CBR_GUY_IA

#5
1. See the precaution in the Steering Rack Guide Spring Installation Procedure" of this TSB.

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

3. Record the radio presets.

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

5. Disconnect the negative (-) battery terminal.

6. Remove the steering wheel cover lower No. 3.

7. Remove the steering wheel cover lower No. 2.

8. Remove the horn button assembly.

NOTE: If the airbag connector is disconnected with the ignition switch ON, DTCs will be recorded.








A. Using a Torx socket wrench (Torx socket wrench [T=30]), loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.

NOTE: When removing the horn button assembly, take care not to pull the airbag wire harness.







B. Pull out the horn button assembly from the steering wheel assembly.

C. Using a screwdriver, release the lock part of each of the airbag connectors and disconnect the 2 airbag connectors.

D. Disconnect the horn ground harness from the horn button assembly.








CAUTION: ^ When storing the horn button assembly, keep the upper surface of the pad facing upward.

^ Never disassemble the horn button assembly.

9. Remove the steering wheel assembly.

A. With steering pad switch: Disconnect the connector.

B. Remove the steering wheel assembly set nut.









C. Set the SST on the steering wheel assembly.

D. Remove the steering wheel assembly.

^ SST P/N: 09950-50013-01 (09951-05010, 09952-05010, 09953-05020, 09954-05020)


10. Install the steering wheel assembly.

A. Install the new steering wheel assembly with the steering set nut.

Torque: 50 N.m (510 kgf.cm, 37 ft.-lbf)

B. With steering pad switch: Connect the connector.


11. Install the horn button assembly.

NOTE: ^ Make sure the horn button assembly is installed to the specified torque.

^ If the horn button assembly has been dropped or there are cracks, dents, or other defects in the case of the connector, replace the horn button assembly with a new one.

^ When installing the horn button assembly, take care that the harness does not interfere with other parts and the wires are NOT pinched between other parts.









A. Connect the horn ground harness to the horn button assembly.

B. Connect the 2 airbag connectors.

C. Install the horn button assembly after confirming that the circumference groove of torx screw is caught on the screw case.

D. Using a torx socket wrench (Torx socket wrench [T=30]), torque the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in.-lbf)

12. Install the steering wheel cover lower No. 2.

13. Install the steering wheel cover lower No. 3.

14. Ensure that the front wheels are facing straight ahead.

15. Install the negative (-) battery terminal.

16. Inspect the SRS warning light.

17. 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."

CBR_GUY_IA

NOTE: This bulletin has two links

Antitheft - Diagnostic Tester Immobilizer Function
Information
Antitheft - Diagnostic Tester Immobilizer Function
Operation Procedure

#1

SPECIAL SERVICE TOOLS
SS003-02
REVISED

December 11, 2002

Title:
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS

Models:
Applicable Toyota Models

TSB REVISION NOTICE:

^ August 26, 2005: The model years for each model have been specifically defined in the "Applicable Vehicles" section. The following vehicles have been added to the "Applicable Vehicles" section: Avalon, Corolla, Highlander, Matrix, Prius, RAV4, Scion tC, Sequoia, Solara, & Tacoma. The "Required SSTs" section has been updated.

^ June 17, 2003: Camry and Sienna added to applicable vehicles; screen flows revised (screen C) in Figures 2, 3, and 4. Previous versions of this TSB should be discarded.


Introduction

The Diagnostic Tester incorporates support for Immobilizer system service. This bulletin covers the following Immobilizer functions available using the Diagnostic Tester on applicable models:

^ Transponder Key Type
^ Transponder Code Registration
^ Transponder Code Erasure
^ Transponder ECU Reset
^ Transponder ECU Replacement
^ Engine ECU Replacement

NOTE: The available functions and procedures for the models listed in this TSB differ from previous models and other Immobilizer systems currently in use on Toyota vehicles.







Parts Information







Warranty Information







Applicable Vehicles







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.

Function Description

1. Transponder Key Type

Before any Immobilizer functions are performed, verify the type of transponder key that you are attempting to use for the service operation. Some functions may only be performed with a registered Master Key.

2. Transponder Code Registration

This function allows the registration of additional transponder keys (Master or Sub) using a registered Master Key.

3. Transponder Code Erasure

This function allows the user to erase all the transponder keys except the registered Master Key used during this function.

4. Transponder ECU Reset

This function allows the registration of a new Master Key even if all original Master Keys are lost. Once the Immobilizer system is reset, all previous registered keys will be erased.

5. Transponder ECU Replacement

When the Transponder ECU is replaced, the transponder keys must be registered to the new ECU, auto registration closed, and ECU communication completed.

6. Engine ECU Replacement

When the Engine ECU is replaced, ECU communication must be completed to synchronize an encrypted security code between the engine and Transponder ECUs.

#2
1. Transponder Key Type

Before any Immobilizer functions are performed, verify the type of transponder key that you are attempting to use for the service operation. Some functions may only be performed with a registered Master Key.

A. Insert the current key into the ignition cylinder and turn to the ON position.

HINT: The Immobilizer key blanks for the models listed in this TSB are preconfigured as Master or Sub Keys. Master Key blanks cannot be registered as Sub Keys nor can Sub Key blanks be registered as Master Keys. Also, the flat key is now enabled as a full function Master Key that must be registered.








B. Follow the screen flow in Figure 1 to determine the key type.

C. Key type and registration status will be indicated on the Immobilizer data list (Figure 1, screen E).

^ MATCH" = The key in the ignition cylinder matches this key type.

^ NO MATCH" = The key in the ignition cylinder does NOT match this key type.


2. Transponder Code Registration

This function allows the normal registration of additional transponder keys (Master or Sub) using a registered Master Key.

NOTE: This function requires the use of one registered Master Key. The use of a Sub Key will NOT complete Transponder Code Registration. Attempting registration of additional keys with only a Sub Key will result in errors and incomplete registration.








HINT: The Immobilizer key blanks for the models listed in this TSB are preconfigured as Master or Sub Keys. Master Key blanks cannot be registered as Sub Keys nor can Sub Key blanks be registered as Master Keys. Also, the flat key is now enabled as a full function Master Key that must be registered.

A. Insert a registered Master Key into the ignition cylinder and turn to the ON position.








B. Follow the screen flow in Figure 2 to register new Master or Sub keys. It is possible to register up to 5 Master Keys and 3 Sub Keys.

C. Be sure to follow the instructions on key insertion, ignition ON/OFF and key removal exactly as described on the Diagnostic Tester.

3. Transponder Code Erasure

This function allows the user to erase all the transponder keys except the registered Master Key used during this function.

NOTE: This function requires the use of one registered Master Key. The use of a Sub Key will NOT complete Transponder Code Erasure.

A. Insert a registered Master Key into the ignition cylinder and turn to the ON position.









B. Follow the screen flow in Figure 3 shown to erase all Master or Sub keys, except the registered Master Key used for this procedure.

4. Transponder ECU Reset

This function allows the registration of a new Master Key even if all original Master Keys are lost. Once the Immobilizer system is reset, all previous registered keys will be erased. Use a new transponder Master Key to complete Transponder ECU Reset.


Immobilizer Reset

The Immobilizer Reset function is a 4-step process:

A. Using the Diagnostic Tester, retrieve a "Seed Number" through the OBD/MOBD Immobilizer function.

^ A "Seed Number" is a unique number provided by the Diagnostic Tester and validated at TMS in order to return a Passcode.


B. Using the TIS (Technical Information System) workstation, select Immobilizer Reset, and complete the request form to retrieve a "Passcode Number."

^ A "Passcode Number" is a unique number required by the Diagnostic Tester to reset the ECU allowing it to accept a new Master Key.


C. Enter the "Passcode Number" received from TIS into the Diagnostic Tester, register any additional customer keys, and close auto registration mode.

D. Confirm successful Immobilizer reset and new Master Key registration.

A. Connect the Diagnostic Tester to DLC3 and turn ignition ON.

a. Using the Diagnostic Tester, retrieve a "Seed Number" through the OBD/MOBD Immobilizer function.









b. Follow each step outlined in Figure 4.








B. Using the TIS (Technical Information System) workstation, select Immobilizer Reset, and complete the request form to retrieve a "Passcode Number."

a. Click on Diagnostics.

b. Click on Immobilizer Reset.









c. Read the instructions on the screen and click on Continue. (See Figure 6)








d. Complete the request form and enter the "Seed Number" from the Diagnostic Tester. Click on Submit (Figure 7).

NOTE: All fields must be completed.







e. TIS will now return the Passcode that needs to be entered into the Diagnostic Tester.

NOTE: The Passcode given by TIS is only valid for one Immobilizer Reset Event.







C. Using the numbered keys (0-9) on the Diagnostic Tester, enter the "Passcode Number" received from TIS into the Diagnostic Tester (see Figure 9). Press ENTER to clear all registered transponder codes except the Master key in the ignition cylinder.

NOTE: ^ During the reset process do not remove the key from the ignition.

^ This step takes approximately 16 minutes.

^ Following a reset, the Transponder ECU is in auto registration mode.

^ Auto registration mode allows 3 Master Keys and one Sub Key to register automatically.

^ To register additional keys, remove the Master Key currently in the ignition. Insert keys (Master or Sub) into the ignition cylinder without turning the ignition on or off - simply insert and remove. (See Figure 9, screen D.)

NOTE: ^ If 4 keys are registered at this time, auto registration mode is automatically closed.

^ If less than 4 keys are registered at this time, auto registration mode must be closed manually by cycling the ignition ON/OFF more than 5 times in 10 seconds. (See Figure 9, screen E.)

^ If more than 4 keys need to be registered, use Transponder Code Registration.

D. Verify that keys are registered correctly by starting the engine with each newly registered key.

NOTE: ^ If the vehicle starts, the new key code was registered correctly.

^ If the vehicle does not start with any key, perform the Immobilizer Reset function again.

^ If only one of the registered keys will not start the vehicle, attempt to register the key again following the Transponder Code Registration procedure.

5. Transponder ECU Replacement

When the Transponder ECU is replaced, the transponder keys must be registered, auto registration closed, and ECU communication completed.

A. Replacement transponder ECUs are in auto registration mode. This allows transponder keys to automatically register as they are inserted into the ignition cylinder. It is possible to automatically register up to 3 Master Keys, and 1 Sub Key. Since the transponder ECU can distinguish the key type (Master or Sub), the registration order is not specified.

NOTE: ^ If 4 keys are registered at this time, auto registration mode is closed.

^ If less than 4 keys are registered at this time, auto registration mode must be closed manually by cycling the ignition ON/OFF more than 5 times in 10 seconds.

^ If more than 4 keys need to be registered, use Transponder Code Registration procedure.

B. Once auto registration mode is closed, ECU Communication must be performed between the transponder ECU and the Engine ECU. Complete ECU communication using the following steps:

a. Insert a registered Master Key into the ignition cylinder.

b. Turn the ignition ON (engine OFF).










c. Short Tc and CG terminals of DLC3 using Diagnosis Check Wire (SST 09843-18020 or equivalent) and leave for 30 minutes. (See Figure 10.)

d. After 30 minutes, turn ignition OFF and remove check wire from DLC3.

e. Start the vehicle to confirm successful ECU communication.

NOTE: If ECU communication is not completed correctly, the engine will not start and DTC B2799 will be set. DTC B2799 will be cleared after the engine starts correctly.

6. Engine ECU Replacement








When the Engine ECU is replaced, ECU communication must be completed. ECU Communication must be performed between the transponder ECU and the Engine ECU. Complete ECU communication using the following steps:

A. Insert a registered Master Key into the ignition cylinder.

B. Turn the ignition ON (engine OFF).








C. Short Tc and CG terminals of DLC3 using Diagnosis Check Wire (SST 09843-18020 or equivalent) and leave for 30 minutes. (See Figure 11.)

D. After 30 minutes, turn ignition OFF and remove check wire from DLC3

E. Start the vehicle to confirm successful ECU communication.

NOTE: If ECU communication is not completed correctly, the engine will not start and DTC B2799 will be set. DTC B2799 will be cleared after the engine starts correctly.

CBR_GUY_IA

PRODUCT GENERAL INFORMATION
PG018-02
REVISED

August 30, 2002

Title:
DRIVER'S DOOR POWER WINDOW AND MOON ROOF INITIALIZATION

Models:
'03 - '06 4Runner

TSB REVISION NOTICE:

^ August 19, 2005: 2004 - 2006 model years have been added to Applicable Vehicles.

^ December 6, 2002: The "Troubleshooting" section has been added.


Previous versions of this TSB should be discarded.

Introduction

This bulletin outlines the initialization procedure for the driver's door power window and the moon roof on 2003 - 2006 model year 4Runner vehicles.

If the battery has been disconnected, the ECU will not be able to detect and memorize the driver's door power window and moon roof positions, resulting in the following features being inoperative:

^ One-touch open and close of driver's door power window with jam protection.

^ One-touch slide open and close of moon roof with jam protection.

^ One-touch tilt up and down of moon roof with jam protection.


Please use the following initialization procedure whenever the battery has been disconnected.

Applicable Vehicles:^ 2003 - 2006 model year 4Runner vehicles.








Warranty Information

Initialization Procedure

Driver's Door Power Window

With ignition switch in the "ON" position, do the following:

NOTE: At this time, the power switch for the driver's door window should be blinking.







1. Push down and hold the driver's door power window switch to completely open the window.








2. Pull and hold up the driver's door power window switch until the window closes. Continue holding the switch for approximately one second until the switch changes from blinking to a constant illumination.

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

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


TROUBLESHOOTING:

If power window is unable to close after initialization, perform the following procedure.

NOTE: If the power window switch is continuously operated for a long time, the power window motor will stop to prevent additional load on the motor. Continuing to press the power window switch even after the motor has stopped will cause the switch to blink and will restrict the AUTO UP/DOWN function and remote UP/DOWN function. If this happens, wait for a few minutes before attempting to reset the motor again.

1. Disconnect the negative (-) battery terminal. After 10 seconds, reconnect the battery terminal.

2. Turn the ignition switch to the "ON" position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately one second after the door glass is fully closed.

> Check for proper operation of the AUTO UP/DOWN function.


3. If the power window motor is still unable to close:

Turn the ignition switch to the "ON" position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately 12 seconds after the door glass is fully closed.

> Check for proper operation of the AUTO UP/DOWN function.



Moon Roof

With ignition switch in the "ON" position, do the following:







1. Push and hold the "TILT UP" side of the switch until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm [0.39 in.] at the rear).

2. Check for proper operation of the "one-touch slide open/close" and "one-touch tilt up/down" functions by pushing the switch briefly to the "SLIDE OPEN" and "TILT UP" positions.

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

CBR_GUY_IA

ELECTRICAL
EL011-05

Title:
A/C LIGHT FLASHING - MAGNETIC
CLUTCH RELAY

Models:
'01 - '04 Camry, ECHO, & Celica
'02 - '04 4Runner, Corolla, & MR2 Spyder
'03 - '04 Highlander, Matrix, Sienna, & Solara

June 3, 2005

Introduction

This bulletin is to provide information regarding countermeasures to the A/C magnetic clutch relay for A/C light flashing (inoperative A/C) issues on some vehicles equipped with a magnetic clutch compressor.

Applicable Vehicles

^ 2001 - 2004 model year Camry, ECHO, and Celica vehicles.

^ 2002 - 2004 model year 4Runner, Corolla, and MR2 Spyder vehicles.

^ 2003 - 2004 model year Highlander, Matrix, Sienna, and Solara vehicles.








Parts Information

Inspection Procedure

1. Locate the A/C magnetic clutch relay.

2. Verify the part number printed on the side of the relay.

A. If the part number is 90987-02022, please replace the relay with the countermeasured relay P/N 90987-02028.

B. If the part number does not match 90987-02022, then please diagnose problems by referring to the Technical Information System (TIS): applicable model year and vehicle Repair Manual: Air Conditioning: Troubleshooting.


NOTE :Relays other than P/N 90987-02028 should not be used for this application.







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.

CBR_GUY_IA

ENGINE
EG014-05

Title:
RADIATOR CAP INSPECTION

Models:
All Toyota Models

March 28, 2005

Introduction

The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models.

Applicable Vehicles

^ All Toyota and Scion models.








Required Equipment







Warranty Information







Required SSTs

Radiator Cap Identification Procedure







1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating.

2. Proceed to the required inspection procedure for the radiator cap and kPa rating.








Radiator Cap Inspection Procedure

Type: N-cap, 88 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen.

3. Check that points "C" and "D" are not stuck together.

4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.

^ Radiator Cap Tester:
Snap-On/Sun P/N SVTS262A
(or equivalent)


5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:

^ SST P/N 09230-00030-01
(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01









6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT :Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.








Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.







Type: N-cap, 108 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen.

3. Check that points "C" and "D" are not stuck together.

4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.

^ Radiator Cap Tester:
Snap-On/Sun P/N SVTS262A
(or equivalent)


5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:

^ SST P/N 09230-00030-01
(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01









6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT :Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.








Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: Compact Cap, 88 kPa







1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A" and "B" are not deformed, cracked, or swollen.

3. Check that points "B" and "C" are not stuck together.

4. Apply engine coolant to point "B" before using the radiator cap tester.

^ Radiator Cap Tester:
Snap-On/Sun P/N SVTS262A
(or equivalent)


5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:

^ SST P/N 09230-00030-01
(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01









6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT :Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.








Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.







Type: Compact Cap, 108 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A" and "B" are not deformed, cracked, or swollen.

3. Check that points "B" and "C" are not stuck together.

4. Apply engine coolant to point "B" before using the radiator cap tester.

^ Radiator Cap Tester:
Snap-On/Sun P/N SVTS262A
(or equivalent)


5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:

^ SST P/N 09230-00030-01
(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01)









6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT :Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.








Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: Plastic Cap, 108 kPa







1. Remove coolant and any foreign material on 0-ring "A."

2. Check that 0-ring "A" is not deformed, cracked, or swollen.

3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester.

^ Radiator Cap Tester:
Snap-On/Sun P/N SVTS262A
(or equivalent)


4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:

^ SST P/N 09230-00030-01
(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01









5. When using the radiator cap tester, tilt it more than 30 degrees.

6. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT :Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.








Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

CBR_GUY_IA

PA003-02
REVISED

June 4, 2002

Title
REFINISHING REPLACEMENT BUMPER COVERS

Models
All '83 - '05 Models

TSB REVISION NOTICE:^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded.

Introduction
In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers.






Applicable Vehicles
^ All 1983 - 2005 model year Toyota vehicles.

Required Tools & Material






Note: Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products.

Warranty Information






Refinishing Procedure

1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.

Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty.

2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned.

3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed.

4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel.

5. Degrease the surface with a wax, grease, and silicone remover.

Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions.

6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.

7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned.

8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed.

9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel.

Note: Never use a red shop towel to wipe the surface (contains silicone).

10. Assure the bumper is firmly held in place to a steady fixture.

11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations.

12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations.

13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations.

14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.)


For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative.

CBR_GUY_IA

ENGINE
EG005-05

Title:
M.I.L. "ON" DTC P0136 AND/OR P0156

Models:
'03 - '04 4Runner (1GR-FE V6)

February 11, 2005

Introduction

Under certain driving conditions, some 2003 - 2004 model year 1GR-FE (V6) 4Runner vehicles may exhibit a M.I.L. "ON" condition with one of the following DTCs.

^ P0136 (Oxygen Sensor Circuit Malfunction [Bank 1, Sensor 2])

^ P0156 (Oxygen Sensor Circuit Malfunction [Bank 2, Sensor 2])


The design of the Oxygen Sensor has been modified to prevent these conditions.

Applicable Vehicles

2003 - 2004 model year 4Runner vehicles equipped with 1GR-FE (V6) engine.







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.

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







Required SSTs

Repair Procedure

1. Confirm the stored DTC using the Toyota Diagnostic Tester.

2. Replace the rear Oxygen Sensor related to the stored" DTC. Refer to the Technical Information System (TIS), 2003 or 2004 model year 4Runner Repair Manual: Emission Control: Emission Control System (1GR-FE): Location.

3. Clear code and road test to confirm repair.

CBR_GUY_IA

ENGINE
EG020-03
REVISED

Title:
M.I.L. "ON" DTC P0441, P0442, AND/OR P0446

Models:
'03 4Runner & Tundra, '04 Sienna

December 17, 2003

TSB REVISION NOTICE :

^ January 6, 2005: The model years of Applicable Vehicles and Production Change Effective VINs have been updated.

The previous TSB should be discarded.


Introduction

Some 2003 model year 4Runner and Tundra, and 2004 model year Sienna vehicles may experience a M.I.L. "ON" condition with DTC P0441, P0442 and/or P0446 due to a sticking EVAP Purge Vacuum Switching Valve (VSV). The EVAP Purge VSV has been improved to correct the M.I.L. "ON" condition.

Applicable Vehicles

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

^ 2004 model year Sienna vehicles produced BEFORE the Production Change Effective VINs shown below.







Production Change 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.

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







Parts Information







Required SSTs

Repair Procedure

Refer to the Technical Information System (TIS): Applicable year and model Repair Manual: Diagnostics: SFI System: P0441, P0442, P0446, P0456.

CBR_GUY_IA

ENGINE
EG048-04
REVISED

Title:
REPAIR MANUAL SUPPLEMENT:
LEV II EVAP SYSTEM CHECK.
DTC P0441, P0442, P0446, P0451,
P0452, P0453, P0455 & P0456

Models:
'03 - '04 4Runner & Tundra, '04 Camry, Highlander, Sienna & Solara

November 12, 2004

TSB REVISION NOTICE :January 6, 2005: A change has been made to the diagram in section "A. LEV II SYS CHECK Description" ("CCV Stuck Open" changed to "EVAP VSV Stuck Open").

The previous TSB should be discarded.

Introduction

This TSB provides detailed instructions for a new LEV II EVAP System Check function using the Diagnostic Tester.

The LEV II System Check allows the Diagnostic Tester to display the fuel tank vapor pressure as the EVAP VSV and the CCV are operated in a specific six-step pattern. Problems with the EVAP system are quickly isolated by observing the change in vapor pressure during each step.

Once the vehicle condition is corrected, the LEV II System Check can also be used to confirm the repair before the vehicle is returned to the customer.

The inspection procedure using the LEV II System Check (LEV II SYS CHECK) is described in this bulletin. This function is available using a Diagnostic Tester with version 11.0a software (or newer).







Table of Contents







Warranty Information

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles equipped with 2UZ-FE and 1GR-FE engines.

^ 2003 - 2004 model year Tundra vehicles equipped with 5VZ-FE and 2UZ-FE engines.

^ 2004 model year Camry vehicles equipped with 2AZ-FE, 1MZ-FE and 3MZ-FE engines.

^ 2004 model year Highlander and Sienna vehicles equipped with 3MZ-FE engine. 2004 model year Solara vehicles equipped with 2AZ-FE and 3MZ-FE engines.








Required SSTs







Terms & Definitions







Section A - LEV II SYS CHECK Description







Section B - DTC Check










































Section C - LEV II SYS CHECK (Diagnostic Tester System Test)

















Section D - Air Inlet Restriction Inspection







Section E - EVAP VSV Stuck-Open Inspection



























Section F - Leak Check or No Vacuum Drawn on System Inspection

















Section G - CCV Diagnostics



























Section H - EVAP VSV Diagnostics

















Section I - EVAP System Description












Section J - EVAP System DTC Description






















Section K - EVAP Monitor Description

















Section L - OBD II EVAP Monitor Specifications

CBR_GUY_IA

TRANSMISSION & CLUTCH
TC002-03
REVISED

Title:
ECM RESET MEMORY FUNCTION

Models:
'00 - '05 All Models

June 10, 2003

TSB REVISION NOTICE :

^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised.

^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.

^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.


Previous versions of this TSB should be discarded.

Introduction

Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module (ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns.

CAUTION :Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns.







Required SSTs







Warranty Information

Applicable Vehicles







Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions:







Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions:

Reset Procedure 1

1. Connect the Toyota Diagnostic Tester to the vehicle.








2. Reset the ECM (PCM). Refer to the procedures below.

3. Start the engine and warm it up to normal operating temperatures before test-driving.

4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified.


Reset Procedure 2

1. Disconnect the negative battery cable for 5 minutes.

2. Reconnect battery cable.

3. Start the engine and warm it up to normal operating temperatures before test-driving.

4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified.

CBR_GUY_IA

Paint - Iron Rust Contamination Repair
Notes

PAINT
PA005-04
REVISED

November 16, 2004

Title
IRON PARTICLE RUST CONTAMINATION REPAIR

Models
'94 - Current Toyota & '04 - Current Scion

TSB REVISION NOTICE:
^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Magic ©Special Cleaner Concentrate is not an oxalic acid solution); Applicable Vehicles has been defined more clearly.
The previous TSB should be discarded.

Introduction
The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust.

Applicable Vehicles
^ 1994 - Current model year Toyota vehicles.
^ 2004 - Current model year Scion vehicles.

Condition
During rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks train wheels exposure to heavy machinery facilities gnnding welding etc.

Inspection
This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as hood roof or deck lid.

Caution: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance.

Repair
Washing the affected paint surfaces with Auto Magic ©Special Cleaner Concentrate is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto Magic ©Special Cleaner Concentrate is described in this bulletin.

Warranty Information






Required Tools & Materials






General Precautions
Warning: Auto Magic ©Special Cleaner Concentrate is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use.

Caution: Consult local or state regulations regarding the handling, use, and disposal of Auto Magic ©Special Cleaner Concentrate prior to use.

Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result.

Repair Procedure

1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water.

2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface.

3. Thoroughly rinse vehicle with fresh water.

4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal.

5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish.

CBR_GUY_IA

HEATING & AIR CONDITIONING
AC009-04

Title:
SENSOR INSPECTION FOR AIR
CONDITIONING SYSTEM

Models
'89 - Current All Models

December 16, 2004

Introduction

This service bulletin contains inspection procedures to more precisely confirm proper operation of the following temperature sensors of the air conditioning system. Follow the procedures in this service bulletin when inspecting these sensors. These contents will be reflected in future repair manuals.

^ Room Temperature Sensor

^ Ambient Temperature Sensor

^ Air Duct Sensor

^ Evaporator Temperature Sensor

^ Solar Sensor Room Humidity Sensor


Applicable Vehicles

All 1989 - Current model year Toyota vehicles.







Warranty Information

Inspection Procedure

1. Inspect Room Temperature Sensor.












A. Measure the sensor resistance.


NOTE :

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.








HINT :As the temperature increases, the resistance decreases.












2. Inspect Ambient Temperature Sensor.

A. Measure the sensor resistance according to the selected graph (specification).



NOTE :

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.








HINT :As the temperature increases, the resistance decreases.

3. Inspect Air Duct Sensor.

A. Measure the sensor resistance according to the table and graph (specification).



NOTE :

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.








HINT :As the temperature increases, the resistance decreases.







4. Inspect Evaporator Temperature Sensor.












Select the appropriate graph (specification) using the table.

NOTE :Please inspect the sensors for model years not indicated by this bulletin, according to the instructions in the applicable repair manual.












A. Measure the sensor resistance according to the selected graph (specification).

NOTE :

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.


HINT :As the temperature increases, the resistance decreases.

5. Inspect Solar Sensor.








Four types of solar sensors are used on Toyota vehicles depending on the vehicle specifications. The inspection procedure for each type of sensor differs from the others. Select the appropriate inspection procedure from the table according to vehicle specifications and perform the inspection.

Procedure A:







a. Disconnect the solar sensor connector.

b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.


NOTE :

^ Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, connect the positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor.


HINT :If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.








Standard:

Procedure B:







a. Disconnect the solar sensor connector.

b. Measure the resistance between terminals 2 and 3 of the solar sensor under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.


NOTE :When using an analog tester, connect the positive (+) lead to terminal 3 and negative (-) lead to terminal 2 of the solar sensor.

HINT :If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.








Standard:

Procedure C:

a. Turn the ignition switch ON.








b. Measure the voltage between terminals TSR (+) and CLTE (-) of the connector under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.


HINT :

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.









Standard:







c. Measure the voltage between terminals TSL (+) and CLTE (-) of the connector under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.


HINT :

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.









Standard:

Procedure D:

a. Turn the ignition switch ON.








b. Using the tester, measure the voltage between terminals TSD (+) and CLTE (-) of the connector under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.


HINT :

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.









Standard:

6. Inspect Room Humidity Sensor.












Measure the humidity and output voltage of the humidity sensor when the sensor is installed on the vehicle and the temperature at the humidity sensor position (room temperature sensor position) is 77°F (25°C). If the output voltage is within the specifications according to the graph and table, the sensor is normal.

HINT :For the inspection procedure of the room temperature sensor, refer to "Room Temperature Sensor Inspection Procedure" in this bulletin.

A. Turn the ignition switch to the ON position.

B. Measure the voltage between terminal VO (3) and GND (2) of the room humidity sensor.

C. Measure the humidity and voltage when the room temperature (humidity sensor position) is 77°F (25°C). According to the result, determine whether the sensor is normal or not.

CBR_GUY_IA

TRANSMISSION & CLUTCH
TC009-04

Title:
A340 TRANSMISSION SOLENOID IDENTIFICATION

Models:
Applicable 4Runner, Sequoia, T100, Tacoma & Tundra

December 15, 2004

Introduction

This service bulletin provides information on the proper identification of the 4 solenoids used in an A340 transmission.

Applicable Vehicles

^ 1990 - 2004 model year 4Runner vehicles.

^ 2001 - 2004 model year Sequoia vehicles.

^ 1993 - 1998 model year T1OO vehicles.

^ 1995 - 2005 model year Tacoma vehicles.

^ 2000 - 2004 model year Tundra vehicles.








Parts Information

Provided below is a chart listing the Repair Manual name of each solenoid used in the A340 transmission as well as the part name description provided in the Electronic Parts Catalog.

NOTE :Part numbers have not been included due to possible future part number changes.

Refer to the parts catalog for proper current part number.







Warranty Information







Transmission Solenoid Identification

CBR_GUY_IA

BODY
BO010-04
REVISED

Title:
REAR SEAT CENTER ARMREST
CUP HOLDER

Models:
'03 - '04 4Runner

June 7, 2004

TSB REVISION NOTICE :October 12, 2004: The image for Repair Procedure 5B has been updated.
The previous TSB should be discarded.

Introduction
The rear seat armrest and cup holder are now available as separate spare parts. Now, when replacing the cup holder, the rear seat armrest assembly does not have to be replaced.







NOTE :If the customer is experiencing an armrest cup holder rattle, please refer to TSB No. NV006-03 "Rear Seat Center Armrest Cup Holder Rattle."

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles.








Parts Information







Warranty Information

Repair Procedure

NOTE :If the customer is experiencing an armrest cup holder rattle, please refer to TSB No. NV006-03 "Rear Seat Center Armrest Cup Holder Rattle."







1. Remove Armrest from Seat.

2. Open Zipper on Rear of Armrest.

NOTE :The zipper is installed with its tabs tucked into the inside of the cover.

A. The ends of the zipper are concealed in the cover. Pull out both ends of the zipper from the cover.

B. To unlock the zipper, flip the zipper's tab so that it points away from the direction the zipper will be opened.

C. Open the zipper by pushing the tip of the tab.









3. Roll Up Cover.

A. After opening the zipper, roll up the cover.

B. Roll up the cover until the foam pad's 3 holes are revealed.









4. Remove Cup Holder.

A. Remove the screws from each of the 3 holes.

B. Pull the cup holder out of the armrest. If the cup holder is difficult to remove, hold the armrest with the cup holder facing down and shake the armrest for cup holder removal.


NOTE :Be careful not to drop the cup holder.








5. Install New Cup Holder.

A. Install the new cup holder by pushing it into the opening of the armrest.









B. When pushing the cup holder into the armrest, make sure that the plastic strips are retracted into the armrest interior.








C. Insert the cup holder until the cup holder's screw holes are aligned with the 3 circular holes on the armrest. After the cup holder has been aligned, once again make sure that the plastic strips are retracted into the armrest interior.

D. Install a screw in each of the 3 holes on the armrest to affix the armrest to the cup holder.

E. Make sure that the cup holder is secure by pulling on the cup holder.








6. Return Cover and Zipper to Their Original State.

A. Unroll the cover and close the zipper.









HINT :Use a piece of wire or a paper clip to facilitate re-zipping the zipper.








B. To lock the zipper, flip the zipper's tab so that it faces the direction the zipper would be opened.

C. Conceal the ends of the zipper inside the cover.

7. Install Armrest to Seat.

NOTE :Be careful not to damage the zipper or other exterior portions of the armrest.

CBR_GUY_IA

NVH
NVH013-03
REVISED

Title:
MOON ROOF (SLIDING ROOF) RATTLE

Models:
'03 - '04 4Runner

November 10, 2003

TSB REVISION NOTICE :^ September 7, 2004: Applicable Vehicles includes 2004 model year and a note has been added to the Production Change Information to clarify vehicles built at the Tahara and Hino plants.
^ January 22, 2004: "Notice".
^ November 20 2003: The Parts Information Table has been updated since the Sliding Roof Housing Sub-Assembly is not required for the repair procedure.
Previous versions of this TSB should be discarded.

TSB UPDATE NOTICE :This TSB updates NV003-03 and NVOO9-02. TSBs NVOO3-03 and NV009-02 are now obsolete and should be discarded.

Introduction







Customers may experience a persistent rattle noise from the moon roof (also known as a sliding roof). The following procedure has been developed to improve this condition.

Applicable Vehicles

2003 - 2004 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown in the Production Change Information table.







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

There are eight field fix methods covered on the following pages. One or all of these methods may be used depending on the source of the noise being addressed on a particular vehicle. The main source of rattle noise is the moon roof wind deflector rods (Section 1). It is highly recommended to re-test for the customer complaint after each section. Section 3 requires removal of the moon roof housing sub-assembly. Perform this section only after all other measures have failed.

Repair Procedure:
Section 1

SECTION 1: Install Tubing On Wind Deflector Rods

1. Add a piece of hose included in the Moon Roof Rattle Field Fix Kit (P/N 63207-35040) to moon roof wind deflector rod (both sides).

A. Open the moon roof to the full open position by pressing the rocker switch.


NOTE :The moon roof must be opened fully to ensure proper operation after the field fix is complete.







B. Remove the wind deflector by pressing down on the guide block release lever using a small screwdriver.

NOTICE :To prevent breakage of the guide block release lever when the outside temperature is below 40°F (40 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.







C. Pull back on the moon roof wind deflector guide block.

D. Slide the moon roof wind deflector toward the front of the moonroof.








E. Insert a small screwdriver between the moon roof wind deflector rod and the aluminum moon roof track and twist. The rod will snap free of the moon roof guide rail holder.








F. Replace the moon roof wind deflector guide rail holder with new service part included in the Moon Roof Rattle Field Fix Kit, (P/N 63207-35040), and apply grease included in the kit to the moon roof wind deflector guide rail holder.








G. Add piece of hose included in kit (P/N 63207-35040) to the moon roof wind deflector rod (both sides).

Sliding roof wind deflector rod hose:

L: 150 mm (6in.)

Internal diameter: 5 mm (0.2 in.)

External diameter: 8 mm (0.3 in.)

NOTE :Using a larger diameter hose may result in moon roof operation malfunction.








H. Reinstall the moon roof wind deflector rod and wind deflector.

NOTE :Ensure that the moon roof wind deflector rod is installed securely in the guide block's forward most position.

2. Apply grease included in the kit (P/N 63207-35040) to moon roof wind deflector rod clamp.

NOTE :The moon roof wind deflector rod clamp is located at the rear of the moon roof opening (both sides).

A. Ensure the moon roof is in the full open position.









B. Apply grease to the rod behind the clamp.

C. Partially close the moon roof then reopen. The moon roof wind deflector rod will have moved forward carrying grease inside the clamp.

HINT :Ensure grease gets between the rod and clamp surfaces.

D. Re-test vehicle for customer complaint. Stop here if customer complaint is resolved. If rattle noise is still present, continue on to Section 2.

Repair Procedure:
Section 2

SECTION 2: Apply Grease and Felt to Moon Roof Area







1. Apply felt squares to the guide rail garnish and the moon roof side garnish.

A. Remove the moon roof side garnish and moon roof guide rail garnish.

B. Apply three pieces of felt to the moon roof side garnish.

"a" Felt Dimensions:
Length: 10 mm (0.4 in.)
Width: 10 mm (0.4 in.)
Thickness: 1.0 mm (0.04 in.)

"b" Felt Dimensions:
Length: 15 mm (0.6 in.)
Width: 12 mm (0.5 in.)
Thickness: 1.0 mm (0.04 in.)













C. Apply nine felt pieces to the moon roof side rail garnish. Please see the table for felt sizes and locations.

D. Reinstall the moon roof guide rail garnish and moon roof side garnish.








2. Fit a piece of felt to the front side bottom of the moon roof garnish as shown in the illustration.

3. Reinstall the moon roof garnish.








4. Apply grease to drive cable pin. Using a brush, apply Body Grease W (P/N 08887-02007) to the housing drive cable pin as shown in the shaded area.

A. Tilt moon roof up.

B. Remove moon roof side garnish.

C. Apply grease to the pin as shown in the shaded area in the illustration.

D. Reinstall moon roof side garnish.


NOTE :Before reinstallation, see page 6 for modification to side garnish.








5. Apply grease to drive cable lifter pin.

Using a brush, apply Body Grease W (P/N 08887-02007) to the housing drive cable lifter pin surface as shown in the shaded area.

A. Tilt moon roof up.

B. Remove moon roof side garnish.

C. Apply grease to pin as shown in the shaded area in the illustration.

D. Reinstall moon roof side garnish.

E. Apply grease to drive cable pin.

F. Apply grease to drive cable lifter pin.









6. Fit three pieces of felt to the moon roof housing wind deflector tray.

A. Remove the original pieces of felt.

B. Apply one piece of felt to the center of the moon roof housing wind deflector tray.

C. Apply one piece each at the right and left corners of the moon roof housing wind deflector tray.


NOTE :If 4 mm (0.2 in.) thick felt is not available, multiple pieces may be layered in order to obtain the desired thickness.

7. Fit felt and clear tape to moon roof center reinforcement. Fit a piece of clear tape (P/N 3M SJ6595) and felt (2 mm (0.1 in.) thick from Noise Kit, P/N 08231-00801) to the center moon roof reinforcement.

8. Remove the interior light.

A. For the interior light with rear seat audio system, refer to the Technical Information System (TIS), 2003 4Runner Repair Manual: Exterior/Interior Trim: Roof Headlining: Replacement









B. For the interior light without rear seat audio system, disengage the 4 clips shown in the illustration.








9. Disconnect the four hook and loop fasteners located behind the sunshade that secure the roof headlining to the roof.

NOTE :It is not necessary to remove the headliner to complete this operation.








10. Measure and cut the tape and felt.








A. Cut clear tape (P/N 3M SJ6595) and felt (2 mm (0.1 in.) thick from Noise Kit, P/N 08231-00801) to the sizes shown in the illustration.

B. Remove release paper from tape.

NOTE o not remove the release paper from the felt.








C. Superimpose the felt onto the tape, and make four slits as shown in the illustration.

NOTE :Slits allow for air evacuation.








11. Lift up sunshade trim, position the tape and felt to the center upper surface of the center moon roof reinforcement (black metal painted parts) which is located rearward of the sunshade trim handle. Attach the tape securely to the reinforcement as shown in the illustration.

12. Reconnect the four hook and loop fasteners located behind the sunshade that secure the roof headliner to the roof.

13. Reinstall the interior light.

14. Re-test for customer complaint. Stop here if customer complaint resolved. If customer complaint still present, continue on to Section 3.


SECTION 3: Remove Moon Roof Housing Sub-Assembly and Apply Felt to Moon Roof Housing Brace

1. Apply two pieces of felt to the center moon roof housing reinforcement and two pieces of urethane sponge to the right and left drive cable housing.








A. Remove the moon roof housing from the vehicle (refer to the Technical Information System [TIS], 2003 4Runner Repair Manual: Sliding Roof/Convertible:

Sliding Roof: Replacement).








B. Cut felt to size indicated below and slide under the edge of the center moon roof housing reinforcement.

NOTE o not remove the release paper until the felt is properly positioned under the center moon roof housing reinforcement.

C. After removing the release paper, fold the felt over the top of the center moon roof housing reinforcement.

D. Complete steps "B" and "C" for both driver's and passenger's sides.









E. Wrap drive cables with urethane sponge at each corner.

NOTE :The location of the sponge should be where the cable housings cross at both right and left corners.