate the tie rod end sub-assembly LH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011









15. Separate the tie rod end sub-assembly RH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011


16. Remove the steering sliding yoke.








A. Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2, and steering intermediate shaft assembly.

B. Remove bolt A and bolt B from the steering sliding yoke.

C. Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2.

D. Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove.

17. Remove steering intermediate shaft No. 2.

A. Mark the matchmarks on the power steering gear assembly and steering intermediate shaft sub-assembly No. 2.

B. Remove bolt C and the intermediate shaft sub-assembly No. 2 from the power steering gear assembly.


18. Disconnect the pressure feed tube assembly.








A. Using the 17 mm Union nut wrench (or equivalent), loosen the flare nut and disconnect the pressure feed tube.








B. Remove the 2 bolts and separate the pressure feed tube assembly from the frame sub-assembly.








19. Disconnect the steering gear outlet return tube.

A. Remove the clip and disconnect the return hose.









B. Using the 17 mm Union nut wrench (or equivalent), remove the outlet return tube.








20. Remove the 2 bolts, 2 nuts, and power steering link assembly.

NOTE: Be sure to only turn the bolt as the nut has a detent.

HINT: After loosening the 2 bolts, raise the bolt from the frame. Slide the power steering gear assembly and the bolt as a unit to the position where the bolt can be pulled out.








21. Carefully secure the power steering gear assembly in a vise (if available, use SST P/N: 09612-00012-01).

22. Remove the rack guide.








A. Using the SST, remove the lock nut as shown in the illustration.

SST P/N: 09922-10010-01








B. Using a hexagon wrench (24 mm), remove the rack guide spring cap.

C. Remove the spring and rack guide.

23. Install the rack guide spring.

A. Install the rack guide and new spring (P/N: 44215-35010).

B. Apply sealant to 2 or 3 threads of the rack guide spring cap.

Sealant: Three Bond 1344, Loctite 242, or equivalent.









C. Using a hexagon wrench (24 mm), temporarily install the spring cap.

24. Adjust the total preload.








A. Using a hexagon wrench (24 mm), tighten the rack guide spring cap.

Torque: 25 N.m (250 kgf.cm, 18 ft.-lbf)

B. Turn the cap an additional 30°counterclockwise.








C. Using the SST, turn the control valve shaft right and left 1 or 2 times.

^ SST P/N: 09616-00010-02


D. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring has no tension.








E. Using the SST, a torque wrench, and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

^ SST 09616-00010-02

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in..lbf)


NOTE: When making the adjustment, be sure to turn the cap in the clockwise direction.

F. Apply sealant to 2 or 3 threads of the lock nut.

Sealant: Three Bond 1344, Loctite 242, or equivalent

G. Temporarily install the lock nut.








H. Using a hexagon wrench (24 mm), holding the rack guide from rotating, and using the SST, torque the nut.

^ SST 09922-10010-01

Torque: 69 N.m (700 kgf.cm, 51 ft.-lbf) for use with SST


I. Recheck the total preload.

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in.-lbf)








25. Install the power steering link assembly into the vehicle with the 2 bolts and 2 nuts. Torque: 100 N.m (1,020 kgf.cm, 74 ft.-lbf)

NOTE: The nut has a detent, so never turn the nut. Be sure to turn the bolt.

NOTE: Insert the bolts and position it with the power steering gear assembly as a unit.

Then install the bolts on the frame.








26. Install the front stabilizer bar.

27. Install the 2 front stabilizer bar bushings No. 1.

NOTE: ^ Install the bushing to the inner side of the bushing stopper on the stabilizer bar.









^ Install the stabilizer bushing No. 1 as shown in the illustration.

28. Install the front LH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)








29. Install the front RH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)

30. Install the front stabilizer link assembly LH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








31. Install the front stabilizer link assembly RH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

32. Connect the steering gear outlet return tube.

A. Using the 17 mm Union nut wrench (or equivalent), connect the outlet return tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).









^ This torque wrench should be held as shown in the illustration.








B. Install the hose with the clip.

33. Connect the pressure feed tube assembly.








A. Install the pressure feed tube assembly to the frame sub-assembly with the 2 bolts.

Torque: 28 N.m (286 kgf.cm, 21 ft.-lbf)

B. Using the 17 mm Union nut wrench (or equivalent), tighten the flare nut and connect the pressure feed tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

NOTE: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).








^ This torque wrench should be held as shown in the illustration.








34. Install the steering intermediate shaft No. 2.

A. Align the matchmarks on the power steering gear assembly and steering intermediate shaft No. 2.

B. Install the steering intermediate shaft No. 2 to the power steering gear assembly with the bolt.

Torque: 36 N.m (360 kgf.cm, 27 ft.-lbf)


35. Install the steering sliding yoke.

A. Align the matchmarks on the steering column and steering slide yoke.

B. Install the steering sliding yoke to the steering column assembly and slide it upward.

C. Align the matchmarks on the intermediate shaft sub-assembly No. 2 and steering sliding yoke.

D. Install the sliding yoke to the intermediate shaft sub-assembly No. 2 with the bolt A and bolt B.

Torque: Bolt A, B: 36 N.m (370 kgf.cm, 27 ft.-lbf)


36. Connect the tie rod end sub-assembly LH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


37. Connect the tie rod end sub-assembly RH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


38. Install the engine under cover sub-assembly No. 1 with the 4 bolts.

39. Install the engine under cover assembly rear with the 6 bolts.

40. Install the front wheel.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.-lbf)

41. Place the front wheels facing straight ahead.

42. Add power steering fluid.

43. Bleed the power steering fluid.

A. Check the fluid level.

B. Ensure that the front of the vehicle is slightly higher than the rear of the vehicle to aid in air bleeding of the steering rack.

C. Turn the steering wheel. With the engine stopped, turn the wheel slowly from lock to lock several times.

D. Lower the vehicle.

E. Reconnect the negative (-) battery terminal.

F. Start the engine. Run the engine at idle for a few minutes.

G. Turn the steering wheel.

a. With the engine idling, turn the wheel to left or right 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 step "a" several times.


H. Stop the engine.









I. Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

J. Check the fluid level.

44. Check the power steering fluid leakage.

45. Inspect and adjust the wheel alignment. Inspect the vehicle alignment using the instructions provided on the Technical Information System (TIS): 2003 or 2004 model year 4Runner Repair Manual: Front Suspension: Front Wheel Alignment: Adjustment.

46. Return to "Diagnostic Procedure", step 4, to continue procedure.

NOTE: Prior to returning the vehicle to the vehicle to the customer, re-initialize the power windows and moon roof. Refer to TSB No. PG021-02, "Back Door Power Window Initialization During PDS," and TSB No. EL009-04, "Power Window/Roof Initialization Procedures."