ELECTRICAL
EL009-04

Title:
POWER WINDOW / ROOF
INITIALIZATION PROCEDURES

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

August 10, 2004

Introduction

This bulletin clarifies the initialization procedures that are necessary if power is lost to the driver's door, moon roof, or back door ECU. It is necessary to re-initialize one or more of these systems if the main power source is lost either by a battery being disconnected, fuse being removed, or ECU disconnected from power. This TSB will aid in recognizing the available systems for faster and more accurate service.

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles.

^ 2004 model year Highlander, Prius, Sienna and Solara vehicles.


System Identification

The following table contains all the necessary information to correctly identify vehicles that require initialization. Always verify proper operation after the initialization procedure has been completed.







Application Chart







Warranty Information







Initialization Procedure

A. Power Window (Driver's Door) (4Runner, Prius, Sienna, Solara)

1. Turn the ignition switch ON.

2. Open the window halfway by pressing the power window switch.

3. Fully pull up the switch until the power window is fully closed and continue to hold the switch for at least three (3) seconds after the power window is fully closed.

4. Check that the "AUTO UP/DOWN" function operates normally.


B. Back Door Power Window (4Runner)

1. Turn the ignition switch ON.

2. Open the back door glass.

3. Press the back door power window switch until the door glass is fully closed and continue to hold the switch one (1) second or more after the door glass is fully closed.

4. Check that the "AUTO UP/DOWN" function operates normally.


C. Power Sliding Roof (4Runner, Sienna, Solara)

1. Turn the ignition switch ON.

2. Initialize the sliding roof by pressing and holding the TILT UP switch until the roof glass tilts upward fully (the roof glass automatically tilts downward slightly after fully tilting upward).

3. Release the switch.

4. Check that the "AUTO OPEN/CLOSE" function operates normally.


HINT :IF the AUTO OPEN/CLOSE function operates normally, reset operations have been completed at this time. However, if abnormal, follow these steps:

^ Disconnect the negative battery terminal for 12 seconds.

^ Reconnect the battery terminal.

^ Perform the initialization procedure.


D. Power Sliding Roof (Highlander)

1. Turn the ignition switch to the "ON" position.

2. Push and hold the moon roof switch to the "TILT - UP" side until the following cycle of the moon roof operation is completed.

Closing --> Fully tilt up --> Fully tilt down --> Fully slide open --> Fully slide close.

3. After the cycle of operation above is completed, the initialization is completed.

4. Check for the "One-touch slide open and close" and "One-touch tilt up and down" functions by pushing the switch briefly to the "SLIDE - OPEN" and "TILT - UP" sides.

BODY
BO013-04

June 15, 2004

Title:
SEAT CUSHION HEIGHT ADJUSTMENT HANDLE IMPROVEMENT

Models:
'03 - '04 4Runner

Introduction

Some 2003 and 2004 model year 4Runner vehicles may experience a condition where the seat cushion height adjustment handle is contacted while entering or exiting the vehicle causing the seat adjustment to change. A new seat cushion height adjustment handle has been developed to correct this condition.

Applicable Vehicles^ 2003 - 2004 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Warranty Information

Applicable Warranty:

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

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







Parts Information

Repair Procedure

Refer to the Technical Information System (T.I.S), 2003 or 2004 model year 4Runner Repair Manual: Seat; Front Seat Assembly LH (Manual Seat Type); Overhaul Step 3.

1. Remove the seat cushion height adjustment handle No. 2.








A. Using a screwdriver, disengage the 3 claws and remove the seat cushion height adjustment handle LH.

HINT: Tape the screwdriver tip before use.

B. Remove the 2 screws and the seat cushion height adjustment handle.

2. Replace the seat cushion height adjustment handle with a new service part.

3. Installation is the reverse order of removal.

ENGINE
EG015-04

Title:
EXCESSIVE SULFUR DIOXIDE ODOR

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

May 27, 2004

Introduction

Some customers may complain of excessive sulfur dioxide odor on 2003-2004 model year 4Runner (1GR-FE) vehicles under the following conditions:

^ Stop and go driving.

^ Heavy acceleration.

In order to reduce the sulfur dioxide odor, the Electronic Control Module (ECM) (SAE term: Powertrain Control Module/PCM) fuel cut control logic has been modified and a new catalyst is provided. Follow the repair procedure to reflash the ECM and replace the catalytic converter assembly.
NOTE :For more complete understanding of the root cause, refer to TSB No. EG003-03 "Sulfur Odor From Exhaust," dated February 24, 2003.

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles equipped with the 1GR-FE engine produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Specified Major Emission Control Component Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.

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












Parts Information

NOTE :Authorized Modification Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through Dealer Daily or by calling the MDC at 1-800-622-2033.







Required SSTs







ECM (PCM) Identification Chart

NOTE :2003 model year 4Runner vehicles, which have been flash reprogrammed using the procedures in this TSB, will contain upgraded 2004 model year OBD Illogic. Refer to the 2004 model year 4Runner Repair Manual information on the Technical Information System (TIS) when checking Powertrain Diagnostic Trouble Codes (DTCs) on 2003 model year vehicles that have been reprogrammed.

ECM Reprogram Procedure







1. Check for the Authorized Modification Label affixed to the vehicle in the location shown in Figure 2. If there is no label present, proceed to step 2.








2. Connect the Diagnostic Tester to the vehicle and select "CURRENT ECU CAL" from the "ECU REPROGRAM MAIN MENU." To determine the vehicle's current ECM (PCM) calibration, see Figure 1 shown.

3. Proceed to Flash Reprogram the ECM (PCM) by following the procedures in TSB No. 55002-01 titled "ECU Flash Reprogramming Process," for 2001 and later applicable models.

NOTE :Errors during the flash reprogramming process can PERMANENTLY DAMAGE the vehicle's ECM (PCM). In order to minimize this risk follow the steps below:

^ Make sure that the current battery voltage is no less than 11.4 volts.

^ Install a battery charger and set on a low setting to assure that the battery voltage DOES NOT FALL BELOW 11.4 VOLTS during the reprogramming.

^ If battery's state of charge is in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester."

^ Confirm that the engine hood is up, parking brake is set and all accessories are OFF (i.e., audio system, A/C, interior lights, headlights, etc).

^ DO NOT perform the reprogramming process until the engine room temperature is 158°F (70°C) or less.

^ Confirm cable connections between the vehicle and the Diagnostic Tester are secured.

^ In case of Error Message "Cannot Go To Reprogram Mode," refer to TSB No. SS00-01 "ECU Flash Reprogramming Error Message."

^ Do not interrupt the vehicle during the reprogramming process, keep all doors closed.


4. Select the proper ECM (PCM) calibration file for the model year vehicle and reprogram the ECM (PCM).

5. After completing the ECM (PCM) reprogram, the zero point calibration must be performed. Refer to TSB No. BR001-04 "Zero Point Calibration."

6. Start the engine and warm up the vehicle to normal operating temperatures before test-driving.

7. Test drive vehicle to confirm proper operation and to readjust the ECM (PCM) "Learned Values."

^ Drive the vehicle using light to moderate acceleration in mostly stop and go type driving.

^ Allow the vehicle to shift fully through all gears and at various shifter positions (D, 3, 2, L).


8. Enter the following information on the Authorized Modification Label shown in Figure 2 using a permanent marker.

^ ECM (PCM) part number.

^ New ECM (PCM) calibration number.

^ Your dealer code.

^ Reprogramming date.

^ This TSB number.



Catalytic Converter Replacement Procedure

Refer to the Technical Information System (TIS) 2003 or 2004 model year 4Runner Repair Manual: Exhaust Pipe Assy (1GR-FE).

DRIVELINE & DIFFERENTIAL
DL001-04
REVISED

Title:
4WD ECU SERVICE PRECAUTIONS

Models:
'03 - '04 4Runner

April 29, 2004

TSB REVISION NOTICE :May 12, 2004: The Applicable Vehicles section has been changed.
All previous versions of this TSB should be discarded.

Introduction

When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing Repair Manual diagnostic procedures may cause the transfer case actuator to activate and damage the transfer case actuator.

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles equipped with V6 or V8 engines and multi-mode 4WD and full-time 4WD ONLY.


Repair Procedure

CAUTION :Irreparable damage to the transfer case actuator may result when the proper precautions and repair procedures are NOT followed. Damage to the actuator caused by improper repair procedures is NOT a warrantable repair.

Refer to the Technical Information System (TIS) for proper repair precautions. Use the applicable model year 4Runner Repair Manual: Introduction; Repair Instruction; Precaution.







Warranty Information

BODY
BO005-04
REVISED

Title:
WINDSHIELD MOLDING DEFORMATION

Models:
'03 - '04 4Runner

March 19, 2004

TSB REVISION NOTICE :April 28, 2004: A note has been added to step 4 to clarify the removal of the roof rack. All previous versions of this TSB should be discarded.

Introduction
Some 2003 - 2004 model year 4Runner vehicles may experience windshield moldings that have warped or lifted. Replace windshield moldings with a new service part to correct the condition.

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Warranty Information

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

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







Required SSTs







Required Tools & Material







Parts Information

4Runner with Roof Rack Repair Procedure

For further information, refer to the Technical Information System (TIS): 2003 or 2004 model year 4Runner Repair Manual: Exterior/Interior Trim: Roof Drip Side Finish Moulding LH.







1. Remove the roof rack assembly.

2. Remove the front roof rack leg cover.

A. Using a screwdriver, disengage the four claws and clip that secure the leg cover to the roof rack end support leg.


NOTE :Tape the screwdriver tip before use to help prevent vehicle damage.

3. Repeat step 2 for each of the remaining three leg covers.

4. Remove the eight bolts that secure the roof rack legs to the roof.








NOTE :To help prevent nut plate from disengaging and coming loose from the roof assembly, remove bolts identified with a "1" first, then remove bolts identified with a "2."

5. Using a torx wrench (T25), remove the eight bolts from the underside of the right and left side roof rack cross bar joints. Remove roof rack assembly from vehicle roof.








6. Remove front fender to cowl side seal.

A. The fender to cowl side seal is held in place with a clip and two claws.

B. With the hood open, use the SST plastic pry tool to pry the side seal loose.

^ SST P/N 00002-06000-01


C. Remove the fender to cowl side seal.









7. Remove windshield molding.

A. Starting at the base of the windshield, carefully pull the windshield molding out by hand.









8. Thoroughly clean the roof rail with 3M(TM) General Purpose Adhesive Cleaner (3M(TM) P/N 08984) to ensure proper adhesion of the new windshield molding.

9. Install outside windshield molding No. 1.








A. Install the middle of the molding securely against the upper windshield molding as shown in the illustration.

B. Remove the backing from each of the two areas of adhesive tape and install the rear end of the molding to the roof.

C. Install the front end of the molding along the side of the windshield.

10. Reinstall the front fender to cowl side seal.

11. Reinstall the roof rack assembly in reverse order of removal.

A. Using 3MTM General Purpose Adhesive Cleaner (3M(TM) P/N 08984), clean the adhesive from the bolts and threads.









B. Apply Loc-Tite(R) Permanent Strength Thread Locker (Loc-Tite(R) P/N Loc-Tite(R) 26231) to the last two or three threads at the bolt end.








12. Install the right and left roof rack assembly with the eight bolts.

Torque: 7.4 ft.lbf (10.0 N.m, 102 kgf.cm)








NOTE :Use new seals (P/N 63437-60020) for each of the eight roof rack assembly bolts.

4Runner without Roof Rack Repair Procedure







1. Remove front roof drip side molding end cover.

A. Using a screwdriver, disengage the two claws and remove the molding end cover.


NOTE :Tape the screwdriver tip before use to help prevent vehicle damage.








2. Remove front fender to cowl side seal.

A. The fender to cowl side seal is held in place with a clip and two claws.

B. With the hood open, use a plastic pry tool to pry the side seal loose.

^ SST P/N 00002-06000-01


C. Remove the fender to cowl side seal.









3. Remove windshield molding.

A. Starting at the base of the windshield, carefully pull the windshield molding out by hand.









4. Thoroughly clean the exposed metal roof rail as shown to the right with 3M(TM) General Purpose Adhesive Cleaner (3M(TM) P/N 08984) to ensure proper adhesion of the new windshield molding.

5. Install outside windshield molding No. 1.








A. Install the middle of the molding securely against the upper windshield molding as shown in the illustration.

B. Remove the backing from each of the 2 areas of adhesive tape and install the rear end of the molding to the roof.

C. Install the front end of the molding along the side of the windshield.

6. Reinstall the front fender to cowl side seal.

7. Reinstall the roof front drip side molding end cover.

BODY
BO007-04

Title:
FRONT SEAT TRACK COVER
REMOVAL PROCESS

Models:
'03 - '04 4Runner

April 28, 2004

Introduction







Please follow this TSB for proper removal methods for front seat track covers (track cover).

Applicable Vehicles

^ 2003 - 2004 model year 4Runner vehicles.








Warranty Information

Removal and Installation Procedure

1. Remove the seat track bracket cover.

A. Insert a flat-head screwdriver approximately 5.0 mm (0.197 in.) into the area between the track cover interior claw's lower part and floor carpet.


NOTE :Tape the screwdriver tip before use.












B. Place an object with a height of approximately 5.0 to 8.0 mm (0.197 to 0.315 in.) below the screwdriver. Use the object as the screwdriver's fulcrum and push down on the screwdriver to release the track cover's inside claw, as shown in the illustration.








C. Lift up the front tip of the track cover (1). Then push the inside claw (2) toward the claw on the opposite side to release the outside claw.








D. After the 2 claws have been released, carefully lift up and remove the track cover.








2. Reinstall track cover.

NOTE :Be sure to check for damage to the track cover before reinstalling. If track cover is damaged, replace it with a new service part.


Install the seat track bracket cover outer FR LH.

A. Insert the track cover interior 2 guides in between the seat rail and seat leg. Then slightly lift up the track cover's rear part (1) and carefully push the track cover in until it cannot be pushed in any further (2).








B. Carefully insert the track cover's exterior claw into the seat leg corner's groove according to the procedure shown in the illustration
(1 --> 2 --> 3).

C. Carefully push the cover directly from the top of the track cover's interior claw to insert it into the seat leg corner's groove, as shown in the illustration (4).

D. Wiggle the seat track cover to ensure that it is snapped securely into place.

NOTE :Use the same installation procedure on other locations.

NVH
NV002-04

March 17, 2004

Title:
BODY MOUNT NOISE

Models:
'03 4Runner

Introduction







The following field fix procedure was developed to help reduce the possibility of noise from the left front body mount.

Applicable Vehicles^ 2003 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.

Repair Procedure







Before performing field fix procedures contained in this bulletin, remove the nut, flat washer and lower cushion from the left front body mount, or any other body mount that exhibits noise, and inspect the upper cushion for damage as shown. If the upper cushion is damaged, out of position, and/or contact between the bolt collar and the frame body mounting flange is evident, follow the procedures provided below.







1. Align body with frame.

A. Loosen all eight (8) body mounts.

B. Remove the nut, flat washer and lower cushion from each of the eight (8) body mounting bolts.

C. Remove the bolts, bolt collars and upper cushions from each of the eight (8) body mounts.

NOTE: Replace any damaged body mount parts before reassembly.

2. Adjust body-to-frame alignment to achieve proper body mount alignment.

3. Reinstall each of the eight (8) body mounts in reverse order of removal.

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

ELECTRICAL
EL003-04

March 3, 2004

Title:
JUMP STARTING VEHICLES EQUIPPED WITH CRANK HOLD FEATURE

Models:
'03 (& Later) 4Runner, Land Cruiser, Sequoia & Tundra

Introduction

The Crank Hold System was introduced on applicable vehicles beginning with the 2003 model year for improved starting and starting system reliability.

The Engine Control Module (ECM, SAE term: Powertrain Control Module/PCM) controls the starter in vehicles equipped with the Crank Hold System. In the event of a discharged battery, follow the procedures listed in this bulletin.

Applicable Vehicles^ 2003 (and later) model year 4Runner, Land Cruiser, Sequoia and Tundra vehicles equipped with the Crank Hold System.








Required SSTs

NOTE: Additional SSTs may be ordered by calling SPX-OTC at 1-800-933-8335.







Warranty Information

Jump Start Instruction

This system requires higher battery voltage than a conventional starting system to operate. In addition to following the jump start procedures found in the applicable Owner's Manual, vehicles with a very low state of charge (below 6 volts) may require some extra steps to get started.

^ Use very good quality jump cables or jump boxes.

^ It is necessary to have the donor vehicle's engine running while jump starting.

^ Extended connection time to a donor vehicle is sometimes necessary to bring the discharged battery up to a minimum required voltage.

^ You will NOT be able to jump start a vehicle with a frozen battery.

^ Vehicle batteries with a very low state of charge may require some charging before the vehicle will jump start.

NOTE: Never jump start a vehicle with a frozen battery. This will put undue stress on the charging system once the vehicle is started. Bring the frozen battery into a warm building and charge after it has thawed out. Test battery with a Toyota Midtronics Battery Tester before returning to service.

BODY
BO001-04

January 14, 2004

Title
BACK DOOR STAY (DAMPER)

Models
'03 4Runner

Introduction

To ensure back door support on certain 2003 model year 4Runner vehicles, the back door stays have been changed.







NOTE: Before installing new back door stays, check the lot number located at the base of each stay body as indicated in the illustration shown. If the lot numbers match those indicated below, do NOT install them:

^ RH: 1EK25WJ80

^ LH: 1EK25WJ84








Parts Information







Warranty Information

Applicable Warranty*:

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

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

Repair Procedure

For further information, refer to the Technical Information System (TIS): 2003 model year 4Runner Repair Manual: Engine Hood/Door: Back Door Damper Stay Sub-assembly LH.

1. Remove the back door stay sub-assembly.








A. Remove the two bolts that secure the stay to the back door.

HINT: Ensure the back door is properly supported in the open position before removing the two back door stay bolts from the back door.

B. Remove the one bolt that secures the stay to the vehicle body.








NOTE: Before installing new back door stays, check the lot number located at the base of each stay body as indicated in the illustration. If the lot numbers match those indicated below, do NOT install them:

^ RH: 1EK25WJ80

^ LH: 1EK25WJ84

2. Install the new back door stay.

A. Install the two bolts that secure the stay to the back door.

Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)

B. Install the one bolt that secures the stay to the vehicle body.

Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)


3. Repeat steps 1 and 2 for the opposite side.

SPECIAL SERVICE TOOLS
SS002-03

December 17, 2003

Title
O2S TEST RESULTS (MODE 05)

Models
All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB

Introduction

This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition.

Applicable Vehicles^ All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.


Function Description

Checking O2S Test Results

To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete.

The process for checking 02S test results is described in the following three basic steps:

1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.








Required SSTs

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







Warranty Information

Completing O2S Readiness Monitor

1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.

2. Start the engine.








3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.

HINT: The 02S Monitor is completed when the following conditions are met:

^ Two (2) minutes or more passed after the engine start.

^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.

^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.

^ Vehicle is in closed loop.

^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).

A. Allow the engine to idle for two minutes.

B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).

C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.

D. Stop the vehicle and allow the engine to idle for more than 20 seconds.

E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)


In addition, perform the following steps for the Rear O2S Readiness Monitor:

A. Select second gear.

B. Allow the vehicle to run at 30 mph (48 km/h) or more.

C. Keep the accelerator pedal "off-idle" for more than 10 seconds.

D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut).

E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).

F. Repeat steps B - E at least twice in one driving cycle.



Accessing O2S Test Results

1. On the Diagnostic Tester* screen, select the following menus:

^ DIAGNOSTICS

^ CARB OBD II

^ O2S TEST RESULTS









A list of the available oxygen sensors will be displayed.

2. Select the desired oxygen sensor and press Enter.

NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display."








3. Compare the test results with the values listed in the Failure Threshold Chart.

* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures.


Comparing O2S Test Results to Failure Thresholds

1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin.








2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.

3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example.

Example:








A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).

B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart.

C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."

17 x 0.3906 = 6.6%

D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal.

NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.

^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.

^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.

^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.

NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255).



























O2S Application Table

O2S Failure Threshold Charts







CHART 1







CHART 2







CHART 3







CHART 4







CHART 5







CHART 6







CHART 7







CHART 8







CHART 9







CHART 10







CHART 11







CHART 12







CHART 13







CHART 14







CHART 15







CHART 16







CHART 17







CHART 18







CHART 19







CHART 20












CHART 21







CHART 22












CHART 23












CHART 24







CHART 25












CHART 26












CHART 27












CHART 28












CHART 29







CHART 30

BRAKES
BR005-03

December 4, 2003

Title
VSC LIGHT ON - DTC C1203

Models
'03 4Runner

Introduction

Some 2003 model year 4Runner vehicles may experience a VSC light ON condition and DTC C1203 in the Skid Control Computer memory. A modification to the Skid Control Computer logic has been made to prevent this condition.

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








Production Change Information







Warranty Information

Applicable Warranty:

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

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







Required SSTs

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







Parts Information

The identification method is as follows:

1. A yellow 15 mm round sticker is affixed near the part number label on the supply part box, not on the part. The yellow sticker identifying the countermeasure (C/M) part will be discontinued at the end of March, 2004.

2. After the yellow sticker is discontinued, confirm the C/M part by inspecting the lot number on the Skid Control Computer.








3. The lot number on the Skid Control Computer part number label must be "3H18" or later.


Repair Procedure

1. Remove Instrument Panel Finish Plate.

2. Remove Instrument Panel Finish Panel Sub-assembly Lower.

3. Remove Instrument Panel Lower LH.

4. Remove Instrument Panel Junction Block Assembly.








A. Remove the bolt and 2 nuts, then move the instrument panel junction block assembly aside.

5. Remove Skid Control Computer Assembly.

A. Disconnect the 4 Skid Control Computer assembly connectors.









B. Remove the 2 nuts and the Skid Control Computer assembly.

C. Disconnect the skid control buzzer connector and remove the skid control buzzer assembly from Skid Control Computer assembly.

6. Install Skid Control Computer Assembly.

A. Install the skid control buzzer on the Skid Control Computer assembly, and connect the skid control buzzer connector.









B. Install the Skid Control Computer assembly with 2 nuts.

Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)

C. Connect the 4 Skid Control Computer assembly connectors.

7. Install Instrument Panel Junction Block Assembly.








A. Install the instrument panel junction block assembly with bolt and 2 nuts.

8. Install Instrument Panel Lower LH.

9. Install Instrument Panel Finish. Panel Sub-assembly Lower.

10. Install Instrument Panel Finish Plate.

11. Perform Zero Point Calibration of Yaw Rate and Deceleration Sensors as shown.


Calibration Procedure With Diagnostic Tester

Zero Point Calibration of Yaw Rate and Deceleration Sensors Using the Diagnostic Tester.

When having replaced the yaw rate sensor, deceleration sensor or the ECU, perform the process for zero point of yaw rate and deceleration sensors as shown below.

NOTE: While performing the zero point procedure, do not tilt, move or shake the vehicle. The vehicle must remain in a stationary condition throughout the entire process. Do not start the engine and be sure to perform the procedure on a level surface with an inclination of less than 1%.

1. Connect Diagnostic Tester to DLC3.












2. Follow the flow chart shown for the calibration procedure.


Calibration Procedure With SST

Zero Point Calibration of Yaw Rate and Deceleration Sensors Using SST 09843-18040.

When having replaced the yaw rate sensor, deceleration sensor or the ECU, perform the process for zero point of yaw rate and deceleration sensors as shown below.

NOTE: While performing the zero point procedure, do not tilt, move or shake the vehicle. The vehicle must remain in a stationary condition throughout the entire process. Do not start the engine and be sure to perform the procedure on a level surface with an inclination of less than 1%.

1. Ensure the shift lever is in "P" range.

2. Turn the ignition switch ON.








3. Using SST 09843-18040, repeat a cycle of short and open between terminals Ts and CG of DLC3 4 times or more within 8 seconds. Verify that the VSC indicator light is lit indicating the recorded zero point is erased.

4. Turn the ignition switch OFF.

5. Be sure the terminals Ts and CG of DLC3 are disconnected.

6. Turn the ignition switch ON.

7. Check that the VSC warning light goes off about 15 seconds after the ignition switch is turned ON.

8. After ensuring that the VSC warning light remains OFF for 2 seconds, turn the ignition switch OFF.

9. Connect the terminal Ts and CG of DLC3 using SST 09843-18040.

10. Turn the ignition switch ON.

11. After turning the ignition switch ON, check that the VSC warning light is lit for about 4 seconds and then starts quick blinking at 0.13 second intervals.

12. After ensuring the blinking of the VSC warning light for 2 seconds, turn the ignition switch OFF.

13. Remove the SST from terminals Ts and CG of DLC3.


Confirm Zero Point Calibration

Drive the vehicle to confirm there are no re-occurring lights or DTCs.

NVH
NV013-03
REVISED

November 10, 2003

Title:
MOON ROOF (SLIDING ROOF) RATTLE

Models:
'03 4Runner

TSB UPDATE NOTICE:

This TSB updates NV003-03 and NV009-02 TSBs NV003-03 and NV009-02 are now obsolete and should be discarded.

TSB REVISION 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.

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 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown below.








Production Change Information







Warranty Information

Applicable Warranty:

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

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







Parts Information

Repair Procedure

There are eight field fix methods covered. 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.

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.








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

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








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
Internal diameter: 5 mm
External diameter: B mm

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 root 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 root 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.


SECTION 2: Apply Grea3e 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
Width: 10 mm
Thickness: 1.0 mm

"b" Felt Dimensions:
Length: 15 mm
Width: 12 mm
Thickness: 1.0 mm













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 modify the 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 off 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 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 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 thick from Noise Kit, P/N 08231-00801) to the sizes shown in the illustration.

B. Remove release paper from tape.

NOTE: Do 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 and slide under the edge of the center moon roof housing reinforcement.

NOTE: Do 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.

ELECTRICAL
EL016-03

October 24, 2003

Title:
IMMOBILIZER SYSTEM: VEHICLES EQUIPPED WITH TRANSPONDER ECU

Models:
'01 - '03 Prius & '03 4Runner, Camry, Land Cruiser & Sequoia

Introduction

On Toyota vehicles that are equipped with the Immobilizer system, the Immobilizer function is either incorporated in the ECM (SAE term: Powertrain Control Module/PCM) or in a separate Transponder ECU. This TSB clarifies Immobilizer related service procedures on vehicles equipped with a Transponder ECU.

Applicable Vehicles^ 2001 - 2003 model year Prius vehicles.
^ 2003 model year 4Runner, Land Cruiser, and Sequoia vehicles.
^ 2003 model year Camry vehicles equipped with 1MZ - FE engine and 5-speed Automatic Transmission.








Required SSTs

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







Warranty Information

Operation Procedure

For vehicles equipped with the Transponder ECU, the Immobilizer disables the engine from starting (via fuel and spark delivery) utilizing an ignition key with an ID code. Transponder ECU systems communicate with a transponder chip embedded in the grip of the ignition key. This ID code is different for each key and must be registered in the vehicle Transponder ECU.







With the exception of Prius, Immobilizer keys designed for transponder type systems are identified by a dot ("o") mark on the key shank just below the key grip (see illustration).

NOTE: The part numbers for these transponder type keys are new; it is recommended that your parts department look up the correct Immobilizer keys for your particular application. Previous model year's Master and Sub keys are incompatible with the models listed in "Applicable Vehicles."







Immobilizer functions vary by model. Use the chart as an aid when identifying Immobilizer keys and functions.

Immobilizer Reset and Diagnostic Tester Support:

For most vehicles, the Diagnostic Tester incorporates support to add, delete or remove keys into the Immobilizer system. To perform the Immobilizer functions it is necessary to have the most current Diagnostic Tester software available. For more detailed Diagnostic Tester information, refer to TSB No. SS003-02, "Diagnostic Tester Immobilizer Functions."

ECU ID Communication:

When replacing the ECM (SAE term: PCM) or the Transponder ECU a "handshake" procedure must be performed. This ECU ID communication is necessary to enable the Transponder ECU and the ECM to recognize each other before the vehicle will start.

Complete ECU communication using the following steps:

1. Insert a Master key into the ignition cylinder.

2. Turn the ignition ON (engine OFF).

3. Short Tc and CG terminals of DLC3 using the Diagnostic Check Wire (SST 09843-18020 or equivalent) and leave for 30 minutes.

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

5. Register any additional keys as necessary.

6. Start the vehicle to confirm successful ECU communication.


Key Programming:







To program or delete a key, a registered Master key is necessary unless the Transponder ECU has been reset or replaced. The Transponder ECU system incorporates a black "Master" key and a gray "Sub" key. The process during registration of these two keys is identical. The key itself now determines if it functions as Master or Sub, not the registration procedure. The maximum number of allowable Master and Sub keys vary by model. Refer to the chart.

For additional details related to Immobilizer, refer to the vehicle specific Repair Manual on the Technical Information System (TIS) or TSB No. SS003-02, "Diagnostic Tester Immobilizer Functions."

BODY
BO019-03

October 17, 2003

Title:
REAR WIPER ARM PERFORMANCE

Models:
'03 4Runner

Introduction







The rear wiper arm hinge has been strengthened to improve performance on 2003 model year 4Runner vehicles.

Applicable Vehicles^ 2003 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.

Repair Procedure

For more information, refer to the Technical Information System (TIS) 2003 4Runner Repair Manual: Wiper & Washer, Rear Wiper Motor Assembly.







1. Remove the rear wiper arm head cap by releasing the four claws.

2. Remove the retainer nut, then remove the rear wiper arm.








3. Install new rear wiper arm.

A. Clean the rear wiper pivot serration with a wire brush.

B. Ensure the rear wiper motor is in the automatic stop position.

HINT: To ensure that the rear wiper is in the automatic stop position:a) Turn the rear wiper motor switch to the ON position.
b) Turn the wiper motor switch to the OFF position.









C. Hold the slider in position "A" and install the arm and blade assembly temporarily with the retainer nut finger tight.

D. Move the slider into position "B" and tighten the nut to complete wirer arm installation.

Torque: 5.5 Nm (56 kgf.cm, 49 in..lbf)

HINT: Hold down on the wiper arm at the hinge point with firm pressure to facilitate retainer nut installation.

E. Move the rear wiper arm assembly back to position "A".

F. Check for proper operation of the rear wiper using caution not to scratch the glass.

NOTE: To prevent scratching of the glass surface, use running water or windshield washer fluid to lubricate the surface of the rear glass when operating the rear wiper.

NVH
NV006-03
REVISED

June 24, 2003

Title:
REAR SEAT CENTER ARMREST CUP HOLDER RATTLE

Models:
'03 4Runner

TSB REVISION NOTICE :September 30, 2003: VIN information has been added. The previous TSB should be discarded.

Introduction

Some customers may experience abnormal noise from the rear seat armrest cup holder while driving. The following procedure was developed to reduce noise from this area.

Applicable Vehicles^ 2003 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 Tools & Material

Repair Procedure







1. Open the rear seat center armrest cup holder.












2. Fit two pieces of felt to the back side of the rear seat center armrest cup holder as shown.

Length: 175.0 mm
Width: 10.0 mm
Thickness: 1.0 mm









3. Cut two pieces of felt to the dimensions shown.








4. Place the two pieces of felt on top of the manufacturer applied felt in the locations shown.