Toyota Camry service and repair manual 2012 2013 2014 2015 2016 2017

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2012-2017 TOYOTA CAMRY SERVICE AND REPAIR MANUAL

GENERAL INFORMATION Commonly Used Abbreviations

* PLEASE READ THIS FIRST * NOTE:

This article is intended for general information purposes only. This information may not apply to all makes and models. Not all abbreviations are covered as manufacturers add new ones every day.

"A" A Amperes ABS Anti-Lock Brakes ABRS Air Bag Restraint System AC Alternating Current A/C Air Conditioning ACCS A/C Cycling Switch ACCUM Accumulator ACCY Accessory ACT

Air Charge Temperature Sensor ADJ Adjust or Adjustable ADV Advance AFS Airflow Sensor AI Air Injection AIR or A.I.R. Air Injection Reactor AIS Air Injection System Alt. Alternator or Altitude Amp./amp/amps Ampere ASCS Air Suction Control Solenoid ASD Auto Shutdown ASDM Air Bag System Diagnostic Module ASV

Air Suction Valve A/T Automatic Transmission/Transaxle ATC Automatic Temperature Control ATDC After Top Dead Center ATF Automatic Transmission Fluid ATS Air Temperature Sensor Aux. Auxiliary Avg. Average AXOD Automatic Transaxle Overdrive (Ford Models Only)

"B" BAC By-Pass Air Control BAP Barometric Absolute Pressure Sensor BARO Barometric

Batt. Battery Bbl. Barrel (Example: 4-Bbl.) BCM Body Control Module BHP Brake Horsepower BMAP Barometric and Manifold Absolute Pressure Sensor BOO Brake On-Off Switch B/P Backpressure BPS Barometric Pressure Sensor BPT Backpressure Transducer BTDC Before Top Dead Center BTSI Brake Transmission Shift Interlock BTU British Thermal Unit

BVSV Bimetallic Vacuum Switching Valve

"C" °C Celsius (Degrees) Calif. California CANP Canister Purge CARB California Air Resources Board CAT Catalytic Converter CB Circuit Breaker CBD Closed Bowl Distributor cc cubic centimeter CCC Close Coupled Catalyst CCC Computer Command Control CCD

Computer Controlled Dwell CCOT Cycling Clutch Orifice Tube CCW Counterclockwise CDI Capacitor Discharge Ignition CEC Computerized Engine Control CID Cubic Inch Displacement cm Centimeter CMP Camshaft Position Sensor CO Carbon Monoxide CO2 Carbon Dioxide Cont. Continued CONV Convertible CP

Canister Purge CKP Crankshaft Position Sensor CTS Coolant Temperature Sensor Cu. In. Cubic Inch CVC Constant Vacuum Control CV Check Valve or Constant Velocity CW Clockwise CYL or Cyl. Cylinder C3 I Computer Controlled Coil Ignition C4 Computer Controlled Catalytic Converter

"D" "D" Drive DC

Direct Current Or Discharge DDD Dual Diaphragm Distributor Def. Defrost Defog. Defogger DERM Diagnostic Energy Reserve Module DFI Digital Fuel Injection Diag. Diagnostic DTC Diagnostic Trouble Code DIC Driver Information Center DIS Distributorless Ignition System DIST Distribution DLC Data Link Connector DOC

Diesel Oxidation Catalyst DOHC Double Overhead Cam DOT Department of Transportation DPF Diesel Particulate Filter DRB-II Diagnostic Readout Box DVOM Digital Volt-Ohmmeter

"E" EACV Electric Air Control Valve EATX Electronic Automatic Transaxle EBCM Electronic Brake Control Module EBL Electronic Back Light ECM Engine Control Module ECT Engine Coolant Temperature Sensor

EDIS Electronic Distributorless Ignition System EEC Electronic Engine Control EECS Evaporative Emission Control System EEPROM Electronically Erasable PROM EFE Early Fuel Evaporation EGO Exhaust Gas Oxygen Sensor EGR Exhaust Gas Recirculation EOT Engine Oil Temperature ESA Electronic Spark Advance ESC Electronic Spark Control EST Electronic Spark Timing EVAP Fuel Evaporative System

EVIC Electronic Vehicle Information Center EVP EGR Valve Position Sensor EWMA Exponentially Weighted Moving Average (MODE 6) Exc. Except

"F" °F Fahrenheit (Degrees) F/B Fuse Block Fed. Federal FI Fuel Injection FICU Fuel Injection Control Unit FIPL Fuel Injector Pump Lever FLI Fuel Level Indicator FPR-VSV

Fuel Pressure Regulator Vacuum Switching Valve Ft. Lbs. Foot Pounds FWD Front Wheel Drive

"G" g grams Gals. gallons GND or GRND Ground

"H" HAC High Altitude Compensation HC Hydrocarbons H/D Heavy Duty HO2S Heated Exhaust Gas Oxygen Sensor Hg Mercury Hgt.

Height HLDT Headlight HO High Output HO2S Heated Oxygen Sensor HP High Performance HSC High Swirl Combustion HSO High Specific Output HTR Heater Hz Hertz (Cycles Per Second)

"I" IAC Idle Air Control IACV Idle Air Control Valve IAT Intake Air Temperature

IC Integrated Circuit ID Identification I.D. Inside Diameter IFS Independant Front Suspension IFS Inertia Fuel Shutoff (Ford) Ign. Ignition IMRC Intake Manifold Runner Control In. Inches INCH Lbs. Inch Pounds in. Hg Inches of Mercury Inj. Injector IP Instrument Panel

IRS Independant Rear Suspension ISC Idle Speed Control IVD Interactive Vehicle Dynamics (Ford) IVSV Idle Vacuum Switching Valve

"J" J/B Junction Block

"K" KAPWR Keep Alive Power k/ohms kilo-ohms (1000 ohms) kg Kilograms (weight) kg/cm2 Kilograms Per Square Centimeter KM/H Kilometers Per Hour KOEO

Key On, Engine Off KOER Key On, Engine Running KS Knock Sensor kW Kilowatt kV Kilovolt

"L" L Liter lbs. (Lbs. when used in table) Pounds LCD Liquid Crystal Display L/D Light Duty LDP Leak Detection Pump (Part of EVAP system.) LED Light Emitting Diode LH Left Hand

"M" mA Milliamps MA or MAF Mass Airflow MAFS Mass Airflow Sensor MAP Manifold Absolute Pressure MAT Manifold Air Temperature Mem. Memory MEM-CAL Memory Calibration Chip mfd. Microfarads MFI Multiport Fuel Injection MICU Multiplex Integrated Control Unit (Acura/Honda) MIL Malfunction Indicator Light MPI

Multi-Point (Fuel) Injection mm Millimeters MPH Miles Per Hour mV Millivolts

"N" NA Not Available NAC NOx Adsorber Catalyst NCA No Color Available (Wiring Diagrams) NGS New Generation Star N.m Newton Meter No. Number Nos. Numbers NOx Oxides of Nitrogen

"O" O2 Oxygen OBD On-Board Diagnostics OC Oxidation Catalyst OD Overdrive O.D. Outside Diameter OHC Overhead Camshaft OSS Output Speed Sensor O/S Oversize oz. Ounce ozs. Ounces

"P" "P"

Park P/C Printed Circuit PCM Powertrain Control Module PCS Purge Control Solenoid PC-SOL Purge Control Solenoid PCV Positive Crankcase Ventilation PFI Port Fuel Injection PGM-FI Programmed Fuel Injection PID Parameter Identification PIP Profile Ignition Pick-up PNP Park Neutral Position Switch P/N Park/Neutral PRNDL

Park Reverse Neutral Drive Low PROM Programmable Read-Only Memory psi Pounds Per Square Inch P/S Power Steering PSPS Power Steering Pressure Switch PTC Positive Temperature Coefficient PTO Power Take-Off Pts. Pints Pwr. Power

"Q" Qts. Quarts

"R" RABS Rear Anti-Lock Brake System RECIRC

Recirculation RH Right Hand RPM Revolutions Per Minute RWAL Rear Wheel Anti-Lock Brake RWD Rear Wheel Drive

"S" SAS Steering Angle Sensor SBC Single Bed Converter SBEC Single Board Engine Controller SDARS Satellite Digital Audio Radio Service SES Service Engine Soon SFI Sequential (Port) Fuel Injection SIL Shift Indicator Light

SIR Supplemental Inflatable Restraint SOHC Single Overhead Cam SOL or Sol. Solenoid SPFI Sequential Port Fuel Injection SPK Spark Control SPOUT Spark Output SRI Service Reminder Indicator SRS Supplemental Restraint System (Air Bag) STAR Self-Test Automatic Readout STO Self-Test Output SUB-O2 Sub Oxygen Sensor Sw. Switch

Sys. System

"T" TAB Thermactor Air By-Pass TAC Throttle Actuator Module TAD Thermactor Air Diverter TBC Body Control Module (General Motors) TBI Throttle Body Injection TCC Torque Converter Clutch TDC Top Dead Center Temp. Temperature TFI Thick Film Ignition THERMAC Thermostatic Air Cleaner TPM

Tire Pressure Monitor TPMS Tire Pressure Monitor System TPS Throttle Position Sensor/Switch TS Temperature Sensor TV Thermovalve TWC Three-Way Catalyst

"V" V Valve Vac. Vacuum VAF Vane Airflow VAPS Variable Assist Power Steering VCC Viscous Converter Clutch VCRM Variable Control Relay Module

VIN Vehicle Identification Number VM Vacuum Modulator Volt. Voltage VOM Volt-Ohmmeter (Analog) VRV Vacuum Regulator Valve VSS Vehicle Speed Sensor VSV Vacuum Switching Valve

"W" W/ With W/O Without WAC Wide Open Throttle A/C Switch WOT Wide Open Throttle

2012-2017 ACCESSORIES & EQUIPMENT Air Conditioning System (Service Information) (Hybrid)

REFRIGERANT ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HINT: The following examples show the readings of a manifold gauge set and the corresponding air conditioning system problems. a. Read the manifold gauge pressure when the following conditions are met:  Doors are fully open.  The power switch is on (READY).  The A/C switch is on.  The temperature is set to max cool.  The blower speed is set to high.  Temperature at the air inlet with recirculate selected is 30 to 35°C (86 to 95°F). 1. Normally functioning air conditioning system.

Fig. 1: Checking A/C Refrigeration Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GAUGE READING Pressure Refrigerant Side Volume 0.15 to 0.25 MPa (1.5 to 2.5 Low kgf/cm2 , 21 to 36 psi) 1.37 to 1.57 MPa (14 to High 16 kgf/cm2 , 199 to 228 psi) 2. Abnormally functioning air conditioning system. a. During operation, pressure on low pressure side cycles between normal and vacuum

Fig. 2: Identifying LO & HI Pressures Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system

periodically cools and Symptom then fails to cool. Moisture in air conditioning system freezes at expansion valve orifice, causing refrigerant to temporarily Probable Cause stop circulating After system stops, and warms up again, ice melts and normal operation is temporarily restored Cooler dryer (integrated into condenser tank) saturated with moisture Diagnosis

Moisture in air conditioning system freezes at expansion valve orifice and blocks circulation of

refrigerant Replace cooler dryer Remove moisture by repeatedly evacuating air from air conditioning system Corrective Actions Recharge air conditioning system with proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, moisture is present in the air conditioning system. b. Pressure is low on both low and high pressure sides

Fig. 3: Identifying Low Pressure Reading On LO & HI Pressure Sides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool Symptom effectively. Insufficient cooling performance Refrigerant leaks from Probable Cause air conditioning system Insufficient refrigerant Diagnosis Refrigerant leaking Check for refrigerant leaks and repair if necessary Recharge

air conditioning system with proper amount of new or purified refrigerant If gauges Corrective Actions indicate pressure of close to 0, then it is necessary to evacuate air conditioning system after repairing leak TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, there is insufficient refrigerant. c. Pressure is low on both low and high pressure sides

Fig. 4: Identifying Poor Refrigerant Circulation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool effectively. Frost exists Symptom on pipe from condenser to evaporator unit Refrigerant flow is obstructed by dirt Probable Cause inside pipes of condenser core Condenser Diagnosis is clogged Replace Corrective Actions condenser

TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, there is poor circulation of refrigerant d. Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side

Fig. 5: Identifying No Refrigerant Circulation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Symptom

Air conditioning system does not cool effectively. (System may cool occasionally) Frost or condensation is seen on piping on both sides of

receiver/dryer or expansion valve Refrigerant flow is obstructed by moisture or dirt in air Probable Cause conditioning system Expansion valve is stuck closed Refrigerant Diagnosis does not circulate Replace expansion valve Replace condenser Evacuate air Corrective Actions conditioning system and supply proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, the refrigerant does not circulate. e. Pressure is too high on both low and high pressure sides

Fig. 6: Identifying Overcharged System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning Symptom system does not cool effectively. Unable to develop sufficient performance due to excessive Probable Cause amount of refrigerant Cooling effectiveness of condenser is insufficient Excessive amount of refrigerant in air conditioning system -->

excessive refrigerant was added during recharging Cooling effectiveness Diagnosis of condenser is insufficient -> condenser fins are clogged or cooling fan is faulty Clean condenser Check operation of condenser cooling fan If above two corrective actions are normal, Corrective Actions check amount of refrigerant and recharge air conditioning system with proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, the air conditioning system is overcharged or cooling effectiveness of condenser is insufficient.

f. Pressure is too high on both low and high pressure sides

Fig. 7: Identifying Air In The System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool. Symptom The low pressure piping is too hot to touch Air in air Probable Cause conditioning system Air present in air conditioning system Diagnosis

Insufficient vacuum purging when evacuating air

conditioning system Replace cooler dryer Check compressor oil to see if it is dirty or insufficient Corrective Actions Evacuate air conditioning system and recharge it with new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI NOTE:

These gauge indications occur when the air conditioning system has been left open and then recharged without evacuating the system.

HINT: For the example above, air is present in the air conditioning system. g. Pressure is too high on both low and high pressure sides

Fig. 8: Identifying Expansion Valve Malfunction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool effectively. Frost or a Symptom large amount of condensation on piping on low pressure side Expansion valve may be stuck Probable Cause open or metering refrigerant incorrectly Excessive refrigerant in low pressure Diagnosis piping Expansion

valve open too wide Replace Corrective Actions expansion valve TEXT IN ILLUSTRATION *a LO *b HI HINT: For the above example, there is an expansion valve malfunction. h. Pressure is too high on both low and high pressure sides or pressure is too low on high pressure side

Fig. 9: Identifying Insufficient Compressor Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Symptom

Air conditioning system does not cool effectively. Internal leak

in compressor Low compression Leak from a damaged Diagnosis valve or other compressor component Replace Corrective Actions compressor Probable Cause

TEXT IN ILLUSTRATION *a LO *b HI HINT: For the above example, there is insufficient compressor compression. 3. Gauge readings (Reference)

Fig. 10: Identifying Gauge Readings (Reference) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Pressure Pressure on low on high pressure pressure *a side MPa *b side MPa (kgf/cm2 , (kgf/cm2 , psi) psi) Blower Blower *c *d high zone low zone REPLACEMENT REPLACEMENT

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM a. Turn the power switch on (READY). b. Turn the A/C switch on. c. Operate the cooler compressor under the conditions shown below: Item Condition Engine Idling Speed Operating 3 minutes Time or more A/C Switch ON Status Blower Switch HI Status Set MAX Temperature COOL This cause most of the compressor oil from the various components of the A/C system to collect in the A/C compressor. HINT: It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock etc. d. Turn the power switch off. e. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit. HINT:

Use the refrigerant recover unit in accordance with the manufacturer's instruction manual. 2. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT a. Perform vacuum purging using a vacuum pump or appropriate equipment. b. Charge the air conditioning system with refrigerant. Refrigerant type HFC-134a (R134a)

Fig. 11: Identifying State Of Refrigerant Charge Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sub-cool High *a *b System Pressure Standard Refrigerant *c *d charge Amount amount Charge Point where additional *e *f bubbles 100g disappear (3.5oz.) Mean value in

*g

proper range

*h Overcharged

Standard charge amount 480 to 580g (16.9 to 20.4oz.) 

SST: 09985-20010 09985-02010 09985-02050 09985-02060 09985-02070 09985-02080 09985-02090 09985-02110 09985-02130 09985-02140 09985-02150

NOTE:



 

Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor. The refrigerant amount should be checked by quantity (weight). The graph above is shown for reference only. This vehicle is not equipped with a sight glass.

HINT: Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an air conditioning system. 3. WARM UP COMPRESSOR a. Keep the A/C switch on for at least 2 minutes to warm up the compressor. NOTE:

To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

4. INSPECT FOR REFRIGERANT LEAK a. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a

halogen leak detector. b. Carry out the test under the following conditions:  Turn the power switch off.  Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).  Repeat the inspection 2 or 3 times.  Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system. Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2 , 57 to 85 psi) c. Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

Fig. 12: Identifying Halogen Leak Detector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Halogen *1 Leak Detector Inspect *a for Leak d. Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

Fig. 13: Identifying Halogen Leak Detector And Drain Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Halogen *1 Leak Detector Drain *2 Hose HINT: After the blower motor has stopped, leave the cooling unit for more than 15 minutes.  Bring the halogen leak detector sensor under the drain hose.  When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks. e. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak. f. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak. 

HINT: When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

REFRIGERANT LINE COMPONENTS ILLUSTRATION

Fig. 14: Identifying Refrigerant Line Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AIR CONDITIONING UNIT COMPONENTS ILLUSTRATION

Fig. 15: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 17: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 19: Identifying Air Conditioning Unit Replacement Components (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 20: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 21: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 22: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

NOTE:

Make sure to select FACE mode before disconnecting the cable from the negative (-) auxiliary battery terminal.

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM See step 1 2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 4 4. DISCONNECT HEATER OUTLET WATER HOSE a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.

Fig. 23: Identifying Heater Outlet Water Hose Clip

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force to the heater outlet water hose. Prepare a drain pan or cloth in case the coolant leaks.

5. DISCONNECT HEATER INLET WATER HOSE a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.

Fig. 24: Identifying Heater Inlet Water Hose Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force to the heater inlet water hose. Prepare a drain pan or cloth in case the coolant leaks.

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the bolt, and slide the hook connector.

Fig. 25: Identifying Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the suction hose sub-assembly. c. Remove the O-ring from the suction hose sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Disconnect the air conditioner tube and accessory assembly. b. Remove the O-ring from the air conditioner tube and accessory assembly.

NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

8. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to REMOVAL 9. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to REMOVAL 10. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to REMOVAL - Step 2 11. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to REMOVAL - Step 3 12. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedure for the RH side and LH side. 13. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedure for the RH side and LH side. 14. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 2 15. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 3 16. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to REMOVAL 17. REMOVE STEERING POST ASSEMBLY Refer to REMOVAL 18. REMOVE POWER MANAGEMENT CONTROL ECU . Refer to REMOVAL - Step 1 19. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY . Refer to REMOVAL - Step 2 20. REMOVE VEHICLE APPROACHING SPEAKER CONTROLLER . Refer to REMOVAL - Step 12 21. REMOVE ECU INTEGRATION BOX RH . Refer to REMOVAL - Step 12 22. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY See step 14 23. REMOVE FLOOR CARPET HOOK

a. Disengage the 6 guides.

Fig. 26: Identifying Floor Carpet Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION for *A LH Side for *B RH Side b. Disengage the 6 claws and remove the 6 floor carpet hooks.

Fig. 27: Identifying Floor Carpet Claws And Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

LH Side for *B RH Side

*A

24. DISCONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Remove the screw.

Fig. 28: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 29: Identifying Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE REAR NO. 4 AIR DUCT a. Disengage the guide.

Fig. 30: Turning Back The Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn back the floor carpet as shown in the illustration. c. Disengage the 4 claws to remove the rear No. 4 air duct.

Fig. 31: Identifying Rear No. 4 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE FLOOR CARPET BRACKET LH a. Remove the 2 clips.

Fig. 32: Identifying Floor Carpet Bracket LH Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the floor carpet bracket LH. 27. REMOVE REAR NO. 3 AIR DUCT a. Disengage the 2 claws to remove the rear No. 3 air duct.

Fig. 33: Identifying Rear No. 3 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE REAR NO. 2 AIR DUCT a. Disengage the guide.

Fig. 34: Turning Back The Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn back the floor carpet as shown in the illustration. c. Disengage the 4 claws to remove the rear No. 2 air duct.

Fig. 35: Identifying Rear No. 2 Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE FLOOR CARPET BRACKET RH a. Remove the 2 clips.

Fig. 36: Identifying Floor Carpet Bracket RH Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the floor carpet bracket RH. 30. REMOVE REAR NO. 1 AIR DUCT a. Disengage the 2 claws to remove the rear No. 1 air duct.

Fig. 37: Identifying Rear No. 1 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET a. Remove the screw and No. 1 console box mounting bracket from the lower shift lever assembly.

Fig. 38: Identifying No. 1 Console Box Mounting Bracket Screw

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Remove the clip and the No. 1 console box duct.

Fig. 39: Identifying No. 1 Console Box Duct (W/ Rear Register Duct) Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY a. Disconnect each connector.

Fig. 40: Identifying Wire Harness Connectors And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth *1 Wire b. Disengage each clamp. c. Disconnect the connector. d. Disengage each clamp.

Fig. 41: Identifying Instrument Panel To Cowl Brace Sub-Assembly Bolt, Nuts, And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the bolt and 2 nuts. f. Remove the screw and the instrument panel to cowl brace sub-assembly. 34. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY a. Disconnect the connector.

Fig. 42: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth *1 Wire b. Disengage each clamp. c. Remove the bolt and disconnect the earth wire. d. Remove the bolt and 2 nuts.

Fig. 43: Identifying No. 2 Instrument Panel Brace Sub-Assembly Bolt, Nuts, And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the screw and the No. 2 instrument panel brace sub-assembly. 35. REMOVE INSTRUMENT PANEL SAFETY PAD CAP a. Put protective tape around the 5 instrument panel safety pad caps.

Fig. 44: Identifying Instrument Panel Safety Pad Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for LH Side for RH *B Side Protective *1 Tape

*A

b. Using a screwdriver, remove the 5 instrument panel safety pad caps. 36. REMOVE FRONT LOWER PANEL PACKING a. Remove the 2 front lower panel packings as shown in the illustration.

Fig. 45: Identifying Front Lower Panel Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT NOTE:





Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break. When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

a. Disengage 3 claws to open the 3 clamps.

Fig. 46: Disengaging Claws To Open Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the center airbag sensor connectors from the center airbag sensor assembly as shown in the illustration.

Fig. 47: Identifying Center Airbag Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center

Airbag *1 Sensor Connector NOTE:

c. d. e. f.

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

Disconnect the 3 connectors. Disengage the 3 clamps. Move the shift lever to N. Disconnect the end of the transmission control cable assembly from the lower shift lever assembly.

Fig. 48: Identifying Transmission Control Cable Assembly End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the 4 bolts and lower shift lever assembly.

Fig. 49: Identifying Lower Shift Lever Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the 4 bolts and shift lever support.

Fig. 50: Identifying Shift Lever Support Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

i. Remove the bolt.

Fig. 51: Identifying Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Disconnect the connector. k. Using a screwdriver, disengage the 2 claws to unlock the retainer as shown in the illustration.

Fig. 52: Identifying Claws To Unlock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Retainer *2 Tape l. Disengage the claw and disconnect the airbag connector as shown in the illustration.

Fig. 53: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. m. Disengage each clamp.

Fig. 54: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth *1 -Wire n. Remove the 2 bolts and disconnect the 2 earth wires. o. Disconnect the connector.

Fig. 55: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. p. Disengage each clamp. q. Remove the 2 nuts. r. Remove the bolt and disconnect the earth wire.

Fig. 56: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth Connector *1 *2 Wire Holder s. Disengage each clamp. t. Remove the 2 bolts.

Fig. 57: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. u. Remove the 5 bolts and the nut as shown in the illustration.

Fig. 58: Identifying Instrument Panel Reinforcement Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Movable *1 *2 Body Collar Instrument *3 Panel - Reinforcement Step *a Step 1 *b 2 Step *c Step 3 *d 4 v. w. x. y.

Remove the instrument panel reinforcement assembly with air conditioning unit with the nut. Disconnect the cooler drain hose. Remove the bolt. Disengage the 3 guides and remove the instrument panel reinforcement with air conditioning unit as shown in the illustration.

Fig. 59: Identifying Instrument Panel Reinforcement Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE AIR CONDITIONING UNIT ASSEMBLY a. Remove the 3 bolts and the air conditioning unit assembly from the instrument panel reinforcement assembly.

Fig. 60: Identifying Air Conditioning Unit Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY a. Disengage the 2 claws and guide, and remove the No. 1 air duct sub-assembly as shown in the illustration.

Fig. 61: Identifying No. 1 Air Duct Sub-Assembly Claws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY a. Disengage the 2 claws and 2 guides, and remove the No. 6 heater to register duct assembly as shown in the illustration.

Fig. 62: Identifying No. 6 Heater To Register Duct Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE COOLER THERMISTOR HOSE a. Disengage the clamp and remove the cooler thermistor hose.

Fig. 63: Identifying Cooler Thermistor Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE ASPIRATOR a. Disengage the 2 claws and remove the aspirator.

Fig. 64: Identifying Aspirator Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY a. Remove the heater packing as shown in the illustration.

Fig. 65: Removing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 5 connectors.

Fig. 66: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 5 clamps and remove the air conditioning harness assembly. 6. REMOVE COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve.

Fig. 67: Identifying Cooler Expansion Valve And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY See step 5 8. REMOVE QUICK HEATER ASSEMBLY a. Disengage the 2 clamps.

Fig. 68: Identifying Quick Heater Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the screw.

Fig. 69: Identifying Quick Heater Bracket And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the guide and remove the quick heater bracket. d. Disengage the 2 clamps.

Fig. 70: Identifying Quick Heater Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the 2 screws.

Fig. 71: Identifying Quick Heater Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the quick heater assembly as shown in the illustration.

Fig. 72: Removing The Quick Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Remove the 3 screws and then the No. 1 air conditioning radiator damper servo sub-assembly.

Fig. 73: Identifying No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

Fig. 74: Locating Air Mix Control Servo Motor Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY a. Disengage the 3 claws and remove the heater clamp.

Fig. 75: Identifying Heater Clamp And Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the screw and clamp.

Fig. 76: Identifying Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the heater radiator unit sub-assembly as shown in the illustration.

Fig. 77: Removing Heater Radiator Unit Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Prepare a drain pan or cloth in case the cooling water leaks.

12. REMOVE NO. 1 COOLER THERMISTOR See step 2 13. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Remove the No. 1 cooler evaporator sub-assembly from the blower assembly as shown in the illustration.

Fig. 78: Removing No. 1 Cooler Evaporator Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

Fig. 79: Installing O-Rings To Cooler Evaporator No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REASSEMBLY REASSEMBLY

1. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.

Fig. 80: Installing O-Rings To Cooler Evaporator No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Compressor oil ND-OIL 11 or equivalent b. Install the No. 1 cooler evaporator sub-assembly to the blower assembly.

Fig. 81: Installing No. 1 Cooler Evaporator Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 COOLER THERMISTOR See step 1 3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY a. Install the heater radiator unit sub-assembly as shown in the illustration.

Fig. 82: Installing Heater Radiator Unit Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clamp with the screw.

Fig. 83: Identifying Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 3 claws and install the heater clamp.

Fig. 84: Identifying Heater Clamp And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Using the reference point, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

Fig. 85: Identifying Air Mix Damper Servo Sub-Assembly Component Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *1 Point 5. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo subassembly are positioned in the correct orientation as shown in the illustration.

Fig. 86: Correct Orientation Of Slots, Links And Gears Of No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air

conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward. c. Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

Fig. 87: Rotating Link Of Air Conditioning Radiator Assembly (To The Left) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.

Fig. 88: Rotating Link Of Air Conditioning Radiator Assembly (To The Bottom) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Mode Switching *a -Duct Hole e. Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

Fig. 89: Rotating Lever Of Air Conditioning Radiator Assembly To The Top Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

Fig. 90: Rotating Link Of Air Conditioning Radiator Assembly (To The In-Line Position) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION In-line *a -Position g. Wrap the upper and lower links with vinyl tape to hold them in the in-line position.

Fig. 91: Wrap Upper And Lower Links With Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vinyl *1 Tape h. Install the link of the No. 1 air conditioning radiator damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

Fig. 92: Identifying No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Link Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *a *c

Guide No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Slot Link Guide Pin (B)

*2

No. 1 Air Conditioning Radiator Damper Servo Sub-assembly

*b

Link Guide Pin (A)

-

-

i. Install the guide hole of the No. 1 air conditioning radiator damper servo sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration. j. Temporarily install the screw (up to 4 or 5 threads). NOTE:





Make sure that the link guide pin (B) is inserted in the No. 1 air conditioning radiator damper servo sub-assembly slot. Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.

k. Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

Fig. 93: Lifting Air Outlet Control Servo Motor Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Move the air conditioning radiator assembly gear so that alignment holes of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly are aligned.

Fig. 94: Aligning No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly And Air Conditioning Radiator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. 1 Air Conditioning Air Radiator Conditioning Damper Radiator *a *b Servo SubAssembly assembly Alignment Hole Alignment Hole Air Conditioning Radiator *c Assembly - Gear Alignment Hole m. Insert a screwdriver into the aligned holes as shown in the illustration.

Fig. 95: Aligning Air Outlet Control Servo Motor Sub-Assembly Using Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. n. Make sure that all the links and gears are in the positions shown in the illustration.

Fig. 96: Proper Link And Gear Positioning Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Screwdriver Link is inserted guide pin *a into *b is alignment inserted. holes. Link is Link is *c positioned to *d positioned left side. at bottom. Each link guide pin is inserted in Lever is its No. 1 Air *e Conditioning *f positioned at top. radiator damper servo subassembly

slot Links are in*g - line. o. Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

Fig. 97: Pushing Air Outlet Control Servo Motor Sub-Assembly Into Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position. After pushing the servos into position, keep them in place by holding them until the screws are installed.

HINT: Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard. p. Remove the screwdriver. q. Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo subassembly with the 2 remaining screws.

Fig. 98: Identifying Air Outlet Control Servo Motor Sub-Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. r. Remove the vinyl tape. 6. INSTALL QUICK HEATER ASSEMBLY a. Insert the quick heater assembly as shown in the illustration.

Fig. 99: Installing Quick Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 screws.

Fig. 100: Identifying Quick Heater Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 2 clamps.

Fig. 101: Identifying Quick Heater Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the guide.

Fig. 102: Identifying Quick Heater Bracket And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the quick heater bracket with the screw. f. Engage the 2 clamps and install the quick heater assembly.

Fig. 103: Identifying Quick Heater Assembly Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY See step 1 8. INSTALL COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.

Fig. 104: Identifying Cooler Expansion Valve And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 9. INSTALL AIR CONDITIONING HARNESS ASSEMBLY a. Engage the 5 clamps to install air conditioning harness assembly.

Fig. 105: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the 5 connectors. c. Install the heater packing as shown in the illustration.

Fig. 106: Installing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL ASPIRATOR a. Engage the 2 claws to install the aspirator.

Fig. 107: Identifying Aspirator Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL COOLER THERMISTOR HOSE a. Engage the clamp to install the cooler thermistor hose.

Fig. 108: Identifying Cooler Thermistor Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY a. Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

Fig. 109: Identifying No. 6 Heater To Register Duct Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY a. Engage the 2 claws and guide to install the No. 1 air duct sub-assembly as shown in the illustration.

Fig. 110: Identifying No. 1 Air Duct Sub-Assembly Claws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY a. Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

Fig. 111: Identifying Air Conditioning Unit Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT NOTE:





Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break. When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

a. Disengage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

Fig. 112: Identifying Instrument Panel Reinforcement Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the instrument panel reinforcement assembly with the 3 bolts and 2 new bolts in the order shown in the illustration.

Fig. 113: Identifying Instrument Panel Reinforcement Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Movable *1 *2 Body Collar Instrument *3 Panel - Reinforcement Step *a Step 1 *b 2 Step *c Step 3 *d 4 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

c. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) d. Install the bolt. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) e. Install the 2 bolts.

Fig. 114: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration.

f. Install the instrument panel reinforcement assembly with air conditioning unit with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) g. Install the 2 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) h. Engage each clamp. i. Connect the connector. j. Install the 2 nuts and connect the connector holder.

k. Install the bolt and connect the earth wire. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) l. Engage each clamp. m. Connect the connector. n. Install the 2 bolts and connect the 2 earth wires. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) o. Engage each clamp. p. Pass the drain cooler hose through the vehicle securely.

Fig. 115: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: q. r. s. t.

Connect the drain cooler hose firmly to prevent water leaks.

Engage each clamp. Connect the connector. Engage each clamp. Engage the claw to connect the airbag connector as shown in the illustration.

Fig. 116: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. u. Engage the 2 claws to lock the retainer as shown in the illustration.

Fig. 117: Identifying Claws To Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer v. Connect the connector. w. Install the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) x. Install the shift lever support with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) y. Check that the park/neutral position switch and the shift lever are in N.

z. Install the lower shift lever assembly with the 4 bolts in the order shown in the illustration.

Fig. 118: Identifying Shift Lever Support Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) aa. Slide the slider of the transmission control cable assembly in the direction indicated by the arrow and pull the lock piece outward.

Fig. 119: Identifying Transmission Control Cable Assembly Slider Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Slider Lock *2 Piece *a Slide *b Pull ab. Install the end of the transmission control cable assembly to the lower shift lever assembly.

Fig. 120: Installing End Of Transmission Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Piece NOTE:

 

Check that the lock piece is pulled up. Install the cable end all the way to the base of the pin.

ac. Push the lock piece into the adjuster case. NOTE:



Check that the park/neutral position switch and the shift lever are in neutral.



Securely push in the lock piece until the slider lock is engaged.

ad. Connect each connector.

Fig. 121: Identifying Center Airbag Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center Airbag *1 Sensor Connector ae. Engage the 3 clamps. af. Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

ag. Engage the 3 claws to close the 3 clamps as shown in the illustration.

Fig. 122: Engaging Claws To Close Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL FRONT LOWER PANEL PACKING a. Install the 2 front lower panel packings shown in the illustration.

Fig. 123: Identifying Front Lower Panel Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL INSTRUMENT PANEL SAFETY PAD CAP a. Install 5 new instrument panel safety pad caps.

Fig. 124: Identifying Instrument Panel Safety Pad Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for *A LH Side for *B RH Side 5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY a. Install the screw. b. Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) c. Connect the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. Engage each clamp. e. Connect the connector. 6. INSTALL INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY a. Install the screw. b. Install the instrument panel to cowl brace sub-assembly with the bolt and 2 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) c. Connect the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

7. 8. 9. 10.

11.

d. Engage each clamp. e. Connect each connector. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Install the No. 1 console box duct with the clip. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET a. Install the No. 1 console mounting bracket with the screw. INSTALL REAR NO. 3 AIR DUCT a. Engage the 2 claws to install the rear No. 3 air duct. INSTALL FLOOR CARPET BRACKET LH a. Engage the 2 guides. b. Install the floor carpet bracket LH with the 2 clips. INSTALL REAR NO. 4 AIR DUCT a. Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.

Fig. 125: Identifying Rear No. 4 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the guide to install the floor carpet to the original position as shown in the illustration.

Fig. 126: Identifying Floor Carpet Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 127: Identifying Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the screw. 13. INSTALL REAR NO. 1 AIR DUCT a. Engage the 2 claws to install the rear No. 1 air duct. 14. INSTALL FLOOR CARPET BRACKET RH a. Engage the 2 guides. b. Install the floor carpet bracket RH with the 2 clips. 15. INSTALL REAR NO. 2 AIR DUCT a. Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.

Fig. 128: Identifying Rear No. 2 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the guide to install the floor carpet to the original position as shown in the illustration.

Fig. 129: Identifying Floor Carpet Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL FLOOR CARPET HOOK a. Engage the 6 claws to install the 6 floor carpet hooks. b. Engage the 6 guides. 17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY See step 1 18. INSTALL ECU INTEGRATION BOX RH . Refer to INSTALLATION - Step 2 19. INSTALL VEHICLE APPROACHING SPEAKER CONTROLLER . Refer to INSTALLATION Step 1 20. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY . Refer to INSTALLATION - Step 2 21. INSTALL POWER MANAGEMENT CONTROL ECU . Refer to INSTALLATION - Step 3 22. INSTALL STEERING POST ASSEMBLY

Refer to INSTALLATION 23. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION 24. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to INSTALLATION - Step 4 25. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to INSTALLATION - Step 5 26. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to INSTALLATION 27. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to INSTALLATION 28. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to INSTALLATION - Step 4 29. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to INSTALLATION Step 5 30. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedure for the RH side and LH side. 31. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedure for the RH side and LH side. 32. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioner tube and accessory assembly. Compressor oil ND-OIL 11 or equivalent c. Install the O-ring to the air conditioner tube and accessory assembly. d. Install the air conditioner tube and accessory assembly. 33. CONNECT SUCTION HOSE SUB-ASSEMBLY

a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose subassembly. Compressor oil ND-OIL 11 or equivalent c. Connect the O-ring to the suction hose sub-assembly. d. Connect the suction hose sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 130: Identifying Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

f. Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 34. CONNECT HEATER INLET WATER HOSE a. Install the heater inlet water hose and attach the clip. 35. CONNECT HEATER OUTLET WATER HOSE a. Install the heater outlet water hose and attach the clip. 36. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 18 37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION 38. INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1 39. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 2 40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT See step 2 41. WARM UP COMPRESSOR See step 3 42. INSPECT FOR REFRIGERANT LEAK See step 4 43. INITIALIZATION SERVO MOTOR Refer to INITIALIZATION

BLOWER UNIT COMPONENTS ILLUSTRATION

Fig. 131: Identifying Blower Unit Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 132: Identifying Blower Unit Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE AIR CONDITIONING UNIT ASSEMBLY

Refer to REMOVAL 2. 3. 4. 5.

REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See step 1 REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY See step 2 REMOVE AIR CONDITIONING HARNESS ASSEMBLY See step 5 REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY a. Remove the 6 screws.

Fig. 133: Identifying Blower Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws and remove the blower assembly with cooler evaporator sub-assembly. DISASSEMBLY

DISASSEMBLY

1. 2. 3. 4.

REMOVE COOLER EXPANSION VALVE See step 6 REMOVE NO. 1 COOLER THERMISTOR See step 2 REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY See step 13 REMOVE DRAIN COOLER HOSE a. Remove the drain cooler hose from the air conditioning radiator assembly.

Fig. 134: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE AIR DUCT SUB-ASSEMBLY a. Disengage the 4 claws and remove the air duct sub-assembly.

Fig. 135: Identifying Air Duct Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE AIR FILTER COVER PLATE a. Disengage the 2 claws and remove the air filter cover plate.

Fig. 136: Identifying Air Filter Cover Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE CLEAN AIR FILTER a. Remove the clean air filter as shown in the illustration.

Fig. 137: Removing Air Filter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 BLOWER DAMPER SERVO SUB-ASSEMBLY a. Remove the 3 screws and No. 1 blower damper servo sub-assembly.

Fig. 138: Identifying No. 1 Blower Damper Servo Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Remove the 3 screws and blower motor with fan sub-assembly.

Fig. 139: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Install the blower motor with fan sub-assembly with the 3 screws.

Fig. 140: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 BLOWER DAMPER SERVO SUB-ASSEMBLY a. Install the No. 1 blower damper servo sub-assembly with the 3 screws.

Fig. 141: Identifying No. 1 Blower Damper Servo Sub-Assembly Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL CLEAN AIR FILTER a. Install the clean air filter as shown in the illustration.

Fig. 142: Installing Air Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL AIR FILTER COVER PLATE a. Engage the 2 claws to install the air filter cover plate.

Fig. 143: Identifying Air Filter Cover Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL AIR DUCT SUB-ASSEMBLY a. Engage the 4 claws to install the air duct sub-assembly.

Fig. 144: Identifying Air Duct Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL DRAIN COOLER HOSE a. Install the drain cooler hose to the blower case assembly.

Fig. 145: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hose *1 Notch Blower Case *2 Assembly Rib 7. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY See step 1 8. INSTALL NO. 1 COOLER THERMISTOR See step 1 9. INSTALL COOLER EXPANSION VALVE See step 8 INSTALLATION INSTALLATION

1. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY a. Engage the 4 claws. b. Install the blower assembly with cooler evaporator sub-assembly with the 6 screws. 2. INSTALL AIR CONDITIONING HARNESS ASSEMBLY See step 9 3. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY See step 12 4. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See step 13

5. INSTALL AIR CONDITIONING UNIT ASSEMBLY Refer to INSTALLATION

FRONT BLOWER MOTOR COMPONENTS ILLUSTRATION

Fig. 146: Identifying Front Blower Motor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 35 2. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Disconnect the connector. b. Remove the 3 screws and blower motor with fan sub-assembly.

Fig. 147: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the blower motor with fan sub-assembly, do not damaged or strike it.

INSTALLATION INSTALLATION

1. INSTALL BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Install the blower motor with fan sub-assembly with the 3 screws. NOTE:

When installing the blower motor with fan sub-assembly do not damaged or strike it.

b. Connect the connector. 2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17

PTC HEATER ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 148: Identifying PTC Heater Assembly Replacement Components (1 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 149: Identifying PTC Heater Assembly Replacement Components (2 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 150: Identifying PTC Heater Assembly Replacement Components (3 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 151: Identifying PTC Heater Assembly Replacement Components With Torque Specifications (4 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 152: Identifying PTC Heater Assembly Replacement Components With Torque Specifications (5 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 153: Identifying PTC Heater Assembly Replacement Components With Torque Specifications (6 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to REMOVAL 2. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to REMOVAL 3. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedure as for the LH side. 4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT:

Use the same procedure as for the LH side. 5. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 7. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 8. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 9. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 8 10. REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 12 11. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 12. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 14 13. REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 14. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 16 15. REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 17 16. REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY . Refer to REMOVAL - Step 7 17. REMOVE NO. 4 CONSOLE BOX DUCT . Refer to REMOVAL - Step 8 18. REMOVE CONSOLE BOX CARPET . Refer to REMOVAL - Step 9 19. REMOVE REAR CONSOLE BOX ASSEMBLY . Refer to REMOVAL - Step 10 20. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 21. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 22. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 23. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 24. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 25. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 26. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 27. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to REMOVAL - Step 29 28. REMOVE FRONT DOOR SCUFF PLATE RH . Refer to REMOVAL - Step 31 29. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH . Refer to REMOVAL - Step 32 30. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 33 31. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 34 32. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 35

33. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 34. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 37 35. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL Step 46 36. REMOVE FRONT NO. 2 CONSOLE BOX INSERT . Refer to REMOVAL - Step 47 37. REMOVE CONSOLE BOX INSERT . Refer to REMOVAL - Step 48 38. REMOVE FLOOR CARPET BRACKET LH See step 26 39. REMOVE FLOOR CARPET BRACKET RH See step 29 40. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET See step 31 41. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) See step 32 42. REMOVE LOWER SHIFT LEVER ASSEMBLY . Refer to REMOVAL - Step 22 43. REMOVE SHIFT LEVER SUPPORT . Refer to REMOVAL - Step 23 44. REMOVE QUICK HEATER ASSEMBLY a. Disconnect the quick heater connector.

Fig. 154: Identifying Quick Heater Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt. c. Disengage the 4 clamps. d. Remove the 2 screws.

Fig. 155: Identifying Quick Heater Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the quick heater assembly as shown in the illustration.

Fig. 156: Removing Quick Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT QUICK HEATER ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 157: Identifying Quick Heater Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition I41-1(B) Below 1 Always a1-1(E) ohms I41-2(B) Below 1 Always a1-1(E) ohms TEXT IN ILLUSTRATION Component without

harness connected *a (Quick Heater Assembly) If the result is not as specified, replace the quick heater assembly. INSTALLATION INSTALLATION

1. INSTALL QUICK HEATER ASSEMBLY a. Insert the quick heater assembly as shown in the illustration.

Fig. 158: Installing Quick Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 screws. c. Engage the 4 clamps. d. Install the quick heater assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) e. Connect the quick heater connector. 2. INSTALL SHIFT LEVER SUPPORT . Refer to INSTALLATION - Step 1

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

INSTALL LOWER SHIFT LEVER ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) See step 7 INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET See step 8 INSTALL FLOOR CARPET BRACKET LH See step 10 INSTALL FLOOR CARPET BRACKET RH See step 14 INSTALL CONSOLE BOX INSERT . Refer to INSTALLATION - Step 4 INSTALL FRONT NO. 2 CONSOLE BOX INSERT . Refer to INSTALLATION - Step 5 INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 6 INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 47 INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH . Refer to INSTALLATION - Step 48 INSTALL FRONT DOOR SCUFF PLATE RH . Refer to INSTALLATION - Step 21 INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to INSTALLATION - Step 23 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL REAR CONSOLE BOX ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL CONSOLE BOX CARPET . Refer to INSTALLATION - Step 2 INSTALL NO. 4 CONSOLE BOX DUCT . Refer to INSTALLATION - Step 3 INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY . Refer to INSTALLATION - Step 4 INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 35

31. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 36 32. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37 33. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 38 34. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39 35. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 44 36. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 45 37. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 38. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 39. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 40. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 41. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to INSTALLATION 42. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to INSTALLATION 43. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedure as for the LH side. 44. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedure as for the LH side. 45. INSPECT SHIFT LEVER POSITION . Refer to ADJUSTMENT - Step 1

COOLER EXPANSION VALVE COMPONENTS ILLUSTRATION

Fig. 159: Identifying Cooler Expansion Valve Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 160: Identifying Cooler Expansion Valve Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

When removing the cooler expansion valve by itself, be sure to install a new cooler expansion valve and new bolt for suction hose sub-assembly.

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM See step 1

2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 3. 4. 5. 6.

REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 4 DISCONNECT SUCTION HOSE SUB-ASSEMBLY See step 6 DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY See step 7 REMOVE COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts.

Fig. 161: Identifying Cooler Expansion Valve Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the bolt for the suction hose sub-assembly halfway to the cooler expansion valve.

Fig. 162: Identifying Suction Hose Sub-Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt for Suction *1 Hose Subassembly c. Hold the bolt and pull it to remove the cooler expansion valve as shown in the illustration.

Fig. 163: Removing Cooler Expansion Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

Fig. 164: Identifying No. 1 Cooler Evaporator Sub-Assembly O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. 1 cooler *1 evaporator subassembly INSTALLATION INSTALLATION

1. INSTALL COOLER EXPANSION VALVE a. Apply sufficient compressor oil to 2 new O-rings and the fitting surfaces of the cooler expansion valve. Compressor oil ND-OIL 11 or equivalent b. Install the 2 new O-rings to the No. 1 cooler evaporator sub-assembly. c. Using a 4 mm hexagon wrench, install the new cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 2. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY See step 32 3. CONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose subassembly. Compressor oil ND-OIL 11 or equivalent c. Connect the O-ring to the suction hose sub-assembly. d. Connect the suction hose sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 165: Identifying Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Insert the hose joint into the fitting hole securely and tighten a new bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 18 5. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION 6. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT See step 2 7. WARM UP COMPRESSOR See step 3

8. INSPECT FOR REFRIGERANT LEAK See step 4

COMPRESSOR COMPONENTS ILLUSTRATION

Fig. 166: Identifying Compressor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM See step 1 2. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 3. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL 4. CHECK TERMINAL VOLTAGE a. Remove the connector cover assembly. Refer to REMOVAL - Step 4 . b. Check the terminal voltage. Refer to REMOVAL - Step 5 . c. Install the connector cover assembly. Refer to INSTALLATION - Step 19 . 5. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor with motor assembly.

Fig. 167: Identifying No. 1 Cooler Refrigerant Discharge Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the bolt and disconnect the suction hose sub-assembly from the compressor with motor assembly.

Fig. 168: Identifying Suction Hose Sub-Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the suction hose sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

7. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY a. Disconnect connector B.

Fig. 169: Identifying Compressor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Green*1 colored Lock b. Release the green-colored lock and disconnect connector A as shown in the illustration. WARNING: Wear insulated gloves when performing the following steps.

NOTE:

Insulate the connector by sealing it with tape.

c. Remove the bolt and 2 nuts and compressor with motor assembly.

Fig. 170: Identifying Compressor Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using an E8 "TORX" socket, remove the 2 stud bolts.

Fig. 171: Identifying Compressor Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSPECT COMPRESSOR OIL a. When replacing the electric inverter compressor with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor with motor assembly before installation.

Fig. 172: Identifying Compressor Service Valve And Oil Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard (Oil capacity inside the new compressor with motor assembly: 120 to 135 cc (4.2 to 4.8 fl. oz.)) (Remaining oil amount in the removed compressor with motor assembly) = (Oil amount to be removed from the new compressor) NOTE:









When checking the compressor oil level, observe the precautions on the cooler removal/installation. If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling. If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks. Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in a leakage of electric power.

2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY a. Using an E8 "TORX" socket, and install the 2 stud bolts.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Install the compressor with motor assembly with the bolt and 2 nuts.

Fig. 173: Order To Tighten Compressor Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tighten the 2 bolts and nut in the order shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) c. Connect connector A and lock the green-colored lock as shown in the illustration.

Fig. 174: Identifying Compressor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Green*1 colored Lock d. Connect connector B. 3. CONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly. Compressor oil

ND-OIL 11 or equivalent c. Install the O-ring to the suction hose sub-assembly. NOTE:





Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects. Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

d. Install the suction hose sub-assembly to the compressor with motor assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly. Compressor oil ND-OIL 11 or equivalent c. Install the O-ring to the No. 1 cooler refrigerant discharge hose. NOTE:





Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects. Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

d. Install the No. 1 cooler refrigerant discharge hose to the compressor with motor assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION 6. INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT See step 2 8. WARM UP COMPRESSOR See step 3 9. INSPECT FOR REFRIGERANT LEAK See step 4

CONDENSER COMPONENTS ILLUSTRATION

Fig. 175: Identifying Condenser Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 176: Identifying Condenser Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 177: Identifying Condenser Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. INSPECT COOLER CONDENSER ASSEMBLY a. If the cooler condenser assembly fins are dirty, clean them with water and dry with compressed air. NOTE:

Do not damage the cooler condenser assembly fins.

b. If any cooler condenser assembly fins are bent, straighten them using a screwdriver or pliers. 2. INSPECT FOR REFRIGERANT LEAK a. Using a halogen leak detector, check pipe joints for refrigerant leaks. b. If a refrigerant leak is detected in a joint, check the torque of the joint. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM See step 1 3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL 6. 7. 8. 9. 10. 11.

REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE NO. 5 INVERTER BRACKET . Refer to REMOVAL - Step 12 REMOVE UPPER RADIATOR SUPPORT . Refer to REMOVAL - Step 18 REMOVE RADIATOR SIDE DEFLECTOR RH . Refer to REMOVAL - Step 10 REMOVE RADIATOR SIDE DEFLECTOR LH a. Disengage the 3 claws and guide, and remove the radiator side deflector LH as shown in the illustration.

Fig. 178: Identifying Radiator Side Deflector LH Claws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the cooler condenser assembly.

Fig. 179: Identifying No. 1 Cooler Refrigerant Discharge Hose Bolt At Condenser Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

13. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Remove the bolt and disconnect the air conditioner tube and accessory assembly from the cooler condenser assembly.

Fig. 180: Identifying Air Conditioner Tube Bolt At Condenser Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the air conditioner tube and accessory assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

14. REMOVE COOLER CONDENSER ASSEMBLY a. Remove the 4 bolts.

Fig. 181: Identifying Cooler Condenser Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the radiator assembly in the direction indicated by the arrow.

Fig. 182: Pulling The Radiator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 bolts.

Fig. 183: Identifying Radiator Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the cooler condenser assembly as shown in the illustration.

Fig. 184: Removing Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE COOLER DRYER a. Using a 14 mm straight hexagon wrench, remove the cap from the modulator.

Fig. 185: Identifying Modulator Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 14 mm Straight *1 Hexagon Wrench b. Using pliers, remove the cooler dryer from the modulator.

Fig. 186: Identifying Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL COOLER DRYER a. Using pliers, install a new cooler dryer to the modulator.

Fig. 187: Identifying Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surfaces of the cap.

Fig. 188: Compressor Oil Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Compressor oil ND-OIL 11 or equivalent c. Using a 14 mm straight hexagon wrench, install the cap to the modulator.

Fig. 189: Identifying Modulator Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 14 mm Straight *1 Hexagon Wrench Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) NOTE:





Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter. Do not use any compressor oil other than ND-OIL 11 or equivalent.

INSTALLATION INSTALLATION

1. INSTALL COOLER CONDENSER ASSEMBLY a. Insert the cooler condenser as shown in the illustration.

Fig. 190: Installing Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the 2 bolts .

Fig. 191: Identifying Cooler Condenser Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the cooler condenser assembly with the 2 bolts and 2 bolts. Bolt Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Bolt Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) HINT: If the cooler condenser assembly is replaced with a new one, add compressor oil to the new cooler

condenser assembly. Capacity 40 cc (1.4 fl. oz.) Compressor oil ND-OIL 11 or equivalent 2. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Remove the vinyl tape from the tube and the connector part of the cooler condenser assembly. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint. Compressor oil ND-OIL 11 or equivalent c. Install the O-ring to the air conditioner tube and accessory assembly. d. Install the air conditioner tube and accessory assembly to the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil ND-OIL 11 or equivalent c. Install the O-ring to the No. 1 cooler refrigerant discharge hose. d. Install the No. 1 cooler refrigerant discharge hose to the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. INSTALL RADIATOR SIDE DEFLECTOR LH a. Engage the guide and 3 claws to install the radiator side deflector LH as shown in the illustration.

Fig. 192: Identifying Radiator Side Deflector LH Claws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. 6. 7. 8. 9. 10.

INSTALL RADIATOR SIDE DEFLECTOR RH . Refer to INSTALLATION - Step 2 INSTALL UPPER RADIATOR SUPPORT . Refer to INSTALLATION - Step 2 INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL NO. 5 INVERTER BRACKET . Refer to INSTALLATION - Step 26 INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION

11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after

the cable is reconnected. Refer to INITIALIZATION . 12. 13. 14. 15. 16.

INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT See step 2 WARM UP COMPRESSOR See step 3 INSPECT FOR REFRIGERANT LEAK See step 4 ADJUST HOOD SUB-ASSEMBLY Refer to ADJUSTMENT - Step 2

ROOM TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 193: Identifying Room Temperature Sensor Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 194: Identifying Room Temperature Sensor Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 7. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 8. REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 12 9. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 10. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 14 11. REMOVE ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Disengage the 2 claws as shown in the illustration.

Fig. 195: Removing Room Temperature Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hose and connector and remove the room temperature sensor (cooler thermistor).

INSPECTION INSPECTION

1. INSPECT ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Measure the resistance according to the value(s) in the table below.

Fig. 196: Identifying Room Temperature Sensor Connector Terminal Identification And Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 3.00 to I57-1 (+) - 10°C (50° 3.73 I57-2 (-) F) kohms 2.45 to I57-1 (+) - 15°C (59° 2.88 I57-2 (-) F) kohms 1.95 to I57-1 (+) - 20°C (68° 2.30 I57-2 (-) F) kohms 1.60 to I57-1 (+) - 25°C (77° 1.80 I57-2 (-) F) kohms 1.28 to I57-1 (+) - 30°C (86° 1.47 I57-2 (-) F) kohms 1.00 to I57-1 (+) - 35°C (95° 1.22 I57-2 (-) F) kohms 0.80 to I57-1 (+) - 40°C 1.00 I57-2 (-) (104°F) kohms 0.65 to I57-1 (+) - 45°C 0.85 I57-2 (-) (113°F) kohms 0.50 to I57-1 (+) - 50°C 0.70 I57-2 (-) (122°F) kohms 0.44 to I57-1 (+) - 55°C 0.60 I57-2 (-) (131°F) kohms 0.36 to I57-1 (+) - 60°C 0.50 I57-2 (-) (140°F) kohms If the resistance is not as specified, replace the room temperature sensor (cooler thermistor). TEXT IN ILLUSTRATION Component without harness *a connected (Room Temperature Sensor

(Cooler Thermistor)) Sensing *b Portion Resistance *c (kohms) Allowable *d Range Temperature *e (°C (°F)) NOTE:





Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph). INSTALLATION INSTALLATION

1. INSTALL ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Connect the connector and hose. b. Engage the 2 claws to install the room temperature sensor (cooler thermistor) as shown in the illustration.

Fig. 197: Installing Room Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 38 3. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39 4. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 40 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 8. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 9. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

10. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

HUMIDITY SENSOR COMPONENTS ILLUSTRATION

Fig. 198: Identifying Humidity Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE PROTECTOR a. Disengage the 2 claws and remove the protector.

Fig. 199: Identifying Protector Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE HUMIDITY SENSOR (AIR CONDITIONING THERMISTOR ASSEMBLY) a. Disconnect the connector.

Fig. 200: Identifying Humidity Sensor Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Release the stopper by pulling it down.

Fig. 201: Removing Humidity Sensor & Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Stopper c. Remove the humidity sensor (air conditioning thermistor assembly) as shown in the illustration. INSPECTION INSPECTION

1. INSPECT AIR CONDITIONING THERMISTOR ASSEMBLY a. for Glass temperature sensor 1. Remove the air conditioning thermistor assembly (glass temperature sensor).

Fig. 202: Identifying Air Conditioning Thermistor Connector Terminal Identification and Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition S3-1 5.92 to 10°C (50° (SEG3) 6.09 F) S3-4 (TFG) kohms S3-1 4.94 to 15°C (59° (SEG3) 5.07 F) S3-4 (TFG) kohms S3-1 4.20 to 20°C (68° (SEG3) 4.29 F) S3-4 (TFG) kohms S3-1 3.64 to 25°C (77° (SEG3) 3.70 F) S3-4 (TFG) kohms S3-1 3.19 to 30°C (86° (SEG3) 3.26 F) S3-4 (TFG) kohms S3-1 2.85 to 35°C (95° (SEG3) 2.91 F) S3-4 (TFG) kohms S3-1 2.58 to 40°C (SEG3) 2.64 (104°F) S3-4 (TFG) kohms S3-1 2.37 to 45°C (SEG3) 2.43 (113°F) S3-4 (TFG) kohms S3-1 2.21 to 50°C (SEG3) 2.26 (122°F) S3-4 (TFG) kohms S3-1 2.07 to 55°C (SEG3) 2.12 (131°F) S3-4 (TFG) kohms S3-1 1.97 to 60°C (SEG3) 2.01 (140°F) S3-4 (TFG) kohms NOTE:



Hold the sensor only by its connector. Touching the



sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the air conditioning thermistor assembly (glass temperature sensor). TEXT IN ILLUSTRATION Component without harness connected (Air *a Conditioning Thermistor Assembly (Glass Temperature Sensor)) Heat *b Conduction Sheet Part Resistance *c (kohms) Temperature *d (°C (°F)) b. for Glass surroundings temperature sensor 1. Remove the air conditioning thermistor assembly (glass surroundings temperature sensor).

Fig. 203: Identifying Air Conditioning Thermistor Connector Terminal Identification and Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition S3-1 5.92 to 10°C (50° (SEG3) 6.09 F) S3-2 (TNG) kohms S3-1 4.94 to 15°C (59° (SEG3) 5.07 F) S3-2 (TNG) kohms S3-1 4.20 to 20°C (68° (SEG3) 4.29 F) S3-2 (TNG) kohms S3-1 3.64 to 25°C (77° (SEG3) 3.70 F) S3-2 (TNG) kohms S3-1 3.19 to 30°C (86° (SEG3) 3.26 F) S3-2 (TNG) kohms S3-1 2.85 to 35°C (95° (SEG3) 2.91 F) S3-2 (TNG) kohms S3-1 2.58 to 40°C (SEG3) 2.64 (104°F) S3-2 (TNG) kohms S3-1 2.37 to 45°C (SEG3) 2.43 (113°F) S3-2 (TNG) kohms S3-1 2.21 to 50°C (SEG3) 2.26 (122°F) S3-2 (TNG) kohms S3-1 2.07 to 55°C (SEG3) 2.12 (131°F) S3-2 (TNG) kohms S3-1 1.97 to 60°C (SEG3) 2.01 (140°F) S3-2 (TNG) kohms NOTE:





HINT:

Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the air conditioning thermistor assembly (glass surroundings temperature sensor). TEXT IN ILLUSTRATION Component without harness connected (Air Conditioning *a Thermistor Assembly (Glass Surroundings Temperature Sensor)) Heat *b Conduction Sheet Part Resistance *c (kohms) Temperature *d (°C (°F)) c. for Humidity sensor 1. Remove the air conditioning thermistor assembly (humidity sensor) with the connector still connected.

Fig. 204: Identifying Air Conditioning Thermistor Connector Terminal Identification and Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Turn the power switch on (IG).

3. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition S3-1 Humidity (SEG3) - is 5 to 15 1.01 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 15 to 25 1.37 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 25 to 35 1.73 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 35 to 45 2.09 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 45 to 55 2.45 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 55 to 65 2.81 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 65 to 75 3.17 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 75 to 85 3.53 V S3-3 (RH) % S3-1 Humidity (SEG3) - is 85 to 95 3.89 V S3-3 (RH) % NOTE:







HINT:

Do not touch the sensor as body heat will affect the inspection results. When performing the inspection, hold the sensor by its connector. Allow the sensor to acclimate to the ambient temperature and humidity before performing the inspection. The specified voltages in the table above are based on inspections performed when the ambient temperature is 25°C (77°F).

As the humidity increases, the voltage increases (see the graph). If the voltage is not as specified, replace the air conditioning thermistor assembly (humidity sensor). TEXT IN ILLUSTRATION Component without harness connected (Air *a Conditioning Thermistor Assembly (Humidity Sensor)) Heat *b Conduction Sheet Part *c Voltage (V) Relative *d Humidity (%) INSTALLATION INSTALLATION

1. INSTALL HUMIDITY SENSOR (AIR CONDITIONING THERMISTOR ASSEMBLY) a. Engage the 2 brackets, and carefully install the humidity sensor (air conditioning thermistor assembly) to the glass surface, preventing air bubbles from forming between the contact surfaces.

Fig. 205: Installing Humidity Sensor To Glass Surface & Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Stopper *2 Bracket b. Push in the stopper. c. Connect the connector. 2. INSTALL PROTECTOR a. Engage the 2 claws and temporarily install the protector.

AMBIENT TEMPERATURE SENSOR COMPONENTS

ILLUSTRATION

Fig. 206: Identifying Ambient Temperature Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 2. REMOVE AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Disconnect the connector.

Fig. 207: Identifying Ambient Temperature Sensor Connector Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and remove the ambient temperature sensor (thermistor assembly). INSPECTION INSPECTION

1. INSPECT AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 208: Identifying Ambient Temperature Sensor Connector Terminal Identification and Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 3.00 to A3-1 (-) - 10°C (50° 3.73 A3-2 (+) F) kohms 2.45 to A3-1 (-) - 15°C (59° 2.88 A3-2 (+) F) kohms 1.95 to A3-1 (-) - 20°C (68° 2.30 A3-2 (+) F) kohms 1.60 to A3-1 (-) - 25°C (77° 1.80 A3-2 (+) F) kohms 1.28 to A3-1 (-) - 30°C (86° 1.47 A3-2 (+) F) kohms 1.00 to A3-1 (-) - 35°C (95° 1.22 A3-2 (+) F) kohms 0.80 to A3-1 (-) - 40°C 1.00 A3-2 (+) (104°F) kohms 0.65 to A3-1 (-) - 45°C 0.85 A3-2 (+) (113°F) kohms 0.50 to A3-1 (-) - 50°C 0.70 A3-2 (+) (122°F) kohms 0.44 to A3-1 (-) - 55°C 0.60 A3-2 (+) (131°F) kohms 0.36 to A3-1 (-) - 60°C 0.50 A3-2 (+) (140°F) kohms If the resistance is not as specified, replace the ambient temperature sensor (thermistor assembly). TEXT IN ILLUSTRATION Component without harness *a connected (Ambient Temperature Sensor

(Thermistor Assembly)) Sensing *b Portion Resistance *c (kohms) Allowable *d Range Temperature *e (°C (°F)) NOTE:





Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph). INSTALLATION INSTALLATION

1. INSTALL AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Engage the clamp to install the ambient temperature sensor (thermistor assembly). b. Connect the connector. 2. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4

FRONT EVAPORATOR TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 209: Identifying Front Evaporator Temperature Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY See step 5 2. REMOVE NO. 1 COOLER THERMISTOR a. Disengage the 2 clamps.

Fig. 210: Identifying No. 1 Cooler Thermistor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the No. 1 cooler thermistor. INSPECTION INSPECTION

1. INSPECT EVAPORATOR TEMPERATURE SENSOR (NO. 1 COOLER THERMISTOR) a. Measure the resistance according to the value(s) in the table below.

Fig. 211: Identifying Evaporator Temperature Sensor Connector Terminal Identification And Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 7.30 to -10°C a1-1 - a1-2 9.10 (14°F) kohms 5.65 to -5°C (23° a1-1 - a1-2 6.95 F) kohms 4.40 to 0°C (32° 5.35 a1-1 - a1-2 F) kohms 3.40 to 5°C (41° a1-1 - a1-2 4.15 F) kohms 2.70 to 10°C (50° 3.25 a1-1 - a1-2 F) kohms 2.14 to 15°C (59° a1-1 - a1-2 2.58 F) kohms 1.71 to 20°C (68° a1-1 - a1-2 2.05 F) kohms 1.38 to 25°C (77° 1.64 a1-1 - a1-2 F) kohms 1.11 to 30°C (86° a1-1 - a1-2 1.32 F) kohms If the resistance is not as specified, replace the evaporator temperature sensor (No. 1 cooler thermistor). TEXT IN ILLUSTRATION Component without harness connected *a (Evaporator Temperature Sensor (No. 1 Cooler Thermistor)) Sensing *b Portion Resistance

*c (kohms) Allowable *d Range Temperature *e (°C (°F)) NOTE:





Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph). INSTALLATION INSTALLATION

1. INSTALL NO. 1 COOLER THERMISTOR a. Install the No. 1 cooler thermistor as shown in the illustration.

Fig. 212: Installing No. 1 Cooler Thermistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Part Length 34.3 1.35 A mm in. 20.9 0.82 B mm in. 50 1.96 C mm in. TEXT IN ILLUSTRATION Fixed *a Part *b Sensor

Part NOTE:









Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured. When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration). After inserting the thermistor, do not apply excessive force to the wire. Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".

b. Engage the 2 clamps. 2. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY See step 1

SOLAR SENSOR COMPONENTS ILLUSTRATION

Fig. 213: Identifying Solar Sensor Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 214: Identifying Solar Sensor Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 215: Identifying Solar Sensor Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to REMOVAL - Step 2 for Navigation Receiver Type: Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 6. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 8. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 9. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 11. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 12. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 13. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to REMOVAL - Step 29 14. REMOVE SOLAR SENSOR (AUTOMATIC LIGHT CONTROL SENSOR) a. Disengage the 2 claws and remove the solar sensor (automatic light control sensor).

Fig. 216: Identifying Solar Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT SOLAR SENSOR (AUTOMATIC LIGHT CONTROL SENSOR) a. Disconnect the I61 solar sensor (automatic light control sensor) connector.

Fig. 217: Identifying I61 Solar Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition I61-6 (CLTB) - Power Below 1 I61-3 switch off V (CLTE) I61-6 (CLTB) I61-3

11 to 14 V Power switch on

(CLTE)

(IG)

TEXT IN ILLUSTRATION Front view of wire harness connector (to Solar *a Sensor (Automatic Light Control Sensor)) If the voltage is not as specified, repair or replace the wire harness or connector. c. Reconnect the I61 solar sensor (automatic light control sensor) connector.

Fig. 218: Identifying I61 Solar Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the power switch on (IG). e. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Sensor is I61-1 (TSL) exposed 0.8 to 4.3 - I613 to electric V (CLTE) light I61-1 (TSL) Sensor is

- I61-3 (CLTE) I61-2 (TSR) I61-3 (CLTE) I61-2 (TSR) I61-3 (CLTE)

covered Below 0.8 with a V cloth Sensor is exposed 0.8 to 4.3 to electric V light Sensor is covered Below 0.8 V with a cloth

TEXT IN ILLUSTRATION Component with harness connected (Solar *a Sensor (Automatic Light Control Sensor)) NOTE:





The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 1 (2) and the positive (+) lead to terminal 6 of the solar sensor (automatic light control sensor). Do not bring the positive and negative tester probes too close to each other as a short circuit may occur.

HINT: 



Use an incandescent light for inspection. Bring it within about 30 cm (11.8 in.) of the solar sensor (automatic light control sensor). As the inspection light is moved away from the sensor, the voltage decreases.

If the voltage is not as specified, replace the solar sensor (automatic light control sensor). INSTALLATION INSTALLATION

1. INSTALL SOLAR SENSOR (AUTOMATIC LIGHT CONTROL SENSOR)

2. 3. 4. 5. 6. 7. 8. 9. 10.

a. Engage the 2 claws to install the solar sensor (automatic light control sensor). INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to INSTALLATION - Step 23 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to INSTALLATION - Step 3 for Navigation Receiver Type: Refer to INSTALLATION - Step 3

AIR CONDITIONING PRESSURE SENSOR COMPONENTS ILLUSTRATION

Fig. 219: Identifying Air Conditioning Pressure Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT AIR CONDITIONING PRESSURE SENSOR a. Check the wire harness. 1. Disconnect the A55 air conditioning pressure sensor connector. 2. Disconnect the I77 air conditioning amplifier assembly connector. 3. Measure the resistance according to the value(s) in the table below. Standard Resistance

Tester Specified Condition Connection Condition A55-1 (-) Below 1 I77-13 (SG- Always ohms 2) A55-2 (PR) Below 1 Always - I77-9 ohms (PRE) A55-3 (+) Below 1 I77-10 (S5- Always ohms 3) A55-1 (-) 10 kohms Body Always or higher ground A55-2 (PR) 10 kohms - Body Always or higher ground A10-3 (+) 10 kohms Always Body or higher ground If the resistance is not as specified, repair the wire harness. 4. Reconnect the I77 air conditioning amplifier assembly connector. 5. Turn the power switch on (IG). 6. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection condition Condition A55-3 (+) - Power 4.75 to Body switch on 5.25 V ground (IG) If the voltage is not as specified, repair the wire harness or replace air conditioning amplifier assembly. b. Check the air conditioning pressure sensor. 1. Install a manifold gauge set. 2. Connect the connector to the air conditioning pressure sensor. 3. Turn the power switch on (READY). 4. Turn the A/C switch on. 5. Measure the voltage according to the value(s) in the table below.

Fig. 220: Identifying Air Conditioning Amplifier Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. Standard Voltage Tester Specified Condition Connection Condition Refrigerant pressure: (less than 3025 kPa I77-9 (30.9 (PRE) kgf/cm2, 0.50 to I77-13 (SG- 439 psi) 4.80 V 2) and more than 176 kPa (1.8 kgf/cm2, 25 psi)) If the voltage is not as specified, replace the air conditioning pressure sensor. TEXT IN ILLUSTRATION

Component with harness connected *a (Air Conditioning Amplifier) REMOVAL REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM See step 1 2. REMOVE AIR CONDITIONER PRESSURE SENSOR a. Disconnect the connector. b. Remove the air conditioner pressure sensor.

Fig. 221: Identifying Air Conditioner Pressure Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not deform the piping.

INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONER PRESSURE SENSOR

a. Apply a sufficient amount of compressor oil to a new air conditioner pressure sensor. Compressor oil ND-OIL 11 or equivalent NOTE:





Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign matter. Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

b. Install the new air conditioner pressure sensor. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) NOTE:

 

Do not deform the piping. Make sure to confirm that the piping does not disengage from the plastic clamp.

c. Connect the connector. 2. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT See step 2 3. WARM UP COMPRESSOR See step 3 4. INSPECT FOR REFRIGERANT LEAK See step 4

AIR CONDITIONING PANEL COMPONENTS ILLUSTRATION

Fig. 222: Identifying Air Conditioning Panel Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 223: Identifying Air Conditioning Panel Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 224: Identifying Air Conditioning Panel Replacement Components (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 225: Identifying Air Conditioning Panel Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 226: Identifying Air Conditioning Panel Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to REMOVAL - Step 2 for Navigation Receiver Type: Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 6. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 9. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 11. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 12. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 13. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 11 14. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 12 15. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 13 16. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 14 17. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 15 18. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive

Parking Assist System) . Refer to REMOVAL - Step 16 19. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 10 20. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 11 21. REMOVE AIR CONDITIONING CONTROL ASSEMBLY a. Disengage the 4 clips and guide, and remove the air conditioning control assembly as shown in the illustration.

Fig. 227: Removing Air Conditioning Control Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY a. Engage the guide and 4 clips to install the air conditioning control assembly as shown in the illustration.

Fig. 228: Installing Air Conditioning Control Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 8 3. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 9 4. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 10 5. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 11 6. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 12 7. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 8. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 5 9. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 6 10. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 11. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 12. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7

13. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 14. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 15. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 16. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 17. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION 18. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

20. INSTALL LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to INSTALLATION - Step 3 for Navigation Receiver Type: Refer to INSTALLATION - Step 3

ECO SWITCH COMPONENTS ILLUSTRATION

Fig. 229: Identifying ECO Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 12 REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE ECO MODE SWITCH (ECO SWITCH ASSEMBLY) a. Disengage the 2 claws and remove the ECO mode switch (eco switch assembly).

Fig. 230: Identifying ECO Switch Component And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION

INSPECTION

1. INSPECT ECO MODE SWITCH (ECO SWITCH ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 231: Identifying ECO Mode Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition ECO mode I49-6 (E) - switch I49-9 (eco Below 1

(ECU)

switch ohms assembly) on ECO mode I49-6 (E) - switch 10 kohms I49-9 (eco or higher switch (ECU) assembly) off TEXT IN ILLUSTRATION Component without harness connected (ECO *a Mode Switch (Eco Switch Assembly)) If the result is not as specified, replace the ECO mode switch (eco switch assembly). b. Check that the switch illuminates. 1. Apply auxiliary battery voltage to the ion generator switch assembly and check that the switch illuminates. OK Tester Specified Connection Condition Auxiliary battery positive (+) --> Terminal 8 (ILL+) Illuminates Auxiliary battery negative (-) --> Terminal 7 (ILL-)

If the result is not as specified, replace the ECO mode switch (eco switch assembly). INSTALLATION INSTALLATION

1. INSTALL ECO MODE SWITCH (ECO SWITCH ASSEMBLY) a. Engage the 2 claws to install the ECO mode switch (eco switch assembly). 2. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 35 3. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 36 4. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37 5. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 40

AIR CONDITIONING AMPLIFIER COMPONENTS ILLUSTRATION

Fig. 232: Identifying Air Conditioning Amplifier Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 233: Identifying Air Conditioning Amplifier Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 4 . 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 5 . 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 33 7. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 34 8. REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 9. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 35 10. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 11. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 37 12. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to REMOVAL - Step 12 13. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to REMOVAL Step 12 14. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY a. Disconnect each connector. b. Remove the 2 screws.

Fig. 234: Identifying Air Conditioning Amplifier Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides and remove the air conditioning amplifier assembly. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY a. Engage the 2 guides. b. Install the air conditioning amplifier assembly with the 2 screws. c. Connect each connector. 2. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to INSTALLATION - Step 2 3. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to INSTALLATION - Step 2 4. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 5. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 7. INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 8. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37

9. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION - Step 47 10. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 44 . 11. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 45 . 12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 14. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

RELAY (W/ PTC HEATER) ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT PTC HEATER RELAY (PTC HTR NO. 1, PTC HTR NO. 2)

Fig. 235: Inspecting PTC Heater Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery voltage 10 kohms 3-5 not or higher applied to terminals 1 and 2 Auxiliary battery voltage Below 1 3-5 applied to ohms terminals 1 and 2 If the result is not as specified, replace the relay.

2012-2017 ACCESSORIES & EQUIPMENT Air Conditioning System (Service Information) (Except Hybrid) - Camry

REFRIGERANT ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HINT: The following examples show the readings of a manifold gauge set and the corresponding air conditioning system problems. a. Read the manifold gauge pressure when the following conditions are met:  Doors are fully open.  The engine is idling.  The A/C switch is on.  The temperature is set to max cool.  The blower speed is set to high.  Temperature at the air inlet with recirculate selected is 30 to 35°C (86 to 95°F). 1. Normally functioning air conditioning system.

Fig. 1: Checking Refrigerant Pressure - Normally Functioning Refrigeration System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GAUGE READING Pressure Refrigerant Side Volume 0.15 to 0.25 MPa (1.5 to 2.5 Low kgf/cm2 , 21 to 36 psi) 1.37 to 1.57 MPa (14 to High 16 kgf/cm2 , 199 to 228 psi) 2. Abnormally functioning air conditioning system. a. During operation, pressure on low pressure side cycles between normal and vacuum

Fig. 2: Checking Refrigerant Pressure - Moisture Present In Air Conditioning System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning

system periodically Symptom cools and then fails to cool. Moisture in air conditioning system freezes at expansion valve orifice, causing refrigerant to temporarily Probable Cause stop circulating After system stops, and warms up again, ice melts and normal operation is temporarily restored Cooler dryer (integrated into condenser tank) saturated with moisture Diagnosis Moisture in air conditioning system freezes at expansion valve orifice and blocks circulation

of refrigerant Replace cooler dryer Remove moisture by repeatedly evacuating air from air conditioning system Corrective Actions Recharge air conditioning system with proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, moisture is present in the air conditioning system. b. Pressure is low on both low and high pressure sides

Fig. 3: Checking Refrigerant Pressure - Insufficient Refrigerant Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool Symptom effectively. Insufficient cooling performance Refrigerant leaks from Probable Cause air conditioning system Insufficient refrigerant Diagnosis Refrigerant leaking Check for refrigerant leaks and repair if necessary Recharge

air conditioning system with proper amount of new or purified refrigerant If gauges Corrective Actions indicate pressure of close to 0, then it is necessary to evacuate air conditioning system after repairing leak TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, there is insufficient refrigerant. c. Pressure is low on both low and high pressure sides

Fig. 4: Checking Refrigerant Pressure - Poor Circulation Refrigerant Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool effectively. Frost exists Symptom on pipe from condenser to evaporator unit Refrigerant flow is obstructed by dirt Probable Cause inside pipes of condenser core Condenser Diagnosis is clogged Replace Corrective Actions condenser

TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, there is poor circulation of refrigerant d. Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side

Fig. 5: Checking Refrigerant Pressure - Refrigerant Does Not Circulate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Symptom

Air conditioning system does not cool effectively. (System may cool occasionally) Frost or condensation is seen on piping on both sides of

receiver/dryer or expansion valve Refrigerant flow is obstructed by moisture or dirt in air Probable Cause conditioning system Expansion valve is stuck closed Refrigerant Diagnosis does not circulate Replace expansion valve Replace condenser Evacuate air Corrective Actions conditioning system and supply proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, the refrigerant does not circulate. e. Pressure is too high on both low and high pressure sides

Fig. 6: Checking Refrigerant Pressure - Air Conditioning System Is Overcharged Or Cooling Effectiveness Of Condenser Is Insufficient Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning Symptom system does not cool effectively. Unable to develop sufficient performance due to excessive Probable Cause amount of refrigerant Cooling effectiveness of condenser is insufficient Excessive amount of refrigerant in air conditioning

system --> excessive refrigerant was added during recharging Cooling effectiveness Diagnosis of condenser is insufficient -> condenser fins are clogged or cooling fan is faulty Clean condenser Check operation of condenser cooling fan If above two corrective actions are normal, Corrective Actions check amount of refrigerant and recharge air conditioning system with proper amount of new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI HINT: For the example above, the air conditioning system is overcharged or cooling effectiveness of condenser is insufficient.

f. Pressure is too high on both low and high pressure sides

Fig. 7: Checking Refrigerant Pressure - Air Conditioning System Has Been Left Open And Recharged Without Evacuating System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool. Symptom The low pressure piping is too hot to touch Air in air Probable Cause conditioning system Air present in air conditioning system Diagnosis

Insufficient vacuum purging when evacuating

air conditioning system Replace cooler drier Check compressor oil to see if it is dirty or insufficient Corrective Actions Evacuate air conditioning system and recharge it with new or purified refrigerant TEXT IN ILLUSTRATION *a LO *b HI NOTE:

These gauge indications occur when the air conditioning system has been left open and then recharged without evacuating the system.

HINT: For the example above, air is present in the air conditioning system. g. Pressure is too high on both low and high pressure sides

Fig. 8: Checking Refrigerant Pressure - Expansion Valve Malfunction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Air conditioning system does not cool effectively. Frost or a Symptom large amount of condensation on piping on low pressure side Expansion valve may be stuck Probable Cause open or metering refrigerant incorrectly Excessive refrigerant in low pressure Diagnosis piping Expansion

valve open too wide Replace Corrective Actions expansion valve TEXT IN ILLUSTRATION *a LO *b HI HINT: For the above example, there is an expansion valve malfunction. h. Pressure is too high on both low and high pressure sides or pressure is too low on high pressure side

Fig. 9: Checking Refrigerant Pressure - Insufficient Compressor Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Symptom

Air conditioning system does not cool effectively. Internal leak

in compressor Low compression Leak from a damaged Diagnosis valve or other compressor component Replace Corrective Actions compressor Probable Cause

TEXT IN ILLUSTRATION *a LO *b HI HINT: For the above example, there is insufficient compressor compression. 3. Gauge readings (Reference)

Fig. 10: Identifying Gauge Readings (Reference) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Pressure Pressure on low on high pressure pressure *a side MPa *b side MPa (kgf/cm2 , (kgf/cm2 , psi) psi) Blower Blower *c *d high zone low zone REPLACEMENT REPLACEMENT

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM a. Turn the A/C switch on. b. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor. c. Turn the ignition switch off. d. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit. 2. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT a. Perform vacuum purging using a vacuum pump or appropriate equipment. b. Charge the air conditioning system with refrigerant. Refrigerant type HFC-134a (R134a)

Fig. 11: Identifying State Of Refrigerant Charge Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sub-cool High *a *b System Pressure Standard Refrigerant *c *d charge Amount amount Charge Point where additional *e *f bubbles 100g disappear (3.5oz.) Mean value in *g *h Overcharged proper range Standard charge amount 480 to 580g (16.9 to 20.4oz.) 

SST: 09985-20010 09985-02010 09985-02050

09985-02060 09985-02070 09985-02080 09985-02090 09985-02110 09985-02130 09985-02140 09985-02150 NOTE:



 

Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor. The refrigerant amount should be checked by quantity (weight). The graph above is shown for reference only. This vehicle is not equipped with a sight glass.

HINT: Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an air conditioning system. 3. WARM UP ENGINE a. Keep the A/C switch on for at least 2 minutes to warm up the compressor. NOTE:

To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

4. INSPECT FOR REFRIGERANT LEAK a. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector. b. Carry out the test under the following conditions:  Ignition switch off.  Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).  Repeat the inspection 2 or 3 times.  Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system. Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2 , 57 to 85

psi) c. Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

Fig. 12: Identifying Halogen Leak Detector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Halogen *1 Leak Detector Inspect *a for Leak d. Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

Fig. 13: Identifying Halogen Leak Detector And Drain Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Halogen *1 Leak Detector Drain *2 Hose HINT: After the blower motor has stopped, leave the cooling unit for more than 15 minutes.  Bring the halogen leak detector sensor under the drain hose.  When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks. e. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak. f. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak. 

HINT: When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

REFRIGERANT LINE COMPONENTS ILLUSTRATION

Fig. 14: Identifying Refrigerant Line (For 2AR-FE) (For TMMK Made) Replacement Components With Torque Specifications (1 Of 3)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 15: Identifying Refrigerant Line (For 2AR-FE) (For SIA Made) Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 16: Identifying Refrigerant Line (For 2GR-FE) Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM (for SIA Made) . See step 1.

2. REMOVE PIPING CLAMP (for SIA Made) a. While pressing the end of the suction hose sub-assembly into the end of the suction pipe subassembly, use pliers to squeeze together both sides of the piping clamp until it breaks apart.

Fig. 17: Removing Piping Clamp (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Suction pipe *1 Subassembly Suction Hose *2 Subassembly Piping *3 Clamp *a Press In NOTE:

Make sure that fragments of the piping clamp do not enter the piping.

b. Separate the suction hose sub-assembly. NOTE:

Clean off any dirt or water near the ends of the suction hose subassembly and suction tube sub-assembly.

c. Remove the 2 O-rings from the suction hose sub-assembly. NOTE:

Wrap the open ends of the separated suction pipe sub-assembly and suction hose sub-assembly with vinyl tape to prevent dirt or water from entering.

INSTALLATION INSTALLATION

1. INSTALL PIPING CLAMP (for SIA Made) a. Remove the vinyl tape from the open ends of the suction pipe sub-assembly and suction hose subassembly. b. Install a new piping clamp onto the suction hose sub-assembly.

Fig. 18: Identifying Piping Clamp (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piping *1 Clamp *2 Groove Suction Hose *3 Subassembly NOTE:

Securely engage the inside step of the piping clamp in the suction hose groove.

c. Thoroughly coat 2 new O-rings and the contact surface of the suction hose sub-assembly with compressor oil (ND-OIL8). d. Install the 2 O-rings onto the suction hose sub-assembly. NOTE:

Do not let foreign matter adhere to the O-ring or O-ring seal.

e. Engage the suction tube sub-assembly and suction hose sub-assembly by matching the alignment marks.

Fig. 19: Installing Piping Clamp (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Large Diameter *1 Section of Piping Clamp Alignment *2 Mark NOTE:

Insert them by holding the pipe, not the piping clamp.

f. Securely insert the piping clamp to the point where the large diameter section of the piping clamp is covered by the suction pipe sub-assembly.

Fig. 20: Identifying Large Diameter Section of Piping Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Large Diameter *1 Section of Piping Clamp HINT: When inserting, make sure that a click sound is heard.  Check that the suction pipe is securely inserted by pulling it. 2. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for SIA Made) . See step 2. 3. WARM UP ENGINE (for SIA Made) . See step 3. 4. INSPECT FOR REFRIGERANT LEAK (for SIA Made) . See step 4. 

AIR CONDITIONING UNIT COMPONENTS ILLUSTRATION

Fig. 21: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 22: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 23: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 24: Identifying Air Conditioning Unit Replacement Components (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 25: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 26: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 27: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 28: Identifying Air Conditioning Unit Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

NOTE:

Make sure to select FACE mode before disconnecting the cable from the negative (-) battery terminal.

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1. 2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL . 3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 3. 4. DISCONNECT HEATER OUTLET WATER HOSE a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.

Fig. 29: Locating Heater Outlet Water Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force to the heater outlet water hose. Prepare a drain pan or cloth in case the coolant leaks.

5. DISCONNECT HEATER INLET WATER HOSE a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.

Fig. 30: Locating Heater Inlet Water Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force to the heater inlet water hose. Prepare a drain pan or cloth in case the coolant leaks.

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) a. Remove the bolt, and slide the hook connector.

Fig. 31: Disconnecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the suction hose sub-assembly. c. Remove the O-ring from the suction hose sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

7. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made) a. Remove the bolt, and slide the hook connector.

Fig. 32: Disconnecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the suction pipe sub-assembly. c. Remove the O-ring from the suction pipe sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

8. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Disconnect the air conditioner tube and accessory assembly. b. Remove the O-ring from the air conditioner tube and accessory assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

9. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to REMOVAL . 10. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to REMOVAL . 11. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to REMOVAL . 12. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to REMOVAL . 13. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to REMOVAL - Step 2 . 14. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to REMOVAL - Step 3 . 15. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Manual Seat) HINT: Use the same procedure for the RH side and LH side. 16. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Power Seat) HINT: Use the same procedure for the RH side and LH side. 17. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Manual Seat) HINT: Use the same procedure for the RH side and LH side. 18. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Power Seat) HINT: Use the same procedure for the RH side and LH side. 19. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 2. 20. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual

(SOS) Switch) . Refer to REMOVAL - Step 3 . 21. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to REMOVAL . 22. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 . 23. REMOVE STEERING COLUMN ASSEMBLY Refer to REMOVAL . 24. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY . Refer to REMOVAL - Step 2. 25. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to REMOVAL - Step 12 . 26. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to REMOVAL Step 11 . 27. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY . See step 13. 28. REMOVE FLOOR CARPET HOOK a. Disengage the 6 guides.

Fig. 33: Identifying Floor Carpet Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

LH Side for *B RH Side

*A

b. Disengage the 6 claws and remove the 6 floor carpet hooks.

Fig. 34: Identifying Floor Carpet Claws And Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

LH Side for *B RH Side

*A

29. DISCONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Remove the screw.

Fig. 35: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 36: Disconnecting Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE REAR NO. 4 AIR DUCT a. Disengage the guide.

Fig. 37: Turning Back The Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn back the floor carpet as shown in the illustration. c. Disengage the 4 claws to remove the rear No. 4 air duct.

Fig. 38: Removing Rear No. 4 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE FLOOR CARPET BRACKET LH a. Remove the 2 clips.

Fig. 39: Identifying Floor Carpet Bracket LH Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the floor carpet bracket LH. 32. REMOVE REAR NO. 3 AIR DUCT a. Disengage the 2 claws to remove the rear No. 3 air duct.

Fig. 40: Identifying Rear No. 3 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE REAR NO. 2 AIR DUCT a. Disengage the guide.

Fig. 41: Turning Back The Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn back the floor carpet as shown in the illustration. c. Disengage the 4 claws to remove the rear No. 2 air duct.

Fig. 42: Removing Rear No. 2 Air Duct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE FLOOR CARPET BRACKET RH a. Remove the 2 clips.

Fig. 43: Identifying Floor Carpet Bracket RH Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the floor carpet bracket RH. 35. REMOVE REAR NO. 1 AIR DUCT a. Disengage the 2 claws to remove the rear No. 1 air duct.

Fig. 44: Identifying Rear No. 1 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Remove the clip and the No. 1 console box duct.

Fig. 45: Identifying No. 1 Console Box Duct (w/ Rear Register Duct)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY a. Disconnect each connector.

Fig. 46: Identifying Wire Harness Connectors And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth *1 Wire b. Disengage each clamp. c. Disconnect the connector. d. Remove the bolt and disconnect the earth wire.

e. Remove the bolt and 2 nuts.

Fig. 47: Identifying Instrument Panel To Cowl Brace Sub-Assembly Bolt, Nuts, And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the screw and the instrument panel to cowl brace sub-assembly. 38. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY a. Disconnect the connector.

Fig. 48: Identifying Wire Harness Connectors And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth *1 Wire b. Disengage each clamp. c. Remove the bolt and disconnect the earth wire. d. Remove the bolt and 2 nuts.

Fig. 49: Identifying No. 2 Instrument Panel Brace Sub-Assembly Bolt, Nuts, And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the screw and the No. 2 instrument panel brace sub-assembly. 39. REMOVE INSTRUMENT PANEL SAFETY PAD CAP a. Put protective tape around the 5 instrument panel safety pad caps.

Fig. 50: Identifying Instrument Panel Safety Pad Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for LH Side for RH *B Side Protective *1 Tape

*A

b. Using a screwdriver, remove the 5 instrument panel safety pad caps. 40. REMOVE FRONT LOWER PANEL PACKING a. Remove the 2 front lower panel packings as shown in the illustration.

Fig. 51: Identifying Front Lower Panel Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 41. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT NOTE:





a. for 10 Speakers:

Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break. When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

1. Disengage the 3 clamps.

Fig. 52: Locating Instrument Panel Reinforcement Assembly With Air Conditioning Unit Clamps (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Manual (SOS) Switch: 1. Disengage the clamp.

Fig. 53: Locating Instrument Panel Reinforcement Assembly With Air Conditioning Unit Clamp (w/ Manual (SOS) Switch) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage 3 claw to open the 3 clamps.

Fig. 54: Disengaging Claws To Open Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the connector from the airbag sensor assembly as shown in the illustration.

Fig. 55: Locating Airbag Sensor Assembly Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Smart

Key System Airbag *1 Sensor Assembly

*A

NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Disconnect the connector. f. Disengage each clamp. g. Using a screwdriver, disengage the 2 claws to unlock the retainer as shown in the illustration.

Fig. 56: Identifying Claws To Unlock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Retainer *2 Tape h. Disengage the claw and disconnect the airbag connector as shown in the illustration.

Fig. 57: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Disengage each clamp.

Fig. 58: Identifying Power Tilt And Power Telescopic Steering Column Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for Power Tilt and Power *A - Telescopic Steering Column Earth *1 *2 Protector Wire j. Disengage each clamp. k. for Power Tilt and Power Telescopic Steering Column: 1. Remove the nut and disconnect the protector. l. Disconnect the connector.

Fig. 59: Identifying Wire Harness Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. m. Disengage each clamp. n. Remove the bolt and disconnect the earth wire.

Fig. 60: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Earth Connector *1 *2 Wire Holder o. p. q. r.

Remove the 2 nuts and disconnect the connector holder. Disconnect the connector. Disengage each clamp. Remove the 2 bolts.

Fig. 61: Identifying Connector Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. s. Remove the 5 bolts and the nut as shown in the illustration.

Fig. 62: Removing Instrument Panel Reinforcement And Movable Collar Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Movable *1 *2 Body Collar Instrument *3 Panel - Reinforcement Step *a Step 1 *b 2 Step *c Step 3 *d 4 t. Disconnect the cooler drain hose. u. Disengage the 3 guides and remove the instrument panel reinforcement with air conditioning unit as shown in the illustration.

Fig. 63: Removing Instrument Panel Reinforcement Assembly With Air Conditioning Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Engine *1 Immobiliser - System v. w/ Engine Immobiliser System: 1. Disengage the claw and 2 guides and remove the transponder key ECU assembly as shown in the illustration. 42. REMOVE TRANSPONDER KEY ECU ASSEMBLY (w/ Engine Immobiliser System) a. Disconnect the connector and remove the transponder key ECU assembly.

Fig. 64: Locating Transponder Key ECU Assembly (w/ Engine Immobiliser System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. REMOVE AIR CONDITIONING UNIT ASSEMBLY a. Remove the 3 bolts and the air conditioning unit assembly from the instrument panel reinforcement assembly.

Fig. 65: Locating Air Conditioning Unit Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY a. Disengage the 2 claws and guide, and remove the No. 1 air duct sub-assembly as shown in the illustration.

Fig. 66: Removing No. 1 Air Duct Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY a. Disengage the 2 claws and 2 guides, and remove the No. 6 heater to register duct assembly as shown in the illustration.

Fig. 67: Identifying No. 6 Heater To Register Duct Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE COOLER THERMISTOR HOSE (for Automatic Air Conditioning System) a. Disengage the clamp and remove the cooler thermistor hose.

Fig. 68: Locating Cooler Thermistor Hose (For Automatic Air Conditioning System) Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE ASPIRATOR a. Disengage the 2 claws and remove the aspirator.

Fig. 69: Identifying Aspirator Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System) a. Remove the heater packing as shown in the illustration.

Fig. 70: Removing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 4 connectors.

Fig. 71: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 5 clamps and remove the air conditioning harness assembly. 6. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System) a. Remove the heater packing as shown in the illustration.

Fig. 72: Removing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 5 connectors.

Fig. 73: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 5 clamps and remove the air conditioning harness assembly. 7. REMOVE COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve.

Fig. 74: Identifying Cooler Expansion Valve And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY . See step 6. 9. REMOVE NO. 1 COOLER THERMISTOR . See step 2. 10. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Remove the No. 1 cooler evaporator sub-assembly from the blower assembly as shown in the illustration.

Fig. 75: Removing No. 1 Cooler Evaporator Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

Fig. 76: Identifying O-Rings To Cooler Evaporator No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

11. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) a. Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

Fig. 77: Locating Air Mix Control Servo Motor Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY a. Disengage the 3 claws and remove the heater clamp.

Fig. 78: Identifying Heater Clamp And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the screw and clamp.

Fig. 79: Identifying Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly as shown in the illustration.

Fig. 80: Removing Heater Radiator Unit Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Prepare a drain pan or cloth in case the cooling water leaks.

13. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Remove the 3 screws and then the No. 2 air conditioning radiator damper servo sub-assembly.

Fig. 81: Identifying No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY a. Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo subassembly are positioned in the correct orientation as shown in the illustration.

Fig. 82: Correct Orientation Of Slots, Links And Gears Of No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward. c. Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

Fig. 83: Rotating Link Of Air Conditioning Radiator Assembly (To The Left) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.

Fig. 84: Rotating Link Of Air Conditioning Radiator Assembly (To The Bottom) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mode *a Switching - Duct

Hole e. Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

Fig. 85: Rotating Lever Of Air Conditioning Radiator Assembly (To The Top) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

Fig. 86: Rotating Link Of Air Conditioning Radiator Assembly (To The In-Line Position) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION In-line *a -Position g. Wrap the upper and lower links with vinyl tape to hold them in the in-line position.

Fig. 87: Identifying Vinyl Tape Wrap On Upper And Lower Links Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vinyl *1 Tape h. Install the link of the No. 1 air conditioning radiator damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

Fig. 88: Identifying No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly Link Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Air Conditioning Radiator *1 Guide *2 Damper Servo Subassembly No. 1 Air Conditioning Radiator Link Guide *a Damper *b Pin (A) Servo Subassembly Slot Link Guide *c - Pin (B) i. Install the guide hole of the No. 1 air conditioning radiator damper servo sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration. j. Temporarily install the screw (up to 4 or 5 threads). NOTE:



Make sure that the link guide pin (B) is inserted in the No. 1 air



conditioning radiator damper servo sub-assembly slot. Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.

k. Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

Fig. 89: Lifting Air Outlet Control Servo Motor Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Move the air conditioning radiator assembly gear so that alignment holes of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly are aligned.

Fig. 90: Aligning No. 1 Air Conditioning Radiator Damper Servo Sub-Assembly And Air Conditioning Radiator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Air Conditioning Air Radiator Conditioning Damper Radiator *a *b Servo SubAssembly assembly Alignment Alignment Hole Hole Air Conditioning Radiator Assembly *c - Alignment Gear Alignment Hole m. Insert a screwdriver into the aligned holes as shown in the illustration.

Fig. 91: Aligning Air Outlet Control Servo Motor Sub-Assembly Using Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. n. Make sure that all the links and gears are in the positions shown in the illustration.

Fig. 92: Proper Link And Gear Positioning Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Screwdriver Link is inserted guide pin *a into *b is alignment inserted. holes. Link is Link is *c positioned *d positioned to left side. at bottom. Each link guide pin is inserted in Lever is *e its air outlet *f positioned control at top. servo motor slot. Links are *g - in-line.

o. Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

Fig. 93: Pushing Air Outlet Control Servo Motor Sub-Assembly Into Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position. After pushing the servos into position, keep them in place by holding them until the screws are installed.

HINT: Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard. p. Remove the screwdriver. q. Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo subassembly with the 2 remaining screws.

Fig. 94: Identifying Air Outlet Control Servo Motor Sub-Assembly And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. r. Remove the vinyl tape. 2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY a. Install the heater radiator unit sub-assembly to the air conditioner radiator assembly.

Fig. 95: Installing Heater Radiator Unit Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clamp with the screw.

Fig. 96: Identifying Screw And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 3 claws and install the heater clamp.

Fig. 97: Identifying Heater Clamp And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) a. Using the reference point, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

Fig. 98: Identifying No. 2 Air Conditioning Radiator Damper Servo Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *a Point 4. INSTALL NO. 1 COOLER THERMISTOR . See step 1. 5. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.

Fig. 99: Identifying O-Rings To Cooler Evaporator No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Compressor oil ND-OIL 8 or equivalent b. Install the No. 1 cooler evaporator sub-assembly to the blower assembly.

Fig. 100: Installing No. 1 Cooler Evaporator Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY . See step 1. 7. INSTALL COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.

Fig. 101: Identifying Cooler Expansion Valve And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System) a. Engage the 5 clamps to install air conditioning harness assembly.

Fig. 102: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the 4 connectors. c. Install the heater packing as shown in the illustration.

Fig. 103: Installing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System) a. Engage the 5 clamps to install air conditioning harness assembly.

Fig. 104: Identifying Air Conditioning Harness Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the 5 connectors. c. Install the heater packing as shown in the illustration.

Fig. 105: Installing Heater Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL ASPIRATOR a. Engage the 2 claws to install the aspirator.

Fig. 106: Identifying Aspirator Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL COOLER THERMISTOR HOSE (for Automatic Air Conditioning System) a. Engage the clamp to install the cooler thermistor hose.

Fig. 107: Locating Cooler Thermistor Hose (For Automatic Air Conditioning System) Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY a. Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

Fig. 108: Identifying No. 6 Heater To Register Duct Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY a. Engage the 2 claws and guide to install the No. 1 air duct sub-assembly as shown in the illustration.

Fig. 109: Installing No. 1 Air Duct Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY a. Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

Fig. 110: Locating Air Conditioning Unit Assembly Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

2. INSTALL TRANSPONDER KEY ECU ASSEMBLY (w/ Engine Immobiliser System) a. Connect the connector and install the transponder key ECU assembly. 3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT NOTE:





Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break. When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

a. w/ Engine Immobiliser System: 1. Disengage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

Fig. 111: Installing Instrument Panel Reinforcement Assembly With Air Conditioning Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Engine *A Immobiliser - System b. Install the instrument panel reinforcement assembly with the 3 bolts and 2 new bolts in the order shown in the illustration.

Fig. 112: Installing Instrument Panel Reinforcement And Movable Collar Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Movable *1 *2 Body Collar Instrument *3 Panel - Reinforcement Step *a Step 1 *b 2 Step *c Step 3 *d 4 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE:

c. Install the bolt.

Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) d. Install the instrument panel reinforcement assembly with air conditioning unit with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) e. Pass the cooler drain hose through the vehicle securely.

Fig. 113: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Connect the cooler drain hose firmly to prevent water leaks.

f. Install the 2 bolts.

Fig. 114: Identifying Connector Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration.

g. Engage each clamp. h. Connect each connector. i. Connect the bolts and connect the 3 earth wires. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) j. for Power Tilt and Power Telescopic Steering Column: 1. Connect the protector with the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) k. Engage the claw to connect the airbag connector as shown in the illustration.

Fig. 115: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Engage the 2 claws to lock the retainer as shown in the illustration.

Fig. 116: Identifying Claws To Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer m. Engage each clamp.

Fig. 117: Locating Airbag Sensor Assembly Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Smart

Key System Airbag *a Sensor Assembly

*A

n. Connect each connector. o. Engage the 2 clamps. p. Connect the connector to the airbag sensor assembly as shown in the illustration. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

q. Engage the 3 claws to close the 3 clamps as shown in the illustration.

Fig. 118: Engaging Claws To Close Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. r. w/ Manual (SOS) Switch: 1. Engage the clamp. s. for 10 Speakers: 1. Engage the 3 clamps. 4. INSTALL FRONT LOWER PANEL PACKING a. Install the 2 front lower panel packings shown in the illustration.

Fig. 119: Identifying Front Lower Panel Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL INSTRUMENT PANEL SAFETY PAD CAP a. Install 5 new instrument panel safety pad caps.

Fig. 120: Identifying Instrument Panel Safety Pad Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for *A LH Side for *B RH Side 6. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY a. Install the screw and 2 nuts. Nut Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) b. Install the No. 2 instrument panel brace sub-assembly with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) c. Connect the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. Engage each clamp. e. Connect the connector. 7. INSTALL INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY a. Install the screw and 2 nuts. Nut Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) b. Install the instrument panel to cowl brace sub-assembly with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) c. Connect the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. Engage each clamp. e. Connect each connector. 8. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Install the No. 1 console box duct with the clip. 9. INSTALL REAR NO. 3 AIR DUCT

a. Engage the 2 claws to install the rear No. 3 air duct. 10. INSTALL FLOOR CARPET BRACKET LH a. Engage the 2 guides. b. Install the floor carpet bracket LH with the 2 clips. 11. INSTALL REAR NO. 4 AIR DUCT a. Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.

Fig. 121: Installing Rear No. 4 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the guide to install the floor carpet to the original position as shown in the illustration.

Fig. 122: Installing Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 123: Connecting Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the screw. 13. INSTALL REAR NO. 1 AIR DUCT a. Engage the 2 claws to install the rear No. 1 air duct. 14. INSTALL FLOOR CARPET BRACKET RH a. Engage the 2 guides. b. Install the floor carpet bracket RH with the 2 clips. 15. INSTALL REAR NO. 2 AIR DUCT a. Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.

Fig. 124: Installing Rear No. 2 Air Duct Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the guide to install the floor carpet to the original position as shown in the illustration.

Fig. 125: Turning Back The Floor Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL FLOOR CARPET HOOK a. Engage the 6 claws to install the 6 floor carpet hooks. b. Engage the 6 guides. 17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY . See step 1. 18. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to INSTALLATION - Step 1 . 19. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to INSTALLATION - Step 2 . 20. INSTALL STEERING COLUMN ASSEMBLY Refer to INSTALLATION .

21. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 22. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION . 23. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to INSTALLATION - Step 4 . 24. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to INSTALLATION - Step 5 . 25. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to INSTALLATION . 26. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to INSTALLATION . 27. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to INSTALLATION . 28. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to INSTALLATION . 29. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to INSTALLATION - Step 4 . 30. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to INSTALLATION Step 5 . 31. INSTALL FRONT SEAT ASSEMBLY RH (for TMMK Made Manual Seat) HINT: Use the same procedure for the RH side and LH side. 32. INSTALL FRONT SEAT ASSEMBLY RH (for TMMK Made Power Seat) HINT: Use the same procedure for the RH side and LH side. 33. INSTALL FRONT SEAT ASSEMBLY RH (for SIA Made Manual Seat) HINT: Use the same procedure for the RH side and LH side.

34. INSTALL FRONT SEAT ASSEMBLY RH (for SIA Made Power Seat) HINT: Use the same procedure for the RH side and LH side. 35. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube and accessory assembly. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the air conditioning tube and accessory assembly. d. Install the air conditioning tube and accessory assembly. 36. CONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose subassembly. Compressor oil ND-OIL 8 or equivalent c. Connect the O-ring to the suction hose sub-assembly. d. Connect the suction hose sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 126: Connecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 37. CONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made) a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe subassembly. Compressor oil ND-OIL 8 or equivalent

c. Connect the O-ring to the suction pipe sub-assembly. d. Connect the suction pipe sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 127: Connecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 38. CONNECT HEATER INLET WATER HOSE a. Install the heater inlet water hose and attach the clip. 39. CONNECT HEATER OUTLET WATER HOSE a. Install the heater outlet water hose and attach the clip.

40. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 14 . 41. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION . 42. 43. 44. 45. 46. 47. 48. 49.

ADD ENGINE COOLANT (for 2AR-FE) . Refer to REPLACEMENT - Step 2 . ADD ENGINE COOLANT (for 2GR-FE) . Refer to REPLACEMENT - Step 2 . INSPECT FOR COOLANT LEAK (for 2AR-FE) . Refer to ON-VEHICLE INSPECTION - Step 1 . INSPECT FOR COOLANT LEAK (for 2GR-FE) . Refer to ON-VEHICLE INSPECTION - Step 1 . CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. WARM UP ENGINE . See step 3. INSPECT FOR REFRIGERANT LEAK . See step 4. INITIALIZATION SERVO MOTOR (for Automatic Air Conditioning System) Refer to INITIALIZATION .

50. INITIALIZATION SERVO MOTOR (for Manual Air Conditioning System) Refer to INITIALIZATION .

BLOWER UNIT COMPONENTS ILLUSTRATION

Fig. 128: Identifying Blower Unit Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 129: Identifying Blower Unit Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE AIR CONDITIONING UNIT ASSEMBLY

Refer to REMOVAL. 2. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY . See step 1. 3. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY . See step 2. 4. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System) . See step 5. 5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System) . See step 6. 6. REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY a. Remove the 6 screws.

Fig. 130: Identifying Blower Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws and remove the blower assembly with cooler evaporator sub-assembly.

DISASSEMBLY DISASSEMBLY

1. 2. 3. 4.

REMOVE COOLER EXPANSION VALVE . See step 7. REMOVE NO. 1 COOLER THERMISTOR . See step 2. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY . See step 10. REMOVE DRAIN COOLER HOSE a. Remove the drain cooler hose from the blower case assembly.

Fig. 131: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE AIR DUCT SUB-ASSEMBLY a. Disengage the 4 claws and remove the air duct sub-assembly.

Fig. 132: Identifying Air Duct Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE AIR FILTER COVER PLATE a. Disengage the 2 claws and remove the air filter cover plate.

Fig. 133: Identifying Air Filter Cover Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE CLEAN AIR FILTER a. Remove the clean air filter as shown in the illustration.

Fig. 134: Removing Air Filter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 BLOWER DAMPER SERVO SUB-ASSEMBLY a. Remove the 3 screws and No. 1 blower damper servo sub-assembly.

Fig. 135: Identifying No. 1 Blower Damper Servo Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Remove the 3 screws and blower motor with fan sub-assembly.

Fig. 136: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Install the blower motor with fan sub-assembly with the 3 screws.

Fig. 137: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 BLOWER DAMPER SERVO SUB-ASSEMBLY a. Install the No. 1 blower damper servo sub-assembly with the 3 screws.

Fig. 138: Identifying No. 1 Blower Damper Servo Sub-Assembly Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL CLEAN AIR FILTER a. Install the clean air filter as shown in the illustration.

Fig. 139: Installing Air Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL AIR FILTER COVER PLATE a. Engage the 2 claws to install the air filter cover plate.

Fig. 140: Identifying Air Filter Cover Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL AIR DUCT SUB-ASSEMBLY a. Engage the 4 claws to install the air duct sub-assembly.

Fig. 141: Identifying Air Duct Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL DRAIN COOLER HOSE a. Install the drain cooler hose as shown in the illustration.

Fig. 142: Identifying Drain Cooler Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hose *1 Notch Blower Case *2 Assembly Rib 7. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY . See step 5. 8. INSTALL NO. 1 COOLER THERMISTOR . See step 1. 9. INSTALL COOLER EXPANSION VALVE . See step 7. INSTALLATION INSTALLATION

1. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY a. Engage the 2 claws. b. Install the blower assembly with cooler evaporator sub-assembly with the 6 screws. c. Engage the 3 clamps. 2. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System) . See step 8.

3. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System) . See step 9. 4. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY . See step 1. 5. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY . See step 12. 6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY . See step 13. 7. INSTALL AIR CONDITIONING UNIT ASSEMBLY Refer to INSTALLATION.

FRONT BLOWER MOTOR COMPONENTS ILLUSTRATION

Fig. 143: Identifying Front Blower Motor Replacement Components

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 36 . 2. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Disconnect the connector. b. Remove the 3 screws and blower motor with fan sub-assembly.

Fig. 144: Identifying Blower Motor With Fan Sub-Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not remove the blower motor with fan sub-assembly if it has been damaged or impacted.

INSTALLATION INSTALLATION

1. INSTALL BLOWER MOTOR WITH FAN SUB-ASSEMBLY a. Install the blower motor with fan sub-assembly with the 3 screws. NOTE:

Do not install the blower motor with fan sub-assembly if it has been

damaged or impacted. b. Connect the connector. 2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 .

COOLER EXPANSION VALVE COMPONENTS ILLUSTRATION

Fig. 145: Identifying Cooler Expansion Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

When removing the cooler expansion valve by itself, be sure to install a new

cooler expansion valve and new bolt for suction hose sub-assembly. 1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1. 2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL . 3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 3. 4. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) . See step 6. 5. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made) . See step 7. 6. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY . See step 8. 7. REMOVE COOLER EXPANSION VALVE a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts.

Fig. 146: Identifying Cooler Expansion Valve Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the bolt for the suction hose sub-assembly halfway to the cooler expansion valve.

Fig. 147: Identifying Cooler Expansion Valve Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt for Suction *a Hose Subassembly c. Hold the bolt and pull it to remove the cooler expansion valve as shown in the illustration.

Fig. 148: Removing Cooler Expansion Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

Fig. 149: Identifying No. 1 Cooler Evaporator Sub-Assembly O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. 1 cooler *1 evaporator subassembly INSTALLATION INSTALLATION

1. INSTALL COOLER EXPANSION VALVE a. Apply sufficient compressor oil to 2 new O-rings and the fitting surfaces of the cooler expansion valve. Compressor oil ND-OIL8 or equivalent b. Install the 2 new O-rings to the No. 1 cooler evaporator sub-assembly. c. Using a 4 mm hexagon wrench, install the new cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 2. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY . See step 35. 3. CONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose subassembly. Compressor oil ND-OIL 8 or equivalent c. Connect the O-ring to the suction hose sub-assembly. d. Connect the suction hose sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 150: Connecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Insert the pipe joint into the fitting hole securely and tighten a new bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. CONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made) a. Remove the vinyl tape from the pipe. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe subassembly. Compressor oil ND-OIL 8 or equivalent

c. Connect the O-ring to the suction pipe sub-assembly. d. Connect the suction pipe sub-assembly. e. Move the hook connector in the direction indicated by the arrow in the illustration.

Fig. 151: Connecting Suction Hose Hook Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Insert the pipe joint into the fitting hole securely and tighten a new bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 14 . 6. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Refer to INSTALLATION . 7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. 8. WARM UP ENGINE . See step 3. 9. INSPECT FOR REFRIGERANT LEAK . See step 4.

COMPRESSOR (FOR 2AR-FE) COMPONENTS ILLUSTRATION

Fig. 152: Identifying Compressor (For 2AR-FE) Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 153: Identifying Compressor (For 2AR-FE) Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT COMPRESSOR FOR METALLIC SOUND

a. Check if there is abnormal metallic sound from the compressor when the A/C switch is on and the compressor operates. If abnormal metallic sound is heard, replace the compressor assembly with pulley. 2. INSPECT REFRIGERANT PRESSURE HINT: Refer to ON-VEHICLE INSPECTION. 3. INSPECT FOR LEAKAGE OF REFRIGERANT a. Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly with pulley. 4. INSPECT COMPRESSOR ASSEMBLY WITH PULLEY a. Check operation of compressor assembly with pulley. 1. Start the engine. 2. Inspect the compressor pulley.

Fig. 154: Identifying Compressor Assembly With Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compressor *a Assembly *b Pulley with Pulley

Standard The compressor shaft rotates along with the pulley. If the result is not as specified, replace the compressor assembly with pulley. REMOVAL REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1. 2. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL . 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE V-RIBBED BELT . Refer to REMOVAL - Step 5 . 5. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the bolt.

Fig. 155: Identifying Compressor Assembly Connectors And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 connectors. c. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor assembly with pulley.

Fig. 156: Identifying No. 1 Cooler Refrigerant Discharge Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) a. Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.

Fig. 157: Identifying Suction Hose Sub-Assembly And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the suction hose sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

7. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) a. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor assembly with pulley.

Fig. 158: Identifying Suction Hose Sub-Assembly And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the No. 1 cooler refrigerant suction hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

8. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY a. Remove the 2 bolts and 2 nuts.

Fig. 159: Identifying Compressor Assembly With Pulley And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an E8 "TORX" socket, remove the 2 stud bolts and compressor assembly with pulley.

Fig. 160: Identifying Compressor Assembly With Pulley And Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HINT: Leave the 2 stud bolts in the vehicle with the remaining in the compressor assembly with pulley. INSPECTION INSPECTION

1. INSPECT COMPRESSOR ASSEMBLY WITH PULLEY (COMPRESSOR SOLENOID) a. Measure the resistance according to the value(s) in the table below.

Fig. 161: Inspecting Compressor Assembly With Pulley (Compressor Solenoid) Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance

Tester Specified Condition Connection Condition E74-1 20°C (68° 10 to 11 (SOL-) F) ohms E74-2 (SOL+) TEXT IN ILLUSTRATION Component without harness connected *a (Compressor Assembly with Pulley (Compressor Solenoid)) If the resistance is not as specified, replace the compressor assembly with pulley. INSTALLATION INSTALLATION

1. ADJUST COMPRESSOR OIL LEVEL a. When replacing the compressor with a new one: 1. Remove the drain bolt (washer).

Fig. 162: Locating Compressor Drain Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drain *1 bolt (washer) 2. Gradually discharge the inert gas from the service valve. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.

Fig. 163: View Of Oil Amount Drained From Removed Cooler Compressor Assembly And Reserve Chamber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit. TEXT IN ILLUSTRATION Removed *1 Compressor Amount of oil drain *2 from removed compressor Amount of oil remaining in the *3 reserve chamber (60 cc (3.66 fl.oz))

Standard (The amount of oil inside a new compressor: 100 (+15) cc (6.10 (+0.92) fl.oz)) - (The amount of oil remaining in the old compressor A + oil remaining in the reserve chamber: 60 cc (3.66 fl.oz)) = (The amount of oil to be removed from the new compressor) NOTE:



When A + 60 cc (3.66 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume. Example: If A = 45 cc (2.75 fl.oz), A + 60 cc (3.66 fl.oz) = 105 cc (6.41 fl.oz). If the standard volume is 100 cc (6.10 fl.oz), install the compressor as is.







When checking the compressor oil level, observe the precautions for cooler removal/installation. If the amount of oil remaining in the removed compressor is too low, check for oil leaks. Use ND-OIL8 or equivalent for compressor oil.

3. Install the drain bolt (washer). Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) b. If draining the oil is difficult, drain the oil using the following procedure: 1. Remove the suction seal cap. 2. Lightly shake the compressor with the suction port facing down, and drain the oil (*1).

Fig. 164: Identifying Draining Oil From Compressor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not allow the pulley to come into contact with the compressor oil.

c. With the DL pulley facing down, rotate the pulley in the direction shown by the arrow 10 times at a rate of approximately once every 2 seconds (*2).

Fig. 165: Rotating Pulley To Remove Oil (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the pulley is rotated, refrigerant or oil might splash out. Thus, keep your face away from the compressor port. d. Rotate the pulley once in the direction shown by the arrow while quickly turning the compressor so the pulley is up (*3).

Fig. 166: Rotating Pulley To Remove Oil (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Proceed with the above procedure (*1) and drain the oil (*4). f. Drain the oil by repeating the procedures above approximately 5 times (from (*2) to (*4)). 2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY a. Using an E8 "TORX" socket, temporarily install the compressor assembly with pulley with the 2 stud bolts.

Fig. 167: Identifying Compressor Assembly With Pulley And Stud Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Tighten the stud bolts in the order shown in the illustration. b. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

Fig. 168: Identifying Compressor Assembly With Pulley And Fasteners With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) HINT: Tighten the bolts and nuts in the order shown in the illustration to install the compressor. 3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the attached vinyl tape from the hose. b. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the No. 1 cooler refrigerant discharge hose. d. Install the No. 1 cooler refrigerant discharge hose onto the compressor and pulley with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. INSTALL SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) a. Remove the attached vinyl tape from the hose.

b. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring onto the suction hose sub-assembly. d. Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) e. Connect the 2 connectors. f. Install the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) a. Remove the attached vinyl tape from the hose. b. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring onto the No. 1 cooler refrigerant suction hose. d. Install the No. 1 cooler refrigerant suction hose onto the compressor assembly with pulley with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) e. Connect the 2 connectors. f. Install the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 6. INSTALL V-RIBBED BELT . Refer to INSTALLATION - Step 1 . 7. INSTALL FRONT FENDER APRON SEAL RH 8. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION . 9. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. 10. WARM UP ENGINE . See step 3.

11. INSPECT FOR REFRIGERANT LEAK . See step 4.

COMPRESSOR (FOR 2GR-FE) COMPONENTS ILLUSTRATION

Fig. 169: Identifying Compressor (For 2GR-FE) Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 170: Identifying Compressor (For 2GR-FE) Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1.

2. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL . 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE V-RIBBED BELT . Refer to REMOVAL - Step 5 . 5. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Disconnect the 3 connectors.

Fig. 171: Identifying Compressor Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clamps. c. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and magnetic clutch.

Fig. 172: Identifying No. 1 Cooler Refrigerant Discharge Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the bolt and disconnect the suction hose sub-assembly from the compressor and magnetic clutch.

Fig. 173: Identifying Suction Hose Sub-Assembly And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the suction hose sub-assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

7. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

Fig. 174: Identifying Compressor And Magnetic Clutch Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Remove the 4 bolts and compressor and magnetic clutch and bracket. DISASSEMBLY DISASSEMBLY

1. REMOVE COOLER BRACKET a. Disconnect the connector.

Fig. 175: Identifying Cooler Bracket Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. c. Remove the screw and cooler bracket. 2. REMOVE MAGNET CLUTCH ASSEMBLY a. Clamp the cooler compressor in a vise between aluminum plates.

Fig. 176: Removing Magnet Clutch Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, hold the magnet clutch hub.  SST: 07112-76060 c. Remove the bolt, magnet clutch hub and magnet clutch washer(s). HINT: There is no set number of magnet clutch washers that are used for adjusting clutch clearance. d. Using a snap ring expander, remove the snap ring and magnet clutch rotor.

Fig. 177: Identifying Snap Ring And Magnet Clutch Rotor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the seal cover of the bearing when removing the snap ring.

e. Disengage the clamp. f. Using a snap ring expander, remove the snap ring and magnet clutch stator.

Fig. 178: Identifying Snap Ring And Magnet Clutch Stator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT COOLER COMPRESSOR ASSEMBLY (A/C LOCK SENSOR) a. Measure the resistance according to the value(s) in the table below.

Fig. 179: Inspecting Cooler Compressor Assembly (A/C Lock Sensor) Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition E73-1 (SSR+) - 20°C (68° 160 to 320 F) ohms E73-2 (SSR-) TEXT IN ILLUSTRATION Component without harness

connected (Cooler Compressor *a Assembly (A/C Lock Sensor)) If the resistance is not as specified, replace the cooler compressor assembly. 2. INSPECT COOLER COMPRESSOR ASSEMBLY (COMPRESSOR SOLENOID) a. Measure the resistance according to the value(s) in the table below.

Fig. 180: Inspecting Cooler Compressor Assembly (Compressor Solenoid) Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition E74-1 20°C (68° 10 to 11 (SOL-) F) ohms E74-2 (SOL+) TEXT IN ILLUSTRATION Component without harness connected *a (Cooler Compressor Assembly (Compressor Solenoid)) If the resistance is not as specified, replace the cooler compressor assembly. 3. INSPECT COOLER COMPRESSOR ASSEMBLY a. Disconnect the E73 cooler compressor assembly connector. b. Disconnect the a2 magnetic clutch assembly connector. c. Measure the resistance according to the value(s) in the table below.

Fig. 181: Inspecting E73 Cooler Compressor Assembly & A2 Magnetic Clutch Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition E73-3 Below 1 (MG+) Always ohms a2-1 E73-3 (MG+) 10 kohms Always Body or higher ground

If the resistance is not as specified, replace the cooler compressor assembly. TEXT IN ILLUSTRATION Component without harness *a connected (Cooler Compressor Assembly) Component without harness *b connected (Magnetic Clutch Assembly) REASSEMBLY REASSEMBLY

1. INSTALL MAGNET CLUTCH ASSEMBLY a. Install the magnet clutch stator with the parts aligned as shown in the illustration.

Fig. 182: Installing Magnet Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using a snap ring expander, install a new snap ring with the chamfered side facing outward.

Fig. 183: Installing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the clamp. d. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing outward.

Fig. 184: Installing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the seal cover of the bearing when installing the snap ring.

e. Install the magnet clutch washer(s) and magnet clutch hub. NOTE:

Do not change the combination of the magnet clutch washer(s) used before disassembly.

f. Using SST, hold the magnet clutch hub and install the bolt.  SST: 07112-76060

Fig. 185: Installing Magnet Clutch Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) NOTE:

Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.

2. INSTALL COOLER BRACKET a. Install the cooler bracket with the screw.

Fig. 186: Identifying Cooler Bracket Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clamp. c. Connect the connector. 3. INSPECT MAGNET CLUTCH CLEARANCE a. Clamp the cooler compressor in a vise between aluminum plates.

Fig. 187: Measuring Magnet Clutch Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Set the dial indicator to the magnet clutch hub. c. Connect a battery positive lead to terminal 3 of the magnet clutch connector and a negative lead to the ground wire. Turn the magnet clutch on and off and measure the clearance. Standard clearance 0.35 to 0.60 mm (0.014 to 0.024 in.) If the measured value is not within the standard clearance, remove the magnet clutch hub and adjust the clearance using magnet clutch washers to obtain the standard clearance. Magnet clutch washer thickness 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) NOTE:

Adjustment should be performed with 3 or fewer magnet clutch washers.

d. Remove the cooler compressor from the vise.

INSTALLATION INSTALLATION

1. ADJUST COMPRESSOR OIL a. When replacing the compressor with a new one: 1. Remove the drain bolt (washer).

Fig. 188: Locating Compressor Drain Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drain *1 bolt (washer) 2. Gradually discharge the inert gas from the service valve. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.

Fig. 189: View Of Oil Amount Drained From Removed Cooler Compressor Assembly And Reserve Chamber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit. TEXT IN ILLUSTRATION Removed *1 Compressor Amount of oil drain *2 from removed compressor Amount of oil remaining in the *3 reserve chamber (60 cc (3.66 fl.oz))

Standard (The amount of oil inside a new compressor: 100 (+15) cc (6.10 (+0.92) fl.oz)) - (The amount of oil remaining in the old compressor A + oil remaining in the reserve chamber: 60 cc (3.66 fl.oz)) = (The amount of oil to be removed when replacing the compressor) NOTE:



When A + 60 cc (3.66 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume. Example: If A = 45 cc (2.75 fl.oz), A + 60 cc (3.66 fl.oz) = 105 cc (6.41 fl.oz). If the standard volume is 100 cc (6.10 fl.oz), install the compressor as is.







When checking the compressor oil level, observe the precautions for cooler removal/installation. If the amount of oil remaining in the removed compressor is too low, check for oil leaks. Use ND-OIL8 or equivalent for compressor oil.

3. Install the drain bolt (washer). Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) b. If draining the oil is difficult, drain the oil using the following procedure: 1. Remove the suction seal cap. 2. Lightly shake the compressor with the suction port facing down, and drain the oil (*1).

Fig. 190: Identifying Draining Oil From Compressor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not allow the pulley to come into contact with the compressor oil.

c. With the pulley facing down, rotate the hub in the direction shown by the arrow 10 times at a rate of approximately once every 2 seconds (*2).

Fig. 191: Rotating Pulley To Remove Oil (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the pulley is rotated, refrigerant or oil might splash out. Thus, keep your face away from the compressor port. d. Rotate the hub once in the direction shown by the arrow while quickly turning the compressor so the pulley is up (*3).

Fig. 192: Rotating Pulley To Remove Oil (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Proceed with the above procedure (*1) and drain the oil (*4). f. Drain the oil by repeating the procedures above approximately 5 times (from (*2) to (*4)). 2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH a. Install the compressor and magnetic clutch and bracket with the 4 bolts.

Fig. 193: Identifying Compressor And Magnetic Clutch Fasteners With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) NOTE:

Tighten the bolts in the order shown in the illustration to install the cooler compressor.

3. CONNECT SUCTION HOSE SUB-ASSEMBLY a. Remove the vinyl tape from the hose and compressor and magnetic clutch. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the suction hose sub-assembly. d. Connect the suction hose sub-assembly to the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE a. Remove the vinyl tape from the hose and compressor and magnetic clutch. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the No. 1 cooler refrigerant discharge hose. d. Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) e. Engage the 2 clamps and connect the 3 connectors. 5. INSTALL V-RIBBED BELT . Refer to INSTALLATION - Step 1 . 6. INSTALL FRONT FENDER APRON SEAL RH 7. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION . 8. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. 9. WARM UP ENGINE . See step 3. 10. INSPECT FOR REFRIGERANT LEAK . See step 4.

CONDENSER COMPONENTS ILLUSTRATION

Fig. 194: Identifying Condenser (For 2AR-FE) Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 195: Identifying Condenser (For 2GR-FE) Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 196: Identifying Condenser Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT COOLER CONDENSER ASSEMBLY a. If the cooler condenser assembly fins are dirty, clean them with water and dry with compressed air. NOTE:

Do not damage the cooler condenser assembly fins.

b. If any cooler condenser assembly fins are bent, straighten them using a screwdriver or pliers. 2. INSPECT FOR REFRIGERANT LEAK a. Using a halogen leak detector, check pipe joints for refrigerant leaks. b. If a refrigerant leak is detected in a joint, check the torque of the joint. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1. 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL . 5. 6. 7. 8. 9.

REMOVE BATTERY (for 2GR-FE) . Refer to REMOVAL - Step 22 . REMOVE INLET AIR CLEANER ASSEMBLY (for 2AR-FE) . Refer to REMOVAL - Step 19 . REMOVE INLET NO. 2 AIR CLEANER (for 2GR-FE) . Refer to REMOVAL - Step 18 . REMOVE INLET NO. 1 AIR CLEANER (for 2GR-FE) . Refer to REMOVAL - Step 23 . REMOVE RADIATOR RESERVE TANK ASSEMBLY (for 2AR-FE) . Refer to REMOVAL - Step 11 . 10. REMOVE RADIATOR RESERVE TANK ASSEMBLY (for 2GR-FE) . Refer to REMOVAL - Step 13 . 11. REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 .

12. REMOVE UPPER RADIATOR SUPPORT (for 2AR-FE) . Refer to REMOVAL - Step 15 . 13. REMOVE UPPER RADIATOR SUPPORT (for 2GR-FE) . Refer to REMOVAL - Step 17 . 14. REMOVE RADIATOR SIDE DEFLECTOR LH a. Disengage the 3 claws and guide remove the radiator side deflector LH.

Fig. 197: Identifying Radiator Side Deflector LH Guide And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE RADIATOR SIDE DEFLECTOR RH a. Disengage the 3 claws and guide remove the radiator side deflector RH.

Fig. 198: Identifying Radiator Side Deflector RH Guide And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for TMMK Made) a. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the condenser.

Fig. 199: Locating No. 1 Cooler Refrigerant Discharge Hose (For TMMK Made) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

17. DISCONNECT DISCHARGE TUBE (for SIA Made) a. Remove the bolt and disconnect the discharge tube from the condenser.

Fig. 200: Locating Discharge Tube (For SIA Made) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the discharge tube. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

18. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY a. Remove the bolt and disconnect the air conditioning tube and accessory assembly from the condenser.

Fig. 201: Locating Air Conditioning Tube And Accessory Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the air conditioning tube and accessory assembly. NOTE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

19. REMOVE COOLER CONDENSER ASSEMBLY a. Remove the 4 bolts.

Fig. 202: Locating Cooler Condenser Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides and remove the cooler condenser assembly as shown in the illustration.

Fig. 203: Removing Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE COOLER DRYER a. Using a 14 mm straight hexagon wrench, remove the cap from the modulator.

Fig. 204: Identifying Modulator Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 14 mm Straight *1 Hexagon Wrench b. Using pliers, remove the cooler dryer from the modulator.

Fig. 205: Identifying Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL COOLER DRYER a. Using pliers, install a new cooler dryer to the modulator.

Fig. 206: Identifying Cooler Dryer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surfaces of the cap.

Fig. 207: View Of O-Ring On Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Compressor oil ND-OIL 8 or equivalent c. Using a 14 mm straight hexagon wrench, install the cap to the modulator.

Fig. 208: Identifying Modulator Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 14 mm Straight *1 Hexagon Wrench Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) NOTE:





Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter. Do not use any compressor oil other than ND-OIL 8 or equivalent.

INSTALLATION INSTALLATION

1. INSTALL COOLER CONDENSER ASSEMBLY a. Engage the 2 guides as shown in the illustration.

Fig. 209: Installing Cooler Condenser Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the cooler condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser. Capacity 40 cc (1.4 fl. oz.) Compressor oil

ND-8 or equivalent 2. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY a. Remove the vinyl tape from the tube and the connecting part of the cooler condenser assembly. b. Sufficiently apply compressor oil to a new O-ring to the fitting surface of the tube joint. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the air conditioning tube and accessory assembly. d. Install the air conditioning tube and accessory assembly to the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for TMMK Made) a. Remove the vinyl tape from the pipe and the connecting part of the cooler condenser assembly. b. Sufficiently apply compressor oil to a new O-ring to the fitting surface of the pipe joint. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring to the No. 1 cooler refrigerant discharge hose. d. Install the No. 1 cooler refrigerant discharge hose to the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. CONNECT DISCHARGE TUBE (for SIA Made) a. Remove the vinyl tape from the pipe and the connecting part of the cooler condenser assembly. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil ND-OIL 8 or equivalent c. Install the O-ring the discharge tube. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) d. Install the discharge tube to the cooler condenser assembly with the bolt. 5. INSTALL RADIATOR SIDE DEFLECTOR LH a. Engage the guide and 3 claws to install the radiator side deflector LH.

6. INSTALL RADIATOR SIDE DEFLECTOR RH a. Engage the guide and 3 claws to install the radiator side deflector RH. 7. INSTALL UPPER RADIATOR SUPPORT (for 2AR-FE) . Refer to INSTALLATION - Step 2 . 8. INSTALL UPPER RADIATOR SUPPORT (for 2GR-FE) . Refer to INSTALLATION - Step 2 . 9. INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 . 10. INSTALL RADIATOR RESERVE TANK ASSEMBLY (for 2AR-FE) . Refer to INSTALLATION Step 6 . 11. INSTALL RADIATOR RESERVE TANK ASSEMBLY (for 2GR-FE) . Refer to INSTALLATION Step 6 . 12. INSTALL INLET AIR CLEANER ASSEMBLY (for 2AR-FE) . Refer to INSTALLATION - Step 53 . 13. INSTALL INLET NO. 1 AIR CLEANER (for 2GR-FE) . Refer to INSTALLATION - Step 54 . 14. INSTALL INLET NO. 2 AIR CLEANER (for 2GR-FE) . Refer to INSTALLATION - Step 59 . 15. INSTALL BATTERY (for 2GR-FE) . Refer to INSTALLATION - Step 55 . 16. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION . 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

18. 19. 20. 21.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. WARM UP ENGINE . See step 3. INSPECT FOR REFRIGERANT LEAK . See step 4. ADJUST HOOD SUB-ASSEMBLY Refer to ADJUSTMENT .

ROOM TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 210: Identifying Room Temperature Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4 . 3. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 . 4. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 5. REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 11 . 6. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 . 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL -

Step 47 . 8. REMOVE ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Disengage the 2 claws as shown in the illustration.

Fig. 211: Removing Room Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the cooler thermistor hose and connector and remove the room temperature sensor (cooler thermistor). INSPECTION INSPECTION

1. INSPECT ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Measure the resistance according to the value(s) in the table below.

Fig. 212: Inspecting Room Temperature Sensor (Cooler Thermistor) With Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 3.00 to I57-1 (+) - 10°C (50° 3.73 I57-2 (-) F) kohms 2.45 to I57-1 (+) - 15°C (59° 2.88 I57-2 (-) F) kohms 1.95 to I57-1 (+) - 20°C (68° 2.30 I57-2 (-) F) kohms 1.60 to I57-1 (+) - 25°C (77° 1.80 I57-2 (-) F) kohms 1.28 to I57-1 (+) - 30°C (86° 1.47 I57-2 (-) F) kohms 1.00 to I57-1 (+) - 35°C (95° 1.22 I57-2 (-) F) kohms 0.80 to I57-1 (+) - 40°C 1.00 I57-2 (-) (104°F) kohms 0.65 to I57-1 (+) - 45°C 0.85 I57-2 (-) (113°F) kohms 0.50 to I57-1 (+) - 50°C 0.70 I57-2 (-) (122°F) kohms 0.44 to I57-1 (+) - 55°C 0.60 I57-2 (-) (131°F) kohms 0.36 to I57-1 (+) - 60°C 0.50 I57-2 (-) (140°F) kohms If the resistance is not as specified, replace the room temperature sensor (cooler thermistor). TEXT IN ILLUSTRATION Component without harness *a connected (Room Temperature Sensor

(Cooler Thermistor)) Sensing *b Portion Resistance *c (kohms) Allowable *d Range Temperature *e (°C (°F)) NOTE:





Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph found in Fig. 212). INSTALLATION INSTALLATION

1. INSTALL ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) a. Connect the connector and cooler thermistor hose. b. Engage the 2 claws to install the room temperature sensor (cooler thermistor) as shown in the illustration.

Fig. 213: Installing Room Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 6 . 3. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 41 . 4. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 42 . 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 . 7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 43 . 8. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 .

AMBIENT TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 214: Identifying Ambient Temperature Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 . 2. REMOVE AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Disconnect the connector.

Fig. 215: Locating Ambient Temperature Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and remove the ambient temperature sensor (thermistor assembly). INSPECTION INSPECTION

1. INSPECT AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 216: Inspecting Ambient Temperature Sensor (Thermistor Assembly) With Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance

Tester Specified Condition Connection Condition 3.00 to A3-1 (-) - 10°C (50° 3.73 A3-2 (+) F) kohms 2.45 to A3-1 (-) - 15°C (59° 2.88 A3-2 (+) F) kohms 1.95 to A3-1 (-) - 20°C (68° 2.30 A3-2 (+) F) kohms 1.60 to A3-1 (-) - 25°C (77° 1.80 A3-2 (+) F) kohms 1.28 to A3-1 (-) - 30°C (86° 1.47 A3-2 (+) F) kohms 1.00 to A3-1 (-) - 35°C (95° 1.22 A3-2 (+) F) kohms 0.80 to A3-1 (-) - 40°C 1.00 A3-2 (+) (104°F) kohms 0.65 to A3-1 (-) - 45°C 0.85 A3-2 (+) (113°F) kohms 0.50 to A3-1 (-) - 50°C 0.70 A3-2 (+) (122°F) kohms 0.44 to A3-1 (-) - 55°C 0.60 A3-2 (+) (131°F) kohms 0.36 to A3-1 (-) - 60°C 0.50 A3-2 (+) (140°F) kohms If the resistance is not as specified, replace the ambient temperature sensor (thermistor assembly). TEXT IN ILLUSTRATION Component without harness *a connected (Ambient Temperature Sensor

(Thermistor Assembly)) Sensing *b Portion Resistance *c (kohms) Allowable *d Range Temperature *e (°C (°F)) 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 (see the graph found in Fig. 216). INSTALLATION INSTALLATION

1. INSTALL AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) a. Engage the clamp to install the ambient temperature sensor (thermistor assembly). b. Connect the connector. 2. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 .

FRONT EVAPORATOR TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 217: Identifying Front Evaporator Temperature Sensor Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY Refer to REMOVAL. 2. REMOVE NO. 1 COOLER THERMISTOR a. Disengage the 2 clamps.

Fig. 218: Identifying No. 1 Cooler Thermistor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the No. 1 cooler thermistor. INSPECTION INSPECTION

1. INSPECT EVAPORATOR TEMPERATURE SENSOR (NO. 1 COOLER THERMISTOR) a. Measure the resistance according to the value(s) in the table below.

Fig. 219: Inspecting Evaporator Temperature Sensor (No. 1 Cooler Thermistor) With Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance

Tester Specified Condition Connection Condition 7.30 to -10°C a1-1 - a1-2 9.10 (14°F) kohms 5.65 to -5°C (23° a1-1 - a1-2 6.95 F) kohms 4.40 to 0°C (32° 5.35 a1-1 - a1-2 F) kohms 3.40 to 5°C (41° a1-1 - a1-2 4.15 F) kohms 2.70 to 10°C (50° 3.25 a1-1 - a1-2 F) kohms 2.14 to 15°C (59° a1-1 - a1-2 2.58 F) kohms 1.71 to 20°C (68° a1-1 - a1-2 2.05 F) kohms 1.38 to 25°C (77° 1.64 a1-1 - a1-2 F) kohms 1.11 to 30°C (86° a1-1 - a1-2 1.32 F) kohms TEXT IN ILLUSTRATION Component without harness connected *a (Evaporator Temperature Sensor (No. 1 Cooler Thermistor)) Sensing *b Portion Resistance *c (kohms) Allowable *d Range

*e

Temperature (°C (°F))

If the resistance is not as specified, replace the evaporator temperature sensor (No. 1 cooler thermistor). NOTE:





Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature.

HINT: As the temperature increases, the resistance decreases (see the graph found in Fig. 219). INSTALLATION INSTALLATION

1. INSTALL NO. 1 COOLER THERMISTOR a. Install the No. 1 cooler thermistor as shown in the illustration.

Fig. 220: Installing No. 1 Cooler Thermistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Part Length 34.3 1.35 A mm in. 20.9 0.82 B mm in. 50 1.96 C mm in. TEXT IN ILLUSTRATION Fixed *a Part *b Sensor

Part NOTE:









Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured. When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration). After inserting the thermistor, do not apply excessive force to the wire. Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".

b. Engage the 2 clamps. 2. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY Refer to INSTALLATION.

SOLAR SENSOR COMPONENTS ILLUSTRATION

Fig. 221: Identifying Solar Sensor Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 222: Identifying Solar Sensor Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 . 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 . 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 8 . 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 9 . 11. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 8 . 12. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to REMOVAL - Step 30 . 13. REMOVE SOLAR SENSOR a. Disengage the 2 claws and remove the solar sensor.

Fig. 223: Identifying Solar Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT SOLAR SENSOR (AUTOMATIC LIGHT CONTROL SENSOR) a. Disconnect the solar sensor (automatic light control sensor) connector.

Fig. 224: Inspecting Solar Sensor (Automatic Light Control Sensor) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition I61-6 (CLTB) - Ignition Below 1 I61-3 switch off V (CLTE) I61-6 (CLTB) I61-3

Ignition switch

11 to 14 V

(CLTE)

ON

TEXT IN ILLUSTRATION Front view of wire harness connector (to Solar *a Sensor (Automatic Light Control Sensor)) If the voltage is not as specified, repair or replace the wire harness or connector. c. Reconnect the solar sensor (automatic light control sensor) connector.

Fig. 225: Inspecting Solar Sensor (Automatic Light Control Sensor) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the ignition switch to ON. e. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Sensor is I61-1 (TSL) exposed 0.8 to 4.3 - I61-3 to electric V (CLTE) light I61-1 (TSL) Sensor is

- I61-3 (CLTE) I61-2 (TSR) I61-3 (CLTE) I61-2 (TSR) I61-3 (CLTE)

covered Below 0.8 with a V cloth Sensor is exposed 0.8 to 4.3 to electric V light Sensor is covered Below 0.8 V with a cloth

TEXT IN ILLUSTRATION Component with harness connected (Solar *a Sensor (Automatic Light Control Sensor)) NOTE:





The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 (2) and the negative (-) lead to terminal 6 of the solar sensor (automatic light control sensor). Do not bring the positive and negative tester probes too close to each other as a short circuit may occur.

HINT: 



Use an incandescent light for inspection. Bring it within about 30 cm (11.8 in.) of the solar sensor (automatic light control sensor). As the inspection light is moved away from the sensor, the voltage decreases.

If the voltage is not as specified, replace the solar sensor (automatic light control sensor). INSTALLATION INSTALLATION

1. INSTALL SOLAR SENSOR

2. 3. 4. 5. 6. 7. 8. 9. 10.

a. Engage the 2 claws to install the solar sensor. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to INSTALLATION - Step 23 . INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 . INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 . INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 . INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 . INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 . INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION .

11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

AIR CONDITIONING PRESSURE SENSOR COMPONENTS ILLUSTRATION

Fig. 226: Identifying Air Conditioning Pressure Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT AIR CONDITIONING PRESSURE SENSOR a. Check the wire harness. 1. Disconnect the A55 air conditioning pressure sensor connector. 2. Disconnect the I77 air conditioning amplifier assembly connector. 3. Measure the resistance according to the value(s) in the table below. Standard Resistance

Tester Specified Condition Connection Condition A55-1 (-) Below 1 I77-13 (SG- Always ohms 2) A55-2 (PR) Below 1 Always - I77-9 ohms (PRE) A55-3 (+) Below 1 I77-10 (S5- Always ohms 3) A55-1 (-) 10 kohms Body Always or higher ground A55-2 (PR) 10 kohms - Body Always or higher ground A55-3 (+) 10 kohms Always Body or higher ground If the resistance is not as specified, repair the wire harness. 4. Reconnect the I77 air conditioning amplifier assembly connector. 5. Turn the ignition switch to ON. 6. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection condition Condition A55-3 (+) - Ignition 4.75 to Body switch 5.25 V ground ON If the voltage is not as specified, repair the wire harness or replace air conditioning amplifier assembly. b. Check the air conditioning pressure sensor. 1. Connect the connector to the air conditioning pressure sensor. 2. Install a manifold gauge set. 3. Warm up the engine. 4. Turn the A/C switch on. 5. Measure the voltage according to the value(s) in the table below.

Fig. 227: Inspecting Air Conditioning Pressure Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. Standard Voltage Tester Specified Condition Connection Condition Refrigerant pressure: (less than 3025 kPa (30.9 I77-9 (PRE) - kgf/cm2 , 0.50 to I77-13 (SG- 439 psi) 4.80 V 2) and more than 176 kPa (1.8 kgf/cm2 , 25 psi)) If the voltage is not as specified, replace the air conditioning pressure sensor. TEXT IN ILLUSTRATION

Component with harness connected *a (Air Conditioning Amplifier) REMOVAL REMOVAL

1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . See step 1. 2. REMOVE AIR CONDITIONER PRESSURE SENSOR a. Disconnect the connector. b. Remove the air conditioner pressure sensor.

Fig. 228: Identifying Air Conditioner Pressure Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not deform the piping.

INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONER PRESSURE SENSOR

a. Apply a sufficient amount of compressor oil to a new air conditioner pressure sensor. Compressor oil ND-OIL 8 or equivalent NOTE:





Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign matter. Do not use any compressor oil other than ND-OIL 8 or equivalent. If any compressor oil other than ND-OIL 8 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

b. Install the new air conditioner pressure sensor. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) NOTE:

 

Do not deform the piping. Make sure to confirm that the piping does not disengage from the plastic clamp.

c. Connect the connector. 2. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . See step 2. 3. WARM UP ENGINE . See step 3. 4. INSPECT FOR REFRIGERANT LEAK . See step 4.

AIR CONDITIONING PANEL COMPONENTS ILLUSTRATION

Fig. 229: Identifying Air Conditioning Panel Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 230: Identifying Air Conditioning Panel Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 231: Identifying Air Conditioning Panel Replacement Components (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 232: Identifying Air Conditioning Panel Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 233: Identifying Air Conditioning Panel Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 . 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 . 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 8 . 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 9 . 11. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 8 . 12. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 10 . 13. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 11 . 14. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 12 . 15. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 13 . 16. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 14 . 17. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 15 . 18. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 . 19. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 10 . 20. REMOVE AIR CONDITIONING CONTROL ASSEMBLY

a. Disengage the 4 clips and guide, and remove the air conditioning control assembly as shown in the illustration.

Fig. 234: Removing Air Conditioning Control Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY a. Engage the guide and 4 clips to install the air conditioning control assembly as shown in the illustration.

Fig. 235: Installing Air Conditioning Control Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 8. 3. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 9. 4. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 10 . 5. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 11 . 6. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 12 . 7. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 . 8. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 5 . 9. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 6 . 10. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 . 11. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 . 12. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 .

13. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 . 14. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 . 15. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . 16. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . 17. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION . 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

AIR CONDITIONING AMPLIFIER COMPONENTS ILLUSTRATION

Fig. 236: Identifying Air Conditioning Amplifier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 4 . 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 34 . 6. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 35 . 7. REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 14 . 8. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 36 . 9. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 8 . 10. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 38 . 11. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to REMOVAL - Step 12 . 12. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to REMOVAL Step 11 . 13. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY a. Disconnect each connector. b. Remove the 2 screws.

Fig. 237: Identifying Air Conditioning Amplifier Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides and remove the air conditioning amplifier assembly. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY a. Engage the 2 guides. b. Install the air conditioning amplifier assembly with the 2 screws. c. Connect each connector. 2. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH) . Refer to INSTALLATION - Step 1 . 3. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) . Refer to INSTALLATION - Step 2 . 4. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 . 5. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 . 7. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 39 . 8. INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 .

9. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION - Step 46 . 10. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 43 . 11. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 44 . 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 ACCESSORIES & EQUIPMENT Audio / Video System (Service Information) (Hybrid)

RADIO RECEIVER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Radio Receiver Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Radio Receiver Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Radio Receiver Replacement Components (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Radio Receiver Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Identifying Radio Receiver Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION (for Radio and Display Type with Intuitive Parking Assist System)

NOTE:







After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . A Hard Disk Drive (HDD) is built into the radio and display receiver assembly to store multi-media data, and is used for the audio and visual system. Therefore, care must be taken when handling the radio and display receiver assembly. When removing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) a. Apply protective tape to the area shown in the illustration.

Fig. 6: Identifying Protective Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 7: Identifying Radio Receiver Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the radio receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 8: Identifying Radio Receiver Assembly Clips

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the radio receiver assembly with air conditioning control assembly. 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) a. Apply protective tape to the areas shown in the illustration.

Fig. 9: Identifying Protective Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 10: Identifying Radio Receiver Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the radio receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 11: Identifying Radio Receiver Assembly Clips

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the radio receiver assembly with air conditioning control assembly. HINT: w/ Navigation System: Do not disconnect the extension module connector. 11. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) a. Remove the 5 screws and No. 1 radio bracket.

Fig. 12: Identifying No. 1 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) a. Remove the 5 screws and No. 2 radio bracket.

Fig. 13: Identifying No. 2 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Remove the 5 screws and No. 1 radio bracket.

Fig. 14: Identifying No. 1 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Navigation System: 1. Remove the 7 screws and No. 1 radio bracket.

Fig. 15: Identifying No. 1 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Remove the 5 screws and No. 2 radio bracket.

Fig. 16: Identifying No. 2 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Navigation System: 1. Remove the 7 screws and No. 2 radio bracket.

Fig. 17: Identifying No. 2 Radio Bracket And Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Remove the 5 screws and No. 1 radio receiver bracket.

Fig. 18: Identifying No. 1 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Remove the 5 screws and No. 2 radio receiver bracket.

Fig. 19: Identifying No. 2 Radio Bracket And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 21 18. REMOVE EXTENSION MODULE (for Radio and Display Type) w/ Navigation System: Refer to REMOVAL - Step 10 19. REMOVE RADIO RECEIVER ASSEMBLY (for Radio Receiver Type) 20. REMOVE RADIO AND DISPLAY RECEIVER ASSEMBLY (for Radio and Display Type) 21. REMOVE HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 13 22. REMOVE NAVIGATION ECU SUB-ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) INSTALLATION INSTALLATION

1. PRECAUTION (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When installing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. INSTALL RADIO RECEIVER ASSEMBLY (for Radio Receiver Type) 3. INSTALL RADIO AND DISPLAY RECEIVER ASSEMBLY (for Radio and Display Type)

4. INSTALL NAVIGATION ECU SUB-ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) 5. INSTALL HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 6. INSTALL EXTENSION MODULE (for Radio and Display Type) w/ Navigation System: Refer to INSTALLATION - Step 1 7. INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 8. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) a. Install the No. 1 radio bracket with the 5 screws. 9. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) a. Install the No. 2 radio bracket with the 5 screws. 10. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Install the No. 1 radio bracket with the 5 screws. b. w/ Navigation System: 1. Install the No. 1 radio bracket with the 7 screws. 11. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Install the No. 2 radio bracket with the 5 screws. b. w/ Navigation System: 1. Install the No. 2 radio bracket with the 7 screws. 12. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Install the No. 1 radio receiver bracket with the 5 screws. 13. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Install the No. 2 radio receiver bracket with the 5 screws. 14. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the radio receiver assembly with air conditioning control assembly. c. Install the radio receiver assembly with air conditioning control assembly with the 4 bolts. 15. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the radio receiver assembly with air conditioning control assembly.

16. 17. 18. 19. 20.

c. Install the radio receiver assembly with air conditioning control assembly with the 4 bolts. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

21. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 3 23. INSPECT HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) Refer to OPERATION CHECK 24. REPLACED OPERATION (w/ Parking Assist Monitor System) Refer to CALIBRATION

STEREO COMPONENT AMPLIFIER COMPONENTS ILLUSTRATION

Fig. 20: Identifying Stereo Component Amplifier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH Refer to REMOVAL 2. REMOVE AUDIO AMPLIFIER COVER a. Using a clip remover, remove the 2 clips and audio amplifier cover.

Fig. 21: Identifying Audio Amplifier Cover Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET a. Remove the bolt and disconnect the ground wire.

Fig. 22: Identifying Stereo Component Amplifier Assembly Connectors And Ground Wire

Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector. c. Disengage the clamp. d. Remove the bolt.

Fig. 23: Identifying Stereo Component Amplifier Assembly Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the 2 guides and remove the stereo component amplifier assembly with bracket. 4. REMOVE NO. 2 AMPLIFIER BRACKET a. Remove the 2 screws and No. 2 amplifier bracket.

Fig. 24: Identifying No. 2 Amplifier Bracket Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 AMPLIFIER BRACKET a. Remove the 2 screws and No. 1 amplifier bracket.

Fig. 25: Identifying No. 1 Amplifier Bracket Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY INSTALLATION INSTALLATION

1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY 2. INSTALL NO. 1 AMPLIFIER BRACKET a. Install the No. 1 amplifier bracket with the 2 screws. 3. INSTALL NO. 2 AMPLIFIER BRACKET a. Install the No. 2 amplifier bracket with the 2 screws. 4. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET a. Engage the 2 guides to the vehicle body to temporarily install the stereo component amplifier assembly with bracket. b. Install the stereo component amplifier assembly with bracket with the bolt. c. Engage the clamp. d. Connect each connector. e. Connect the ground wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. INSTALL AUDIO AMPLIFIER COVER a. Install the audio amplifier cover with the 2 clips. 6. INSTALL FRONT SEAT ASSEMBLY LH Refer to INSTALLATION

FRONT DOOR SPEAKER COMPONENTS ILLUSTRATION

Fig. 26: Identifying Front Door Speaker Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4

2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 5 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 6 4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 7 5. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 8 6. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 10 8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 12 9. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY a. Disconnect the connector.

Fig. 27: Identifying Front No. 1 Speaker Assembly Screws And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 screws. c. Disengage the 2 claws and remove the front No. 1 speaker assembly.

Fig. 28: Identifying Front No. 1 Speaker Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

INSPECTION INSPECTION

1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 6 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 29: Identifying Rear Speaker Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 3.2 to 4.8 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Front No. 1 Speaker Assembly) 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 30: Identifying Front No. 1 Speaker Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 4.6 to 6.6 1 (+) - 2 (-) Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Front No. 1 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY a. Engage the 2 claws to the vehicle body to temporarily install the front No. 1 speaker assembly. b. Install the front No. 1 speaker assembly with the 4 screws.

Fig. 31: Identifying Front No. 1 Speaker Assembly Screws (LH/RH Sides) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. *A

LH Side

*B

RH Side

NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration.

2. 3. 4. 5. 6. 7. 8. 9.

c. Connect the connector. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 37 INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 39 INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 41 INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 42 INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 43 INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 44 INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 45

INSTRUMENT PANEL SPEAKER COMPONENTS ILLUSTRATION

Fig. 32: Identifying Instrument Panel Speaker Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 33: Identifying Instrument Panel Speaker Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 34: Identifying Instrument Panel Speaker Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 6 3. REMOVE FRONT PILLAR GARNISH . Refer to REMOVAL - Step 7 4. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY . Refer to REMOVAL Step 41 5. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY a. Remove the 2 screws.

Fig. 35: Identifying No. 2 Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lift the front No. 2 speaker assembly and disconnect the connector to remove the speaker.

Fig. 36: Identifying No. 2 Speaker Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

6. REMOVE LUGGAGE TRIM SERVICE HOLE COVER (for 10 Speakers) except Radio and Display Type without Intuitive Parking Assist System: Refer to REMOVAL - Step 2 7. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. REMOVE REAR CONSOLE BOX ASSEMBLY (for 10 Speakers) Refer to REMOVAL 9. REMOVE BOX BOTTOM MAT (for 10 Speakers) . Refer to REMOVAL - Step 24 10. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 25 11. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 22

12. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 23 13. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) for Radio and Display Type: See step 10 14. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) for Navigation Receiver Type: Refer to REMOVAL - Step 9 15. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 29 16. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. Remove the 2 screws.

Fig. 37: Identifying Front No. 3 Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lift the front No. 3 speaker assembly and disconnect the connector to remove the speaker.

Fig. 38: Identifying Front No. 3 Speaker Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

INSPECTION INSPECTION

1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 6 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 39: Identifying Front No. 2 Speaker Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 2 (TWR-) 10 kohms Always 4 (TWR+) or higher 1 (-) - 2 Below 1 Always (TWR-) ohms 3 (+) - 4 Below 1 Always (TWR+) ohms 2 (TWL-) 10 kohms Always 4 (TWL+) or higher

1 (-) - 2 (TWL-) 3 (+) - 4 (TWL+)

Always Always

Below 1 ohms Below 1 ohms

If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION *A for RH *B for LH Component without harness *a connected (Front No. 2 Speaker Assembly) d. When there is a possibility that either the right or left speaker is malfunctioning, interchange the speakers and perform an inspection. If the malfunction disappears after interchanging the speakers, replace the malfunctioning speaker. HINT: Connect all connectors to the speakers when performing an inspection. If the result is not as specified, replace the speaker. 2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 40: Identifying Front No. 2 Speaker Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 3.4 to 5.2 3-4 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Front No. 2 Speaker Assembly) 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 41: Identifying Front No. 3 Speaker Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 6.8 to 10.2 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Front No. 3 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY a. Connect the connector. b. Install the front No. 2 speaker assembly with the 2 screws.

Fig. 42: Identifying Front No. 2 Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration. 2. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 3. INSTALL FRONT PILLAR GARNISH . Refer to INSTALLATION - Step 42 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP for LH side: Refer to INSTALLATION - Step 43 for RH side: Refer to INSTALLATION - Step 47 5. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. Connect the connector. b. Install the front No. 3 speaker assembly with the 2 screws.

Fig. 43: Identifying Front No. 3 Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration. 6. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 23 7. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) for Radio and Display Type: See step 15 8. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) for Navigation Receiver Type: Refer to INSTALLATION - Step 7 9. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 29 10. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 30 11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 27 12. INSTALL BOX BOTTOM MAT (for 10 Speakers) . Refer to INSTALLATION - Step 28 13. INSTALL REAR CONSOLE BOX ASSEMBLY (for 10 Speakers) Refer to INSTALLATION 14. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

15. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for 10 Speakers) except Radio and Display Type without Intuitive Parking Assist System: Refer to INSTALLATION Step 3

REAR PACKAGE TRAY SPEAKER COMPONENTS

ILLUSTRATION

Fig. 44: Identifying Rear Package Tray Speaker Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 45: Identifying Rear Package Tray Speaker Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 46: Identifying Rear Package Tray Speaker Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. 5. 6. 7. 8. 9. 10.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 13 11. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 12. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 13. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 14. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 14 15. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 15 16. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to

17. 18. 19. 20. 21. 22.

REMOVAL - Step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 20 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 19 REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE REAR SPEAKER ASSEMBLY a. Disconnect the connector.

Fig. 47: Identifying Rear Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 screws and rear speaker assembly. NOTE:

Do not touch the cone part of the speaker.

HINT: If the rear speaker assembly is difficult to remove, turn back the No. 1 upper back panel hole cover so that the rear speaker assembly can be removed. 23. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. Disconnect the connector.

Fig. 48: Identifying Rear No. 2 Speaker Assembly Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and rear No. 2 speaker assembly. NOTE:

Do not touch the cone part of the speaker.

INSPECTION INSPECTION

1. INSPECT REAR SPEAKER ASSEMBLY a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 49: Identifying Rear Speaker Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance FOR 6 SPEAKERS: Tester Specified Condition Connection Condition 3.2 to 4.8 1-2 Always ohms FOR 10 SPEAKERS: Tester Specified Condition Connection Condition 1-2

Always

4.8 to 6.8

ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Rear Speaker Assembly) 2. INSPECT REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 50: Identifying Rear No. 2 Speaker Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 6.8 to 10.2 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Rear No. 2 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL REAR SPEAKER ASSEMBLY a. Install the rear speaker assembly with the 4 screws.

Fig. 51: Identifying Rear Speaker Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Do not touch the cone part of the speaker.

HINT: Install the screws in the order shown in the illustration. b. Connect the connector. 2. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. Install the rear No. 2 speaker assembly with the bolt.

Fig. 52: Identifying Rear No. 2 Speaker Assembly Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

3. 4. 5. 6.

Do not touch the cone part of the speaker.

b. Connect the connector. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1

7. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 7 8. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 9. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 10. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 11. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 12. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 16. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 17. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 18. INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 19. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 20. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 21. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 23. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

RADIO ANTENNA CORD COMPONENTS ILLUSTRATION

Fig. 53: Identifying Radio Antenna Cord Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 54: Identifying Radio Antenna Cord Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 55: Identifying Radio Antenna Cord Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Refer to REMOVAL 2. REMOVE NO. 3 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 5 3. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 6 4. REMOVE ANTENNA CORD SUB-ASSEMBLY a. Disengage the 8 clamps and remove the antenna cord sub-assembly.

Fig. 56: Identifying Antenna Cord Sub-Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 6. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY a. Peel back the tape used to secure the antenna cord only to the extent that allows removal of the No. 2 antenna cord sub-assembly. HINT: Tape is not available as a supply part. Try to leave as much tape as possible on the roof headlining

so that the tape can be reused. b. Remove the No. 2 antenna cord sub-assembly from the roof headlining.

Fig. 57: Identifying No. 2 Antenna Cord Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof *1 Tape - -

*a Front

- -

INSTALLATION INSTALLATION

1. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY HINT: The double-sided tape and tape are not available as supply parts. If these pieces of still have enough adhesion to secure the roof headlining and antenna cord, reuse them. If the roof headlining has been replaced with a new one, or if the tape and/or the double-sided tape is no longer sticky, apply new tape following the procedure below. a. Apply new double-sided tape.

Fig. 58: Identifying No. 2 Antenna Cord Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof Double*1 sided - Tape *a Front

*b Doublesided

Tape Size DOUBLE-SIDED TAPE SIZE Area Dimension 1.0 mm A (0.0394 in.) 10.0 mm B (0.394 in.) 1. Remove the old double-sided tape from the roof headlining assembly. 2. Prepare the appropriate amount of new double-sided tape. HINT: Be careful not to touch the adhesive surface. 3. Apply the double-sided tape to the roof headlining while aligning the tape with the markings on the roof headlining assembly. 4. Peel off the release paper from the double-sided tape. b. Install the No. 2 antenna cord sub-assembly to the roof headlining assembly from the front of the vehicle.

Fig. 59: Installing The No. 2 Antenna Cord Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o Sliding w/ Sliding *A *B Roof Roof Double*1 *2 Tape sided Tape Marking *3 *4 Protrusion Tape Adjustment *5 - Area

*a Front

- -

HINT: Align the taped part of the antenna cable with the protrusion of the roof headlining, and apply tape to secure the cable to the headlining. c. Put the strips of tape back to the positions shown in the illustration in order to secure the antenna cord to the roof headlining assembly. HINT: If the tape is no longer sticky, use other tape, such as packing tape, that has enough adhesion to secure the antenna cord to the roof headlining assembly.  For the right front corner of the roof headlining assembly, align the marking tape on the antenna cord with the protrusion of the roof headlining, and wrap tape around the antenna cord and roof headlining assembly once or twice to securely hold them.  For the right rear corner of the roof headlining assembly, align the marking tape on the antenna cord with the rear edge of the roof headlining, and secure the antenna cord to the roof headlining assembly with tape.  If the entire length of the antenna cord does not fit, adjust the length by tucking in the cord at the area shown in the illustration. 2. INSTALL ROOF HEADLINING ASSEMBLY 

Refer to INSTALLATION 3. INSTALL ANTENNA CORD SUB-ASSEMBLY a. Engage the 8 clamps to install the antenna cord sub-assembly. 4. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 6 5. INSTALL NO. 3 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 7 6. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION

AMPLIFIER ANTENNA COMPONENTS ILLUSTRATION

Fig. 60: Identifying Amplifier Antenna Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 61: Identifying Amplifier Antenna Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. 5. 6. 7.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 8. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 25 . 9. REMOVE AMPLIFIER ANTENNA ASSEMBLY a. Disconnect the 4 connectors and disengage the clamp.

Fig. 62: Identifying Amplifier Antenna Assembly Connectors And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and the amplifier antenna assembly. INSTALLATION INSTALLATION

1. INSTALL AMPLIFIER ANTENNA ASSEMBLY a. Install the amplifier antenna assembly with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) b. Connect the 4 connectors and engage the clamp. 2. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 21 . 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 4. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 5. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 6. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 7. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 9. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

STEREO JACK ADAPTER ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 63: Identifying Stereo Jack Adapter Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 4. REMOVE NO. 1 STEREO JACK ADAPTER ASSEMBLY a. Disengage the 2 claws to remove the No. 1 stereo jack adapter assembly.

Fig. 64: Identifying No. 1 Stereo Jack Adapter Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 STEREO JACK ADAPTER ASSEMBLY a. Engage the 2 claws to install the No. 1 stereo jack adapter assembly. 2. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 3. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 4. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

WINDOW GLASS ANTENNA WIRE ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT WINDOW GLASS ANTENNA WIRE a. Check for continuity of the antenna.

Fig. 65: Checking For Continuity Of Each Antenna Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tester

*a Probe Antenna *b Wire *c Tin Foil HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTE:





When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring resistance, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration.

OK There is continuity in the antenna. If the result is not as specified, repair the window glass antenna wire. REPAIR REPAIR

1. REPAIR WINDOW GLASS ANTENNA WIRE

Fig. 66: Identifying Window Glass Antenna Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Repair *1 Point Masking *2 Tape Broken *3 Wire a. b. c. d.

Clean the broken wire tips with a grease, wax and silicone remover. Place masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Using a fine tip brush, apply a small amount of the repair agent to the wire.

Fig. 67: Applying Repair Agent To Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fine *1 Tip Brush Repair *2 Point e. After a few minutes, remove the masking tape.

SATELLITE RADIO ANTENNA COMPONENTS ILLUSTRATION

Fig. 68: Identifying Satellite Radio Antenna Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 2. REMOVE ROOF ANTENNA ASSEMBLY a. Disconnect the connector.

Fig. 69: Identifying Roof Antenna Nut And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the antenna nut. c. Disengage the 2 claws.

Fig. 70: Identifying Roof Antenna Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 3 guides and remove the roof antenna assembly.

Fig. 71: Identifying Roof Antenna Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ROOF ANTENNA ASSEMBLY a. Engage the 3 guides and 2 claws to the vehicle body to temporarily install the roof antenna assembly. b. Place the antenna cord in the cutout of the antenna nut.

Fig. 72: Identifying Roof Antenna Nut And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout c. Install the roof antenna assembly with the antenna nut. Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) d. Connect the connector. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION

NOISE FILTER COMPONENTS ILLUSTRATION

Fig. 73: Identifying Noise Filter Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 74: Identifying Noise Filter Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT RADIO SETTING CONDENSER (for High Mounted Stop Light) a. With the radio setting condenser installed, check that there is no looseness or other abnormalities. b. Remove the bolt. c. Disengage the clamp and disconnect the radio setting condenser with wire harness from the vehicle body.

d. Measure the resistance and voltage of the radio setting condenser according to the value(s) in the table below. NOTE:

Before measuring the resistance and voltage, be sure to use insulated probes to avoid a short circuit between the tester terminal and bracket.

Fig. 75: Inspecting Radio Setting Condenser Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection

Condition 

1-2 

1-3





1 - Body ground

Power switch off High mounted stop light off Window defogger off Luggage compartment room light off

Specified Condition 10 kohms or higher

10 kohms or higher

Below 1 ohms

Standard Voltage Tester Connection

Condition 

2 - Body ground





3 - Body ground





2 - Body ground





3 - Body ground



Specified Condition

Power switch on Below 1 (IG) V High mounted stop light off Window defogger off Below 1 Luggage V compartment room light off Power switch on (IG) 11 to 14 V High mounted stop light on Window defogger on Luggage 11 to 14 V compartment room light on

TEXT IN ILLUSTRATION Radio *a Setting Condenser 2. INSPECT RADIO SETTING CONDENSER (for Window Defogger) a. With the radio setting condenser installed, check that there is no looseness or other abnormalities. b. Remove the bolt. c. Disengage the 2 clamps and disconnect the radio setting condenser with wire harness from the vehicle body. d. Measure the resistance and voltage of the radio setting condenser according to the value(s) in the table below.

Fig. 76: Identifying Radio Setting Condenser Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection

Condition 

1 (+B) - 2 (GND)





3 - Body ground



Specified Condition

Power switch off 10 kohms High or higher mounted stop light off Window defogger off Luggage Below 1 compartment ohms room light off

Standard Voltage Tester Connection

Condition 

Power switch on

Specified Condition



1 - Body ground









1 - Body ground





(IG) High mounted stop light off Below 1 Window V defogger off Luggage compartment room light off Power switch on (IG) High mounted stop light on 11 to 14 V Window defogger on Luggage compartment room light on

TEXT IN ILLUSTRATION Radio *a Setting Condenser REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the

negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE RADIO SETTING CONDENSER (for High Mounted Stop Light) NOTE:

When the terminal covers are removed, the radio setting condenser must be replaced because the terminal covers and condenser are supplied as a set.

a. Remove the bolt.

Fig. 77: Identifying Radio Setting Condenser Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and disconnect the radio setting condenser with wire harness from the vehicle body. c. Disengage the claw and pull out the cover as shown in the illustration.

Fig. 78: Identifying Radio Setting Condenser, Clamps & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a screwdriver, disengage the 6 claws and remove the 2 terminal covers with wire harness from the condenser.

Fig. 79: Disengaging Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, bend back and break off the claw as shown in the illustration.

Fig. 80: Identifying Bending The Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the terminal cover from the wire harness. NOTE:







Make sure to hold the wire harness on the crimping side of the terminal when disconnecting the wire harness from the terminal cover. Make sure not to bend the exposed wire when disconnecting the wire harness from the terminal cover. Check for deformation of the terminal after the wire harness has been removed from the terminal cover.

8. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Window Defogger) . Refer to REMOVAL - Step 13 9. REMOVE ROOF SIDE INNER GARNISH LH (for Window Defogger) . Refer to REMOVAL Step 25 10. REMOVE RADIO SETTING CONDENSER (for Window Defogger) NOTE:

When the terminal cover is removed, the radio setting condenser must be replaced because the terminal cover and condenser are supplied as a set.

a. Remove the bolt.

Fig. 81: Identifying Radio Setting Condenser Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clamps and disconnect the radio setting condenser with wire harness from the vehicle body. c. Using a screwdriver, disengage the 3 claws and remove the terminal cover with wire harness from the condenser.

Fig. 82: Removing Terminal Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a screwdriver, bend back and break off the claw as shown in the illustration.

Fig. 83: Breaking Claw with Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the terminal cover from the wire harness. NOTE:







Make sure to hold the wire harness on the crimping side of the terminal when disconnecting the wire harness from the terminal cover. Make sure not to bend the exposed wire when disconnecting the wire harness from the terminal cover. Check for deformation of the terminal after the wire harness has been removed from the terminal cover.

INSTALLATION INSTALLATION

1. INSTALL RADIO SETTING CONDENSER (for Window Defogger) a. Engage the claw to install a new terminal cover to the wire harness.

Fig. 84: Identifying Claw And Terminal Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:









Make sure to hold the wire harness so that the crimping side of the terminal is facing up when installing the wire harness to the terminal cover. Make sure not to bend the exposed wire when installing the wire harness to the terminal cover. Do not use excessive force when inserting the wire harness into the terminal cover. If the terminal cover has been deformed at installation, replace the terminal and terminal cover with new ones.

b. Engage the 3 claws to install the new terminal cover with wire harness to a new condenser.

Fig. 85: Identifying New Terminal Cover With Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Do not use excessive force when inserting the terminal cover into the condenser. If the terminal cover has been deformed at installation, replace the terminal, terminal cover and condenser with new ones.

c. Engage the 2 clamps to temporarily install a new radio setting condenser with wire harness. d. Install the new radio setting condenser with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL ROOF SIDE INNER GARNISH LH (for Window Defogger) . Refer to INSTALLATION - Step 21 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Window Defogger) . Refer to INSTALLATION - Step 26 4. INSTALL RADIO SETTING CONDENSER (for High Mounted Stop Light) a. Engage the claw to install a new terminal cover to the wire harness.

Fig. 86: Installing Radio Setting Condenser Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:









Make sure to hold the wire harness so that the crimping side of the terminal is facing up when installing the wire harness to the terminal cover. Make sure not to bend the exposed wire when installing the wire harness to the terminal cover. Do not use excessive force when inserting the wire harness into the terminal cover. If the terminal cover has been deformed at installation, replace the terminal and terminal cover with new ones.

b. Engage the 6 claws to install the 2 new terminal covers with wire harness to a new condenser.

Fig. 87: Engaging Claws & Installing Terminal Covers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Do not use excessive force when inserting the terminal cover into the condenser. If the terminal cover has been deformed at installation, replace

the terminal, terminal cover and condenser with new ones. c. Engage the claw to insert the cover as shown in the illustration.

Fig. 88: Engaging Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the clamp to temporarily install a new radio setting condenser with wire harness. e. Install the new radio setting condenser with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. 6. 7. 8.

INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 10. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

2012-2017 ACCESSORIES & EQUIPMENT Audio / Video System (Service Information) (Except Hybrid) - Camry

RADIO RECEIVER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Radio Receiver Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Radio Receiver Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Radio Receiver Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Radio Receiver Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION (for Radio and Display Type with Intuitive Parking Assist System)

NOTE:







After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . A Hard Disk Drive (HDD) is built into the radio and display receiver assembly to store multi-media data, and is used for the audio and visual system. Therefore, care must be taken when handling the radio and display receiver assembly. When removing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 4. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 6. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 . 7. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 . 8. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) a. Apply protective tape to the area shown in the illustration.

Fig. 5: Identifying Protective Tape Around Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio Receiver Type) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 6: Identifying Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio Receiver Type) Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the radio receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 7: Identifying Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio Receiver Type) Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the radio receiver assembly with air conditioning control assembly. 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) a. Apply protective tape to the area shown in the illustration.

Fig. 8: Identifying Protective Tape Around Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio And Display Type) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 9: Identifying Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio And Display Type) Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the radio receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 10: Identifying Radio Receiver Assembly With Air Conditioning Control Assembly (For Radio And Display Type) Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the radio receiver assembly with air conditioning control assembly. HINT: w/ Navigation System: Do not disconnect the extension module connector. 10. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) a. Remove the 5 screws and No. 1 radio bracket.

Fig. 11: Locating No. 1 Radio Bracket Fasteners (For Radio Receiver Type) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) a. Remove the 5 screws and No. 2 radio bracket.

Fig. 12: Locating No. 2 Radio Bracket Fasteners (For Radio Receiver Type) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Remove the 5 screws and No. 1 radio bracket.

Fig. 13: Locating No. 1 Radio Bracket Fasteners (For Radio And Display Type) (w/o Navigation System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Navigation System: 1. Remove the 7 screws and No. 1 radio bracket.

Fig. 14: Locating No. 1 Radio Bracket Fasteners (For Radio And Display Type) (w/ Navigation System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Remove the 5 screws and No. 2 radio bracket.

Fig. 15: Locating No. 2 Radio Bracket Fasteners (For Radio And Display Type) (w/o Navigation System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Navigation System: 1. Remove the 7 screws and No. 2 radio bracket.

Fig. 16: Locating No. 2 Radio Bracket Fasteners (For Radio And Display Type) (w/ Navigation System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Remove the 5 screws and No. 1 radio receiver bracket.

Fig. 17: Locating No. 1 Radio Receiver Bracket Fasteners (For Radio And Display Type With Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Remove the 5 screws and No. 2 radio receiver bracket.

Fig. 18: Locating No. 2 Radio Receiver Bracket Fasteners (For Radio And Display Type With Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 20 . 17. REMOVE EXTENSION MODULE (for Radio and Display Type) w/ Navigation System: Refer to REMOVAL - Step 10 . 18. REMOVE RADIO RECEIVER ASSEMBLY (for Radio Receiver Type) 19. REMOVE RADIO AND DISPLAY RECEIVER ASSEMBLY (for Radio and Display Type) 20. REMOVE HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 12 . 21. REMOVE NAVIGATION ECU SUB-ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) INSTALLATION INSTALLATION

1. PRECAUTION (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When installing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. INSTALL RADIO RECEIVER ASSEMBLY (for Radio Receiver Type)

3. INSTALL RADIO AND DISPLAY RECEIVER ASSEMBLY (for Radio and Display Type) 4. INSTALL NAVIGATION ECU SUB-ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) 5. INSTALL HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 . 6. INSTALL EXTENSION MODULE (for Radio and Display Type) w/ Navigation System: Refer to INSTALLATION . 7. INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 . 8. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) a. Install the No. 1 radio bracket with the 5 screws. 9. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) a. Install the No. 2 radio bracket with the 5 screws. 10. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Install the No. 1 radio bracket with the 5 screws. b. w/ Navigation System: 1. Install the No. 1 radio bracket with the 7 screws. 11. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) a. w/o Navigation System: 1. Install the No. 2 radio bracket with the 5 screws. b. w/ Navigation System: 1. Install the No. 2 radio bracket with the 7 screws. 12. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Install the No. 1 radio receiver bracket with the 5 screws. 13. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) a. Install the No. 2 radio receiver bracket with the 5 screws. 14. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the radio receiver assembly with air conditioning control assembly. c. Install the radio receiver assembly with air conditioning control assembly with the 4 bolts. 15. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the radio receiver assembly with air

16. 17. 18. 19. 20.

conditioning control assembly. c. Install the radio receiver assembly with air conditioning control assembly with the 4 bolts. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 . INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 . INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION .

21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSPECT HARD DISK DRIVE (for Radio and Display Type with Intuitive Parking Assist System) Refer to OPERATION CHECK . 23. REPLACED OPERATION (w/ Parking Assist Monitor System) Refer to CALIBRATION .

STEREO COMPONENT AMPLIFIER COMPONENTS ILLUSTRATION

Fig. 19: Identifying Stereo Component Amplifier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH Refer to REMOVAL . 2. REMOVE AUDIO AMPLIFIER COVER a. Using a clip remover, remove the 2 clips and audio amplifier cover.

Fig. 20: Locating Audio Amplifier Cover Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET a. Remove the bolt and disconnect the ground wire.

Fig. 21: Locating Stereo Component Amplifier Assembly With Bracket, Ground Wire Bolt

And Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector. c. Disengage the clamp. d. Remove the bolt.

Fig. 22: Locating Stereo Component Amplifier Assembly With Bracket Bolt And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the 2 guides and remove the stereo component amplifier assembly with bracket. 4. REMOVE NO. 2 AMPLIFIER BRACKET a. Remove the 2 screws and No. 2 amplifier bracket.

Fig. 23: Locating No. 2 Amplifier Bracket Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 AMPLIFIER BRACKET a. Remove the 2 screws and No. 1 amplifier bracket.

Fig. 24: Locating No. 1 Amplifier Bracket Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY INSTALLATION INSTALLATION

1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY 2. INSTALL NO. 1 AMPLIFIER BRACKET a. Install the No. 1 amplifier bracket with the 2 screws. 3. INSTALL NO. 2 AMPLIFIER BRACKET a. Install the No. 2 amplifier bracket with the 2 screws. 4. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET a. Engage the 2 guides to the vehicle body to temporarily install the stereo component amplifier assembly with bracket. b. Install the stereo component amplifier assembly with bracket with the bolt. c. Engage the clamp. d. Connect each connector. e. Connect the ground wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. INSTALL AUDIO AMPLIFIER COVER a. Install the audio amplifier cover with the 2 clips. 6. INSTALL FRONT SEAT ASSEMBLY LH Refer to INSTALLATION .

FRONT DOOR SPEAKER COMPONENTS ILLUSTRATION

Fig. 25: Identifying Front Door Speaker Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 .

2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 4 . 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 5 . 4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 6 . 5. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 7 . 6. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 . 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 9 . 8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 . 9. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY a. Disconnect the connector.

Fig. 26: Locating Front No. 1 Speaker Assembly Fasteners And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 screws. c. Disengage the 2 claws and remove the front No. 1 speaker assembly.

Fig. 27: Locating Front No. 1 Speaker Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

INSPECTION INSPECTION

1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 6 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 28: Identifying Speaker Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 3.2 to 4.8 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Front No. 1 Speaker Assembly) 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 29: Inspecting Speaker Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 4.6 to 6.6 1 (+) - 2 (-) Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Front No. 1 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY a. Engage the 2 claws to the vehicle body to temporarily install the front No. 1 speaker assembly. b. Install the front No. 1 speaker assembly with the 4 screws.

Fig. 30: Locating Front No. 1 Speaker Assembly Fasteners And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. *A

LH Side

*B

RH Side

NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration.

2. 3. 4. 5. 6. 7. 8. 9.

c. Connect the connector. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 38 . INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 40 . INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 42 . INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 43 . INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 44 . INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 45 . INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 46 .

INSTRUMENT PANEL SPEAKER COMPONENTS ILLUSTRATION

Fig. 31: Identifying Instrument Panel Speaker Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 32: Identifying Instrument Panel Speaker Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 5. 3. REMOVE FRONT PILLAR GARNISH . Refer to REMOVAL - Step 6 . 4. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY . Refer to REMOVAL Step 42 . 5. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY a. Remove the 2 screws.

Fig. 33: Identifying Front No. 2 Speaker Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lift the front No. 2 speaker assembly and disconnect the connector to remove the speaker.

Fig. 34: Identifying Front No. 2 Speaker Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. REMOVE REAR CONSOLE BOX ASSEMBLY (for 10 Speakers) Refer to REMOVAL . 8. REMOVE BOX BOTTOM MAT (for 10 Speakers) . Refer to REMOVAL - Step 25 . 9. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 26 . 10. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 23 . 11. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 24 . 12. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers)

For Radio and Display Receiver Type: See step 9. 13. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) For Navigation Receiver Type: Refer to REMOVAL - Step 8 . 14. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 30 . 15. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. Remove the 2 screws.

Fig. 35: Identifying Front No. 3 Speaker Assembly Fasteners (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lift the front No. 3 speaker assembly and disconnect the connector to remove the speaker.

Fig. 36: Identifying Front No. 3 Speaker Assembly Connector (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the speaker cone.

INSPECTION INSPECTION

1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 6 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 37: Inspecting Front No. 2 Speaker Assembly (For 6 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 2 (TWR-) 10 kohms Always 4 (TWR+) or higher 1 (-) - 2 Below 1 Always (TWR-) ohms 3 (+) - 4 Below 1 Always (TWR+) ohms 2 (TWL-) 10 kohms Always 4 (TWL+) or higher

1 (-) - 2 (TWL-) 3 (+) - 4 (TWL+)

Always Always

Below 1 ohms Below 1 ohms

If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION *A for RH *B for LH Component without harness *a connected (Front No. 2 Speaker Assembly) d. When there is a possibility that either the right or left speaker is malfunctioning, interchange the speakers and perform an inspection. If the malfunction disappears after interchanging the speakers, replace the malfunctioning speaker. HINT: Connect all connectors to the speakers when performing an inspection. If the result is not as specified, replace the speaker. 2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 38: Identifying Front No. 2 Speaker Assembly (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 3.4 to 5.2 3-4 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Front No. 2 Speaker Assembly) 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 39: Identifying Front No. 3 Speaker Assembly (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 6.8 to 10.2 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Front No. 3 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY a. Connect the connector. b. Install the front No. 2 speaker assembly with the 2 screws.

Fig. 40: Identifying Front No. 2 Speaker Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration. 2. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 . 3. INSTALL FRONT PILLAR GARNISH . Refer to INSTALLATION - Step 41 . 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP For LH side: Refer to INSTALLATION - Step 42 . For RH side: Refer to INSTALLATION - Step 46 . 5. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) a. Connect the connector. b. Install the front No. 3 speaker assembly with the 2 screws.

Fig. 41: Identifying Front No. 3 Speaker Assembly Fasteners (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not touch the speaker cone.

HINT: Install the screws in the order shown in the illustration. 6. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 23 . 7. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) For Radio and Display Receiver Type: See step 15. 8. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for 10 Speakers) For Navigation Receiver Type: Refer to INSTALLATION - Step 7 . 9. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 29 . 10. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 30 . 11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION - Step 27 . 12. INSTALL BOX BOTTOM MAT (for 10 Speakers) . Refer to INSTALLATION - Step 28 . 13. INSTALL REAR CONSOLE BOX ASSEMBLY (for 10 Speakers) Refer to INSTALLATION . 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for 10 Speakers) NOTE:

except Radio and Display Type without Intuitive Parking Assist System: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REAR PACKAGE TRAY SPEAKER COMPONENTS ILLUSTRATION

Fig. 42: Identifying Rear Package Tray Speaker Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 43: Identifying Rear Package Tray Speaker Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. 4. 5. 6. 7. 8. 9.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 12 . 10. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 13 . 11. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 24 . 12. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 13. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 13 . 14. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 14 . 15. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to REMOVAL - Step 10 . 16. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to

17. 18. 19. 20. 21.

REMOVAL - Step 19 . REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 . REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 18 . REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 19 . REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 20 . REMOVE REAR SPEAKER ASSEMBLY a. Disconnect the connector.

Fig. 44: Locating Rear Speaker Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 screws and rear speaker assembly. NOTE:

Do not touch the cone part of the speaker.

HINT: If the rear speaker assembly is difficult to remove, turn back the No. 1 upper back panel hole cover so that the rear speaker assembly can be removed. 22. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. Disconnect the connector.

Fig. 45: Locating Rear No. 2 Speaker Assembly Faster And Connector (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and rear No. 2 speaker assembly. NOTE:

Do not touch the cone part of the speaker.

INSPECTION INSPECTION

1. INSPECT REAR SPEAKER ASSEMBLY a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 46: Identifying Speaker Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance FOR 6 SPEAKERS: Tester Specified Condition Connection Condition 3.2 to 4.8 1-2 Always ohms FOR 10 SPEAKERS: Tester Specified Condition Connection Condition 1-2

Always

4.8 to 6.8

ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without harness *a connected (Rear Speaker Assembly) 2. INSPECT REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. With the speaker installed, check that there is no looseness or other abnormalities. b. Check that there is no foreign matter in the speaker, no tears on the speaker cone or other abnormalities. c. Measure the resistance of the speaker.

Fig. 47: Identifying Rear No. 2 Speaker Assembly (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 6.8 to 10.2 1-2 Always ohms If the result is not as specified, replace the speaker. TEXT IN ILLUSTRATION Component without

harness connected *a (Rear No. 2 Speaker Assembly) INSTALLATION INSTALLATION

1. INSTALL REAR SPEAKER ASSEMBLY a. Install the rear speaker assembly with the 4 screws.

Fig. 48: Locating Rear Speaker Assembly Fasteners And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Do not touch the cone part of the speaker.

HINT: Install the screws in the order shown in the illustration. b. Connect the connector. 2. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) a. Install the rear No. 2 speaker assembly with the bolt.

Fig. 49: Locating Rear No. 2 Speaker Assembly Faster And Connector (For 10 Speakers) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

3. 4. 5. 6.

Do not touch the cone part of the speaker.

b. Connect the connector. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 . INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 . INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 . INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 .

7. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 7 . 8. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 . 9. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 . 10. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 . 11. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 20 . 12. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . 16. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . 17. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . 18. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 19. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 20. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

RADIO ANTENNA CORD COMPONENTS ILLUSTRATION

Fig. 50: Identifying Radio Antenna Cord Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 51: Identifying Radio Antenna Cord Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 52: Identifying Radio Antenna Cord Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Refer to REMOVAL . 2. REMOVE NO. 3 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 5 . 3. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 6 . 4. REMOVE ANTENNA CORD SUB-ASSEMBLY a. Disengage the 8 clamps and remove the antenna cord sub-assembly.

Fig. 53: Locating Antenna Cord Sub-Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL . 6. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY a. Peel back the tape used to secure the antenna cord only to the extent that allows removal of the No. 2 antenna cord sub-assembly. HINT: Tape is not available as a supply part. Try to leave as much tape as possible on the roof headlining

so that the tape can be reused. b. Remove the No. 2 antenna cord sub-assembly from the roof headlining.

Fig. 54: Identifying No. 2 Antenna Cord Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof *1 Tape - -

*a Front

- -

INSTALLATION INSTALLATION

1. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY HINT: The double-sided tape and tape are not available as supply parts. If these pieces of tape still have enough adhesion to secure the roof headlining and antenna cord, reuse them. If the roof headlining has been replaced with a new one, or if the tape and/or the double-sided tape is no longer sticky, apply new tape following the procedure below. a. Apply new double-sided tape.

Fig. 55: Identifying No. 2 Antenna Cord Sub-Assembly With New Double-Sided Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof Double*1 sided - Tape *a Front

*b Doublesided

Tape Size DOUBLE-SIDED TAPE SIZE Area Dimension 1.0 mm A (0.0394 in.) 10.0 mm B (0.394 in.) 1. Remove the old double-sided tape from the roof headlining assembly. 2. Prepare the appropriate amount of new double-sided tape. HINT: Be careful not to touch the adhesive surface. 3. Apply the double-sided tape to the roof headlining while aligning the tape with the markings on the roof headlining assembly. 4. Peel off the release paper from the double-sided tape. b. Install the No. 2 antenna cord sub-assembly to the roof headlining assembly from the front of the vehicle.

Fig. 56: Identifying No. 2 Antenna Cord Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o Sliding w/ Sliding *A *B Roof Roof Double*1 *2 Tape sided Tape Marking *3 *4 Protrusion Tape Adjustment *5 - Area

*a Front

- -

HINT: Align the taped part of the antenna cable with the protrusion of the roof headlining, and apply tape to secure the cable to the headlining. c. Put the strips of tape back to the positions shown in the illustration in order to secure the antenna cord to the roof headlining assembly. HINT: If the tape is no longer sticky, use other tape, such as packing tape, that has enough adhesion to secure the antenna cord to the roof headlining assembly.  For the right front corner of the roof headlining assembly, align the marking tape on the antenna cord with the protrusion of the roof headlining, and wrap tape around the antenna cord and roof headlining assembly once or twice to securely hold them.  For the right rear corner of the roof headlining assembly, align the marking tape on the antenna cord with the rear edge of the roof headlining, and secure the antenna cord to the roof headlining assembly with tape.  If the entire length of the antenna cord does not fit, adjust the length by tucking in the cord at the area shown in the illustration. 2. INSTALL ROOF HEADLINING ASSEMBLY 

Refer to INSTALLATION . 3. INSTALL ANTENNA CORD SUB-ASSEMBLY a. Engage the 8 clamps to install the antenna cord sub-assembly. 4. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 6 . 5. INSTALL NO. 3 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 7 . 6. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION .

AMPLIFIER ANTENNA COMPONENTS ILLUSTRATION

Fig. 57: Identifying Amplifier Antenna Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 13 . 7. REMOVE ROOF SIDE INNER GARNISH RH

3. 4. 5. 6.

HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 24 . 8. REMOVE AMPLIFIER ANTENNA ASSEMBLY a. Disconnect the 4 connectors and disengage the clamp.

Fig. 58: Identifying Amplifier Antenna Assembly Connectors And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Remove the 2 bolts and the amplifier antenna assembly. INSTALLATION INSTALLATION

1. INSTALL AMPLIFIER ANTENNA ASSEMBLY a. Install the amplifier antenna assembly with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) b. Connect the 4 connectors and engage the clamp. 2. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 20 . 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 4. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . 5. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 6. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 7. DISCONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

STEREO JACK ADAPTER ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 59: Identifying Stereo Jack Adapter Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 4. REMOVE NO. 1 STEREO JACK ADAPTER ASSEMBLY a. Disengage the 2 claws to remove the No. 1 stereo jack adapter assembly.

Fig. 60: Identifying No. 1 Stereo Jack Adapter Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 STEREO JACK ADAPTER ASSEMBLY a. Engage the 2 claws to install the No. 1 stereo jack adapter assembly. 2. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . 3. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . 4. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION .

WINDOW GLASS ANTENNA WIRE ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT WINDOW GLASS ANTENNA WIRE a. Check for continuity of the antenna.

Fig. 61: Checking For Continuity Of Each Antenna Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tester

*a Probe Antenna *b Wire *c Tin Foil HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTE:





When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring resistance, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration.

OK There is continuity in the antenna. If the result is not as specified, repair the window glass antenna wire. REPAIR REPAIR

1. REPAIR WINDOW GLASS ANTENNA WIRE

Fig. 62: Identifying Window Glass Antenna Wire Repair Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Repair *1 Point Masking *2 Tape Broken *3 Wire a. b. c. d.

Clean the broken wire tips with a grease, wax and silicone remover. Place masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Using a fine tip brush, apply a small amount of the repair agent to the wire.

Fig. 63: Applying Repair Agent To Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fine *1 Tip Brush Repair *2 Point e. After a few minutes, remove the masking tape.

SATELLITE RADIO ANTENNA COMPONENTS ILLUSTRATION

Fig. 64: Identifying Satellite Radio Antenna Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL . 2. REMOVE ROOF ANTENNA ASSEMBLY a. Disconnect the connector.

Fig. 65: Locating Roof Antenna Assembly Connector And Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the antenna nut. c. Disengage the 2 claws.

Fig. 66: Locating Roof Antenna Assembly Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 3 guides and remove the roof antenna assembly.

Fig. 67: Locating Roof Antenna Assembly Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ROOF ANTENNA ASSEMBLY a. Engage the 3 guides and 2 claws to the vehicle body to temporarily install the roof antenna assembly. b. Place the antenna cord in the cutout of the antenna nut.

Fig. 68: Locating Roof Antenna Assembly Connector And Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout c. Install the roof antenna assembly with the antenna nut. Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) d. Connect the connector. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION .

NOISE FILTER COMPONENTS ILLUSTRATION

Fig. 69: Identifying Noise Filter Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT RADIO SETTING CONDENSER (for High Mounted Stop Light) a. With the radio setting condenser installed, check that there is no looseness or other abnormalities. b. Remove the bolt. c. Disengage the clamp and disconnect the radio setting condenser with wire harness from the vehicle body.

d. Measure the resistance and voltage of the radio setting condenser according to the value(s) in the table below.

Fig. 70: Inspecting Radio Setting Condenser (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Before measuring the resistance and voltage, be sure to use insulated probes to avoid a short circuit between the tester terminal and bracket.

Standard Resistance Tester Connection

Condition 

1-2 

1-3





1 - Body ground

Ignition switch off High mounted stop light off Window defogger off Luggage compartment room light off

Specified Condition 10 kohms or higher

10 kohms or higher

Below 1 ohms

Standard Voltage Tester Connection

Condition 

2 - Body ground





3 - Body ground





2 - Body ground





3 - Body ground



Specified Condition

Ignition switch ON Below 1 High V mounted stop light off Window defogger off Luggage Below 1 compartment V room light off Ignition switch ON 11 to 14 V High mounted stop light on Window defogger on Luggage 11 to 14 V compartment room light on

TEXT IN ILLUSTRATION Radio *a Setting Condenser 2. INSPECT RADIO SETTING CONDENSER (for Window Defogger) a. With the radio setting condenser installed, check that there is no looseness or other abnormalities. b. Remove the bolt. c. Disengage the 2 clamps and disconnect the radio setting condenser with wire harness from the vehicle body. d. Measure the resistance and voltage of the radio setting condenser according to the value(s) in the table below.

Fig. 71: Inspecting Radio Setting Condenser (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection

Condition 

1 (+B) - 2 (GND)





3 - Body ground



Specified Condition

Ignition switch off 10 kohms High or higher Mounted Stop Light off Window Defogger turned off Below 1 Luggage ohms compartment room light off

Standard Resistance Tester Connection

Condition

Specified Condition





1 - Body ground









1 - Body ground





Ignition switch ON High Mounted Stop Light off 10 kohms Window or higher Defogger turned off Luggage compartment room light off Ignition switch ON High Mounted Stop Light on Below 1 Window ohms Defogger turned on Luggage compartment room light on

TEXT IN ILLUSTRATION Radio *a Setting Condenser REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE RADIO SETTING CONDENSER (for High Mounted Stop Light) NOTE:

When the terminal covers are removed, the radio setting condenser must be replaced because the terminal covers and condenser are supplied as a set.

a. Remove the bolt.

Fig. 72: Locating Radio Setting Condenser Bolt And Clamp (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and disconnect the radio setting condenser with wire harness from the vehicle body. c. Disengage the claw and pull out the cover as shown in the illustration.

Fig. 73: Removing Radio Setting Condenser (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a screwdriver, disengage the 6 claws and remove the 2 terminal covers with wire harness from the condenser.

Fig. 74: Disengaging Claws (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, bend back and break off the claw as shown in the illustration.

Fig. 75: Bending The Claw (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the terminal cover from the wire harness. NOTE:







Make sure to hold the wire harness on the crimping side of the terminal when disconnecting the wire harness from the terminal cover. Make sure not to bend the exposed wire when disconnecting the wire harness from the terminal cover. Check for deformation of the terminal after the wire harness has been removed from the terminal cover.

7. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Window Defogger) . Refer to REMOVAL - Step 12 . 8. REMOVE ROOF SIDE INNER GARNISH LH (for Window Defogger) . Refer to REMOVAL Step 24 . 9. REMOVE RADIO SETTING CONDENSER (for Window Defogger) NOTE:

When the terminal cover is removed, the radio setting condenser must be replaced because the terminal cover and condenser are supplied as a set.

a. Remove the bolt.

Fig. 76: Locating Radio Setting Condenser Bolt And Clamps (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clamps and disconnect the radio setting condenser with wire harness from the vehicle body. c. Using a screwdriver, disengage the 3 claws and remove the terminal cover with wire harness from the condenser.

Fig. 77: Disengaging Claws (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a screwdriver, bend back and break off the claw as shown in the illustration.

Fig. 78: Bending The Claw (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the terminal cover from the wire harness. NOTE:







Make sure to hold the wire harness on the crimping side of the terminal when disconnecting the wire harness from the terminal cover. Make sure not to bend the exposed wire when disconnecting the wire harness from the terminal cover. Check for deformation of the terminal after the wire harness has been removed from the terminal cover.

INSTALLATION INSTALLATION

1. INSTALL RADIO SETTING CONDENSER (for Window Defogger) a. Engage the claw to install a new terminal cover to the wire harness.

Fig. 79: Identifying Claw And Terminal Cover (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:









Make sure to hold the wire harness so that the crimping side of the terminal is facing up when installing the wire harness to the terminal cover. Make sure not to bend the exposed wire when installing the wire harness to the terminal cover. Do not use excessive force when inserting the wire harness into the terminal cover. If the terminal cover has been deformed at installation, replace the terminal and terminal cover with new ones.

b. Engage the 3 claws to install the new terminal cover with wire harness to a new condenser.

Fig. 80: Engaging Claws (For Window Defogger) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Do not use excessive force when inserting the terminal cover into the condenser. If the terminal cover has been deformed at installation, replace the terminal, terminal cover and condenser with new ones.

c. Engage the 2 clamps to temporarily install a new radio setting condenser with wire harness. d. Install the new radio setting condenser with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL ROOF SIDE INNER GARNISH LH (for Window Defogger) . Refer to INSTALLATION - Step 20 . 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Window Defogger) . Refer to INSTALLATION - Step 25 . 4. INSTALL RADIO SETTING CONDENSER (for High Mounted Stop Light) a. Engage the claw to install a new terminal cover to the wire harness.

Fig. 81: Identifying Claw And Terminal Cover (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:









Make sure to hold the wire harness so that the crimping side of the terminal is facing up when installing the wire harness to the terminal cover. Make sure not to bend the exposed wire when installing the wire harness to the terminal cover. Do not use excessive force when inserting the wire harness into the terminal cover. If the terminal cover has been deformed at installation, replace the terminal and terminal cover with new ones.

b. Engage the 6 claws to install the 2 new terminal covers with wire harness to a new condenser.

Fig. 82: Engaging Claws & Installing Terminal Covers (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Do not use excessive force when inserting the terminal cover into the condenser. If the terminal cover has been deformed at installation, replace

the terminal, terminal cover and condenser with new ones. c. Engage the claw to insert the cover as shown in the illustration.

Fig. 83: Installing Radio Setting Condenser (For High Mounted Stop Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the clamp to temporarily install a new radio setting condenser with wire harness. e. Install the new radio setting condenser with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. 6. 7. 8.

INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 TRANSMISSION Automatic Transmission (Diagnostic Codes & Circuit Tests) (U660E) - Camry

AUTOMATIC TRANSAXLE SYSTEM DTC P0500: VEHICLE SPEED SENSOR "A" DESCRIPTION

The speed sensors detect the wheel speed and send the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the TCM via the combination meter. The TCM determines the vehicle speed based on the frequency of these pulse signals.

Fig. 1: Vehicle Speed Sensor Communication Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC No.

DTC Detection Condition

P0500

When the ECT sensor is normal and the counter gear speed is 300 RPM or more, the vehicle speed signal is not input for 2 seconds or more.

Trouble Area     

Open or short in vehicle speed signal circuit Combination meter Vehicle speed sensor (Brake control system) Skid control ECU (Brake control system) TCM

MONITOR DESCRIPTION

The TCM assumes that the vehicle is being driven when the transmission counter gear indicates more than 300 RPM and over 30 seconds have passed since the park/neutral position switch assembly was turned off. If there is no vehicle speed signal with these conditions satisfied, the TCM concludes that there is a vehicle speed signal malfunction. The TCM will turn on the MIL and a DTC will be set. MONITOR STRATEGY

Related DTCs Required sensors/components (Main) Required sensors/components (Sub) Frequency of operation Duration MIL operation Sequence operation

P0500: Vehicle Speed Sensor Circuit Vehicle speed sensor, Combination meter, ABS ECU Counter gear Speed (CS) sensor, ECT sensor Continuous 2 seconds Immediately None

TYPICAL ENABLING CONDITIONS

Engine Transmission counter gear revolution Battery voltage Engine switch Starter Either a or b is met a. All of the following conditions are met ECT ECT sensor fail Time after PNP switch ON to OFF b. All of the following conditions are met ECT ECT sensor fail Time after PNP switch ON to OFF

Running 300 RPM or more 8 V or more on (IG) OFF

20°C (68°F) or more Not detected 2 sec. or more Less than 20°C (68°F) Detected 30 sec. or more

TYPICAL MALFUNCTION THRESHOLDS

Vehicle speed sensor signal

No pulse input

WIRING DIAGRAM

Refer to WIRING DIAGRAM When a DTC P0500 is output, a ground short in the wiring of terminal SPD or an internal ground short in the relevant ECU is suspected. INSPECTION PROCEDURE

NOTE:

PROCEDURE

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

1. READ VALUE USING TECHSTREAM (VEHICLE SPEED) a. Drive the vehicle and check whether the operation of the speedometer in the combination meter assembly is normal. HINT: The vehicle speed sensor is operating normally if the speedometer reading is normal.  If the speedometer does not operate, check it by following the procedure described for a speedometer malfunction. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / ECT / Data List / Vehicle Speed. Drive the vehicle. Read the value displayed on the Techstream. 

b. c. d. e. f. g.

OK Vehicle speeds displayed on tester and speedometer display are equal. NG --> See step 2 OK --> See step 6 2. CHECK COMBINATION METER ASSEMBLY (SPD SIGNAL WAVEFORM) a. Inspect the combination meter assembly using an oscilloscope.

Fig. 2: Checking Combination Meter Assembly (SPD Signal Waveform) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Move the shift lever to N. 2. Jack up the vehicle.

3. Turn the engine switch on (IG). 4. Measure the voltage between the terminal of the combination meter assembly and the body ground while the wheel is turned slowly. Standard Voltage Tester Switch Specified Connection Condition Condition I18-9 (+S) - Engine Voltage Body switch on generated ground (IG) intermittently TEXT IN ILLUSTRATION Component with harness connected *a (Combination Meter Assembly) HINT: The output voltage should fluctuate up and down, similarly to the diagram, when the wheel is turned slowly. NG --> See step 5 OK: Go to next step 3. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - TCM) a. Disconnect the combination meter assembly connector. b. Disconnect the TCM connector. c. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for Open) Tester Specified Condition Connection Condition I18-9 (+S) Below 1 Always E7-3 (SPD) ohms d. Reconnect the combination meter assembly connector. e. Reconnect the TCM connector. NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR (COMBINATION METER

ASSEMBLY - TCM) OK --> See step 4 4. REPLACE TCM. Refer to COMPONENTS 5. GO TO METER / GAUGE SYSTEM (SPEED SIGNAL CIRCUIT). Refer to Speed Signal Circuit 6. SYMPTOM SIMULATION AND DTC CHECK. Refer to HOW TO PROCEED WITH TROUBLESHOOTING DTC P0560: SYSTEM VOLTAGE DESCRIPTION

The battery supplies electricity to the TCM even when the engine switch is off. This power allows the TCM to store data such as DTC history and freeze frame data. If the battery voltage falls below a minimum level, these memories are cleared and the TCM determines that there is a malfunction in the power supply circuit. When the engine is next started, the TCM will illuminate the MIL and set the DTC. DTC No. P0560

DTC Detection Condition Open in TCM back-up power source circuit. DTC is detected for 3 sec. or more (1 trip detection logic).

Trouble Area   

Open in back-up power source circuit SFI system TCM

HINT: If DTC P0560 is set, the TCM does not store other DTCs. MONITOR STRATEGY

Related DTCs Required Sensors/Components (Main) Required Sensors/Components (Sub) Frequency of Operation Duration

P0560: TCM system voltage TCM Continuous 3 seconds Immediate (MIL illuminated after next engine start) None

MIL Operation Sequence of Operation TYPICAL ENABLING CONDITIONS

Monitor runs whenever following DTCs are not present: Stand-by RAM

None Initialized

TYPICAL MALFUNCTION THRESHOLDS

TCM power source

Less than 3.5 V

WIRING DIAGRAM

Fig. 3: TCM Circuit Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

PROCEDURE

1. CHECK DTC OUTPUT a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Enter the following menus: Powertrain / Engine / Trouble Codes. e. Read the DTCs using the Techstream. Result Display (DTC Proceed to Output) No A DTC P0560 is output

(engine control system)

B

B --> See step 4 A: Go to next step 2. INSPECT TCM (POWER SOURCE, GROUND) a. Disconnect the TCM connector. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition E7-1 (BATT) - Always 11 to 14 V E7-8 (E1) c. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition E7-8 (E1) Below 1 Body Always ohms ground NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR (TCM - BATTERY, BODY GROUND) OK --> See step 3 3. REPLACE TCM. Refer to COMPONENTS 4. GO TO DTC P0560 (ENGINE CONTROL SYSTEM / SFI SYSTEM). Refer to DTC P0560: System Voltage DTC P0617: STARTER RELAY CIRCUIT HIGH DESCRIPTION

While the engine is being cranked, battery voltage is applied to terminal STA of the TCM.

If the TCM detects the Starter Control (STA) signal while the vehicle is being driven, it determines that there is a malfunction in the STA circuit. The TCM then illuminates the MIL and sets the DTC. This monitor runs when the vehicle is driven at 20 km/h (12.43 mph) for over 20 seconds. DTC No.

P0617

DTC Detection Condition When conditions (a), (b) and (c) are met, positive (+B) battery voltage 10.5 V or more applied to TCM for 20 seconds (1 trip detection logic): (a) Vehicle speed more than 20 km/h (12.43 mph) (b) Engine speed more than 1000 RPM (c) STA signal ON

Trouble Area

   

Park/Neutral Position switch Starter relay circuit Cranking holding function circuit TCM

MONITOR STRATEGY

Related DTCs Required Sensors/Components (Main) Required Sensors/Components (Sub) Frequency of Operation Duration MIL Operation Sequence of Operation

P0617: Starter signal STARTER relay, PNP switch, engine switch Vehicle speed sensor (VSS), Crankshaft Position (CKP) sensor Continuous 20 seconds Immediate None

TYPICAL ENABLING CONDITIONS

Monitor runs whenever these DTCs are not present: Battery voltage Vehicle speed Engine speed

None 10.5 V or more 12.43 mph (20 km/h) or more 1, 000 RPM or more

TYPICAL MALFUNCTION THRESHOLDS

Starter signal WIRING DIAGRAM

ON

Fig. 4: Park/Neutral Position Switch Circuit Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

HINT: 



The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If the engine does not crank, proceed to the problem symptoms table. Refer to PROBLEM SYMPTOMS TABLE . Read freeze frame data using the Techstream. The TCM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. Refer to FREEZE FRAME DATA .

PROCEDURE

1. READ VALUE USING TECHSTREAM (STARTER SIGNAL) a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Enter the following menus: Powertrain / ECT / Data List. Tester Measurement Normal Diagnostic Display Item/Range Condition Note Open: Starter Starter Starter signal/ operating Signal Open or Close Close: Starter not operating e. Crank the engine. f. Read the value displayed on the Techstream. OK Tester Specified Condition Display Condition Engine Starter switch on Close Signal (IG) Starter Engine is Open Signal cranking NG --> See step 3 OK --> See step 2 2. CHECK FOR INTERMITTENT PROBLEMS. Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE 3. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY a. Disconnect the park/neutral position switch connector.

Fig. 5: Checking Park/Neutral Position Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard Resistance Tester Specified Condition Connection Condition Below 1 P ohms E4-4 (B) Below 1 N E4-9 (L) ohms Except P 10 kohms and N or higher

P E4-1 (RB) E4-9 (L)

R N D

10 kohms or higher 10 kohms or higher 10 kohms or higher 10 kohms or higher

TEXT IN ILLUSTRATION Component without harness *a connected (Park/Neutral Position Switch) NG --> See step 7 OK: Go to next step 4. CHECK HARNESS AND CONNECTOR (TCM - PARK/NEUTRAL POSITION SWITCH) a. Disconnect the TCM connector.

Fig. 6: Checking Harness And Connector (TCM - Park/Neutral Position Switch) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the ST relay from the engine room relay block and junction block assembly. c. Disconnect the park/neutral position switch connector. d. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition E7-10 Engine (STA) Below 1 switch on Body V (IG) ground

TEXT IN ILLUSTRATION Front view of wire *a harness connector (to TCM) NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step 5. CHECK WHETHER DTC OUTPUT RECURS a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Clear the DTCs. Refer to DTC CHECK / CLEAR . e. Drive the vehicle in accordance with the driving pattern described in the Confirmation Driving Pattern. f. Enter the following menus: Powertrain / ECT/ Trouble Codes. g. Read the DTCs. RESULT: Proceed Result to DTC is not OK output DTC P0617 NG is output NG --> See step 6 OK --> END 6. REPLACE TCM. Refer to COMPONENTS 7. REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY. Refer to COMPONENTS DTC P062F: INTERNAL CONTROL MODULE EEPROM ERROR DESCRIPTION

The TCM monitors its internal operation and it will set this DTC when it detects an internal malfunction.

DTC Trouble Detection Area Condition TCM internal TCM error (EEPROM)

DTC No.

P062F

MONITOR DESCRIPTION

The TCM monitors its internal operation. If the internal operation is malfunctioning, the TCM illuminates the MIL and sets a DTC. MONITOR STRATEGY

Related DTCs Required sensors/Components (Main) Required sensors/Components (Related) Frequency of operation Duration MIL operation Sequence of operation

P062F: Internal control module EEPROM error TCM Once per driving cycle 11 seconds Immediate None

TYPICAL ENABLING CONDITIONS

Monitor runs whenever following DTCs not present Time after engine start Battery voltage Engine switch Starter

None 10 seconds or more 8 V or higher on (IG) OFF

TYPICAL MALFUNCTION THRESHOLDS

Permanent fault code data

Mismatch (3 times or more)

INSPECTION PROCEDURE

NOTE:





After turning engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

PROCEDURE

1. READ OUTPUT DTC (DTC P062F) a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Clear DTCs. Refer to DTC CHECK / CLEAR . e. Turn the engine switch off and turn the Techstream off. f. Disconnect the Techstream. g. Disconnect the cable from the negative (-) battery terminal and wait for 1 minute. h. Connect the cable to the negative (-) battery terminal. i. Connect the Techstream to the DLC3. j. Turn the engine switch on (IG). k. Turn the Techstream on. l. Select the following menu items: Powertrain / ECT / Trouble Codes. m. Read DTCs. RESULT Proceed Result to No A output P062F B B --> See step 3 A --> See step 2 2. CHECK FOR INTERMITTENT PROBLEMS. Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE 3. REPLACE TCM. Refer to COMPONENTS DTC P0705: TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) DESCRIPTION

The park/neutral position switch assembly detects the shift lever position and sends signals to the TCM. DTC No.

DTC Detection Condition (A) Any 2 or more signals of the following are ON simultaneously (2trip detection logic)

Trouble Area

  

P0705

NSW input signal is ON. R input signal is ON. D input signal is ON.





(B) All switches are OFF simultaneously for NSW, R and D.



Open or short in park/neutral position switch assembly circuit Park/neutral position switch assembly TCM

MONITOR DESCRIPTION

These DTCs indicate a problem with the park/neutral position switch assembly and the wire harness in the park/neutral position switch assembly circuit. The park/neutral position switch assembly detects the shift lever position and sends signals to the TCM. For safety, the park/neutral position switch assembly detects the shift lever position so that the engine can be started only when the shift lever is in P or N. The park/neutral position switch assembly sends a signal to the TCM according to the shift lever position (R or D). The TCM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The TCM will turn on the MIL and store the DTC. MONITOR STRATEGY

Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0705: Park/neutral position switch/Verify switch input Park/neutral position switch assembly Continuous Condition (A): 2 sec. Condition (B): 60 sec. 2 driving cycles None

TYPICAL ENABLING CONDITIONS

The monitor will run whenever the following DTCs are not present Engine switch Battery voltage TYPICAL MALFUNCTION THRESHOLDS

When either condition below is met: Condition (A) or (B) Condition (A)

None on (IG) 10.5 V or more

When 2 or more of the following signals are input at the same time: Park neutral position ON switch (NSW) R position ON switch D position ON switch Condition (B) When all conditions below are met: Park neutral position OFF switch (NSW) R position OFF switch D position OFF switch COMPONENT OPERATING RANGE

Park/neutral position switch assembly WIRING DIAGRAM

The park/neutral position switch sends only one signal to the TCM

Fig. 7: Park/Neutral Position Switch Assembly Circuit Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

HINT: Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. NOTE:

1. 2. 3. 4. 5.

In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

Warm up the engine. Turn the engine switch off. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on.

6. Enter the following menus: Powertrain / ECT / Data List. 7. According to the display on the Techstream, read the Data List. Tester Measurement Normal Diagnostic Display Item / Range Condition Note When the shift lever  ON: position Shift displayed lever on the is in Techstream P or differs Neutral PNP switch N from the Position status / ON or actual  OFF: SW OFF Shift position, Signal lever adjustment of the PNP is not switch or in P the shift or N cable may be incorrect. When the shift lever position  ON: displayed Shift on the lever Techstream Shift is in differs SW R PNP switch from the Status status / ON or actual  OFF: (R OFF Shift position, Range) lever adjustment of the PNP is not switch or in R the shift cable may be incorrect.



Shift SW

PNP switch

ON: Shift lever is in D or S

When the shift lever position displayed on the Techstream differs from the

Status status / ON or (D OFF Range)



OFF: actual Shift position, lever adjustment of the PNP is not switch or in D the shift or S cable may be incorrect.

PROCEDURE

1. CHECK HARNESS AND CONNECTOR (BATTERY - PARK/NEUTRAL POSITION SWITCH) a. Disconnect the park/neutral position switch assembly connector.

Fig. 8: Checking Harness And Connector (Battery - Park/Neutral Position Switch)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the engine switch on (IG). c. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition E4-1 (RB) - Engine Body switch on 11 to 14 V ground (IG) TEXT IN ILLUSTRATION Front view of wire harness connector *a (to Park/Neutral Position Switch Assembly) NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step 2. CHECK HARNESS AND CONNECTOR (OUTPUT SIGNAL) a. Turn the engine switch on (IG).

Fig. 9: Checking Harness And Connector (Output Signal) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition E4-4 (B) - Engine Body switch on 11 to 14 V ground (IG) TEXT IN ILLUSTRATION Front view

of wire harness connector (to *a Park/Neutral Position Switch Assembly) NG --> See step 5 OK: Go to next step 3. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY a. Disconnect the park/neutral position switch assembly connector.

Fig. 10: Checking Park/Neutral Position Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard Resistance Shift Tester Specified Lever Connection Condition Position Below 1 P or N ohms E4-4 (B) E4-9 (L) Except 10 kohms P and N or higher Below 1 R ohms E4-1 (RB) E4-2 (RL) Except 10 kohms R or higher D, S, Below 1 "+" or ohms "-" E4-1 (RB) E4-7 (DL) Except D, S, 10 kohms "+" and or higher "-" TEXT IN ILLUSTRATION Component without harness connected *a (Park/Neutral Position Switch Assembly) NG --> See step 7 OK: Go to next step 4. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - TCM) a. Connect the park/neutral position switch Assembly connector.

Fig. 11: Checking Harness And Connector (Park/Neutral Position Switch - TCM) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the TCM connectors. c. Turn the engine switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard Voltage Shift Tester Specified Lever Connection Condition Position 11 to 14 E7-15 (R) - R V* Body ground Except Below 1

R D, S, "+" or E7-16 (D) - "-" Body Except ground D, S, "+" and "-"

V 11 to 14 V

Below 1 V

TEXT IN ILLUSTRATION Front view of wire *a harness connector (to TCM) HINT: *: The voltage will drop slightly due to lighting up of the back up light. NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 6 5. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - TCM) a. Turn the engine switch off. b. Disconnect the TCM connector. c. Disconnect the park/neutral position switch Assembly connector. d. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for Open) Tester Specified Condition Connection Condition E4-4 (B) Below 1 E7-11 Always ohms (NSW) Standard Resistance (Check for Short) Tester Specified Condition Connection Condition E4-4 (B) or E7-11

(NSW) Body ground and Always other terminals

10 kohms or higher

NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 6 6. REPLACE TCM. Refer to COMPONENTS 7. REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY. Refer to COMPONENTS DTC P0711: TRANSMISSION FLUID TEMPERATURE SENSOR "A" PERFORMANCE DESCRIPTION

The Automatic Transmission Fluid (ATF) temperature sensor converts the fluid temperature into a resistance value for use by the TCM.

Fig. 12: Temperature And Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. The TCM applies a voltage to the temperature sensor through terminal THO1 of the TCM. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the

sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The TCM calculates the fluid temperature based on the voltage signal. DTC No.

DTC Detection Condition One of the following conditions (A), (B) or (C) is met: (A) (a), (b) and (c) are detected: (2-trip detection logic) 

(a) Intake air and engine coolant temperatures are more than 15°C (59°F) at engine start



(b) Soak time is more than 5 hours



(c) After normal driving for over 10 min. and 5 km (3 mile) or more, ATF temperature is less than 20°C (68°F)

Trouble Area

(B) Both (a) and (b) are detected: (2-trip detection logic) P0711

ATF temperature sensor 

(a) Intake air and engine coolant temperatures are more than -10°C (14°F) at engine start



(b) After normal driving for over 18 min. and 20 sec. and 8 km (5 mile) or more, ATF temperature is less than 20°C (68°F)

(C) Both (a) and (b) are detected: (2-trip detection logic) 

(a) Engine coolant temperature is less than 35° C (95°F) at engine start



(b) ATF temperature is 110°C (230°F) or more when engine coolant temperature reaches 60°C (140°F)

MONITOR DESCRIPTION

This DTC indicates that there is a problem with output signals from the automatic transmission fluid (ATF)

temperature sensor and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature into an electrical resistance value. Based on the resistance, the TCM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault of the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 20°C (68°F) after running the vehicle for a certain period, the TCM interprets this as a fault turns on the MIL, and stores the DTC. MONITOR STRATEGY

Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0711: ATF temperature sensor ATF temperature sensor (TFT sensor) Continuous Condition A, B, C and D: 3 sec. Condition E: Continuous 2 driving cycles None

TYPICAL ENABLING CONDITIONS

ALL: P0712, P0713 (ATF temperature sensor circuit (TFT sensor)) P0115, P0117, P0118 (ECT sensor circuit) P0112, P0113 (IAT sensor circuit) P0715, P0717 (Turbine speed sensor circuit) P0791, P0793 (Intermediate shaft speed sensor circuit) P0748 (Shift solenoid valve SL1 circuit) P0778 (Shift solenoid valve SL2 circuit) The monitor will run whenever this DTC is not present. P0798 (Shift solenoid valve SL3 circuit) P2810 (Shift solenoid valve SL4 circuit) (Not circuit malfunction) P0327, P0328, (KCS sensor circuit) P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P060A, P060B, P060D, P060E, P0657, P1607, P2102, P2103, P2111, P2112, P2118, P2119, P2135 ((ETCS) Electronic throttle control system) U0100 (CAN communication system) P2610 (Soak timer circuit) TFT (Transmission fluid temperature) sensor circuit No circuit malfunction ECT (Engine coolant temperature) sensor circuit No circuit malfunction IAT (Intake air temperature) sensor circuit No circuit malfunction Turbine speed sensor circuit No circuit malfunction Intermediate shaft speed sensor No circuit malfunction

Shift solenoid valve SL1 circuit Shift solenoid valve SL2 circuit Shift solenoid valve SL3 circuit Shift solenoid valve SL4 circuit (KCS) Knock control sensor circuit Soak timer circuit (ETCS) Electronic throttle control system CAN communication system Engine Time after engine start ECT (Engine coolant temperature)

No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction Not system down Not system down Starting 12 sec. or more -15°C (5°F) or more

CONDITION A: Time after engine start except for continuing shift position "N" or "P" *2 Driving distance after engine start *3 IAT *4 ECT (12 sec. after engine start) Soak time Accumulated driving time *1 CONDITION B: Time after engine start except for continuing shift position "N" or "P" *2 Driving distance after engine start *3 IAT *4 ECT (12 sec. after engine start) Accumulated driving time *1 CONDITION C: Time after engine start except for continuing shift position "N" or "P" *2 Driving distance after engine start *3 IAT *4 ECT (12 sec. after engine start) Accumulated driving time *1

10 min. or more 5 km (3.1 miles) or more 15°C (59°F) or more 15°C (59°F) or more 5 hours or more 100 sec. or more

18 min. and 20 sec. or more 8 km (5 miles) or more -10°C (14°F) or more -10°C (14°F) or more 185 sec. or more

30 min. or more 15 km (9.3 miles) or more -15°C (5°F) or more -15°C (5°F) or more 400 sec. or more

CONDITION D: Time after engine start except for continuing shift position "N" or "P" 40 min. or more *2 Driving distance after engine start *3 20 km (12.4 miles) or more Accumulated driving time *1 550 sec. or more

CONDITION E: Time after ECT reaches 60°C (140°F) TFT (12 sec. after engine start) ECT (12 sec. after engine start)

10 sec. or more 110°C (230°F) or more 35°C (95°F) or less

HINT: *1: Following conditions are met Engine speed - Turbine speed Output speed Throttle valve opening angle Shift position Engine However, accumulated driving time is cleared When following condition met Duration time from shift position "N" or "P"

10 RPM or more 400 RPM or more 3% or more Not "N" or "P" Starting

600 sec. or more

*2: Time after engine start except for continuing Shift position "N" or "P" is cleared When following condition met Duration time from shift position "N" or "P"

600 sec. or more

*3: Driving distance is cleared when following condition met Duration time from shift position "N" or "P"

600 sec. or more

*4: Minimum select of following IAT IAT (12 sec. after engine start) When following condition met IAT at duration time from shift position "N" or "P"

600 sec. or more

TYPICAL MALFUNCTION THRESHOLDS

CONDITION A, B, C AND D: Less than 20°C (68°F) (THO = -10°C (14°F) at engine start) (Conditions TFT vary with THO at engine) CONDITION E: TFT

110°C (230°F) or more

COMPONENT OPERATING RANGE

TFT

Atmospheric temperature - approx. 130°C (266°F)

WIRING DIAGRAM

Fig. 13: ATF Temperature Sensor Circuit Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:







Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR . If DTCs P0711 and P2610 are output simultaneously, confirm that the ATF temperature is as specified in "Normal Condition" using the Techstream first. When the ATF temperature is as specified in "Normal Condition", perform troubleshooting for DTC P2610. Refer to DIAGNOSTIC TROUBLE CODE CHART . In the table below, the value listed under "Normal Condition" are reference values.

HINT: Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because

intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. 1. 2. 3. 4. 5. 6. 7.

Warm up the engine. Turn the engine switch off. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / ECT / Data List. According to the display on the Techstream, read the Data List. TCM Tester Display

Measurement Normal Condition Diagnostic Item/Range Note If value is  After stall 40°C (-40° speed test: F) or 150° ATF Approximately C (302°F), temperature 80°C (176°F) ATF A/T Oil sensor value/  While engine Temperature Min.: -40°C (temperature is cold: 1 40°F) sensor circuit is Max.: 215°C Equal to open or (419°F) ambient short temperature circuited

HINT: When DTC P0712 is output and the Techstream indicates 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and the Techstream indicates -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. Temperature Malfunction Displayed -40°C (-40°F) Open circuit 150°C (302° Short circuit F) or more HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 seconds). When P0713 is set, P0711 cannot be detected.

It is not necessary to inspect the circuit when P0711 is set. PROCEDURE

1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Enter the following menus: Powertrain / ECT / Trouble Codes. e. Read the DTCs using the Techstream. Result Display Proceed (DTC to Output) Only P0711 A is output P0711 and B other DTC HINT: If any other codes besides P0711 are output, perform troubleshooting for those DTCs first. B --> See step 3 A: Go to next step 2. CHECK TRANSMISSION FLUID LEVEL a. Check the transmission fluid level. Refer to ADJUSTMENT . OK Automatic transmission fluid level is correct. NG --> ADJUST FLUID LEVEL OK --> See step 4 3. GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART

4. REPLACE ATF TEMPERATURE SENSOR ASSEMBLY. Refer to COMPONENTS DTC P0712: TRANSMISSION FLUID TEMPERATURE SENSOR "A" CIRCUIT LOW INPUT; DTC P0713: TRANSMISSION FLUID TEMPERATURE SENSOR "A" CIRCUIT HIGH INPUT DESCRIPTION

The Automatic Transmission Fluid (ATF) temperature sensor converts the fluid temperature into a resistance value for use by the TCM.

Fig. 14: Temperature And Resistance Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. The TCM applies a voltage to the temperature sensor through terminal THO1 of the TCM. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the

sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The TCM calculates the fluid temperature based on the voltage signal. DTC No.

P0712

P0713

DTC Detection Condition ATF temperature sensor resistance is less than 79 ohms for 0.5 sec. or more (1-trip detection logic) ATF temperature sensor resistance is more than 156 kohms for 0.5 seconds or more. Either of the following conditions is met (1 trip detection logic): Condition (A): 394 seconds or more have elapsed after the engine start when engine coolant temperature or intake air temperature is -29.375°C (20.875°F) or less. Condition (B): 10 seconds or more have elapsed after the engine start when engine coolant temperature and intake air temperature are more than 29.375°C (- 20.875°F).

Trouble Area    

   

Short in ATF temperature sensor circuit Transmission wire ATF temperature sensor TCM

Open in ATF temperature sensor circuit Transmission wire ATF temperature sensor TCM

MONITOR DESCRIPTION

These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the TCM determines the ATF temperature, and the TCM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 ohms*1 or more than 156 kohms*2, the TCM interprets this as a fault in the ATF sensor or wiring. The TCM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT:

The ATF temperature can be checked on the Techstream display. MONITOR STRATEGY

Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) ATF temperature sensor (TFT sensor) Continuous 0.5 sec. Immediate None

TYPICAL ENABLING CONDITIONS

P0712: RANGE CHECK (LOW RESISTANCE) The monitor will run whenever None these DTCs are not present. 8V Battery or voltage more Engine on switch (IG) P0713: Range check (High resistance) One of the following conditions is met: Condition (A) or (B) CONDITION (A) Engine coolant temperature 29.375° (ECT) or C (intake air 20.875° temperature F) or (IAT) at less engine start 394 Time after seconds

engine start or more ECT sensor circuit fail Not (P0115, detected P0117, P0118) IAT sensor circuit fail Not (P0112, detected P0113) CONDITION (B) Engine coolant More temperature than (ECT) or 29.375° intake air C (temperature 20.875° (IAT) at F) engine start 10 Time after seconds engine start or more ECT sensor circuit fail Not (P0115, detected P0117, P0118) IAT sensor circuit fail Not (P0112, detected P0113) TYPICAL MALFUNCTION THRESHOLDS

P0712: RANGE CHECK (LOW RESISTANCE) ATF (TFT) sensor resistance P0713: RANGE CHECK (HIGH RESISTANCE) ATF (TFT) sensor resistance

Less than 79 ohms

More than 156 kohms

COMPONENT OPERATING RANGE

ATF (TFT) sensor resistance WIRING DIAGRAM

79 to 156 kohms

Fig. 15: ATF Temperature Sensor Circuit Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

HINT: Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. NOTE:

1. 2. 3. 4. 5.

In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

Warm up the engine. Turn the engine switch off. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on.

6. Enter the following menus: Powertrain / ECT / Data List. 7. According to the display on the Techstream, read the Data List. TCM Tester Display

Measurement Normal Condition Diagnostic Item/Range Note If value is  After stall 40°C (-40° speed test: ATF F) or 150° Approximately C (302°F), temperature 80°C (176°F) A/T Oil ATF sensor value/  While engine Temperature Min.: -40°C (temperature is cold: 1 40°F) sensor Max.: 215°C circuit is Equal to open or (419°F) ambient short temperature circuited

HINT: When DTC P0712 is output and the Techstream indicates 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and the Techstream indicates -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. Temperature Malfunction Displayed -40°C (-40°F) Open circuit 150°C (302° Short circuit F) or more HINT: If the circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 seconds). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE

1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) a. Remove the TCM from the transaxle.

Fig. 16: Checking Resistance Of Transmission Wire (ATF Temperature Sensor) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Condition Specified Condition Connection 17 (E2) - 18 Always 79 ohms to 156 kohms (THO1) 17 (E2) Body ground and Always 10 kohms or higher other terminals

18 (THO1) - Body ground and Always other terminals

10 kohms or higher

HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. ATF Specified Temperature Condition 5 to 8 10°C (50°F) kohms 2.5 to 4.5 25°C (77°F) kohms 0.22 to 110°C (230° 0.28 F) kohms TEXT IN ILLUSTRATION Component without harness *a connected (Transmission Wire) NG --> See step 2 OK --> See step 4 2. INSPECT ATF TEMPERATURE SENSOR a. Disconnect the ATF temperature sensor connector from the transmission wire.

Fig. 17: Checking ATF Temperature Sensor Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Condition Specified Condition Connection E2 - THO1 Always 79 ohms to 156 kohms E2 - Body ground and Always 10 kohms or higher other terminals THO1 Body ground and Always 10 kohms or higher other terminals HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. ATF Specified Temperature Condition 5 to 8 10°C (50°F) kohms 2.5 to 4.5 25°C (77°F) kohms 0.22 to 110°C (230° 0.28 F) kohms NG --> See step 5 OK --> See step 3 3. REPLACE TRANSMISSION WIRE. Refer to COMPONENTS 4. REPLACE TCM. Refer to COMPONENTS 5. REPLACE ATF TEMPERATURE SENSOR ASSEMBLY. Refer to COMPONENTS DTC P0715: INPUT / TURBINE SPEED SENSOR CIRCUIT MALFUNCTION; DTC P0717: INPUT SPEED SENSOR CIRCUIT NO SIGNAL DESCRIPTION

This sensor detects the rotation speed of the turbine which shows the input revolution (speed) of the transaxle. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the TCM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure

according to various conditions, thus, providing smooth gear shifts.

Fig. 18: Identifying Counter Gear, Clutch Drum, Input Speed Sensor And Output Speed Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1

*3

DTC No. P0715

P0717

Counter Gear Output Speed Sensor NC

DTC Detection Condition When the speed sensor input voltage is either more than 1.9 V or less than 0.1 V for 4.5 seconds or more.(1-trip detection logic) TCM detects conditions (a), (b) and (c) continuously for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (R) is OFF (c) Speed sensor (NT): less than 300 RPM

MONITOR DESCRIPTION

*2

*4

Clutch Drum Input Speed Sensor NT

Trouble Area



 

Transmission revolution sensor (speed sensor NT) Transmission wire TCM

The NT terminal of the TCM detects a revolution signal from the speed sensor (NT) (input RPM). The TCM calculates gear shifts comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear with the shift lever in D, if the input shaft revolution (speed) is less than 300 RPM*1 although the output shaft revolution (speed) is more than 1000 RPM*2, the TCM interprets this as a fault, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY

Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0715: Speed sensor (NT)/Range check P0717: Speed sensor (NT)/Verify pulse input Speed sensor (NT), Speed sensor (NC) Continuous P0715: 4.5 sec. P0717: 5 sec. Immediate None

TYPICAL ENABLING CONDITIONS

P0715: Battery voltage Engine switch Starter

8 V or more on (IG) OFF

P0717: The monitor will run whenever this DTC is not present. Shift change TCM selected gear Output shaft RPM R switch NSW switch Engine Battery voltage Engine switch

P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Shift change is completed before starting next shift change operation 2nd, 3rd, 4th, 5th or 6th 1, 000 RPM or more OFF OFF Running 8 V or more on (IG)

Starter Transmission range switch circuit Turbine speed sensor range check

OFF Not malfunction Not malfunction

TYPICAL MALFUNCTION THRESHOLDS

P0715: Sensor voltage

Less than 0.1 V or more than 1.9 V

P0717: Sensor signal RPM

Less than 300 RPM

COMPONENT OPERATING RANGE

Speed sensor (NT)

Turbine speed is equal to engine speed with lock-up ON

WIRING DIAGRAM

Fig. 19: Transmission Revolution Sensor Circuit Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

HINT: Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. NOTE:

1. 2. 3. 4. 5. 6. 7.

In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

Warm up the engine. Turn the engine switch off. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / ECT / Data List. According to the display on the Techstream, read the Data List. TCM Tester Measurement Display Item/Range

Normal Condition

Diagnostic Note

Lock-up is

SPD (NT)



ON (after warming up engine): Input turbine speed Data is (NT) is displayed equal to in engine increments speed of 50 RPM



OFF (idling with shift lever in N): Input turbine speed

Input shaft speed/ Min.: 0 RPM Max.: 12750 RPM

(NT) is nearly equal to engine speed HINT:  

SPD (NT) is always 0 while driving: Open or short in the sensor or circuit. SPD (NT) is always more than 0 and less than 300 RPM while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit.

PROCEDURE

1. INSPECT TRANSMISSION REVOLUTION SENSOR (SPEED SENSOR INSTALLATION) a. Remove the valve body assembly. b. Make sure that the connector is properly connected, and check the speed sensor installation. Refer to INSTALLATION .

Fig. 20: Inspecting Transmission Revolution Sensor (Speed Sensor Installation) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK The installation bolt is tightened properly and there is no clearance between the sensor and

transaxle case. NG --> See step 6 OK: Go to next step 2. INSPECT TRANSMISSION WIRE a. Remove the TCM.

Fig. 21: Checking Resistance Of Transmission Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the speed sensor connector from the transmission wire. c. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Condition Condition 1 (NTB) sensor Below 1 side - 1 Always ohms (NTB) TCM side 2 (NTO) sensor Below 1 side - 2 Always ohms (NTO) TCM side 1 (NTB) sensor side 10 kohms Body Always or higher ground and other terminals 2 (NTO) sensor side 10 kohms Body Always or higher ground and other terminals TEXT IN ILLUSTRATION Component without harness *a connected (Transmission Wire) *b TCM Side *c Sensor Side NG --> See step 7 OK: Go to next step 3. REPLACE TRANSMISSION REVOLUTION SENSOR Refer to COMPONENTS

NEXT: Go to next step 4. CHECK IF DTC OUTPUT RECURS (SEE IF DTC P0715 AND/OR P0717 OUTPUT AGAIN) a. Connect the Techstream to the DLC3. b. Start the engine and turn the Techstream on. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . HINT: Write down the currently output DTCs before clearing them. d. Perform the monitor drive pattern. Refer to MONITOR DRIVE PATTERN . e. Enter the following menus: Powertrain / ECT / Trouble Codes. f. Read the DTCs using the Techstream. Result Display Proceed (DTC to Output) Only "P0715 or A P0717" is output No B output B --> END A --> See step 5 5. REPLACE TCM. Refer to COMPONENTS 6. REPAIR OR REPLACE TRANSMISSION REVOLUTION SENSOR. Refer to COMPONENTS 7. REPLACE TRANSMISSION WIRE. Refer to COMPONENTS DTC P0724: BRAKE SWITCH "B" CIRCUIT HIGH DESCRIPTION

The purpose of this circuit is to prevent the engine from stalling when the brakes are suddenly applied while driving in the lock-up condition. When the brake pedal is depressed, this switch sends a signal to the TCM. Then the TCM cancels the operation

of the lock-up clutch while braking is in progress. DTC No.

P0724

DTC Detection Condition The stop light switch remains ON even when the vehicle is driven in a STOP (less than 3 km/h (1.86 mph)) and GO (30 km/h (18.65 mph) or more) fashion 5 times. (2-trip detection logic).

Trouble Area 

 

Short in stop light switch signal circuit Stop light switch TCM

MONITOR DESCRIPTION

This DTC indicates that the stop light switch remains ON. When the stop light switch remains ON during "stop and go" driving, the TCM interprets this as a fault in the stop light switch, illuminates the MIL, and stores the DTC. The vehicle must stop (less than 3 km/h (1.86 mph)) and go (30 km/h (18.65 mph) or more) five times for two consecutive driving cycles in order to set this DTC. MONITOR STRATEGY

Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0724: Stop light switch/Range check/Rationality Stop light switch Continuous GO and STOP 5 times 2 driving cycles None

TYPICAL ENABLING CONDITIONS

GO and STOP are defined as follows; THE STOP LIGHT SWITCH REMAINS ON DURING GO AND STOP 5 TIMES. The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.65 mph (30 km/h) or more) 18.65 mph (30 km/h) or more STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Less than 1.86 mph (3 km/h) Starter OFF Battery voltage 8 V or more Engine switch on (IG) TYPICAL MALFUNCTION THRESHOLDS

Switch status WIRING DIAGRAM

ON stuck

Fig. 22: Stop Light Switch Circuit Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

PROCEDURE

1. READ VALUE USING DATA LIST (STP SIGNAL) HINT: Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. NOTE:

In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

a. Turn the engine switch off. b. Connect the Techstream to the DLC3.

c. d. e. f.

Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / ECT / Data List. According to the display on the Techstream, read the Data List. OK Tester Measurement Display Item/Range Stop Stop light Light switch status/ Switch ON or OFF

NOTE:

Normal Condition Brake pedal is 



ON: Depressed OFF: Released

Diagnostic Note

-

In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty.

NG --> See step 2 OK --> CHECK FOR INTERMITTENT PROBLEMS 2. CHECK STOP LIGHT SWITCH ASSEMBLY INSTALLATION a. Check the stop light switch assembly installation. Refer to INSTALLATION . OK Stop light switch assembly is installed correctly. NG --> SECURELY REINSTALL STOP LIGHT SWITCH ASSEMBLY OK: Go to next step 3. INSPECT STOP LIGHT SWITCH ASSEMBLY a. Inspect the stop light switch assembly. Refer to INSPECTION . NG --> See step 5 OK: Go to next step 4. CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - TCM) a. Install the stop light switch assembly.

Fig. 23: Checking Harness And Connector (Stop Light Switch Assembly - TCM) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the stop light switch connector. c. Disconnect the TCM connector. d. Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard Voltage Tester Specified Condition Connection Condition E7-12 (STP) Body

Brake 7.5 to 14 pedal is V depressed

ground E7-12 (STP) Body ground

Brake pedal is released

Below 1 V

TEXT IN ILLUSTRATION Front view of wire *1 harness connector (to TCM) NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 6 5. REPLACE STOP LIGHT SWITCH ASSEMBLY. Refer to COMPONENTS 6. REPLACE TCM. Refer to COMPONENTS DTC P0741: TORQUE CONVERTER CLUTCH SOLENOID PERFORMANCE (SHIFT SOLENOID VALVE SL) SYSTEM DESCRIPTION

The TCM uses signals from the throttle position sensor, air-flow meter, turbine (input) speed sensor, intermediate (counter gear) speed sensor and crankshaft position sensor to help determine the engagement timing of the lock-up clutch. The TCM monitors the engagement of the clutch using the turbine (input) speed sensor, intermediate (counter gear) speed sensor and crankshaft position sensor. Then the TCM compares the engagement condition of the lock-up clutch with the lock-up schedule in the TCM memory to detect shift solenoid valve SL, valve body and torque converter clutch mechanical problems. DTC No.

DTC Detection Condition

Trouble Area 

When both of the following are detected (2-trip detection logic): P0741

 

Lock-up does not occur when requested. Transmission fluid pressure switch No. 3 is ON.

  



MONITOR DESCRIPTION

Shift solenoid valve SL remains closed Valve body is blocked Torque converter assembly Automatic transaxle (clutch, brake or gear etc.) Line pressure is too low

Torque converter lock-up is controlled by the TCM based on the speed sensor (NT), speed sensor (NC), engine speed, engine load, engine temperature, vehicle speed, transmission fluid temperature, and gear selection. The TCM determines the lock-up status of the torque converter by comparing the engine speed (NE) to the input turbine RPM (NT). The TCM calculates the actual transmission gear by comparing the input turbine RPM (NT) to the counter gear RPM (NC). When conditions are appropriate, the TCM requests "lock-up" by applying control voltage to shift solenoid SL. When SL is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the TCM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the TCM interprets this as a fault in shift solenoid valve SL or lock-up system performance. The TCM will turn on the MIL and store the DTC. HINT: Example: When any of the following is met, the system judges it as a malfunction. 

There is a difference in rotation (speed) between the input side (engine speed) and output side (input turbine speed) of the torque converter when the TCM commands lock-up. (Engine speed is at least 70 RPM greater than the input turbine speed.)

MONITOR STRATEGY

Related DTCs

Required sensors/Components

Frequency of operation Duration MIL operation Sequence of operation

P0741: Shift solenoid valve SL OFF malfunction Shift solenoid valve SL, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE), Throttle position sensor (VPA1), Mass air flow sensor (MAF), Transmission temperature sensor (THO1), Engine coolant temperature sensor (ECT) Continuous OFF malfunction 3.5 sec. 2 driving cycles None

TYPICAL ENABLING CONDITIONS

ALL: P0712, P0713 (ATF temperature sensor circuit (TFT sensor)) P0115, P0117, P0118 (ECT sensor circuit)

The monitor will run whenever this DTC is not present. (Not circuit malfunction)

ECT (Engine coolant temperature) Spark advance from Max. retard timing by KCS control Transmission range TFT (Transmission fluid temperature) TFT (Transmission fluid temperature) sensor circuit ECT (Engine coolant temperature) sensor circuit Turbine speed sensor circuit Intermediate shaft speed sensor circuit Shift solenoid valve SL1 circuit Shift solenoid valve SL2 circuit Shift solenoid valve SL3 circuit Shift solenoid valve SL4 circuit Shift solenoid valve SLU circuit Shift solenoid valve SL circuit (KCS) Knock control sensor circuit (ETCS) Electronic throttle control system CAN communication system Engine TCM selected gear Vehicle speed Turbine speed/Output speed (NT/NO) with 1st Turbine speed/Output speed (NT/NO) with 2nd Turbine speed/Output speed (NT/NO) with 3rd Turbine speed/Output speed (NT/NO) with 4th Turbine speed/Output speed (NT/NO) with 5th Turbine speed/Output speed (NT/NO) with 6th

P0715, P0717 (Turbine speed sensor circuit) P0791, P0793 (Intermediate shaft speed sensor circuit) P0748 (Shift solenoid valve SL1 circuit) P0778 (Shift solenoid valve SL2 circuit) P0798 (Shift solenoid valve SL3 circuit) P2810 (Shift solenoid valve SL4 circuit) P2759 (Shift solenoid valve SLU circuit) P2769, P2770 (Shift solenoid valve SL circuit) P0327, P0328, P0332, P0333 (KCS sensor circuit) P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P060A, P060B, P060D, P060E, P0657, P1607, P2102, P2103, P2111, P2112, P2118, P2119, P2135 ((ETCS) Electronic throttle control system) U0100 (CAN communication system) 40°C (104°F) or more 0°CA or more "D" -10°C (14°F) or more No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction No circuit malfunction Not system down Not system down Starting Not 1st 15.5 mph (25 km/h) or more 3.304 to 7.724 1.901 to 2.340 1.399 to 1.649 0.998 to 1.138 0.705 to 0.836 0.568 to 0.695

TYPICAL MALFUNCTION THRESHOLDS

OFF MALFUNCTION: Following conditions are met (a) Engine Speed - Turbine speed (b) Transmission fluid pressure switch

(a) and (b) 70 RPM or more ON

INSPECTION PROCEDURE

NOTE:

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

HINT: Using the Techstream to perform Active Tests allows relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests. 1. PERFORM ACTIVE TEST a. Warm up the engine. b. Turn the engine switch off. c. Connect the Techstream to the DLC3. d. Turn the engine switch on (IG). e. Turn the Techstream on. f. Enter the following menus: Powertrain / ECT / Active Test. g. According to the display on the Techstream, perform the Active Test. Tester Control Test Part Display Range

Activate the ON/OFF Lock Controls Up the shift solenoid SLU and SL to set the automatic

Diagnostic Note Can be used to check SLU and SL solenoid operation. [Vehicle Condition] 

Throttle valve opening angle: Less than

transaxle to the lock-up condition.



20% Vehicle speed:60 km/h (37 mph) or more, and 6th gear

HINT: This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. h. Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: 



When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off.)

Fig. 24: Accelerator Pedal Opening Angle Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PROCEDURE

1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0741) a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Enter the following menus: Powertrain / ECT / Trouble Codes. e. Read the DTCs using the Techstream.

Result Display Proceed (DTC to Output) Only "P0741" A is output "P0741" and B other DTCs HINT: If any other codes besides "P0741" are output, perform the troubleshooting for those DTCs first. B --> See step 8 A: Go to next step 2. CHECK TRANSMISSION WIRE a. Remove the TCM from the transaxle.

Fig. 25: Checking Transmission Wire Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 6 (SL) 20°C (68° 11 to 15 Body F) ohms ground TEXT IN ILLUSTRATION Component

without harness *a connected (Transmission Wire) NG --> See step 6 OK: Go to next step 3. INSPECT SHIFT SOLENOID VALVE SL (OPERATION) a. Remove shift solenoid valve SL.

Fig. 26: Inspecting Shift Solenoid Valve SL (Operation) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Connect a battery positive (+) lead to the terminal of the solenoid valve connector, and a negative () lead to the solenoid body. Then check that the valve moves and makes an operating sound. OK Valve moves and makes an operating sound. TEXT IN ILLUSTRATION Shift Solenoid *1 Valve SL NG --> See step 9 OK: Go to next step 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY a. Check the transmission valve body assembly. Refer to REMOVAL . OK There are no foreign objects on each valve and they operate smoothly. NG --> See step 12 OK: Go to next step 5. INSPECT TORQUE CONVERTER ASSEMBLY a. Check the torque converter assembly. Refer to INSPECTION . OK The torque converter operates normally. NG --> See step 11 OK --> See step 7 6. INSPECT SHIFT SOLENOID VALVE SL (RESISTANCE) a. Remove shift solenoid valve SL.

Fig. 27: Checking Shift Solenoid Valve SL Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition Solenoid Connector 20°C (68° 11 to 15 (SL) F) ohms Solenoid Body (SL) TEXT IN ILLUSTRATION

Shift Solenoid *1 Valve SL NG --> See step 9 OK --> See step 10 7. 8. 9. 10. 11. 12.

REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY. Refer to COMPONENTS GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART REPLACE SHIFT SOLENOID VALVE SL. Refer to COMPONENTS REPLACE TRANSMISSION WIRE. Refer to COMPONENTS REPLACE TORQUE CONVERTER ASSEMBLY. Refer to COMPONENTS REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY. Refer to COMPONENTS

DTC P0746: PRESSURE CONTROL SOLENOID "A" PERFORMANCE (SHIFT SOLENOID VALVE SL1) SYSTEM DESCRIPTION

The TCM uses the vehicle speed signal and signals from the transmission speed sensors (NC, NT) to detect the actual gear (1st, 2nd, 3rd, 4th, 5th or 6th gear). Then the TCM compares the actual gear with the shift schedule in the TCM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No.

DTC Detection Condition The engine revs freely when 1st, 2nd, 3rd, or 4th gear is commanded (2-trip detection logic). When either of the following is detected twice (2-trip detection logic):

P0746

Trouble Area



 



When 5th gear is commanded, 4th gear is engaged. When 6th gear is commanded, 4th gear is engaged



Shift solenoid valve SL1 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.)

MONITOR DESCRIPTION

The TCM commands gear shifts by turning the shift solenoid valves on and off. According to the input shaft revolution (speed), intermediate (counter) shaft revolution (speed) and output shaft revolution (speed), the TCM detects the actual gear (1st, 2nd, 3rd, 4th, 5th or 6th gear). When the gear commanded by the TCM and the actual gear are not the same, the TCM illuminates the MIL and stores the DTC.

MONITOR STRATEGY

Related DTCs

Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation

P0746: Shift solenoid valve SL1 OFF malfunction Shift solenoid valve SL1 ON malfunction Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous ON malfunction: 0.8 sec. OFF malfunction: 0.5 sec. 2 driving cycles None

TYPICAL ENABLING CONDITIONS

ALL: P0712, P0713 (ATF temperature sensor circuit (TFT sensor)) P0115, P0117, P0118 (ECT sensor circuit) P0715, P0717 (Turbine speed sensor circuit) P0791, P0793 (Intermediate shaft speed sensor circuit) P0748 (Shift solenoid valve SL1 circuit) The monitor will run whenever this DTC is not P0778 (Shift solenoid valve SL2 circuit) present. P0798 (Shift solenoid valve SL3 circuit) (Not circuit malfunction) P2810 (Shift solenoid valve SL4 circuit) P0327, P0328, P0332, P0333 (KCS sensor circuit) P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P060A, P060B, P060D, P060E, P0657, P1607, P2102, P2103, P2111, P2112, P2118, P2119, P2135 ((ETCS) Electronic throttle control system) U0100 (CAN communication system) Transmission range "D" TFT (Transmission fluid temperature) -10°C (14°F) or more TFT (Transmission fluid temperature) sensor circuit No circuit malfunction ECT (Engine coolant temperature) sensor circuit No circuit malfunction Turbine speed sensor circuit No circuit malfunction Intermediate shaft speed sensor circuit No circuit malfunction Shift solenoid valve SL1 circuit No circuit malfunction Shift solenoid valve SL2 circuit No circuit malfunction Shift solenoid valve SL3 circuit No circuit malfunction

Shift solenoid valve SL4 circuit (KCS) Knock control sensor circuit (ETCS) Electronic throttle control system CAN communication system Engine OFF MALFUNCTION: TCM selected gear TCM indicated pressure value of SL1 Throttle valve opening angle ON MALFUNCTION: TCM selected gear Vehicle speed ETC (Engine coolant temperature) Throttle valve opening angle

No circuit malfunction No circuit malfunction Not system down Not system down Starting

1st, 2nd, 3rd or 4th 1, 200 kPa 3% or more

5th or 6th 1.2 mph (2 km/h) or more 40°C (104°F) or more 4.5% or more at engine speed 2, 000 RPM (Varies with engine speed)

TYPICAL MALFUNCTION THRESHOLDS

Either of the following conditions is met: OFF MALFUNCTION: Turbine 1, speed 000 Output RPM speed x or Gear more ratio ON MALFUNCTION: Input (turbine) speed/Intermediate 0.998 shaft speed when to output speed less 1.138 than 1, 000 RPM INSPECTION PROCEDURE

NOTE:

PROCEDURE

Perform the universal trip to clear permanent DTCs. Refer to DTC CHECK / CLEAR .

1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746) a. Connect the Techstream to the DLC3. b. Turn the engine switch on (IG). c. Turn the Techstream on. d. Enter the following menus: Powertrain / ECT / Trouble Codes. e. Read the DTCs using the Techstream. Result Display Proceed (DTC to Output) Only "P0746" A is output "P0746" and B other DTCs HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. A --> See step 3 B: Go to next step 2. PERFORM ACTIVE TEST USING TECHSTREAM NOTE: a. b. c. d. e. f. g.

This test should always be performed with at least 2 people.

Warm up the engine. Turn the engine switch off. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / ECT / Active Test. According to the display on the Techstream, perform the Active Test. HINT:

Comparing the gear commanded by the Active Test with the actual gear enables confirmation of the problem. Refer to FAIL-SAFE CHART . Tester Test Part Control Range Display

Operates the shift solenoid Control valves to the allow Shift gears to Position be selected manually.





Diagnostic Note Can be used to check the operation of the shift solenoid valves. Upshifts and downshifts should be performed consecutively. A 10-second Press "-interval is >" button: required Upshift between gear occurs changes. Press "" button: A 10-second Upshift interval is occurs required Press "" button: A 10-second Upshift interval is occurs required Press "" button: Upshift occurs Press "" button: changes. Upshift Do not occurs downshift at Press "" button: required Upshift between gear occurs changes. Press "" button: A 10-second Upshift interval is occurs required

Shift allow Position gears to selected manually.

NOTE:



 

Press "" button: A 10-second Upshift interval is occurs required Press "" button: Upshift occurs Press "" button: changes. Upshift Do not occurs downshift at Press " END PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. CLOCK Symptom Clock does not operate at all.

Clock display illumination malfunction Clock loses or gains time. Clock cannot be adjusted.

Suspected Area Fuse (ECU-ACC, DOME) Wire harness or connector Clock assembly Wire harness or connector Main body ECU (multiplex network body ECU) Clock assembly Clock assembly Clock assembly

See Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL

2012-2017 ACCESSORIES & EQUIPMENT Clock System (Inspection) (Except Hybrid) - Camry

CLOCK SYSTEM PARTS LOCATION ILLUSTRATION

Fig. 1: Identifying Clock System Components Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

1. DIRECT LINE SIGNAL

Fig. 2: Clock System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING

1. VEHICLE BROUGHT TO WORKSHOP NEXT: Go to next step 2. CUSTOMER PROBLEM ANALYSIS NEXT: Go to next step 3. PROBLEM SYMPTOM CONFIRMATION NEXT: Go to next step 4. PROBLEM SIMULATION NEXT: Go to next step 5. PROBLEM SYMPTOMS TABLE a. Refer to Problem Symptoms Table. Refer to PROBLEM SYMPTOMS TABLE. NEXT: Go to next step 6. REPAIR OR REPLACE

NEXT: Go to next step 7. CONFIRMATION TEST NEXT --> END PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. CLOCK Symptom Clock does not operate at all.

Clock display illumination malfunction Clock loses or gains time. Clock cannot be adjusted.

Suspected Area Fuse (ECU-ACC, DOME) Wire harness or connector Clock assembly Wire harness or connector Main body ECU (Multiplex network body ECU) Clock assembly Clock assembly Clock assembly

See Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL Refer to REMOVAL

2012-2017 ENGINE Cooling System (Service Specifications) - Camry (2AR-FE)

2AR-FE COOLING SERVICE DATA SERVICE DATA

THERMOSTAT Condition Standard valve opening temperature Standard valve lift COOLING FAN MOTOR Item Cooling fan motor No. 2 cooling fan motor

Specified Condition 80 to 84°C (176 to 183°F) 10 mm (0.394 in.) or more at 95°C (203°F)

Condition Specified Condition Battery voltage applied at 20°C (68° 5.8 to 7.4 A F) Battery voltage applied at 20°C (68° 5.8 to 7.4 A F)

COOLING FAN RELAY Item

Tester Connection

Specified Condition 10 kohmsor higher (Battery voltage is not applied between terminals 1 and 2) Below 1 ohms (Battery voltage is applied between terminals 1 and 2)

3-5 Cooling fan relay 3-5

RADIATOR Item

Condition Standard value (for brand-new cap)

Radiator cap

Minimum standard value (for used cap)

Specified Condition 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm2 , 13.5 to 17.8 psi) 78.5 kPa (0.8 kgf/cm2 , 11.4 psi)

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS

WATER PUMP Part Tightened

N*m

kgf*cm

ft.*lbf

Water pump x Water inlet housing THERMOSTAT Part Tightened Water inlet x Water inlet housing COOLING FAN MOTOR Part Tightened Fan shroud x cooling fan motor Fan shroud x No. 2 cooling fan motor Fan x Cooling fan motor Fan x No. 2 cooling fan motor

21

214

N*m

15

kgf*cm

10

ft.*lbf

102

N*m

7

kgf*cm

ft.*lbf

2.6

26

23 in.*lbf

2.6

26

23 in.*lbf

6.3 6.3

64 64

56 in.*lbf 56 in.*lbf

RADIATOR Part Tightened N*m Cooler condenser assembly x 6.0 Radiator assembly Upper radiator support sub12 assembly x Body Radiator reserve tank assembly x 7.0 Fan shroud

kgf*cm

ft.*lbf

61

53 in.*lbf

122

9

71

62 in.*lbf

2012-2017 ENGINE Cooling System (Service Specifications) - Camry (2GR-FE)

2GR-FE COOLING SERVICE DATA SERVICE DATA

THERMOSTAT Condition Standard valve opening temperature Standard valve lift COOLING FAN MOTOR Item Cooling fan motor No. 2 cooling fan motor

Condition Specified Condition Battery voltage applied at 20°C (68° 7.3 to 9.3 A F) Battery voltage applied at 20°C (68° 7.3 to 9.3 A F)

COOLING FAN RELAY Item

Tester Connection

3-5 Fan relay 3-5

RADIATOR Item Radiator cap

Condition Standard value (for brand-new cap) Minimum standard value (for used cap)

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS

COOLANT

Specified Condition 80 to 84°C (176 to 183°F) 7.7 mm (0.3031 in.) or more at 95°C (203°F)

Specified Condition 10 kohmsor higher (Battery voltage is not applied between terminals 1 and 2) Below 1 ohms (Battery voltage is applied between terminals 1 and 2)

Specified Condition 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm2 , 13.5 to 17.8 psi) 78.5 kPa (0.8 kgf/cm2 , 11.4 psi)

Part Tightened Cylinder block drain cock plug x Cylinder block Air drain cock plug x Water inlet housing

N*m

kgf*cm

ft.*lbf

13

130

9

13

130

9

WATER PUMP Part Tightened Water pump x for bolt A Timing chain for bolt B cover subfor bolt C assembly Water without SST pump pulley x Water with SST pump Water inlet housing x Timing chain cover sub-assembly V-ribbed belt tensioner pulley x V-ribbed belt tensioner pulley bracket Front No. 1 engine without SST mounting bracket LH x Timing chain with SST cover subassembly

N*m

kgf*cm

ft.*lbf

21

214

15

11

112

8

11

112

8

21

214

15

11

112

8

10

102

7

48

489

35

54

551

40

34

347

25

THERMOSTAT Part Tightened Water inlet x Water inlet housing

N*m 10

kgf*cm 102

ft.*lbf 7

COOLING FAN MOTOR Part Tightened

N*m

kgf*cm

ft.*lbf

Cooling fan motor x Fan shroud No. 2 cooling fan motor x Fan shroud Fan x Cooling fan motor No. 2 Fan x No. 2 Cooling fan motor

2.6

27

23 in.*lbf

2.6

27

23 in.*lbf

6.3

64

56

6.3

64

56

N*m

kgf*cm

ft.*lbf

6.0

61

53 in.*lbf

12

122

9

7.0

71

62 in.*lbf

RADIATOR Part Tightened Radiator assembly x Cooler condenser assembly Upper radiator support subassembly x Body Radiator reserve tank assembly x Fan shroud

2012-2017 ACCESSORIES & EQUIPMENT Cruise Control System (Service Information) (Hybrid)

CRUISE CONTROL MAIN SWITCH COMPONENTS ILLUSTRATION

Fig. 1: Identifying Cruise Control Main Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HORN BUTTON ASSEMBLY Refer to REMOVAL 2. REMOVE CRUISE CONTROL MAIN SWITCH a. Remove the 2 screws.

Fig. 2: Identifying Cruise Control Main Switch Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the cruise control main switch.

Fig. 3: Removing Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT CRUISE CONTROL SWITCH a. Measure the resistance according to the value(s) in the table below.

Fig. 4: Inspecting Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Cruise control switch 1 Mohms (ON-OFF or higher button) released Cruise control 1-3 switch Below 2.5 (ON-OFF ohms button) pushed 235 to 245 +/RES ohms 617 to 643 -/SET ohms

CANCEL

1509 to 1571 ohms

TEXT IN ILLUSTRATION Cruise Control *1 Switch - (ON-OFF button) Component without harness ON*a connected *b OFF (Cruise Control Switch) *c +/RES *d /SET *e CANCEL - INSTALLATION INSTALLATION

1. INSTALL CRUISE CONTROL MAIN SWITCH a. Connect the connector. b. Install the cruise control switch main with the 2 screws shown in the illustration.

Fig. 5: Installing Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) 2. INSTALL HORN BUTTON ASSEMBLY Refer to INSTALLATION

2012-2017 ACCESSORIES & EQUIPMENT Cruise Control System (Service Information) - Camry (Except Hybrid)

CRUISE CONTROL MAIN SWITCH COMPONENTS ILLUSTRATION

Fig. 1: Identifying Cruise Control Main Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HORN BUTTON ASSEMBLY Refer to REMOVAL 2. REMOVE CRUISE CONTROL MAIN SWITCH a. Remove the 2 screws.

Fig. 2: Identifying Cruise Control Main Switch Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the cruise control main switch.

Fig. 3: Removing Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT CRUISE CONTROL SWITCH a. Measure the resistance according to the value(s) in the table below.

Fig. 4: Inspecting Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Cruise control switch 1 Mohms (ON-OFF or higher button) released Cruise control 1-3 switch Below 2.5 (ON-OFF ohms button) pushed +/RES 235 to 245 switch ohms ON -/SET

switch 617 to 643 ON ohms CANCEL 1509 to switch 1571 ON ohms TEXT IN ILLUSTRATION Cruise Control *1 Switch - (ON-OFF button) Component without harness ON*a connected *b OFF (Cruise Control Switch) *c +/RES *d /SET *e CANCEL - INSTALLATION INSTALLATION

1. INSTALL CRUISE CONTROL MAIN SWITCH a. Connect the connector. b. Install the cruise control switch with the 2 screws shown in the illustration.

Fig. 5: Installing Cruise Control Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) 2. INSTALL HORN BUTTON ASSEMBLY Refer to INSTALLATION

2012-2017 DRIVELINE/AXLES Differential (Service Information) (Hybrid)

FRONT AXLE HUB BOLT COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Axle Hub Bolt Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 3. REMOVE FRONT WHEEL 4. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY a. Remove the 2 bolts and separate the front disc brake caliper assembly. NOTE:

Use wire or an equivalent tool to keep the front disc brake caliper assembly from hanging down by the front flexible hose.

5. REMOVE FRONT DISC . Refer to REMOVAL - Step 15 6. REMOVE FRONT AXLE HUB BOLT a. Position the front axle hub bolt to be removed as shown in the illustration.

Fig. 2: Identifying Front Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install 2 nuts to the front axle hub bolts as shown in the illustration.

Fig. 3: Removing Front Axle Hub Stud With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) NOTE:

Install the nuts to prevent damage to the front axle hub bolts.

c. Using SST and a screwdriver or an equivalent tool to hold the front axle hub, remove the front axle hub bolt.  SST: 09628-10011 7. INSTALL FRONT AXLE HUB BOLT a. Position a new front axle hub bolt as shown in the illustration.

Fig. 4: Identifying Front Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the front axle hub bolt to the front axle hub. c. Install a washer and nut to the front axle hub bolt as shown in the illustration.

Fig. 5: Installing Front Axle Hub Stud

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Washer Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) HINT: Recommended washer thickness is 5 mm (0.197 in.) or more. d. Using a screwdriver or an equivalent tool to hold the front axle hub, install the front axle hub bolt by tightening the nut. NOTE:

 

Install the nuts to prevent damage to the front axle hub bolts. Do not damage the threads of the front axle hub bolts.

e. Remove the 3 nuts and washer from the 3 front axle hub bolts. 8. INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 9. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY a. Install the front disc brake caliper assembly to the steering knuckle with the 2 bolts. Torque: 107 N*m (1090 kgf*cm, 79 ft.*lbf) NOTE:

Do not twist the front flexible hose when installing the front disc brake caliper assembly.

10. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR .

FRONT AXLE HUB

COMPONENTS ILLUSTRATION

Fig. 6: Identifying Front Axle Hub Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Identifying Front Axle Hub Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION . 2. 3. 4. 5. 6.

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE FRONT WHEEL SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE FRONT DISC . Refer to REMOVAL - Step 15 INSPECT FRONT AXLE HUB BEARING LOOSENESS a. Using a dial indicator, check for looseness near the center of the front axle hub.

Fig. 8: Inspecting Front Axle Hub Bearing Looseness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum looseness 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the front speed sensor.

If the looseness exceeds the maximum, replace the front axle hub bearing. 7. INSPECT FRONT AXLE HUB RUNOUT

a. Using a dial indicator, check for runout on the surface of the front axle hub outside the hub bolts.

Fig. 9: Inspecting Front Axle Hub Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the front speed sensor.

If the runout exceeds the maximum, replace the front axle hub. 8. INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 9. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY See step 9 10. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2.

b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . REMOVAL REMOVAL

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION NOTE:

2. 3. 4. 5.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE FRONT WHEEL REMOVE FRONT AXLE SHAFT NUT . Refer to REMOVAL - Step 9 SEPARATE FRONT SPEED SENSOR a. Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.

Fig. 10: Locating Front Speed Sensor Clamp And Front Flexible Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to separate the front speed sensor from the front shock absorber completely.

b. Remove the bolt and front speed sensor from the steering knuckle.

Fig. 11: Locating Front Speed Sensor And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

  

6. 7. 8. 9.

Prevent foreign matter from contacting the sensor tip. Be careful not to damage the front speed sensor. Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.

SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE FRONT DISC . Refer to REMOVAL - Step 15 SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 SEPARATE FRONT DRIVE SHAFT ASSEMBLY a. Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.

Fig. 12: Locating Front Drive Shaft Assembly And Front Axle Hub Sub-Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark b. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer. 10. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

Fig. 13: Locating Front Lower Ball Joint Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT AXLE ASSEMBLY a. Remove the 2 bolts, 2 nuts and front axle assembly from the front shock absorber.

Fig. 14: Locating Front Shock Absorber Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

When removing the nuts, keep the bolts from rotating. Be careful not to damage the drive shaft boot or speed sensor rotor.

12. REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR a. Using a screwdriver with its tip wrapped with vinyl tape, remove the front No. 1 wheel bearing dust deflector.

Fig. 15: Removing Front No. 1 Wheel Bearing Dust Deflector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vinyl *1 Tape NOTE:

Be careful not to damage the steering knuckle.

13. REMOVE FRONT AXLE HUB HOLE SNAP RING a. Using snap ring pliers, remove the front axle hub hole snap ring.

Fig. 16: Removing Front Axle Hub Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE FRONT AXLE HUB SUB-ASSEMBLY a. Hold the front axle assembly between aluminium plates in a vise.

Fig. 17: Removing Front Axle Hub Sub-Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not overtighten the vise.

b. Using SST, remove the front axle hub sub-assembly.  SST: 09520-00031 c. Using SST and a press, remove the bearing inner race (outside) from the front axle hub subassembly.

Fig. 18: Identifying Bearing Inner Race (Outside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  



SST: 09555-55010 SST: 09950-60010 09951-00440 SST: 09950-70010 09951-07100

NOTE:

Be careful not to drop the front axle hub sub-assembly.

15. REMOVE FRONT DISC BRAKE DUST COVER a. Remove the 4 bolts and front disc brake dust cover from the steering knuckle.

Fig. 19: Locating Front Disc Brake Dust Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FRONT AXLE HUB BEARING a. Place the bearing inner race (outside) on the front axle hub bearing.

Fig. 20: Identifying Bearing Inner Race (Outside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate V*2 block b. Using SST, a steel plate, V-blocks and a press, remove the front axle hub bearing from the steering knuckle.  SST: 09950-60010 09951-00440 09952-06010  SST: 09950-60020



09951-00750 SST: 09950-70010 09951-07100

NOTE:

Keep the steering knuckle level.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT AXLE HUB BEARING a. Using SST and a press, install a new front axle hub bearing to the steering knuckle.

Fig. 21: Identifying Front Axle Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09950-60020 09951-00810  SST: 09950-70010 09951-07100 2. INSTALL FRONT DISC BRAKE DUST COVER a. Install the front disc brake dust cover to the steering knuckle with the 4 bolts. 

Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 3. INSTALL FRONT AXLE HUB SUB-ASSEMBLY a. Using SST and a press, install the front axle hub sub-assembly to the steering knuckle.

Fig. 22: Installing Front Axle Hub Sub-Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09608-32010  SST: 09950-60010 09951-00610  SST: 09950-70010 09951-07100 4. INSTALL FRONT AXLE HUB HOLE SNAP RING a. Using snap ring pliers, install a new front axle hub hole snap ring. 5. INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR a. Set a new front No. 1 wheel bearing dust deflector to the steering knuckle while aligning the cutout for the speed sensor in the front No. 1 wheel bearing dust deflector with the hole of the steering knuckle. 

b. Using SST and a hammer, install the front No. 1 wheel bearing dust deflector.

Fig. 23: Installing No. 1 Front Wheel Bearing Dust Deflector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09316-60011 09316-00011  SST: 09608-32010  SST: 09950-60010 09951-00500 09952-06010  SST: 09950-60020 09951-00810 c. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front 

drive shaft assembly contact surface of the front axle hub bearing.

Fig. 24: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. 6. INSTALL FRONT AXLE ASSEMBLY a. Install the front axle assembly to the front shock absorber with the 2 bolts and 2 nuts. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

When installing the nuts, keep the bolts from rotating.

7. INSTALL FRONT DRIVE SHAFT ASSEMBLY a. Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

Fig. 25: Locating Front Drive Shaft Assembly And Front Axle Hub Sub-Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the drive shaft boot or speed sensor rotor.

8. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts. Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 9. 10. 11. 12.

CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY See step 9 INSTALL FRONT AXLE SHAFT NUT a. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent. NOTE:





Be sure to perform this work even, when using a new front drive shaft assembly. Keep the threaded parts free of oil and foreign matter.

b. Using a socket wrench (30 mm), install the front axle shaft nut. Torque: 294 N*m (2998 kgf*cm, 217 ft.*lbf) NOTE:

Stake the nut after inspecting for looseness and runout in the following steps.

HINT: Keep depressing the brake pedal to prevent the front drive shaft from rotating. 13. 14. 15. 16. 17. 18. 19.

SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE FRONT DISC . Refer to REMOVAL - Step 15 INSPECT FRONT AXLE HUB BEARING LOOSENESS See step 6 INSPECT FRONT AXLE HUB RUNOUT See step 7 INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY See step 9 INSTALL FRONT SPEED SENSOR a. Install the front speed sensor and front flexible hose to the front shock absorber with the bolt and clamp. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

HINT: Install the speed sensor harness bracket first and then the front flexible hose. b. Install the front speed sensor to the steering knuckle with the bolt. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

20. STAKE FRONT AXLE SHAFT NUT a. Using a chisel and a hammer, stake the front axle shaft nut.

Fig. 26: Staking Front Axle Shaft Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 22. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 23. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT 24. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

STEERING KNUCKLE COMPONENTS ILLUSTRATION

Fig. 27: Identifying Steering Knuckle Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT AXLE ASSEMBLY Refer to REMOVAL 2. REMOVE FRONT LOWER BALL JOINT ASSEMBLY . Refer to REMOVAL - Step 2

3. 4. 5. 6. 7.

REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR See step 12 REMOVE FRONT AXLE HUB HOLE SNAP RING See step 13 REMOVE FRONT AXLE HUB SUB-ASSEMBLY See step 14 REMOVE FRONT DISC BRAKE DUST COVER See step 15 REMOVE STEERING KNUCKLE a. Place the bearing inner race (outside) on the front axle hub bearing.

Fig. 28: Identifying Bearing Inner Race (Outside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate *2 V-

block b. Using SST, a steel plate, V-blocks and a press, remove the front axle hub bearing from the steering knuckle.  SST: 09950-60010 09951-00440 09952-06010  SST: 09950-60020 09951-00750  SST: 09950-70010 09951-07100 NOTE:

Keep the steering knuckle level.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL STEERING KNUCKLE a. Using SST and a press, install a new front axle hub bearing to the steering knuckle.

Fig. 29: Identifying Front Axle Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09950-60020 09951-00810  SST: 09950-70010 09951-07100 INSTALL FRONT DISC BRAKE DUST COVER See step 2 INSTALL FRONT AXLE HUB SUB-ASSEMBLY See step 3 INSTALL FRONT AXLE HUB HOLE SNAP RING See step 4 INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR See step 5 INSTALL FRONT LOWER BALL JOINT ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT AXLE ASSEMBLY 

2. 3. 4. 5. 6. 7.

See step 6

REAR AXLE HUB BOLT COMPONENTS ILLUSTRATION

Fig. 30: Identifying Rear Axle Hub Bolt Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 3. REMOVE REAR WHEEL 4. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY a. Remove the bolt and separate the rear flexible hose from the rear shock absorber.

Fig. 31: Identifying Bolt On Flexible Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts, and separate the rear disc brake caliper assembly. NOTE:

Use wire or an equivalent tool to keep the rear disc brake caliper from hanging down by the flexible hose.

5. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 15 6. REMOVE REAR DISC . Refer to REMOVAL - Step 16 7. REMOVE REAR AXLE HUB BOLT a. Temporarily install 2 nuts to the rear axle hub bolts as shown in the illustration.

Fig. 32: Removing Rear Axle Hub Stud With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) NOTE:

Install the nuts to prevent damage to the rear axle hub bolts.

b. Using SST and a screwdriver or an equivalent tool to hold the rear axle hub and bearing assembly, remove the rear axle hub bolt.  SST: 09611-12010 NOTE:

Do not damage the threads of the rear axle hub bolts.

8. INSTALL REAR AXLE HUB BOLT a. Temporarily install a new rear axle hub bolt to the rear axle hub and bearing assembly.

Fig. 33: Installing Rear Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Washer b. Install a washer and nut to the rear axle hub bolt as shown in the illustration. Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) HINT: Recommended washer thickness is 5 mm (0.197 in.) or more. c. Using a screwdriver or an equivalent tool to hold the rear axle hub and bearing assembly, install the rear axle hub bolt by tightening the nut. NOTE:

 

Install the nuts to prevent damage to the rear axle hub bolts. Do not damage the threads of the rear axle hub bolts.

d. Remove the 3 nuts and washer from the 3 rear axle hub bolts.

9. INSTALL REAR DISC . Refer to INSTALLATION - Step 1 10. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 11. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY a. Install the rear disc brake caliper assembly with the 2 bolts. Torque: 78 N*m (799 kgf*cm, 58 ft.*lbf) b. Install the rear flexible hose to the rear shock absorber with the bolt. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) 12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 13. ADJUST PARKING BRAKE Refer to ADJUSTMENT 14. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR AXLE HUB COMPONENTS ILLUSTRATION

Fig. 34: Identifying Rear Speed Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION

NOTE:

2. 3. 4. 5. 6. 7.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 15 REMOVE REAR DISC . Refer to REMOVAL - Step 16 INSPECT REAR AXLE HUB BEARING LOOSENESS a. Using a dial indicator, check for looseness near the center of the rear axle hub.

Fig. 35: Inspecting Rear Axle Hub Bearing Looseness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum looseness 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the rear axle hub and bearing assembly.

If the looseness exceeds the maximum, replace the rear axle hub and bearing assembly. 8. INSPECT REAR AXLE HUB RUNOUT a. Using a dial indicator, check for runout on the surface of the rear axle hub outside the rear axle hub bolts.

Fig. 36: Inspecting Rear Axle Hub Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.07 mm (0.00276 in.) NOTE:







Ensure that the dial indicator is set perpendicular to the measurement surface. Make sure to install the tip of the dial indicator towards the outside of the rear axle hub bolt. Keep the magnet of the dial indicator away from the rear axle hub and bearing assembly.

If the runout exceeds the maximum, replace the rear axle hub and bearing assembly. 9. INSTALL REAR DISC . Refer to INSTALLATION - Step 1 10. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2

11. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY See step 11 12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 13. ADJUST PARKING BRAKE Refer to ADJUSTMENT 14. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) REMOVAL REMOVAL

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7. 8.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 15 REMOVE REAR DISC . Refer to REMOVAL - Step 16 DISCONNECT SKID CONTROL SENSOR WIRE . Refer to REMOVAL - Step 7 REMOVE REAR AXLE HUB AND BEARING ASSEMBLY a. Remove the 4 bolts and the rear axle hub and bearing assembly from the rear axle carrier sub-

assembly.

Fig. 37: Locating Rear Axle Hub And Bearing Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Use wire or an equivalent tool to keep the parking brake assembly from hanging down by the parking brake cable assembly.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY a. Install the rear axle hub and bearing assembly and parking brake assembly to the rear axle carrier sub-assembly with the 4 bolts. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 2. 3. 4. 5. 6.

INSPECT REAR AXLE HUB BEARING LOOSENESS See step 7 INSPECT REAR AXLE HUB RUNOUT See step 8 CONNECT SKID CONTROL SENSOR WIRE . Refer to INSTALLATION - Step 4 INSTALL REAR DISC . Refer to INSTALLATION - Step 1 INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 7. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY See step 11 8. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 9. ADJUST PARKING BRAKE Refer to ADJUSTMENT

10. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 11. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

REAR AXLE CARRIER COMPONENTS ILLUSTRATION

Fig. 38: Exploded View Of Rear Axle Carrier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no

malfunction, clear the DTC. HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7. 8. 9.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY See step 4 REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 15 REMOVE REAR DISC . Refer to REMOVAL - Step 16 DISCONNECT SKID CONTROL SENSOR WIRE . Refer to REMOVAL - Step 7 REMOVE REAR AXLE HUB AND BEARING ASSEMBLY See step 8 REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL HINT: It is necessary to remove the rear height control sensor sub-assembly when separating the rear No. 2 suspension arm assembly RH.

10. SEPARATE REAR STRUT ROD ASSEMBLY a. Use a jack and wooden block to support the rear axle carrier sub-assembly.

Fig. 39: Identifying Rear Axle Carrier Sub-Assembly Supported By Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block

b. Remove the bolt and nut, and separate the rear strut rod assembly (rear side) from the rear axle carrier sub-assembly. NOTE:

When removing the bolt, keep the nut from rotating.

11. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY . Refer to REMOVAL - Step 3 12. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Remove the bolt and nut, and separate the rear No. 1 suspension arm assembly (outer side) from the rear axle carrier sub-assembly.

Fig. 40: Locating Rear No. 1 Suspension Arm Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

13. REMOVE REAR AXLE CARRIER SUB-ASSEMBLY a. Remove the 2 bolts, 2 nuts and rear axle carrier sub-assembly from the rear shock absorber.

Fig. 41: Locating Rear Axle Carrier Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY a. Install the rear axle carrier sub-assembly to the rear shock absorber with the 2 bolts and 2 nuts. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

While keeping the bolts from rotating, tighten the nuts.

2. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Connect the rear No. 1 suspension arm assembly (outer side) to the rear axle carrier sub-assembly with the bolt and nut. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the front of the vehicle. 3. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY . Refer to INSTALLATION - Step 4 4. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY a. Temporarily tighten the rear strut rod assembly (rear side) to the rear axle carrier sub-assembly with the bolt and nut.

Fig. 42: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Since a stopper nut is used, turn the bolt.

HINT: Insert the bolt from the inside of the vehicle. 5. 6. 7. 8.

INSTALL REAR AXLE HUB AND BEARING ASSEMBLY See step 1 CONNECT SKID CONTROL SENSOR WIRE . Refer to INSTALLATION - Step 4 INSTALL REAR DISC . Refer to INSTALLATION - Step 1 INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 9. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY See step 11

10. STABILIZE SUSPENSION a. Jack up the rear axle carrier sub-assembly, placing a wooden block under it to avoid damage. Apply load to the suspension so that the installed bolt of the rear No. 1 suspension arm assembly (inner side) is horizontally aligned with the center of the rear axle hub.

Fig. 43: Identifying Rear Axle Carrier Sub-Assembly Supported By Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block WARNING: Do not jack up the rear axle carrier sub-assembly too high as the vehicle may fall. NOTE:





When jacking up the rear axle carrier sub-assembly, be sure to jack it up slowly. Make sure to perform this operation with the vehicle kept as low as possible.

11. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Fully tighten the bolt.

Fig. 44: Locating Rear No. 1 Suspension Arm Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

12. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Fully tighten the bolt.

Fig. 45: Locating Rear No. 2 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

13. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY a. Fully tighten the bolt.

Fig. 46: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

14. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION HINT: It is necessary to install the rear height control sensor sub-assembly when installing the rear No. 2 suspension arm assembly RH. 15. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step 2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 16. ADJUST PARKING BRAKE Refer to ADJUSTMENT 17. INSTALL REAR WHEEL

Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 18. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT 19. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION 20. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT 21. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

2012-2017 DRIVELINE/AXLES Differential (Service Information) (Except Hybrid) - Camry

FRONT AXLE HUB BOLT COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Axle Hub Bolt Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT WHEEL 2. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY a. Remove the 2 bolts and separate the front disc brake caliper assembly. NOTE:

Use wire or an equivalent tool to keep the front disc brake caliper assembly from hanging down by the front flexible hose.

3. REMOVE FRONT DISC . Refer to REMOVAL - Step 13 . 4. REMOVE FRONT AXLE HUB BOLT a. Position the front axle hub bolt to be removed as shown in the illustration.

Fig. 2: Identifying Front Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install 2 nuts to the front axle hub bolts as shown in the illustration.

Fig. 3: Removing Front Axle Hub Stud With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) NOTE:

Install the nuts to prevent damage to the front axle hub bolts.

c. Using SST and a screwdriver or an equivalent tool to hold the front axle hub, remove the front axle hub bolt.  SST: 09628-10011 5. INSTALL FRONT AXLE HUB BOLT a. Position a new front axle hub bolt as shown in the illustration.

Fig. 4: Identifying Front Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the front axle hub bolt to the front axle hub. c. Install a washer and nut to the front axle hub bolt as shown in the illustration.

Fig. 5: Installing Front Axle Hub Stud

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Washer Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) HINT: Recommended washer thickness is 5 mm (0.197 in.) or more. d. Using a screwdriver or an equivalent tool to hold the front axle hub, install the front axle hub bolt by tightening the nut. NOTE:

 

Install the nuts to prevent damage to the front axle hub bolts. Do not damage the threads of the front axle hub bolts.

e. Remove the 3 nuts and washer from the 3 front axle hub bolts. 6. INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 . 7. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY a. Install the front disc brake caliper assembly to the steering knuckle with the 2 bolts. Torque: 107 N*m (1090 kgf*cm, 79 ft.*lbf) NOTE:

Do not twist the front flexible hose when installing the front disc brake caliper assembly.

8. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

FRONT AXLE HUB COMPONENTS ILLUSTRATION

Fig. 6: Exploded View Of Front Axle Hub Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 7: Exploded View Of Front Axle Hub Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

HINT:  

1. 2. 3. 4.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE FRONT WHEEL SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE FRONT DISC . Refer to REMOVAL - Step 13 . INSPECT FRONT AXLE HUB BEARING LOOSENESS a. Using a dial indicator, check for looseness near the center of the front axle hub.

Fig. 8: Inspecting Front Axle Hub Bearing Looseness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum looseness 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the front speed sensor.

If the looseness exceeds the maximum, replace the front axle hub bearing. 5. INSPECT FRONT AXLE HUB RUNOUT a. Using a dial indicator, check for runout on the surface of the front axle hub outside the hub bolts.

Fig. 9: Inspecting Front Axle Hub Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the front speed sensor.

If the runout exceeds the maximum, replace the front axle hub. 6. INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 . 7. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY . See step 7. 8. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT WHEEL 2. REMOVE FRONT AXLE SHAFT NUT . Refer to REMOVAL - Step 9 . 3. SEPARATE FRONT SPEED SENSOR a. Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.

Fig. 10: Locating Front Speed Sensor Clamp And Front Flexible Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to separate the front speed sensor from the front shock absorber completely.

b. Remove the bolt and front speed sensor from the steering knuckle.

Fig. 11: Locating Front Speed Sensor And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

  

4. 5. 6. 7.

Prevent foreign matter from contacting the sensor tip. Be careful not to damage the front speed sensor. Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.

SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE FRONT DISC . Refer to REMOVAL - Step 13 . SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 . SEPARATE FRONT DRIVE SHAFT ASSEMBLY a. Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.

Fig. 12: Locating Front Drive Shaft Assembly And Front Axle Hub Sub-Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark b. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer. 8. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

Fig. 13: Locating Front Lower Ball Joint Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE FRONT AXLE ASSEMBLY a. Remove the 2 bolts, 2 nuts and front axle assembly from the front shock absorber.

Fig. 14: Locating Front Shock Absorber Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

When removing the nuts, keep the bolts from rotating. Be careful not to damage the drive shaft boot or speed sensor rotor.

10. REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR a. Using a screwdriver with its tip wrapped with vinyl tape, remove the front No. 1 wheel bearing dust deflector.

Fig. 15: Removing Front No. 1 Wheel Bearing Dust Deflector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vinyl *1 Tape NOTE:

Be careful not to damage the steering knuckle.

11. REMOVE FRONT AXLE HUB HOLE SNAP RING a. Using snap ring pliers, remove the front axle hub hole snap ring.

Fig. 16: Removing Front Axle Hub Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT AXLE HUB SUB-ASSEMBLY a. Hold the front axle assembly between aluminum plates in a vise.

Fig. 17: Removing Front Axle Hub Sub-Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not overtighten the vise.

b. Using SST, remove the front axle hub sub-assembly.  SST: 09520-00031 c. Using SST and a press, remove the bearing inner race (outside) from the front axle hub subassembly.

Fig. 18: Removing Front Axle Hub Sub-Assembly Bearing Inner Race Using SST & Press Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  



SST: 09555-55010 SST: 09950-60010 09951-00440 SST: 09950-70010 09951-07100

NOTE:

Be careful not to drop the front axle hub sub-assembly.

13. REMOVE FRONT DISC BRAKE DUST COVER a. Remove the 4 bolts and front disc brake dust cover from the steering knuckle.

Fig. 19: Locating Front Disc Brake Dust Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE FRONT AXLE HUB BEARING a. Place the bearing inner race (outside) on the front axle hub bearing.

Fig. 20: Removing Front Axle Hub Bearing Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate V*2 block b. Using SST, a steel plate, V-blocks and a press, remove the front axle hub bearing from the steering knuckle.  SST: 09950-60010 09951-00440 09952-06010  SST: 09950-60020



09951-00750 SST: 09950-70010 09951-07100

NOTE:

Keep the steering knuckle level.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT AXLE HUB BEARING a. Using SST and a press, install a new front axle hub bearing to the steering knuckle.

Fig. 21: Installing Front Axle Hub Bearing Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09950-60020 09951-00810  SST: 09950-70010 09951-07100 2. INSTALL FRONT DISC BRAKE DUST COVER a. Install the front disc brake dust cover to the steering knuckle with the 4 bolts. 

Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 3. INSTALL FRONT AXLE HUB SUB-ASSEMBLY a. Using SST and a press, install the front axle hub sub-assembly to the steering knuckle.

Fig. 22: Installing Front Axle Hub Sub-Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09608-32010  SST: 09950-60010 09951-00610  SST: 09950-70010 09951-07100 4. INSTALL FRONT AXLE HUB HOLE SNAP RING a. Using snap ring pliers, install a new front axle hub hole snap ring. 5. INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR a. Set a new front No. 1 wheel bearing dust deflector to the steering knuckle while aligning the cutout for the speed sensor in the front No. 1 wheel bearing dust deflector with the hole of the steering knuckle. 

b. Using SST and a hammer, install the front No. 1 wheel bearing dust deflector.

Fig. 23: Installing No. 1 Front Wheel Bearing Dust Deflector Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09316-60011 09316-00011  SST: 09608-32010  SST: 09950-60010 09951-00500 09952-06010  SST: 09950-60020 09951-00810 c. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front 

drive shaft assembly contact surface of the front axle hub bearing.

Fig. 24: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. 6. INSTALL FRONT AXLE ASSEMBLY a. Install the front axle assembly to the front shock absorber with the 2 bolts and 2 nuts. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

When installing the nuts, keep the bolts from rotating.

7. INSTALL FRONT DRIVE SHAFT ASSEMBLY a. Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

Fig. 25: Locating Front Drive Shaft Assembly And Front Axle Hub Sub-Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the drive shaft boot or speed sensor rotor.

8. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

Fig. 26: Identifying Front Lower Ball Joint Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type

*A A Nut Type *B B Nut 20 mm *a (0.787 in.) 22 mm *b (0.866 in.) Bolt Nut Type A Nut and Bolt Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) Type B Nut and Bolt Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf) NOTE:





9. 10. 11. 12.

The tightening torque for the bolt differs depending on the type of nut. Make sure to tighten the bolt to the same torque as the nuts.

CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 . INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 . INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY . See step 7. INSTALL FRONT AXLE SHAFT NUT a. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent. NOTE:





Be sure to perform this work even, when using a new front drive shaft assembly. Keep the threaded parts free of oil and foreign matter.

b. Using a socket wrench (30 mm), install the front axle hub shaft nut. Torque: 294 N*m (2998 kgf*cm, 217 ft.*lbf) NOTE:

Stake the nut after inspecting for looseness and runout in the following steps.

HINT: Keep depressing the brake pedal to prevent the front drive shaft from rotating. 13. 14. 15. 16. 17. 18. 19.

SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE FRONT DISC . Refer to REMOVAL - Step 13 . INSPECT FRONT AXLE HUB BEARING LOOSENESS . See step 4. INSPECT FRONT AXLE HUB RUNOUT . See step 5. INSTALL FRONT DISC . Refer to INSTALLATION - Step 1 . INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY . See step 7. INSTALL FRONT SPEED SENSOR a. Install the front speed sensor and front flexible hose to the front shock absorber with the bolt and clamp. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

HINT: Install the speed sensor harness bracket first and then the front flexible hose. b. Install the front speed sensor to the steering knuckle with the bolt. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

20. STAKE FRONT AXLE SHAFT NUT a. Using a chisel and a hammer, stake the front axle shaft nut.

Fig. 27: Staking Front Axle Shaft Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT . 23. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE .

STEERING KNUCKLE COMPONENTS ILLUSTRATION

Fig. 28: Exploded View Of Steering Knuckle Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT AXLE ASSEMBLY Refer to REMOVAL. 2. 3. 4. 5.

REMOVE FRONT LOWER BALL JOINT ASSEMBLY . Refer to REMOVAL - Step 2 . REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR . See step 10. REMOVE FRONT AXLE HUB HOLE SNAP RING . See step 11. REMOVE FRONT AXLE HUB SUB-ASSEMBLY . See step 12.

6. REMOVE FRONT DISC BRAKE DUST COVER . See step 13. 7. REMOVE STEERING KNUCKLE a. Place the bearing inner race (outside) on the front axle hub bearing.

Fig. 29: Removing Front Axle Hub Bearing Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate V*2 block b. Using SST, a steel plate, V-blocks and a press, remove the front axle hub bearing from the steering knuckle.







SST: 09950-60010 09951-00440 09952-06010 SST: 09950-60020 09951-00750 SST: 09950-70010 09951-07100

NOTE:

Keep the steering knuckle level.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL STEERING KNUCKLE a. Using SST and a press, install a new front axle hub bearing to the steering knuckle.

Fig. 30: Installing Front Axle Hub Bearing Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09950-60020 09951-00810  SST: 09950-70010 09951-07100 INSTALL FRONT DISC BRAKE DUST COVER . See step 2. INSTALL FRONT AXLE HUB SUB-ASSEMBLY . See step 3. INSTALL FRONT AXLE HUB HOLE SNAP RING . See step 4. INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR . See step 5. INSTALL FRONT LOWER BALL JOINT ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL FRONT AXLE ASSEMBLY 

2. 3. 4. 5. 6. 7.

See step 6.

REAR AXLE HUB BOLT COMPONENTS ILLUSTRATION

Fig. 31: Identifying Rear Axle Hub Bolt Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY a. Remove the bolt and separate the rear flexible hose from the rear shock absorber.

Fig. 32: Identifying Bolt On Flexible Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts, and separate the rear disc brake caliper assembly. NOTE:

Use wire or an equivalent tool to keep the rear disc brake caliper from hanging down by the flexible hose.

3. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 13 . 4. REMOVE REAR DISC . Refer to REMOVAL - Step 14 . 5. REMOVE REAR AXLE HUB BOLT a. Temporarily install 2 nuts to the rear axle hub bolts as shown in the illustration.

Fig. 33: Removing Rear Axle Hub Stud With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) NOTE:

Install the nuts to prevent damage to the rear axle hub bolts.

b. Using SST and a screwdriver or an equivalent tool to hold the rear axle hub and bearing assembly, remove the rear axle hub bolt.  SST: 09611-12010 NOTE:

Do not damage the threads of the rear axle hub bolts.

6. INSTALL REAR AXLE HUB BOLT a. Temporarily install a new rear axle hub bolt to the rear axle hub and bearing assembly.

Fig. 34: Installing Rear Axle Hub Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Washer b. Install a washer and nut to the rear axle hub bolt as shown in the illustration. Recommended service nut Thread diameter: 12.0 mm (0.472 in.) Thread pitch: 1.5 mm (0.0591 in.) HINT: Recommended washer thickness is 5 mm (0.197 in.) or more. c. Using a screwdriver or an equivalent tool to hold the rear axle hub and bearing assembly, install the rear axle hub bolt by tightening the nut. NOTE:

 

Install the nuts to prevent damage to the rear axle hub bolts. Do not damage the threads of the rear axle hub bolts.

d. Remove the 3 nuts and washer from the 3 rear axle hub bolts.

7. INSTALL REAR DISC . Refer to INSTALLATION - Step 1 . 8. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 . 9. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY a. Install the rear disc brake caliper assembly with the 2 bolts. Torque: 78 N*m (799 kgf*cm, 58 ft.*lbf) b. Install the rear flexible hose to the rear shock absorber with the bolt. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) 10. ADJUST PARKING BRAKE Refer to ADJUSTMENT . 11. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR AXLE HUB COMPONENTS ILLUSTRATION

Fig. 35: Identifying Rear Axle Hub Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

HINT:  

1. 2. 3. 4.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 13 . REMOVE REAR DISC . Refer to REMOVAL - Step 14 .

5. INSPECT REAR AXLE HUB BEARING LOOSENESS a. Using a dial indicator, check for looseness near the center of the rear axle hub.

Fig. 36: Inspecting Rear Axle Hub Bearing Looseness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum looseness 0.05 mm (0.00197 in.) NOTE:





Ensure that the dial indicator is set perpendicular to the measurement surface. Keep the magnet of the dial indicator away from the rear axle hub and bearing assembly.

If the looseness exceeds the maximum, replace the rear axle hub and bearing assembly. 6. INSPECT REAR AXLE HUB RUNOUT a. Using a dial indicator, check for runout on the surface of the rear axle hub outside the rear axle hub bolts.

Fig. 37: Inspecting Rear Axle Hub Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.07 mm (0.00276 in.) NOTE:







Ensure that the dial indicator is set perpendicular to the measurement surface. Make sure to install the tip of the dial indicator towards the outside of the rear axle hub bolt. Keep the magnet of the dial indicator away from the rear axle hub and bearing.

If the runout exceeds the maximum, replace the rear axle hub and bearing assembly. 7. INSTALL REAR DISC . Refer to INSTALLATION - Step 1 . 8. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 . 9. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY . See step 9. 10. ADJUST PARKING BRAKE Refer to ADJUSTMENT . 11. INSTALL REAR WHEEL

Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) REMOVAL REMOVAL

HINT:  

1. 2. 3. 4. 5. 6.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 13 . REMOVE REAR DISC . Refer to REMOVAL - Step 14 . DISCONNECT SKID CONTROL SENSOR WIRE . Refer to REMOVAL - Step 7 . REMOVE REAR AXLE HUB AND BEARING ASSEMBLY a. Remove the 4 bolts and the rear axle hub and bearing assembly from the rear axle carrier subassembly.

Fig. 38: Locating Rear Axle Hub And Bearing Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Use wire or an equivalent tool to keep the parking brake assembly from hanging down by the parking brake cable assembly.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY

a. Install the rear axle hub and bearing assembly and parking brake assembly to the rear axle carrier sub-assembly with the 4 bolts. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 2. 3. 4. 5. 6.

INSPECT REAR AXLE HUB BEARING LOOSENESS . See step 5. INSPECT REAR AXLE HUB RUNOUT . See step 6. CONNECT SKID CONTROL SENSOR WIRE . Refer to INSTALLATION - Step 4 . INSTALL REAR DISC . Refer to INSTALLATION - Step 1 . INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 . 7. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY . See step 9. 8. ADJUST PARKING BRAKE Refer to ADJUSTMENT . 9. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

10. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE .

REAR AXLE CARRIER COMPONENTS ILLUSTRATION

Fig. 39: Exploded View Of Rear Axle Carrier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

1. 2. 3. 4. 5. 6. 7.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY . See step 2. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to REMOVAL - Step 13 . REMOVE REAR DISC . Refer to REMOVAL - Step 14 . DISCONNECT SKID CONTROL SENSOR WIRE . Refer to REMOVAL - Step 7 . REMOVE REAR AXLE HUB AND BEARING ASSEMBLY . See step 6. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL . HINT: It is necessary to remove the rear height control sensor sub-assembly when separating the rear No. 2 suspension arm assembly RH.

8. SEPARATE REAR STRUT ROD ASSEMBLY a. Use a jack and wooden block to support the rear axle carrier sub-assembly.

Fig. 40: Identifying Rear Axle Carrier Sub-Assembly Supported By Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block

b. Remove the bolt and nut, and separate the rear strut rod assembly (rear side) from the rear axle carrier sub-assembly. NOTE:

When removing the bolt, keep the nut from rotating.

9. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY . Refer to REMOVAL - Step 3 . 10. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Remove the bolt and nut, and separate the rear No. 1 suspension arm assembly (outer side) from the rear axle carrier sub-assembly.

Fig. 41: Locating Rear No. 1 Suspension Arm Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

11. REMOVE REAR AXLE CARRIER SUB-ASSEMBLY a. Remove the 2 bolts, 2 nuts and rear axle carrier sub-assembly from the rear shock absorber.

Fig. 42: Locating Rear Axle Carrier Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY a. Install the rear axle carrier sub-assembly to the rear shock absorber with the 2 bolts and 2 nuts. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

While keeping the bolts from rotating, tighten the nuts.

2. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Connect the rear No. 1 suspension arm assembly (outer side) to the rear axle carrier sub-assembly with the bolt and nut. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the front of the vehicle. 3. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY . Refer to INSTALLATION - Step 4 . 4. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY a. Temporarily tighten the rear strut rod assembly (rear side) to the rear axle carrier sub-assembly with the bolt and nut.

Fig. 43: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Since a stopper nut is used, turn the bolt.

HINT: Insert the bolt from the inside of the vehicle. 5. 6. 7. 8.

INSTALL REAR AXLE HUB AND BEARING ASSEMBLY . See step 1. CONNECT SKID CONTROL SENSOR WIRE . Refer to INSTALLATION - Step 4 . INSTALL REAR DISC . Refer to INSTALLATION - Step 1 . INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG . Refer to INSTALLATION Step 2 . 9. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY . See step 9.

10. STABILIZE SUSPENSION a. Jack up the rear axle carrier sub-assembly, placing a wooden block under it to avoid damage. Apply load to the suspension so that the installed bolt of the rear No. 1 suspension arm assembly (inner side) is horizontally aligned with the center of the rear axle hub.

Fig. 44: Identifying Rear Axle Carrier Sub-Assembly Supported By Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block WARNING: Do not jack up the rear axle carrier sub-assembly too high as the vehicle may fall. NOTE:





When jacking up the rear axle carrier sub-assembly, be sure to jack it up slowly. Make sure to perform this operation with the vehicle kept as low as possible.

11. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Fully tighten the bolt.

Fig. 45: Locating Rear No. 1 Suspension Arm Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

12. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Fully tighten the bolt.

Fig. 46: Locating Rear No. 2 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

13. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY a. Fully tighten the bolt

Fig. 47: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

14. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION . HINT: It is necessary to install the rear height control sensor sub-assembly when installing the rear No. 2 suspension arm assembly RH. 15. ADJUST PARKING BRAKE Refer to ADJUSTMENT . 16. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 17. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT .

18. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION . 19. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT . 20. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE .

2012-2017 ACCESSORIES & EQUIPMENT Door Control Transmitter (W/O Smart Key System) (Service Information) - Camry (Except Hybrid)

DOOR CONTROL TRANSMITTER (W/O SMART KEY SYSTEM) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Door Control Transmitter Replacement Components (W/O Smart Key System) (For Type A)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Door Control Transmitter Replacement Components (W/O Smart Key System) (For Type B) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TRANSMITTER HOUSING COVER (for Type A) . Refer to REPLACEMENT - Step 1

2. REMOVE DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY (for Type A) . Refer to REPLACEMENT - Step 2 3. REMOVE TRANSMITTER HOUSING COVER (for Type B) . Refer to REPLACEMENT - Step 4 4. REMOVE DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY (for Type B) . Refer to REPLACEMENT - Step 5 INSPECTION INSPECTION

1. INSPECT DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY a. Inspect operation of the door control transmitter module set sub-assembly (for Type A). 1. Remove the transmitter battery from the door control transmitter module set sub-assembly. Refer to REPLACEMENT . 2. Install a new or non-depleted transmitter battery. Refer to REPLACEMENT . NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 3: Inspecting Door Control Transmitter Module Set Sub-Assembly (For Type A) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When a new or non-depleted battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the door control transmitter module set sub-assembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft) from the driver door outside door handle, test the door control transmitter module set sub-assembly by pointing its key plate at the vehicle and pressing a door control transmitter module set sub-assembly switch.

OK The door lock can be operated via the door control transmitter module set sub-assembly. The operational area differs depending on the user, the way the door control transmitter module set sub-assembly is held and the location.  The door control transmitter module set sub-assembly weak radio waves may be affected if the area has strong radio waves or electrical noise. The door control transmitter module set sub-assembly operation area may be shortened or the door control transmitter module set sub-assembly may not function. b. Inspect the battery capacity. 1. Remove the battery from the door control transmitter module set sub-assembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. Refer to REMOVAL. 

NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the battery will not be able to be installed correctly.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 4: Identifying Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Check the transmitter battery voltage.

Fig. 5: Checking Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Measure the transmitter battery voltage while pressing the lock or unlock switch on the door control transmitter module set sub-assembly. Standard voltage Tester Specified Condition Connection Condition Ignition switch off, Battery all doors positive (+) closed and 2.5 to 3.2 - Battery lock or V negative (-) unlock switch is pressed If the result is not as specified, replace the transmitter battery. c. Inspect operation of the door control transmitter module set sub-assembly (for Type B). 1. Remove the transmitter battery from the door control transmitter module set sub-assembly. Refer to REPLACEMENT . 2. Install a new or non-depleted transmitter battery. Refer to REPLACEMENT .

NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 6: Inspecting Door Control Transmitter Module Set Sub-Assembly (For Type B) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When a new or non-depleted battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the door control transmitter module set sub-assembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft) from the driver door outside door handle, test the door control transmitter module set sub-assembly by pointing its key plate at the vehicle and pressing a door control transmitter module set sub-assembly switch. OK The door lock can be operated via the door control transmitter module set sub-assembly. The LED comes on more than once. 



The operational area differs depending on the user, the way the door control transmitter module set sub-assembly is held and the location. The door control transmitter module set sub-assembly weak radio waves may be

affected if the area has strong radio waves or electrical noise. The door control transmitter module set sub-assembly operation area may be shortened or the door control transmitter module set sub-assembly may not function. d. Inspect the battery capacity. 1. Remove the battery from the door control transmitter module set sub-assembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. Refer to REMOVAL. NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the battery will not be able to be installed correctly.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 7: Identifying Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Check the transmitter battery voltage.

Fig. 8: Checking Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Measure the transmitter battery voltage while pressing the lock or unlock switch on the door control transmitter module set sub-assembly. Standard voltage Tester Specified Condition Connection Condition Ignition switch off, Battery all doors positive (+) closed and 2.2 to 3.2

- Battery negative (-)

lock or unlock switch is pressed

V

If the result is not as specified, replace the transmitter battery. INSTALLATION INSTALLATION

1. INSTALL DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY (for Type A) . Refer to REPLACEMENT - Step 8 2. INSTALL TRANSMITTER HOUSING COVER (for Type A) . Refer to REPLACEMENT - Step 9 3. INSTALL DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY (for Type B) . Refer to REPLACEMENT - Step 11 4. INSTALL TRANSMITTER HOUSING COVER (for Type B) . Refer to REPLACEMENT - Step 12

2012-2017 ACCESSORIES & EQUIPMENT Door Control Transmitter (W/ Smart Key System) (Service Information) - Camry (Except Hybrid)

DOOR CONTROL TRANSMITTER (W/ SMART KEY SYSTEM) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Door Control Transmitter Replacement Components (Type A) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Door Control Transmitter Replacement Components (Type B) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TRANSMITTER BATTERY . Refer to REPLACEMENT - Step 1 INSPECTION INSPECTION

1. INSPECT ELECTRICAL KEY TRANSMITTER SUB-ASSEMBLY a. Inspect the operation of the electrical key transmitter sub-assembly (for Type A). 1. Remove the transmitter battery from the electrical key transmitter sub-assembly. Refer to REPLACEMENT . 2. Install a new or known good transmitter battery. Refer to REPLACEMENT . NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 3: Inspecting Electrical Key Transmitter Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If a new or known good battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the electrical key transmitter subassembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft.) away from the driver door outside door handle, test the electrical key transmitter sub-assembly by pointing its key plate at the vehicle and pressing a electrical key transmitter sub-assembly switch. OK The door lock can be operated via the electrical key transmitter sub-assembly. The LED comes on more than once. 



The operation area differs depending on the user, the way the electrical key transmitter sub-assembly is held, and the location. The electrical key transmitter sub-assembly weak radio waves may be affected if the area has strong radio waves or noise. The electrical key transmitter sub-assembly

operation area may be shortened or the electrical key transmitter sub-assembly may not function. b. Inspect the battery capacity (for Type A). 1. Remove the battery. Refer to REPLACEMENT from the electrical key transmitter subassembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the battery will not be able to be installed correctly.

Fig. 4: Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. 3. Check the transmitter battery voltage.

Fig. 5: Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When measuring the battery voltage, while operating the lock sensor of a door handle, bring the electrical key transmitter sub-assembly within the entry operating range to perform the measurement. For the entry operating range, refer to System Description. Refer to SYSTEM DESCRIPTION . Standard Voltage Tester Specified Condition Connection Condition Engine switch off, Battery all doors positive (+) 2.2 to 3.2 closed and V - Battery lock negative (-) sensor touched If the result is not as specified, replace the transmitter battery. c. Inspect operation of the electrical key transmitter sub-assembly (for Type B). 1. Remove the transmitter battery from the electrical key transmitter sub-assembly. Refer to REPLACEMENT . 2. Install a new or normal transmitter battery. Refer to REPLACEMENT .

NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 6: Applying Voltage To Electrical Key Transmitter Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If a new or normal battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the electrical key transmitter sub-assembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft.) away from the driver door outside door handle, test the electrical key transmitter sub-assembly by pointing its key plate at the vehicle and pressing a electrical key transmitter sub-assembly switch. OK The door lock can be operated via the electrical key transmitter sub-assembly. The LED comes on more than once. The operation area differs depending on the user, the way the electrical key transmitter sub-assembly is held, and the location.  The electrical key transmitter sub-assembly weak radio waves may be affected if the area has strong radio waves or noise. The electrical key transmitter sub-assembly operation area may be shortened or the electrical key transmitter sub-assembly may not function. d. Inspect the battery capacity (for Type B). 1. Remove the battery. Refer to REPLACEMENT from the electrical key transmitter subassembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. 

NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the battery will not be able to be installed correctly.

Fig. 7: Identifying Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. 3. Check the transmitter battery voltage.

Fig. 8: Checking Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When measuring the battery voltage, while operating the lock switch of a door handle, bring the electrical key transmitter sub-assembly within the entry operating range to perform the measurement. For the entry operating range, refer to System Description. Refer to SYSTEM DESCRIPTION . Standard Voltage Tester Specified Condition Connection Condition Engine switch off, Battery all doors positive (+) 2.2 to 3.2 closed and V - Battery lock negative (-) sensor touched If the result is not as specified, replace the transmitter battery. INSTALLATION INSTALLATION

1. INSTALL TRANSMITTER BATTERY . Refer to REPLACEMENT - Step 2

2012-2017 ACCESSORIES & EQUIPMENT Door Lock System (Service Information) (Hybrid)

TRANSMITTER BATTERY REPLACEMENT REPLACEMENT

1. REMOVE TRANSMITTER BATTERY NOTE:

Take extra care when handling these precision electronic components.

a. for Type A: 1. Push the release hook knob and extract the mechanical key.

Fig. 1: Release Hook Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Insert a precision screwdriver into the gap, and turn the screwdriver to detach the transmitter housing cover.

Fig. 2: Screwdriver & Transmitter Housing Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. 3. Insert a precision screwdriver into the gap and gently remove the transmitter battery (lithium battery: CR2032).

Fig. 3: Precision Screwdriver Transmitter Battery (Lithium Battery: CR2032) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

 







Do not push the terminals with your finger. Do not forcibly pry up the transmitter battery. The terminals may be damaged. Do not touch the transmitter battery with wet hands. Water may cause rust. Do not touch or move any components inside the transmitter. It may interfere with proper operation. When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical transmitter from being damaged.

HINT: Tape the screwdriver tip before use. b. for Type B: 1. Push the release hook knob and extract the mechanical key.

Fig. 4: Release Hook Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Insert a precision screwdriver into the gap, and turn the screwdriver to detach the transmitter housing cover.

Fig. 5: Screwdriver & Transmitter Housing Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT:

Tape the screwdriver tip before use. 3. Disengage the 2 claws and remove the cover.

Fig. 6: Removing The Battery Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Insert a precision screwdriver into the gap and gently remove the transmitter battery (lithium battery: CR2032).

Fig. 7: Removing Transmitter Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Protective

Tape NOTE:

 







Do not push the terminals with your finger. Do not forcibly pry up the transmitter battery. The terminals may be damaged. Do not touch the transmitter battery with wet hands. Water may cause rust. Do not touch or move any components inside the transmitter. It may interfere with proper operation. When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical transmitter from being damaged.

HINT: Tape the screwdriver tip before use. 2. INSTALL TRANSMITTER BATTERY a. for Type A: 1. Install a new transmitter battery (lithium battery: CR2032) with the positive (+) side facing upward, as shown in the illustration.

Fig. 8: Transmitter Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



 

Do not bend the transmitter battery electrode during insertion. Keep the transmitter cover interior free of dust and oil. When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the

electrical transmitter from being damaged. 2. Install the transmitter housing cover by pressing down on it as shown in the illustration.

Fig. 9: Transmitter Housing Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Insert the mechanical key into the transmitter.

Fig. 10: Mechanical Key Into The Transmitter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Press one of the transmitter switches and check that the LED illuminates. OK Transmitter LED illuminates when switch is pressed. b. for Type B: 1. Install a new transmitter battery (lithium battery: CR2032) with the positive (+) side facing upward, as shown in the illustration.

Fig. 11: Installing Transmitter Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



 

Do not bend the transmitter battery electrode during insertion. Keep the transmitter cover interior free of dust and oil. When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical transmitter from being damaged.

2. Engage the 2 claws and install the cover.

Fig. 12: Installing The Battery Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install the transmitter housing cover by pressing down on it as shown in the illustration.

Fig. 13: Transmitter Housing Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Insert the mechanical key into the transmitter.

Fig. 14: Mechanical Key Into The Transmitter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Press one of the transmitter switches and check that the LED illuminates. OK Transmitter LED illuminates when switch is pressed.

DOOR CONTROL TRANSMITTER COMPONENTS ILLUSTRATION

Fig. 15: Identifying Door Control Transmitter Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Identifying Door Control Transmitter Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TRANSMITTER BATTERY See step 1 INSPECTION INSPECTION

1. INSPECT ELECTRICAL KEY TRANSMITTER SUB-ASSEMBLY a. Inspect the operation of the electrical key transmitter sub-assembly (for Type A). 1. Remove the transmitter battery from the electrical key transmitter sub-assembly. Refer to REPLACEMENT. 2. Install a new or known good transmitter battery. Refer to REPLACEMENT. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 17: 2 New 1.5 V Batteries & Electrical Key Transmitter Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If a new or known good transmitter battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the electrical key transmitter sub-assembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft.) away from the driver door outside door handle, test the electrical key transmitter sub-assembly by pointing its key plate at the vehicle and pressing a electrical key transmitter sub-assembly switch. OK The door lock can be operated via the electrical key transmitter sub-assembly. The LED comes on more than once. 



The operation area differs depending on the user, the way the electrical key transmitter sub-assembly is held, and the location. The electrical key transmitter sub-assembly weak radio waves may be affected if the area has strong radio waves or noise. The electrical key transmitter sub-assembly

operation area may be shortened or the electrical key transmitter sub-assembly may not function. b. Inspect the transmitter battery capacity (for Type A). 1. Remove the transmitter battery. Refer to REPLACEMENT from the electrical key transmitter sub-assembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the transmitter battery will not be able to be installed correctly.

Fig. 18: Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. 3. Check the transmitter battery voltage.

Fig. 19: Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When measuring the transmitter battery voltage, while operating the lock sensor of a door handle, bring the electrical key transmitter sub-assembly within the entry operating range to perform the measurement. For the entry operating range, refer to System Description. Refer to SYSTEM DESCRIPTION . Standard Voltage Tester Specified Condition Connection Condition Power switch off, Battery all doors positive (+) 2.2 to 3.2 closed and V - Battery lock negative (-) sensor touched If the result is not as specified, replace the transmitter battery. c. Inspect operation of the electrical key transmitter sub-assembly (for Type B). 1. Remove the transmitter battery from the electrical key transmitter sub-assembly. Refer to REPLACEMENT. 2. Install a new or normal transmitter battery. Refer to REPLACEMENT.

NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

Fig. 20: Applying Voltage To Electrical Key Transmitter Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If a new or normal transmitter battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the electrical key transmitter subassembly, as shown in the illustration. 3. From outside the vehicle, approximately 1 m (3.28 ft.) away from the driver door outside door handle, test the electrical key transmitter sub-assembly by pointing its key plate at the vehicle and pressing a electrical key transmitter sub-assembly switch. OK The door lock can be operated via the electrical key transmitter sub-assembly. The LED comes on more than once. The operation area differs depending on the user, the way the electrical key transmitter sub-assembly is held, and the location.  The electrical key transmitter sub-assembly weak radio waves may be affected if the area has strong radio waves or noise. The electrical key transmitter sub-assembly operation area may be shortened or the electrical key transmitter sub-assembly may not function. d. Inspect the transmitter battery capacity (for Type B). 1. Remove the transmitter battery. Refer to REPLACEMENT from the electrical key transmitter sub-assembly that does not operate. Attach a lead wire (0.6 mm (0.0236 in.) in diameter or less including wire sheath) with tape or equivalent to the negative terminal. 

NOTE:

Do not wrap the lead wire around a terminal, wedge it between the terminals, or solder it. A terminal may be deformed or damaged, and the transmitter battery will not be able to be installed correctly.

Fig. 21: Identifying Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When replacing the transmitter battery, before starting work, remove static electricity that has built up in the body by touching, for example, the vehicle to prevent the electrical key transmitter from being damaged.

2. Carefully pull the lead wire out from the position shown in the illustration and install the previously removed transmitter battery. 3. Check the transmitter battery voltage.

Fig. 22: Checking Transmitter Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When measuring the transmitter battery voltage, while operating the lock switch of a door handle, bring the electrical key transmitter sub-assembly within the entry operating range to perform the measurement. For the entry operating range, refer to System Description. Refer to SYSTEM DESCRIPTION . Standard Voltage Tester Specified Condition Connection Condition Power switch off, Battery all doors positive (+) 2.2 to 3.2 closed and V - Battery lock negative (-) sensor touched If the result is not as specified, replace the transmitter battery. INSTALLATION INSTALLATION

1. INSTALL TRANSMITTER BATTERY See step 2

DOOR CONTROL SWITCH COMPONENTS ILLUSTRATION

Fig. 23: Identifying Door Control Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 6 2. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 7 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) . Refer to REMOVAL - Step 2 4. REMOVE DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) a. Disengage the 2 claws and remove the door control switch assembly.

Fig. 24: Identifying Door Control Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 25: Identifying Power Window Regulator Master Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition Lock Below 1 2 (L) - 1 (E) switch ohms pushed 10 kohms 2 (L) - 1 (E) off or higher Unlock 9 (UL) - 1 Below 1 switch (E) ohms pushed 9 (UL) - 1 10 kohms off (E) or higher TEXT IN ILLUSTRATION Component without harness connected (Power *a Window Regulator Master Switch Assembly) If the result is not as specified, replace the power window regulator master switch assembly. 2. INSPECT DOOR CONTROL SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 26: Identifying Door Control Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Below 1 4 (L) - 3 (E) Locked ohms 10 kohms 4 (L) - 3 (E) off or higher 2 (UL) - 3 Below 1 Unlocked (E) ohms 2 (UL) - 3 10 kohms off (E) or higher TEXT IN ILLUSTRATION Component without harness connected *a (Door Control Switch Assembly) *b Unlock

*c Lock If the result is not as specified, replace the door control switch assembly. INSTALLATION INSTALLATION

1. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) a. Engage the 2 claws to install the door control switch assembly. 2. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 3. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 43 4. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 42

FRONT DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 27: Identifying Front Door Lock Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 28: Identifying Front Door Lock Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 29: Identifying Front Door Lock Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 5 6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 6 7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 7 8. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 8 9. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 10 11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 12 12. REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 11 13. REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 16 14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 17 15. REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 21 16. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 23 17. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY

(w/ Lock Cylinder) . Refer to DISASSEMBLY - Step 24 18. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 30: Identifying Front Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod b. Slide the front door lock with motor assembly downward, and remove the front door lock with

motor assembly and cables as a unit. c. When reusing the front door lock with motor assembly. 1. Remove the door lock wiring harness seal from the front door lock with motor assembly.

Fig. 31: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to DISASSEMBLY - Step 31 20. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to DISASSEMBLY Step 32 INSPECTION INSPECTION

1. INSPECT FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH a. Check the operation of the door lock motor.

Fig. 32: Inspecting Front Door Lock Assembly LH With Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply auxiliary battery voltage and check the operation of the door lock motor.

OK Connection Result Auxiliary battery positive (+) --> Terminal 4 (L) Locks Auxiliary battery negative (-) --> Terminal 1 (UL) Auxiliary battery positive (+) --> Terminal 1 (UL) Unlocks Auxiliary battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. b. Check the operation of the door unlock detection switch.

Fig. 33: Checking The Operation Of The Door Unlock Detection Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 7 (E) - 8 10 kohms Locked (LSSR) or higher 7 (E) - 8 Below 1 Unlocked (LSSR) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. c. Check the operation of the door key lock and unlock switch.

Fig. 34: Checking The Operation Of The Door Key Lock And Unlock Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition Held to Below 1 9 (L) - 7 (E) lock side ohms Neutral or held to 10 kohms 9 (L) - 7 (E) unlock or higher side Held to 10 (UL) - 7 Below 1 unlock (E) ohms side Neutral or 10 (UL) - 7 10 kohms held to (E) or higher lock side TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. 2. INSPECT FRONT DOOR LOCK WITH MOTOR ASSEMBLY RH a. Check the operation of the door lock motor.

Fig. 35: Inspecting Front Door Lock Assembly RH With Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply auxiliary battery voltage and check the operation of the door lock motor.

OK Connection Result Auxiliary battery positive (+) --> Terminal 4 (L) Locks Auxiliary battery negative (-) --> Terminal 1 (UL) Auxiliary battery positive (+) --> Terminal 1 (UL) Unlocks Auxiliary battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly RH. b. Check the operation of the door unlock detection switch.

Fig. 36: Checking The Operation Of The Door Unlock Detection Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 7 (LSSR) 10 kohms Locked 8 (E) or higher 7 (LSSR) Below 1 Unlocked 8 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to REASSEMBLY Step 17 2. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to REASSEMBLY - Step 18 3. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY NOTE:





When reusing the removed front door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.



Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock with motor assembly.

a. Apply MP grease to the sliding parts of the front door lock with motor assembly. b. When reusing the front door lock with motor assembly. 1. Install a new door lock wiring harness seal to the front door lock with motor assembly. c. Insert the front door lock open rod to the front door lock with motor assembly.

Fig. 37: Identifying Front Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door

Lock *1 Open Rod d. Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 4. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (w/ Lock Cylinder) . Refer to REASSEMBLY - Step 25 5. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY . Refer to REASSEMBLY Step 26 6. INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 28 7. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 32 8. INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 33 9. INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 10. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 37 11. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 39 12. INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 13. INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 41 14. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 42 15. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 43 16. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 44 17. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 45 18. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 20. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION 21. CHECK POWER WINDOW CONTROL SYSTEM Refer to OPERATION CHECK

22. INSPECT SRS WARNING LIGHT  for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM  for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 38: Identifying Rear Door Lock Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 39: Identifying Rear Door Lock Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 40: Identifying Rear Door Lock Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 5 6. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 6 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 7 8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 9 9. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 10 10. DISCONNECT REAR DOOR WEATHERSTRIP . Refer to REMOVAL - Step 10 11. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 13 12. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 14 13. REMOVE REAR DOOR QUARTER WINDOW GLASS a. Remove the rear door quarter window glass as shown in the illustration.

Fig. 41: Removing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 15. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 42: Identifying Rear Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate b. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame. c. When reusing the rear door lock with motor assembly. 1. Remove the door lock wiring harness seal from the rear door lock with motor assembly.

Fig. 43: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to DISASSEMBLY - Step 22 17. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to DISASSEMBLY Step 23 INSPECTION INSPECTION

1. INSPECT REAR DOOR LOCK WITH MOTOR ASSEMBLY LH a. Check the operation of the door lock motor.

Fig. 44: Checking The Operation Of The Door Lock Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply auxiliary battery voltage and check the operation of the door lock motor.

OK Connection Result Auxiliary battery positive (+) --> Terminal 4 (L) Locks Auxiliary battery negative (-) --> Terminal 1 (UL) Auxiliary battery positive (+) --> Terminal 1 (UL) Unlocks Auxiliary battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly LH. b. Check the operation of the unlock detection switch.

Fig. 45: Checking The Operation Of The Unlock Detection Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 6 (LSSR) 10 kohms Locked 9 (E) or higher 6 (LSSR) Below 1 Unlocked 9 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly LH. 2. INSPECT REAR DOOR LOCK WITH MOTOR ASSEMBLY RH a. Check the operation of the door lock motor.

Fig. 46: Checking The Operation Of The Door Lock Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply auxiliary battery voltage and check the operation of the door lock motor.

OK Connection Result Auxiliary battery positive (+) --> Terminal 4 (L) Locks Auxiliary battery negative (-) --> Terminal 1 (UL) Auxiliary battery positive (+) --> Terminal 1 (UL) Unlocks Auxiliary battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly RH. b. Check the operation of the unlock detection switch.

Fig. 47: Checking The Operation Of The Unlock Detection Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 6 (LSSR) 10 kohms Locked 9 (E) or higher 6 (LSSR) Below 1 Unlocked 9 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to REASSEMBLY Step 14 2. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to REASSEMBLY - Step 15 3. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY NOTE:





When reusing the removed rear door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.



Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock with motor assembly.

a. Apply MP grease to the sliding parts of the rear door lock with motor assembly. b. When reusing the rear door lock with motor assembly. 1. Install a new door lock wiring harness seal to the rear door lock with motor assembly. c. Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.

Fig. 48: Identifying Rear Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release

*1 Plate d. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 4. INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 5. INSTALL REAR DOOR QUARTER WINDOW GLASS a. Install the rear door quarter window glass in the direction indicated by the arrow in the illustration.

Fig. 49: Installing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 7. INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 8. INSTALL REAR DOOR WEATHERSTRIP . Refer to INSTALLATION - Step 7 9. INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 10. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 11. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 12. INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31

13. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 14. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

16. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 17. CHECK POWER WINDOW CONTROL SYSTEM Refer to OPERATION CHECK

LUGGAGE COMPARTMENT DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 50: Identifying Luggage Compartment Door Lock Replacement Components With Torque

Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Disconnect the connector. b. Remove the 2 bolts and disengage the luggage compartment door lock assembly.

Fig. 51: Identifying Luggage Compartment Door Lock Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the claw as shown in the illustration.

Fig. 52: Disengaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the luggage door lock control cable sub-assembly and remove the luggage compartment door lock assembly.

Fig. 53: Identifying Luggage Door Lock Control Cable Sub-Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Check the operation of the door lock motor. 1. Move the door lock to the close (lock) position.

Fig. 54: Checking Operation Of The Door Lock Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage to the door lock motor and check operation of the door lock motor.

OK Measurement Specified Condition Condition Auxiliary battery Luggage positive (+) -- compartment > 1 (B) door lock Auxiliary motor open battery (unlock) negative (-) -- operation > 2 (E) TEXT IN ILLUSTRATION Component without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. b. Check the operation of the door courtesy switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 55: Inspecting Luggage Compartment Door Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Door Specified Lock Condition Condition Close 10 kohms 2 (E) - 3 (D+) (Lock) or higher Open Below 1 2 (E) - 3 (D+) (Unlock) ohms

Measurement Condition

TEXT IN ILLUSTRATION Component

without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Apply MP grease to the sliding parts of the luggage compartment door lock assembly. b. Engage the luggage door lock control cable sub-assembly. c. Engage the claw as shown in the illustration.

Fig. 56: Engaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the luggage compartment door lock assembly with the 2 bolts.

Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) e. Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 10

DOOR CONTROL RECEIVER COMPONENTS ILLUSTRATION

Fig. 57: Identifying Door Control Receiver Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 58: Identifying Door Control Receiver Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 8. REMOVE ROOF SIDE INNER GARNISH RH

4. 5. 6. 7.

HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 25 . 9. REMOVE DOOR CONTROL RECEIVER (w/o Tire Pressure Warning System) a. Disconnect the connector.

Fig. 59: Identifying Door Control Receiver Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and door control receiver. 10. REMOVE DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY (w/ Tire Pressure Warning System) a. Disconnect the connector.

Fig. 60: Identifying Door Control And Tire Pressure Monitoring System Receiver Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and door control and tire pressure monitoring system receiver assembly. INSTALLATION INSTALLATION

1. INSTALL DOOR CONTROL RECEIVER (w/o Tire Pressure Warning System) a. Install the door control receiver with the bolt. b. Connect the connector. 2. INSTALL DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY (w/ Tire Pressure Warning System) a. Install the door control and tire pressure monitoring system receiver assembly with the bolt. b. Connect the connector. 3. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 21 . 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 5. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2

6. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 7. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 8. CONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 10. REGISTER TRANSMITTER ID (w/ Tire Pressure Warning System) Refer to REGISTRATION 11. INSPECT TIRE PRESSURE WARNING SYSTEM (w/ Tire Pressure Warning System) Refer to TEST MODE PROCEDURE 12. PERFORM INITIALIZATION (w/ Tire Pressure Warning System) Refer to INITIALIZATION 13. INSPECT SRS WARNING LIGHT  for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM  for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

WIRELESS DOOR LOCK BUZZER COMPONENTS ILLUSTRATION

Fig. 61: Identifying Wireless Door Lock Buzzer Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT WHEEL LH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the LH side and RH side. Refer to REMOVAL - Step 2 . 3. REMOVE FRONT FENDER LINER LH HINT: Use the same procedure for the LH side and RH side. Refer to REMOVAL - Step 3 . 4. REMOVE WIRELESS DOOR LOCK BUZZER

a. Disconnect the connector.

Fig. 62: Identifying Wireless Door Lock Buzzer Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and remove the wireless door lock buzzer. INSTALLATION INSTALLATION

1. INSTALL WIRELESS DOOR LOCK BUZZER a. Engage the clamp to install the wireless door lock buzzer. b. Connect the connector. 2. INSTALL FRONT FENDER LINER LH HINT: Use the same procedure for the LH side and RH side. Refer to INSTALLATION - Step 3 . 3. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the LH side and RH side. Refer to INSTALLATION - Step 4 .

4. INSTALL FRONT WHEEL LH . Refer to INSTALLATION - Step 13

2012-2017 ACCESSORIES & EQUIPMENT Door Lock System (Service Information) - Camry (Except Hybrid)

DOOR CONTROL SWITCH COMPONENTS ILLUSTRATION

Fig. 1: Identifying Door Control Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 5 2. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 6 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) . Refer to REMOVAL - Step 2 4. REMOVE DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) a. Disengage the 2 claws and remove the door control switch assembly.

Fig. 2: Identifying Door Control Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 3: Identifying Power Window Regulator Switch Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition Lock Below 1 2 (L) - 1 (E) switch ohms pushed 10 kohms 2 (L) - 1 (E) off or higher Unlock 9 (UL) - 1 Below 1 switch (E) ohms pushed 9 (UL) - 1 10 kohms off (E) or higher TEXT IN ILLUSTRATION Component without harness connected (Power *a Window Regulator Master Switch Assembly) If the result is not as specified, replace the power window regulator master switch assembly. 2. INSPECT DOOR CONTROL SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 4: Identifying Door Control Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Below 1 4 (L) - 3 (E) Locked ohms 10 kohms 4 (L) - 3 (E) off or higher 2 (UL) - 3 Below 1 Unlocked (E) ohms 2 (UL) - 3 10 kohms off (E) or higher TEXT IN ILLUSTRATION Component without harness connected *a (Door Control Switch Assembly) *b Unlock

*c Lock If the result is not as specified, replace the door control switch assembly. INSTALLATION INSTALLATION

1. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) a. Engage the 2 claws to install the door control switch assembly. 2. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 3. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 44 4. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 43

UNLOCK WARNING SWITCH COMPONENTS ILLUSTRATION

Fig. 5: Identifying Unlock Warning Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. 5. 6. 7.

REMOVE LOWER STEERING COLUMN COVER . Refer to REMOVAL - Step 1 REMOVE UPPER STEERING COLUMN COVER . Refer to REMOVAL - Step 2 REMOVE TRANSPONDER KEY AMPLIFIER . Refer to REMOVAL - Step 2 REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY . Refer to DISASSEMBLY Step 16 8. REMOVE UNLOCK WARNING SWITCH ASSEMBLY a. Disconnect the connector. b. Remove the unlock warning switch assembly by pushing up the center part and releasing the 2 claws.

Fig. 6: Identifying Center Part Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center *a Part HINT: Slide the unlock warning switch assembly in the direction shown by the arrow in the illustration to remove it.

INSPECTION INSPECTION

1. INSPECT UNLOCK WARNING SWITCH ASSEMBLY

Fig. 7: Identifying Unlock Warning Switch Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Switch Specified Connection Condition Condition Switch 10 kohms 1-2 free (Key or higher removed) Switch Below 1 1-2 pushed ohms (Key set) TEXT IN ILLUSTRATION Component without harness connected

(Unlock Warning *a Switch Assembly) If the result is not as specified, replace the unlock warning switch assembly. INSTALLATION INSTALLATION

1. INSTALL UNLOCK WARNING SWITCH ASSEMBLY a. Engage the 2 claws and install the unlock warning switch assembly to the steering column upper bracket. b. Connect the connector. 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. INSPECT STEERING WHEEL CENTER POINT 4. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY . Refer to REASSEMBLY - Step 2 5. INSTALL TRANSPONDER KEY AMPLIFIER . Refer to INSTALLATION - Step 1 6. INSTALL UPPER STEERING COLUMN COVER . Refer to INSTALLATION - Step 2 7. INSTALL LOWER STEERING COLUMN COVER . Refer to INSTALLATION - Step 3 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

FRONT DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 8: Identifying Front Door Lock Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 9: Identifying Front Door Lock Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 4 5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 5 6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 6 7. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 7 8. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 9 10. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 11. REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 10 12. REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 15 13. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 14. REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 20 15. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 22 16. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (w/ Lock Cylinder) . Refer to DISASSEMBLY - Step 23 17. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY

a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 10: Identifying Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod b. Slide the front door lock with motor assembly downward, and remove the front door lock with motor assembly and cables as a unit. c. When reusing the front door lock with motor assembly.

1. Remove the door lock wiring harness seal from the front door lock with motor assembly.

Fig. 11: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to DISASSEMBLY - Step 31 19. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to DISASSEMBLY Step 32 INSPECTION INSPECTION

1. INSPECT FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH a. Check the operation of the door lock motor.

Fig. 12: Inspecting Front Door Lock Assembly With Connector End View LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply battery voltage and check the operation of the door lock motor.

OK Connection Result Battery positive (+) --> Terminal 4 (L) Locks Battery negative (-) --> Terminal 1 (UL) Battery positive (+) --> Terminal 1 (UL) Unlocks Battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. b. Check the operation of the door unlock detection switch.

Fig. 13: Identifying Door Unlock Detection Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 7 (E) - 8 10 kohms Locked (LSSR) or higher 7 (E) - 8 Below 1 Unlocked (LSSR) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. c. Check the operation of the door key lock and unlock switch.

Fig. 14: Identifying Door Key Lock And Unlock Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition Held to Below 1 9 (L) - 7 (E) lock side ohms Neutral or held to 10 kohms 9 (L) - 7 (E) unlock or higher side Held to 10 (UL) - 7 Below 1 unlock (E) ohms side Neutral or 10 (UL) - 7 10 kohms held to (E) or higher lock side TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly LH. 2. INSPECT FRONT DOOR LOCK WITH MOTOR ASSEMBLY RH a. Check the operation of the door lock motor.

Fig. 15: Inspecting Front Door Lock Assembly RH With Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply battery voltage and check the operation of the door lock motor.

OK Connection Result Battery positive (+) --> Terminal 4 (L) Locks Battery negative (-) --> Terminal 1 (UL) Battery positive (+) --> Terminal 1 (UL) Unlocks Battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly RH. b. Check the operation of the door unlock detection switch.

Fig. 16: Identifying Door Unlock Detection Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 7 (LSSR) 10 kohms Locked 8 (E) or higher 7 (LSSR) Below 1 Unlocked 8 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly RH. c. Check the operation of the door key lock and unlock switch (w/o Wireless Door Lock Control Function).

Fig. 17: Identifying Door Key Lock And Unlock Switch Connector Terminal Identification (W/O Wireless Door Lock Control Function) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition Held to Below 1 6 (L) - 8 (E) lock side ohms Neutral or held to 10 kohms 6 (L) - 8 (E) unlock or higher side Held to 5 (UL) - 8 Below 1 unlock (E) ohms side Neutral or 5 (UL) - 8 10 kohms held to (E) or higher lock side TEXT IN ILLUSTRATION Component without harness connected *a (Front Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the front door lock with motor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to REASSEMBLY Step 17 2. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to REASSEMBLY - Step 18

3. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY NOTE:







When reusing the removed front door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock with motor assembly.

a. Apply MP grease to the sliding parts of the front door lock with motor assembly. b. When reusing the front door lock with motor assembly. 1. Install a new door lock wiring harness seal to the front door lock with motor assembly. c. Insert the front door lock open rod to the front door lock with motor assembly.

Fig. 18: Inserting Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod d. Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

4. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (w/ Lock Cylinder) . Refer to REASSEMBLY - Step 25 5. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY . Refer to REASSEMBLY Step 27 6. INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 29 7. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 33 8. INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 34 9. INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 10. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 38 11. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 40 12. INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 13. INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 42 14. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 43 15. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 44 16. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 45 17. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 46 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION 20. CHECK POWER WINDOW CONTROL SYSTEM Refer to OPERATION CHECK 21. INSPECT SRS WARNING LIGHT  for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM  for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 19: Identifying Rear Door Lock Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 20: Identifying Rear Door Lock Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 4 5. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 5 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 6 7. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 8 8. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 9 9. DISCONNECT REAR DOOR WEATHERSTRIP . Refer to REMOVAL - Step 9 10. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 12 11. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 13 12. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 14 13. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 15 14. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 21: Removing Rear Door Lock With Motor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate b. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame. c. When reusing the rear door lock with motor assembly. 1. Remove the door lock wiring harness seal from the rear door lock with motor assembly.

Fig. 22: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to DISASSEMBLY - Step 21 16. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to DISASSEMBLY Step 22 INSPECTION INSPECTION

1. INSPECT REAR DOOR LOCK WITH MOTOR ASSEMBLY LH a. Check the operation of the door lock motor.

Fig. 23: Identifying Door Lock Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply battery voltage and check the operation of the door lock motor.

OK Connection Result Battery positive (+) --> Terminal 4 (L) Locks Battery negative (-) --> Terminal 1 (UL) Battery positive (+) --> Terminal 1 (UL) Unlocks Battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly LH. b. Check the operation of the unlock detection switch.

Fig. 24: Identifying Unlock Detection Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 6 (LSSR) 10 kohms Locked 9 (E) or higher 6 (LSSR) Below 1 Unlocked 9 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly LH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly LH. 2. INSPECT REAR DOOR LOCK WITH MOTOR ASSEMBLY RH a. Check the operation of the door lock motor.

Fig. 25: Identifying Door Lock Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply battery voltage and check the operation of the door lock motor.

OK Connection Result Battery positive (+) --> Terminal 4 (L) Locks Battery negative (-) --> Terminal 1 (UL) Battery positive (+) --> Terminal 1 (UL) Unlocks Battery negative (-) --> Terminal 4 (L) TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly RH. b. Check the operation of the unlock detection switch.

Fig. 26: Identifying Unlock Detection Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition 6 (LSSR) 10 kohms Locked 9 (E) or higher 6 (LSSR) Below 1 Unlocked 9 (E) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Lock with Motor Assembly RH) *b Unlock *c Lock If the result is not as specified, replace the rear door lock with motor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The following procedure is for the LH side.

1. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY . Refer to REASSEMBLY Step 14 2. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY . Refer to REASSEMBLY - Step 15 3. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY NOTE:





When reusing the removed rear door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.



Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock with motor assembly.

a. Apply MP grease to the sliding parts of the rear door lock with motor assembly. b. When reusing the rear door lock with motor assembly. 1. Install a new door lock wiring harness seal to the rear door lock with motor assembly. c. Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.

Fig. 27: Installing Rear Door Lock With Motor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release

*1 Plate d. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 4. INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 5. INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 6. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 7. INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 8. INSTALL REAR DOOR WEATHERSTRIP . Refer to INSTALLATION - Step 7 9. INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 10. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 11. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 12. INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 13. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 14. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

16. CHECK POWER WINDOW CONTROL SYSTEM Refer to OPERATION CHECK

LUGGAGE COMPARTMENT DOOR LOCK COMPONENTS ILLUSTRATION

Fig. 28: Identifying Luggage Compartment Door Lock Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) a. Disconnect the connector. b. Remove the 2 bolts and disengage the luggage compartment door lock assembly.

Fig. 29: Identifying Luggage Compartment Door Lock Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the claw as shown in the illustration.

Fig. 30: Disengaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage the luggage door lock control cable sub-assembly and remove the luggage compartment door lock assembly.

Fig. 31: Identifying Luggage Door Lock Control Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) a. Disconnect the luggage door lock control cable sub-assembly.

Fig. 32: Identifying Luggage Door Lock Control Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector. c. Remove the 2 bolts and luggage compartment door lock assembly.

Fig. 33: Identifying Luggage Compartment Door Lock Assembly Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY (w/o Wireless Door Lock Control System) a. Disengage the claw as shown in the illustration.

Fig. 34: Disengaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the luggage door lock control cable sub-assembly.

Fig. 35: Identifying Luggage Door Lock Control Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Check the operation of the door lock motor. 1. Move the door lock to the close (lock) position.

Fig. 36: Identifying Door Lock Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage to the door lock motor and check operation of the door lock motor. OK Measurement Specified Condition Condition Battery Luggage positive (+) -- compartment > 1 (B) door lock Battery motor open negative (-) -- (unlock) > 2 (E) operation

TEXT IN ILLUSTRATION Component without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. b. Check the operation of the door courtesy switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 37: Identifying Door Courtesy Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance Door Specified Lock Condition Condition Close 10 kohms 2 (E) - 3 (D+) (Lock) or higher Open Below 1 2 (E) - 3 (D+) (Unlock) ohms

Measurement Condition

TEXT IN ILLUSTRATION Component

without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) a. Apply MP grease to the sliding parts of the luggage compartment door lock assembly. b. Engage the luggage door lock control cable sub-assembly. c. Engage the claw as shown in the illustration.

Fig. 38: Engaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Install the luggage compartment door lock assembly with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) e. Connect the connector. 2. INSTALL LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY (w/o Wireless Door Lock Control System) a. Engage the luggage door lock control cable sub-assembly. b. Engage the claw as shown in the illustration.

Fig. 39: Engaging Luggage Compartment Door Lock Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) a. Apply MP grease to the sliding parts of the luggage compartment door lock assembly. b. Install the luggage compartment door lock assembly with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) c. Connect the connector. d. Connect the luggage door lock control cable sub-assembly. 4. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 12

DOOR CONTROL RECEIVER

COMPONENTS ILLUSTRATION

Fig. 40: Identifying Door Control Receiver Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. 4. 5. 6.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 13 7. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 24 .

8. REMOVE DOOR CONTROL RECEIVER (w/o Tire Pressure Warning System) a. Disconnect the connector.

Fig. 41: Identifying Door Control Receiver Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and door control receiver. 9. REMOVE DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY (w/ Tire Pressure Warning System) a. Disconnect the connector.

Fig. 42: Identifying Door Control And Tire Pressure Monitoring System Receiver Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and door control and tire pressure monitoring system receiver assembly. INSTALLATION INSTALLATION

1. INSTALL DOOR CONTROL RECEIVER (w/o Tire Pressure Warning System) a. Install the door control receiver with the bolt. b. Connect the connector. 2. INSTALL DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY (w/ Tire Pressure Warning System) a. Install the door control and tire pressure monitoring system receiver assembly with the bolt. b. Connect the connector. 3. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 20 . 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 5. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1

6. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 7. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. REGISTER DOOR CONTROL TRANSMITTER MODULE SET SUB-ASSEMBLY ID (w/o Smart Key System) HINT: In case of door control receiver or door control and tire pressure monitoring system receiver assembly replacement. Refer to REGISTRATION . 10. REGISTER TRANSMITTER ID (w/ Tire Pressure Warning System) HINT: In case of door control and tire pressure monitoring system receiver assembly replacement. Refer to REGISTRATION . 11. INSPECT TIRE PRESSURE WARNING SYSTEM (w/ Tire Pressure Warning System) HINT: In case of door control and tire pressure monitoring system receiver assembly replacement. Refer to TEST MODE PROCEDURE . 12. PERFORM INITIALIZATION (w/ Tire Pressure Warning System) HINT: In case of door control and tire pressure monitoring system receiver assembly replacement. Refer to INITIALIZATION . 13. INSPECT SRS WARNING LIGHT  for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM  for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

WIRELESS DOOR LOCK BUZZER COMPONENTS ILLUSTRATION

Fig. 43: Identifying Wireless Door Lock Buzzer Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT WHEEL LH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the LH side and RH side. Refer to REMOVAL - Step 2 . 3. REMOVE FRONT FENDER LINER LH HINT: Use the same procedure for the LH side and RH side. Refer to REMOVAL - Step 3 . 4. REMOVE WIRELESS DOOR LOCK BUZZER

a. Disconnect the connector.

Fig. 44: Identifying Wireless Door Lock Buzzer Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and remove the wireless door lock buzzer. INSTALLATION INSTALLATION

1. INSTALL WIRELESS DOOR LOCK BUZZER a. Engage the clamp to install the wireless door lock buzzer. b. Connect the connector. 2. INSTALL FRONT FENDER LINER LH HINT: Use the same procedure for the LH side and RH side. Refer to INSTALLATION - Step 3 . 3. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the LH side and RH side. Refer to INSTALLATION - Step 4 .

4. INSTALL FRONT WHEEL LH . Refer to INSTALLATION - Step 13

2012-2017 ACCESSORIES & EQUIPMENT Door / Hood (Service Information) (Hybrid) - Camry

HOOD ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT HOOD SUB-ASSEMBLY a. Check that the clearance measurements of areas a through d are within each standard range.

Fig. 1: Checking Hood Sub-Assembly Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 2.45 to 6.45 3.55 to 7.55 a mm (0.0965 b mm (0.140 to to 0.254 in.) 0.297 in.) 2.0 to 5.0 mm -1.5 to 1.5 c (0.0787 to d mm (-0.0591 0.197 in.) to 0.0591 in.)

DISASSEMBLY DISASSEMBLY

1. REMOVE HOOD TO RADIATOR SUPPORT SEAL a. Using a clip remover, disengage the 8 clips and remove the hood to radiator support seal.

Fig. 2: Identifying Hood To Radiator Support Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE HOOD INSULATOR a. Using a clip remover, remove the 7 clips.

Fig. 3: Identifying Hood Insulator Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides and remove the hood insulator. 3. REMOVE WASHER NOZZLE SUB-ASSEMBLY . Refer to REMOVAL - Step 1 4. DISCONNECT WASHER HOSE ASSEMBLY a. Disengage the 6 clamps and disconnect the washer hose assembly.

Fig. 4: Identifying Washer Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE HOOD SUPPORT ASSEMBLY LH See step 1 6. REMOVE HOOD SUPPORT ASSEMBLY RH HINT: Use the same procedure as for the LH side. ADJUSTMENT ADJUSTMENT

Fig. 5: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT: 



Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT HOOD SUB-ASSEMBLY See step 1 2. ADJUST HOOD SUB-ASSEMBLY a. Horizontally and vertically adjust the hood. 1. Loosen the 4 hinge bolts of the hood.

Fig. 6: Adjusting Hood Horizontally And Vertically Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust the clearance between the hood and front fender by moving the hood. 3. Tighten the 4 hinge bolts after the adjustment.

Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) b. Adjust the height of the front end of the hood using the cushion rubbers. 1. Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.

Fig. 7: Adjusting Hood Cushion Rubbers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Raise or lower the front end of the hood by turning the 2 cushion rubbers. c. Remove the radiator grille sub-assembly. Refer to REMOVAL . d. Adjust the hood lock. 1. Loosen the 3 bolts.

Fig. 8: Adjusting The Hood Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust the hood lock and tighten the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 3. Check that the striker can engage with the hood lock smoothly. e. Install the radiator grille sub-assembly. Refer to INSTALLATION . REASSEMBLY REASSEMBLY

1. INSTALL HOOD SUPPORT ASSEMBLY LH See step 1 2. INSTALL HOOD SUPPORT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 3. CONNECT WASHER HOSE ASSEMBLY a. Engage the 6 clamps to connect the washer hose assembly.

Fig. 9: Identifying Washer Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. 5. 6. 7.

INSTALL WASHER NOZZLE SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 INSPECT WASHER NOZZLE SUB-ASSEMBLY . Refer to ON-VEHICLE INSPECTION - Step 1 ADJUST WASHER NOZZLE SUB-ASSEMBLY . Refer to ADJUSTMENT - Step 2 INSTALL HOOD INSULATOR a. Engage the 2 guides.

Fig. 10: Identifying Hood Insulator Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the hood insulator with the 7 new clips. 8. INSTALL HOOD TO RADIATOR SUPPORT SEAL a. Engage the 8 clips to install the hood to radiator support seal.

Fig. 11: Identifying Hood To Radiator Support Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HOOD SUPPORT COMPONENTS ILLUSTRATION

Fig. 12: Identifying Hood Support Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE HOOD SUPPORT ASSEMBLY NOTE:







Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing. Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks. In order to prevent the piston rod from deforming, do not apply any horizontal load to the door stay.

a. Using a screwdriver, remove the 2 stop rings as indicated by the arrows, in the order shown in the illustration.

Fig. 13: Removing Hood Support Stop Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. b. Release the ball joint and remove the hood support assembly. NOTE:

Remove the hood support assembly while supporting the hood by hand.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL HOOD SUPPORT ASSEMBLY NOTE:







Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing. Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks. In order to prevent the piston rod from deforming, do not apply any horizontal load to the door stay.

a. When reusing the hood support assembly: 1. Install the 2 stop rings to the hood support assembly.

Fig. 14: Identifying Hood Support Stop Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the hood support assembly.

Fig. 15: Identifying Hood Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Install the hood support assembly while supporting the hood by hand.

c. Check that the hood support assembly is engaged in the ball joint and it cannot be pulled out. DISPOSAL DISPOSAL

1. DISPOSE OF HOOD SUPPORT ASSEMBLY a. Horizontally hold the hood support in a vise with the piston-rod pulled out. b. Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a metal

saw to release the gas.

Fig. 16: Identifying Hood Support Assembly Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Measurement 100 mm (3.94 A-B in.) NOTE:

Although the gas inside the hood support is colorless, odorless and harmless, there is a possibility that metal debris could scatter. Therefore, cover it with a piece of cloth or other material.

HOOD LOCK CONTROL CABLE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 17: Identifying Hood Lock Control Cable Assembly Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Identifying Hood Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE FRONT WHEEL LH 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 2 . 4. REMOVE FRONT FENDER LINER LH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 5. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 7. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 8. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Disconnect the hood lock control cable assembly and remove the hood lock control lever subassembly.

Fig. 19: Identifying Hood Lock Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE HOOD LOCK ASSEMBLY a. w/ Engine Hood Courtesy Switch: 1. Disconnect the connector.

Fig. 20: Identifying Hood Lock Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts.

Fig. 21: Identifying Hood Lock Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the hood lock control cable assembly and remove the hood lock assembly.

Fig. 22: Removing The Hood Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY a. Using a screwdriver, disengage the 5 clamps and hood cable grommet as shown in the illustration.

Fig. 23: Identifying Hood Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hood Hood Lock *1 *2 Cable Control Grommet Cable Hood Lock Washer *3 *4 Control Hose Cable Clamp HINT: Tape the screwdriver tip before use. b. Pull the hood lock control cable assembly from the engine compartment and remove it. INSTALLATION

INSTALLATION

1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY a. Pass the hood lock control cable assembly into the engine compartment. b. Pass the cable through the upper radiator support. c. Engage the hood cable grommet. d. Engage the 5 clamps and install the hood lock control cable assembly. 2. INSTALL HOOD LOCK ASSEMBLY a. Apply MP grease to the sliding areas of the lock.

Fig. 24: Identifying Sliding Areas To Apply Grease Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the hood lock control cable assembly. c. Install the hood lock assembly with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) d. w/ Engine Hood Courtesy Switch: 1. Connect the connector. 3. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Connect the hood lock control cable assembly and install the hood lock control lever sub-assembly. 4. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39

5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 6. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 7. INSTALL FRONT FENDER LINER LH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 3 . 8. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 4 . 9. INSTALL FRONT WHEEL LH . Refer to INSTALLATION - Step 13 10. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION 11. ADJUST HOOD SUB-ASSEMBLY Refer to ADJUSTMENT

FRONT DOOR COMPONENTS ILLUSTRATION

Fig. 25: Identifying Front Door Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 26: Identifying Front Door Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 27: Identifying Front Door Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 28: Identifying Front Door Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 29: Identifying Front Door Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY

DISASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG a. Using a moulding remover, disengage the 3 claws and remove the front door inside handle bezel plug as shown in the illustration.

Fig. 30: Identifying Front Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH a. Disengage the 3 clips and remove the front door lower frame bracket garnish.

Fig. 31: Identifying Front Door Lower Frame Bracket Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 32: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector and remove the power window regulator master switch assembly with front door armrest base panel. 7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 33: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector and remove the power window regulator switch assembly with front door armrest base panel. 8. REMOVE FRONT ARMREST ASSEMBLY a. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the front armrest assembly.

Fig. 34: Identifying Front Armrest Assembly Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY a. Put protective tape around the front door panel.

Fig. 35: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 screws.

Fig. 36: Identifying Front Door Trim Board Screws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 10 clips. d. Pull out the front door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

Fig. 37: Pulling Out Front Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference

*1 Boss Front Door *2 Inner Glass Weatherstrip e. Disengage the reference boss from the front door panel. f. Raise the front door trim board sub-assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip. g. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.

Fig. 38: Disconnecting Front Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY a. Disengage the 2 claws and guides, and remove the front door inside handle sub-assembly.

Fig. 39: Identifying Front Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP a. Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.

Fig. 40: Identifying Front Door Inner Glass Weatherstrip Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 13. 14. 15. 16.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 11 REMOVE FRONT NO. 1 SPEAKER ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE OUTER REAR VIEW MIRROR ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE FRONT DOOR SERVICE HOLE COVER a. Remove the bolt.

Fig. 41: Removing Front Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector. c. Disengage the 5 clamps. d. Remove the front door service hole cover. HINT: Remove any remaining butyl tape from the door. 17. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY a. Remove the grommet.

Fig. 42: Identifying Front Door Grommet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the cable to the negative (-) auxiliary battery terminal. c. Connect the power window regulator master switch assembly and move the front door glass subassembly so that the door glass bolts can be seen. d. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

e. Disconnect the power window regulator master switch assembly. f. Remove the 2 bolts.

Fig. 43: Identifying Front Door Glass Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

After the bolts are removed, do not allow the door glass to fall.

g. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.

Fig. 44: Removing The Front Door Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the door glass.

18. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY a. Loosen the temporary bolt.

Fig. 45: Identifying Front Door Window Regulator Temporary Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt NOTE:

Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and cause damage.

b. Remove the 5 bolts. c. Remove the front door window regulator assembly. d. Remove the temporary bolt from the front door window regulator assembly. 19. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.

Fig. 46: Identifying Front Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION a. Remove the 2 bolts.

Fig. 47: Identifying No. 2 Front Door Stiffener Cushion Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape b. Disengage the 2 guides and remove the No. 2 front door stiffener cushion. 21. REMOVE FRONT DOOR GLASS RUN a. Remove the front door glass run.

Fig. 48: Identifying Front Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY a. Remove the 2 bolts.

Fig. 49: Identifying Front Door Front Lower Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration. 23. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY a. Remove the 2 bolts.

Fig. 50: Identifying Front Door Rear Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration. 24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) a. Remove the hole plug.

Fig. 51: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.

Fig. 52: Removing Front Door Outside Handle Cover With Lock Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the front door outside handle frame subassembly. 25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) a. Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover as shown in the illustration.

Fig. 53: Removing Front Door Outside Handle Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) a. Remove the hole plug.

Fig. 54: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.

Fig. 55: Removing Front Door Outside Handle Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the front door outside handle frame subassembly. 27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY a. Disengage the 2 claws. b. Using a screwdriver, disconnect the connector.

Fig. 56: Identifying Front Door Outside Handle Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the front door outside handle assembly as shown in the illustration.

Fig. 57: Removing Front Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD a. Disengage the 3 claws and remove the front door front outside handle pad.

Fig. 58: Identifying Front Door Front Outside Handle Pad Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD a. Disengage the 2 claws and remove the front door rear outside handle pad.

Fig. 59: Identifying Front Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 60: Removing Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod b. Slide the front door lock with motor assembly downward, and remove the front door lock with motor assembly and cables as a unit. c. When reusing the front door lock with motor assembly: 1. Remove the door lock wiring harness seal from the front door lock with motor assembly.

Fig. 61: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Remove the front door lock remote control cable assembly.

Fig. 62: Removing Front Door Lock Remote Control Cable

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY a. Using a screwdriver, disengage the 3 claws.

Fig. 63: Identifying Front Door Inside Locking Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front door inside locking cable assembly.

Fig. 64: Removing Front Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Disconnect the connector.

Fig. 65: Identifying Connector And Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 clamps. c. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

Fig. 66: Identifying Front Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door *1 Handle Nut *a Outside *b Inside d. Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it. 34. REMOVE FRONT DOOR WIRE a. Disengage the 3 clamps and remove the front door wire.

Fig. 67: Identifying Front Door Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE FRONT DOOR LOCK OPEN ROD a. Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

Fig. 68: Removing Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE FRONT DOOR CHECK ASSEMBLY a. Remove the 3 bolts and front door check assembly.

Fig. 69: Identifying Front Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE FRONT DOOR WEATHERSTRIP a. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.

Fig. 70: Identifying Front Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE DOOR FRAME GARNISH a. Disengage the clip and remove the door frame garnish.

Fig. 71: Identifying Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This garnish needs to be replaced with a new one because the clip will break when removing it. 39. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP a. Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.

Fig. 72: Identifying Front Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE FRONT DOOR PANEL CUSHION a. Disengage the 2 claws and remove the 2 front door panel cushions.

Fig. 73: Identifying Front Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 41. REMOVE DOOR DUST PROOF SEAL a. Remove the door dust proof seal.

Fig. 74: Identifying Door Dust Proof Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY . Refer to REMOVAL - Step 8 43. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING . Refer to REMOVAL - Step 5 44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING . Refer to REMOVAL - Step 6 45. REMOVE FRONT DOOR STRIPE . Refer to REMOVAL - Step 12 46. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE . Refer to REMOVAL - Step 13 ADJUSTMENT ADJUSTMENT

Fig. 75: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT:   



Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT FRONT DOOR a. Check that the clearance measurements of areas a through p are within each standard range.

Fig. 76: Checking Front Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 3.35 to 6.35 9.0 to 12.0 a mm (0.132 to b mm (0.354 to 0.250 in.) 0.472 in.) 3.35 to 6.35 1.7 to 4.7 mm c mm (0.132 to d (0.0669 to 0.250 in.) 0.185 in.) 3.35 to 6.35 1.0 to 4.0 mm e mm (0.132 to f (0.0394 to 0.250 in.) 0.157 in.) 2.3 to 6.3 mm 2.6 to 5.0 mm g (0.0906 to h (0.102 to 0.248 in.) 0.197 in.)

-1.2 to 1.2 mm (-0.0472 to 0.0472 in.) -1.2 to 1.2 k mm (-0.0472 to 0.0472 in.) 2.3 to 4.7 mm m (0.0906 to 0.185 in.) 2.3 to 4.7 mm o (0.0906 to 0.185 in.) i

2.6 to 5.0 mm (0.102 to 0.197 in.) 2.9 to 7.1 mm l (0.114 to 0.280 in.) -1.2 to 1.2 n mm (-0.0472 to 0.0472 in.) -1.2 to 1.2 p mm (-0.0472 to 0.0472 in.) j

2. REMOVE FRONT WHEEL 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 2 . 4. REMOVE FRONT FENDER LINER HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 5. REMOVE FRONT FENDER SEAL a. Disengage the 3 clips and remove the front fender seal.

Fig. 77: Identifying Front Fender Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. ADJUST FRONT DOOR NOTE:

Make sure to turn the power switch off when adjusting door lock strikers.

a. Using SST, loosen the hinge bolts on the vehicle body and adjust the door position.  SST: 09812-00010

Fig. 78: Adjusting The Door Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the hinge bolts on the vehicle body after adjustment.

Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) c. Loosen the hinge bolts on the door and adjust the door position. d. Tighten the hinge bolts on the door after adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) e. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 79: Adjusting Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using a brass bar and a hammer, hit the striker to adjust its position. g. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 7. INSTALL FRONT FENDER SEAL a. Install the front fender seal with new 3 clips.

Fig. 80: Identifying Front Fender Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL FRONT FENDER LINER HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 3 . 9. INSTALL FRONT WHEEL OPENING EXTENSION PAD HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 4 . 10. INSTALL FRONT WHEEL . Refer to INSTALLATION - Step 13

REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

REPAIR INSTRUCTION . Refer to INSTALLATION - Step 2 INSTALL FRONT DOOR LOWER OUTSIDE STRIPE . Refer to INSTALLATION - Step 3 INSTALL FRONT DOOR STRIPE . Refer to INSTALLATION - Step 4 INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING . Refer to INSTALLATION Step 1 6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING . Refer to INSTALLATION Step 2 7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY . Refer to INSTALLATION - Step 2 8. INSTALL DOOR DUST PROOF SEAL a. Install door dust proof seal.

2. 3. 4. 5.

Fig. 81: Identifying Door Dust Proof Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL FRONT DOOR PANEL CUSHION a. Engage the 2 claws to install 2 new front door panel cushions.

Fig. 82: Identifying Front Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP a. Engage the 8 clips to install the front door No. 2 weatherstrip.

Fig. 83: Identifying Front Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL DOOR FRAME GARNISH a. Engage the clip to install a new door frame garnish.

Fig. 84: Identifying Door Frame Garnish Clip

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL FRONT DOOR WEATHERSTRIP a. Engage the 19 clips and install the front door weatherstrip.

Fig. 85: Identifying Front Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. INSTALL FRONT DOOR CHECK ASSEMBLY a. Apply MP grease to the sliding areas of the front door check assembly. b. Apply adhesive to the threads of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

c. Install the front door check assembly with the 3 bolts.

Fig. 86: Identifying Front Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt (A) Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) Bolt (B) Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 14. INSTALL FRONT DOOR LOCK OPEN ROD a. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

Fig. 87: Installing Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL FRONT DOOR WIRE a. Engage the 3 clamps to install the front door wire.

Fig. 88: Identifying Front Door Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly. b. Engage the claw.

Fig. 89: Identifying Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

c. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw and door handle nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) d. Engage the 3 clamps.

Fig. 90: Identifying Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Connect the connector. 17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY a. Install the front door inside locking cable assembly.

Fig. 91: Installing Front Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws.

Fig. 92: Identifying Front Door Inside Locking Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Install the front door lock remote control cable assembly.

Fig. 93: Installing Front Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY NOTE:







When reusing the removed front door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock with motor assembly.

a. Apply MP grease to the sliding parts of the front door lock with motor assembly. b. When reusing the front door lock with motor assembly: 1. Install a new door lock wiring harness seal to the front door lock with motor assembly.

Fig. 94: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the front door lock open rod to the front door lock with motor assembly.

Fig. 95: Inserting Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod d. Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD a. Engage the 2 claws to install the front door rear outside handle pad.

Fig. 96: Identifying Front Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD a. Engage the 3 claws to install the front door front outside handle pad.

Fig. 97: Identifying Front Door Front Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY a. Insert the front end of the front door outside handle assembly into the front door outside handle frame.

Fig. 98: Installing Front Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the rear end of the front door outside handle assembly into the front door outside handle frame, then slide the front door outside handle assembly toward the front of the vehicle to install it. c. Connect the connector.

Fig. 99: Identifying Front Door Outside Handle Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the 2 claws. 23. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) a. Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.

Fig. 100: Installing Front Door Outside Handle Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) a. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

Fig. 101: Installing Front Door Outside Handle Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) b. Install the hole plug.

Fig. 102: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) a. Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.

Fig. 103: Installing Front Door Outside Handle Cover With Lock Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) b. Install the hole plug.

Fig. 104: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY a. Engage the guide as shown in the illustration.

Fig. 105: Identifying Front Door Rear Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front door rear lower frame sub-assembly with the 2 bolts. 27. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY a. Engage the guide as shown in the illustration.

Fig. 106: Identifying Front Door Front Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front door front lower frame sub-assembly with the 2 bolts. 28. INSTALL FRONT DOOR GLASS RUN a. Install the front door glass run.

Fig. 107: Identifying Front Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION a. Clean the front door panel sub-assembly. b. Engage the 2 guides.

Fig. 108: Identifying No. 2 Front Door Stiffener Cushion Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape

c. Install a new No. 2 front door stiffener cushion with the 2 bolts. 30. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY NOTE:

The regulator arm must be below the intermediate position when installing the power window regulator motor.

a. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.

Fig. 109: Identifying Front Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted. 31. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY a. Apply MP grease to the sliding parts of the front door window regulator assembly. b. Install the temporary bolt to the front door window regulator assembly. c. Temporarily install the front door window regulator assembly.

Fig. 110: Identifying Front Door Window Regulator Temporary Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt d. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly. HINT: Tighten the bolts in the order shown in the illustration. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY a. Connect the cable to the negative (-) auxiliary battery terminal. b. Connect the power window regulator master switch assembly and move the front door glass subassembly so that the door glass bolts can be seen. c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized

after the cable is reconnected. Refer to INITIALIZATION . d. Disconnect the power window regulator master switch assembly. e. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.

Fig. 111: Installing The Front Door Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the front door glass sub-assembly with the 2 bolts.

Fig. 112: Identifying Front Door Glass Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) g. Install the grommet.

Fig. 113: Identifying Front Door Grommet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. INSTALL FRONT DOOR SERVICE HOLE COVER a. Apply new butyl tape to the front door panel. b. Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.

Fig. 114: Installing Front Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *1 Point

c. Attach the front door service hole cover according to the reference points on the front door panel. NOTE:

Securely install the front door service hole cover preventing wrinkles and air bubbles.

d. Engage the 5 clamps. e. Install the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

34. 35. 36. 37.

f. Connect each connector. INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 INSTALL OUTER REAR VIEW MIRROR ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT NO. 1 SPEAKER ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP a. Install the front door inner glass weatherstrip.

Fig. 115: Identifying Front Door Inner Glass Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY a. Engage the 2 claws and guide, and install the front door inside handle sub-assembly to the front door trim board sub-assembly.

Fig. 116: Identifying Front Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY a. Connect the front door lock remote control cable assembly and front door inside locking cable assembly.

Fig. 117: Connecting Front Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door Inside *1 Locking Cable Assembly Front Door Lock *2 Remote Control Cable Assembly b. Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Fig. 118: Engaging Front Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference

*1 Boss c. Engage the 10 clips and install to front door trim board sub-assembly.

Fig. 119: Identifying Front Door Trim Board Screws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the 3 screws. e. If protective tape has been applied, remove it. 40. INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 41. INSTALL FRONT ARMREST ASSEMBLY a. Engage the 2 guides, 3 clips and 7 claws, and install the front armrest assembly.

Fig. 120: Identifying Front Armrest Assembly Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) a. Connect each connector. b. Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator master switch assembly with front door armrest base panel.

Fig. 121: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) a. Connect each connector. b. Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator switch assembly with front door armrest base panel.

Fig. 122: Identifying Power Window Regulator Switch Clips, Claws And Guides (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH a. Engage the 3 clips to install the front door lower frame bracket garnish.

Fig. 123: Identifying Front Door Lower Frame Bracket Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG a. Engage the 3 claws to install the front door inside handle bezel plug.

Fig. 124: Identifying Front Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 46. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

47. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 48. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION 49. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK 50. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR DOOR COMPONENTS

ILLUSTRATION

Fig. 125: Identifying Rear Door Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 126: Identifying Rear Door Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 127: Identifying Rear Door Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 128: Identifying Rear Door Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 129: Identifying Rear Door Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG a. Using a moulding remover, disengage the 3 claws and remove the rear door inside handle bezel plug as shown in the illustration.

Fig. 130: Identifying Rear Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL

a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 131: Identifying Rear Power Window Regulator Switch Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the rear power window regulator switch assembly with rear door armrest base panel. 6. REMOVE REAR ARMREST ASSEMBLY a. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the rear armrest assembly.

Fig. 132: Identifying Rear Armrest Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY a. Put protective tape around the rear door panel.

Fig. 133: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 screws.

Fig. 134: Identifying Rear Door Trim Board Sub-Assembly Clips And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 8 clips. d. Pull out the rear door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

Fig. 135: Pulling Out Rear Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Reference Boss Rear Door *2 Inner Glass Weatherstrip *1

e. Disengage the reference boss from the rear door panel. f. Raise the rear door trim board sub-assembly to remove the rear door trim board sub-assembly together with the rear door inner glass weatherstrip. g. Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

Fig. 136: Disconnecting Rear Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Using a screwdriver, disengage the claw and remove the No. 1 door scuff plate clamp from the rear door trim board sub-assembly as shown in the illustration.

Fig. 137: Disengaging No. 1 Door Scuff Plate Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 8. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY a. Disengage the 2 claws and guide, and remove the rear door inside handle sub-assembly.

Fig. 138: Identifying Rear Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP a. Using a screwdriver, disengage the 3 claws and remove the rear door inner glass weatherstrip from the rear door trim board sub-assembly as shown in the illustration.

Fig. 139: Disengaging Rear Door Inner Glass Weatherstrip Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 10. REMOVE REAR DOOR SERVICE HOLE COVER a. Disconnect the connector and remove the rear door service hole cover.

Fig. 140: Removing Rear Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Remove any remaining butyl tape from the door. 11. REMOVE REAR DOOR CHECK ASSEMBLY a. Remove the bolt and 2 nuts, and rear door check assembly.

Fig. 141: Identifying Rear Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE REAR DOOR WEATHERSTRIP a. Using a clip remover, disengage the 20 clips and remove the rear door weatherstrip.

Fig. 142: Identifying Rear Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE REAR DOOR GLASS RUN a. Remove the rear door glass run.

Fig. 143: Identifying Rear Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY a. Remove the 2 bolts and screw, and rear door lower window frame sub-assembly.

Fig. 144: Identifying Rear Door Lower Window Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When the rear door lower window frame sub-assembly is removed, do not allow the rear door quarter window glass to fall.

15. REMOVE REAR DOOR QUARTER WINDOW GLASS a. Remove the rear door quarter window glass with the rear door quarter window weatherstrip as shown in the illustration.

Fig. 145: Removing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door quarter window glass from the rear door quarter window weatherstrip. 16. REMOVE REAR DOOR GLASS SUB-ASSEMBLY a. Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration.

Fig. 146: Removing Rear Door Glass From Rear Door Window Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the door glass.

17. REMOVE REAR DOOR FRAME GARNISH a. Disengage the clip and remove the rear door frame garnish.

Fig. 147: Identifying Rear Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This garnish needs to be replaced with a new one because the clip will break when removing it. 18. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY a. Remove the 4 screws.

Fig. 148: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear door inside panel reinforce sub-assembly. 19. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY a. Disconnect the connector.

Fig. 149: Identifying Rear Door Window Regulator Temporary Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt b. Loosen the temporary bolt. NOTE:

Do not remove the temporary bolt. If the temporary bolt is removed, the rear door window regulator assembly may fall and cause damage.

c. Remove the 3 bolts. d. Remove the rear door window regulator assembly. e. Remove the temporary bolt from the rear door window regulator assembly. 20. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 3 screws and rear power window regulator motor assembly.

Fig. 150: Identifying Rear Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 151: Removing Rear Door Lock With Motor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate b. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame. c. When reusing the rear door lock with motor assembly: 1. Remove the door lock wiring harness seal from the rear door lock with motor assembly.

Fig. 152: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Using a screwdriver, disengage the claw.

Fig. 153: Identifying Rear Door Lock Remote Control Cable Cover Claw

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door lock remote control cable assembly.

Fig. 154: Removing Rear Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY a. Using a screwdriver, disengage the 3 claws.

Fig. 155: Identifying Rear Door Inside Locking Cable Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door inside locking cable assembly.

Fig. 156: Removing Rear Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

24. REMOVE REAR DOOR OUTSIDE HANDLE COVER a. Using a T30 "TORX" socket wrench, loosen the screw.

Fig. 157: Identifying Rear Door Outside Handle Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the rear door outside handle frame subassembly. b. Disengage the claw and remove the rear door outside handle cover. 25. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY a. Pull and hold the release plate of the rear door outside handle frame sub-assembly as shown in the illustration.

Fig. 158: Pulling Rear Door Outside Handle Frame Release Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

The release plate may interfere with the rear door outside handle assembly and may be damaged when removing the rear door outside handle assembly, unless the release plate of the rear door outside handle frame sub-assembly is pulled and held.

b. Remove the rear door outside handle assembly as shown in the illustration.

Fig. 159: Removing Rear Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD a. Disengage the 3 claws and remove the rear door front outside handle pad.

Fig. 160: Identifying Rear Door Front Outside Handle Pad Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD a. Disengage the 2 claws and remove the rear door rear outside handle pad.

Fig. 161: Identifying Rear Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

Fig. 162: Identifying Rear Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

b. Slide the rear door outside handle frame sub-assembly to disengage the claw of the rear door outside handle frame sub-assembly, and then remove it. 29. REMOVE REAR DOOR NO. 2 WEATHERSTRIP a. Using a clip remover, disengage the 5 clips and remove the rear door No. 2 weatherstrip.

Fig. 163: Identifying Rear Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE REAR DOOR PANEL CUSHION a. Disengage the 2 claws and remove the 2 rear door panel cushions.

Fig. 164: Identifying Rear Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. 32. 33. 34. 35.

REMOVE REAR DOOR BELT MOULDING ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING . Refer to REMOVAL - Step 2 REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING . Refer to REMOVAL - Step 3 REMOVE REAR DOOR OUTSIDE STRIPE . Refer to REMOVAL - Step 17 REMOVE REAR DOOR LOWER OUTSIDE STRIPE . Refer to REMOVAL - Step 18

ADJUSTMENT ADJUSTMENT

Fig. 165: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT:   



Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT REAR DOOR a. Check that the clearance measurements of areas a through r are within each standard range.

Fig. 166: Checking Rear Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 3.35 to 6.35 0.6 to 3.6 mm a mm (0.132 to b (0.0236 to 0.250 in.) 0.142 in.) 3.35 to 6.35 0.9 to 3.9 mm c mm (0.132 to d (0.0354 to 0.250 in.) 0.154 in.) 3.35 to 6.35 1.5 to 4.5 mm e mm (0.132 to f (0.0591 to 0.250 in.) 0.177 in.) 3.35 to 6.35 5.4 to 8.4 mm g mm (0.132 to h (0.213 to 0.250 in.) 0.331 in.)

i

k

m

o

q

-1.5 to 1.5 mm (-0.0591 to 0.0591 in.) 2.0 to 5.0 mm (0.0787 to 0.197 in.) 2.9 to 7.1 mm (0.114 to 0.280 in.) -1.2 to 1.2 mm (-0.0472 to 0.0472 in.) -1.2 to 1.2 mm (-0.0472 to 0.0472 in.)

2.0 to 5.0 mm (0.0787 to 0.197 in.) -1.5 to 1.5 l mm (-0.0591 to 0.0591 in.) 2.6 to 5.0 mm n (0.102 to 0.197 in.) 2.6 to 5.0 mm p (0.102 to 0.197 in.) 2.3 to 6.3 mm r (0.0906 to 0.248 in.) j

2. ADJUST REAR DOOR NOTE:

Make sure to turn the power switch off when adjusting door lock strikers.

a. Using SST, loosen the hinge bolts on the vehicle body and adjust the door position.  SST: 09812-00010

Fig. 167: Adjusting The Door Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the hinge bolts on the vehicle body after the adjustment.

Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) c. Loosen the hinge bolts on the door and adjust the door position. d. Tighten the hinge bolts on the door after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) e. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 168: Adjusting Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using a brass bar and a hammer, hit the striker to adjust its position. g. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REPAIR INSTRUCTION . Refer to INSTALLATION - Step 2

2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE . Refer to INSTALLATION - Step 2 3. INSTALL REAR DOOR OUTSIDE STRIPE . Refer to INSTALLATION - Step 3 4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING . Refer to INSTALLATION Step 1 5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING . Refer to INSTALLATION Step 2 6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY . Refer to INSTALLATION - Step 1 7. INSTALL REAR DOOR PANEL CUSHION a. Engage the 2 claws to install 2 new rear door panel cushions.

Fig. 169: Identifying Rear Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

a. Engage the 5 clips to install the rear door No. 2 weatherstrip.

Fig. 170: Identifying Rear Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly. b. Engage the claw.

Fig. 171: Identifying Rear Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

c. Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw and door handle nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD a. Engage the 2 claws to install the rear door rear outside handle pad.

Fig. 172: Identifying Rear Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD a. Engage the 3 claws to install the rear door front outside handle pad.

Fig. 173: Identifying Rear Door Front Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY a. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

Fig. 174: Inserting Rear Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

b. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it. 13. INSTALL REAR DOOR OUTSIDE HANDLE COVER a. Engage the claw and install the rear door outside handle cover.

Fig. 175: Identifying Rear Door Outside Handle Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY a. Install the rear door inside locking cable assembly.

Fig. 176: Installing Rear Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws.

Fig. 177: Identifying Rear Door Inside Locking Cable Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Install the rear door lock remote control cable assembly.

Fig. 178: Removing Rear Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the claw.

Fig. 179: Identifying Rear Door Lock Remote Control Cable Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY NOTE:







When reusing the removed rear door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock with motor assembly.

a. Apply MP grease to the sliding parts of the rear door lock with motor assembly. b. When reusing the rear door lock with motor assembly: 1. Install a new door lock wiring harness seal to the rear door lock with motor assembly.

Fig. 180: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.

Fig. 181: Installing Rear Door Lock With Motor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate d. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTE:

The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.

a. Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

Fig. 182: Identifying Rear Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted. 18. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY a. Apply MP grease to the sliding parts of the rear door window regulator assembly. b. Install the temporary bolt to the rear door window regulator assembly. c. Temporarily install the rear door window regulator assembly.

Fig. 183: Identifying Rear Door Window Regulator Temporary Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt d. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly. HINT: Tighten the bolts in the order shown in the illustration. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 19. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY a. Engage the guide.

Fig. 184: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install a new rear door inside panel reinforce sub-assembly with the 4 screws. 20. INSTALL REAR DOOR FRAME GARNISH a. Engage the clip to install a new rear door frame garnish.

Fig. 185: Identifying Rear Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY a. Slide the rear door glass sub-assembly to install it as shown in the illustration.

Fig. 186: Installing Rear Door Glass From Rear Door Window Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. INSTALL REAR DOOR QUARTER WINDOW GLASS a. Install the rear door quarter window glass to the rear door quarter window weatherstrip. b. Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

Fig. 187: Installing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY a. Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

Fig. 188: Identifying Rear Door Lower Window Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL REAR DOOR GLASS RUN a. Install the rear door glass run.

Fig. 189: Identifying Rear Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. INSTALL REAR DOOR WEATHERSTRIP a. Engage the 20 clips to install the rear door weatherstrip.

Fig. 190: Identifying Rear Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. INSTALL REAR DOOR CHECK ASSEMBLY a. Apply MP grease to the sliding parts of the rear door check assembly. b. Apply adhesive to the threads of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent c. Install the rear door check assembly with the 2 nuts and bolt.

Fig. 191: Identifying Rear Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) Nut Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 27. INSTALL REAR DOOR SERVICE HOLE COVER a. Apply new butyl tape to the rear door panel. b. Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector through a new rear door service hole cover.

Fig. 192: Installing Rear Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *1 Point c. Attach the rear door service hole cover according to the reference points on the rear door panel. NOTE:

Securely install the rear door service hole cover preventing wrinkles and air bubbles.

d. Connect the connector. 28. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP a. Install the rear door inner glass weatherstrip.

Fig. 193: Installing Rear Door Inner Glass Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY a. Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

Fig. 194: Identifying Rear Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY a. Install the No. 1 door scuff plate clamp as shown in the illustration.

Fig. 195: Identifying No. 1 Door Scuff Plate Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

Fig. 196: Connecting Rear Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Door Inside *1 Locking Cable Assembly Rear Door Lock *2 Remote Control Cable Assembly c. Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Fig. 197: Engaging Rear Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

Reference Boss

d. Engage the 8 clips and install the rear door trim board sub-assembly.

Fig. 198: Identifying Rear Door Trim Board Sub-Assembly Clips And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the 3 screws. f. If protective tape has been applied, remove it. 31. INSTALL REAR ARMREST ASSEMBLY a. Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

Fig. 199: Identifying Rear Armrest Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL a. Connect the connector. b. Engage the 4 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

Fig. 200: Identifying Rear Power Window Regulator Switch Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG a. Engage the 3 claws to install the rear door inside handle bezel plug.

Fig. 201: Identifying Rear Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION

35. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 36. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK

LUGGAGE COMPARTMENT DOOR COMPONENTS ILLUSTRATION

Fig. 202: Identifying Luggage Compartment Door Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 203: Identifying Luggage Compartment Door Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER

a. Remove the 13 clips and luggage compartment door cover.

Fig. 204: Identifying Luggage Compartment Door Cover Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE LUGGAGE COMPARTMENT DOOR CUSHION a. Disengage the 2 claws and remove the 2 luggage compartment door panel cushions.

Fig. 205: Identifying Luggage Compartment Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY . Refer to REMOVAL Step 2 4. REMOVE REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) . Refer to REMOVAL - Step 2 5. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY . Refer to REMOVAL - Step 2 6. REMOVE REAR TELEVISION CAMERA ASSEMBLY (w/ Rear Monitor) . Refer to REMOVAL - Step 2 7. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH . Refer to REMOVAL - Step 2 8. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. 9. REMOVE REAR LIGHT ASSEMBLY LH . Refer to REMOVAL - Step 2 10. REMOVE REAR LIGHT ASSEMBLY RH HINT: Use the same procedure as for the LH side. ADJUSTMENT

ADJUSTMENT

Fig. 206: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT: 



1. 2. 3. 4. 5.

Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS . REMOVE LUGGAGE COMPARTMENT DOOR COVER See step 1 REMOVE LUGGAGE COMPARTMENT FLOOR MAT See step 1 REMOVE BAGGAGE HOLDER NET (w/ Partition Net) See step 3 REMOVE REAR FLOOR FINISH PLATE See step 4 ADJUST LUGGAGE COMPARTMENT DOOR a. Loosen the door side hinge bolts to adjust the door horizontally and vertically.

Fig. 207: Adjusting Luggage Compartment Door Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

b. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 208: Adjusting Luggage Compartment Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brass bar and a hammer, hit the striker to adjust its position. d. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 6. 7. 8. 9. 10.

INSTALL REAR FLOOR FINISH PLATE See step 10 INSTALL BAGGAGE HOLDER NET (w/ Partition Net) See step 11 INSTALL LUGGAGE COMPARTMENT FLOOR MAT See step 13 INSTALL LUGGAGE COMPARTMENT DOOR COVER See step 10 INSPECT LUGGAGE COMPARTMENT DOOR a. Check that the clearance measurements of areas a through d are within each standard range.

Fig. 209: Checking Luggage Compartment Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 2.0 to 5.0 mm 6.4 mm (0.252 a b (0.0787 to in.) 0.197 in.) -1.0 to 2.0 3.85 to 7.85 c mm (-0.0394 d mm (0.152 to to 0.0787 in.) 0.309 in.) REASSEMBLY REASSEMBLY

1. INSTALL REAR LIGHT ASSEMBLY LH . Refer to INSTALLATION - Step 1 2. INSTALL REAR LIGHT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 3. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH . Refer to INSTALLATION - Step 2 4. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH

HINT: Use the same procedure as for the LH side. 5. INSTALL REAR TELEVISION CAMERA ASSEMBLY (w/ Rear Monitor) . Refer to INSTALLATION - Step 1 6. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY . Refer to INSTALLATION - Step 4 7. INSTALL REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) . Refer to INSTALLATION - Step 4 8. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY . Refer to INSTALLATION - Step 1 9. INSTALL LUGGAGE COMPARTMENT DOOR CUSHION a. Engage the 2 claws and install the 2 new luggage compartment door panel cushions.

Fig. 210: Identifying Luggage Compartment Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL LUGGAGE COMPARTMENT DOOR COVER a. Install the luggage compartment door cover with the 13 clips.

Fig. 211: Identifying Luggage Compartment Door Cover Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. ADJUST REAR TELEVISION CAMERA ASSEMBLY OPTICAL AXIS (w/ Parking Assist Monitor System) Refer to CALIBRATION

LUGGAGE DOOR HINGE TORSION BAR COMPONENTS ILLUSTRATION

Fig. 212: Identifying Luggage Door Hinge Torsion Bar Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

After installing the torsion bar, use your hand to open and close the luggage

door. Make sure the luggage door can open and close smoothly. 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT a. Remove the luggage compartment floor mat. 2. REMOVE SPARE WHEEL COVER ASSEMBLY a. Remove the spare wheel cover assembly. 3. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) a. Remove the baggage holder net. 4. REMOVE REAR FLOOR FINISH PLATE a. Remove the 5 clips.

Fig. 213: Identifying Rear Floor Finish Plate Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and remove the rear floor finish plate.

Fig. 214: Removing Rear Floor Finish Plate Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Push the 2 pins and remove the 2 No. 1 luggage compartment trim hooks.

Fig. 215: Identifying No. 1 Luggage Compartment Trim Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 6. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER a. Disengage the 8 fasteners.

Fig. 216: Identifying Luggage Compartment Front Trim Cover Claws And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws and remove the luggage compartment front trim cover. 7. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH a. Remove the clip .

Fig. 217: Identifying Luggage Compartment Inner Trim Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Remove the 2 clips . c. Disengage the fastener and remove the luggage compartment inner trim cover LH. 8. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER RH a. Remove the clip .

Fig. 218: Identifying Luggage Compartment Inner Trim Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Remove the 2 clips . c. Disengage the fastener and remove the luggage compartment inner trim cover RH. 9. REMOVE LUGGAGE COMPARTMENT DOOR HINGE COVER LH a. Disengage the 4 claws and remove the luggage compartment door hinge cover LH.

Fig. 219: Identifying Luggage Compartment Door Hinge Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE LUGGAGE COMPARTMENT DOOR HINGE COVER RH HINT: Use the same procedure as for the LH side. 11. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH a. Disengage the hook in the order indicated in the illustration and disconnect the rear seatback lock assembly RH (rear seat lock control cable RH).

Fig. 220: Disconnecting Rear Seatback Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Put protective tape around the luggage door hinge.

Fig. 221: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape c. Using SST, disconnect the luggage door hinge torsion bar LH from the luggage door hinge and the left side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 222: Disconnecting Luggage Door Hinge Torsion Bar LH From Luggage Door Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 claws as shown in the illustration.

Fig. 223: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the luggage door hinge torsion bar LH from the luggage compartment door torsion bar support as shown in the illustration.

Fig. 224: Disconnecting Luggage Door Hinge Torsion Bar LH From Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the luggage door hinge torsion bar LH from the right side of the vehicle body as shown in the illustration.

Fig. 225: Removing Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH a. Put protective tape around the luggage door hinge.

Fig. 226: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using SST, disconnect the luggage door hinge torsion bar RH from the luggage door hinge and the right side of the vehicle body as shown in the illustration.



SST: 09804-24010

Fig. 227: Disconnecting Luggage Door Hinge Torsion Bar RH From Luggage Door Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the luggage door hinge torsion bar RH from the luggage compartment door torsion bar support as shown in the illustration.

Fig. 228: Disconnecting Luggage Door Hinge Torsion Bar RH From Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the luggage door hinge torsion bar RH from the left side of the vehicle body as shown in the illustration.

Fig. 229: Removing Luggage Door Hinge Torsion Bar RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT a. Remove the luggage compartment door torsion bar support as shown in the illustration.

Fig. 230: Removing Luggage Compartment Door Torsion Bar Support

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure to replace the luggage compartment door torsion bar support with a new one.

INSTALLATION INSTALLATION

NOTE:

After installing the torsion bar, use your hand to open and close the luggage door. Make sure the luggage door can open and close smoothly.

1. INSTALL LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT a. Install a new luggage compartment door torsion bar support as shown in the illustration.

Fig. 231: Installing Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL LUGGAGE DOOR HINGE TORSION BAR RH a. Check the identification mark on the luggage door hinge torsion bar RH. w/o Rear Spoiler Green w/ Rear Spoiler

Pink b. Set the tip of the luggage door hinge torsion bar RH in the center installation hole. The upper and lower installation holes are used for adjustment.

Fig. 232: Identifying Upper And Lower Installation Holes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Installation *a Hole Installation *b Hole (For Adjustment) c. Connect the luggage door hinge torsion bar RH to the left side of the vehicle body as shown in the illustration.

Fig. 233: Connecting Luggage Door Hinge Torsion Bar RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the luggage door hinge torsion bar RH to the luggage compartment door torsion bar support as shown in the illustration.

Fig. 234: Connecting Luggage Door Hinge Torsion Bar RH To Luggage Compartment Door

Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, install the luggage door hinge torsion bar RH to the luggage door hinge and the right side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 235: Installing Luggage Door Hinge Torsion Bar RH To Luggage Door Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the protective tape. 3. INSTALL LUGGAGE DOOR HINGE TORSION BAR LH

a. Check the identification mark on the luggage door hinge torsion bar RH. w/o Rear Spoiler White w/ Rear Spoiler Yellow b. Set the tip of the luggage door hinge torsion bar LH in the center installation hole. The upper and lower installation holes are used for adjustment.

Fig. 236: Identifying Upper And Lower Installation Holes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Installation *a Hole Installation *b Hole (For Adjustment) c. Connect the luggage door hinge torsion bar LH to the right side of the vehicle body as shown in the illustration.

Fig. 237: Connecting Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the luggage door hinge torsion bar LH to the luggage compartment door torsion bar support as shown in the illustration.

Fig. 238: Connecting Luggage Door Hinge Torsion Bar LH To Luggage Compartment Door

Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, install the luggage door hinge torsion bar LH to the luggage door hinge and the left side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 239: Installing Luggage Door Hinge Torsion Bar LH To Luggage Door Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Engage the 2 claws as shown in the illustration.

Fig. 240: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Connect the rear seatback lock assembly RH (rear seat lock control cable RH) and engage the hook in the order indicated in the illustration.

Fig. 241: Connecting Rear Seatback Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the protective tape. 4. INSTALL LUGGAGE COMPARTMENT DOOR HINGE COVER LH a. Engage the 4 claws and install the luggage compartment door hinge cover LH. 5. INSTALL LUGGAGE COMPARTMENT DOOR HINGE COVER RH HINT: Use the same procedure as for the LH side. 6. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH a. Install the clip .

Fig. 242: Identifying Luggage Compartment Inner Trim Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Install the 2 clips . c. Engage the fastener and install the luggage compartment inner trim cover LH. 7. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER RH a. Install the clip .

Fig. 243: Identifying Luggage Compartment Inner Trim Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Install the 2 clips . c. Engage the fastener and install the luggage compartment inner trim cover RH. 8. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Engage the 2 pins to install the 2 No. 1 luggage compartment trim hooks.

Fig. 244: Identifying No. 1 Luggage Compartment Trim Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 9. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER a. Engage the 2 claws. b. Engage the 8 fasteners and install the luggage compartment front trim cover. 10. INSTALL REAR FLOOR FINISH PLATE a. Engage the 4 clips and install the rear floor finish plate.

Fig. 245: Installing Rear Floor Finish Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 5 clips. 11. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) a. Install the baggage holder net. 12. INSTALL SPARE WHEEL COVER ASSEMBLY a. Install the spare wheel cover assembly. 13. INSTALL LUGGAGE COMPARTMENT FLOOR MAT a. Install the luggage compartment floor mat.

LUGGAGE DOOR LOCK CONTROL CABLE ASSEMBLY COMPONENTS

ILLUSTRATION

Fig. 246: Identifying Luggage Door Lock Control Cable Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 247: Identifying Luggage Door Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 248: Identifying Luggage Door Lock Control Cable Assembly Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 249: Identifying Luggage Door Lock Control Cable Assembly Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to REMOVAL 2. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to REMOVAL 3. 4. 5. 6. 7.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5

8. REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 19 9. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 7 10. REMOVE LAP BELT OUTER ANCHOR COVER . Refer to REMOVAL - Step 8 11. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 9 12. REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 23 13. REMOVE LUGGAGE COMPARTMENT DOOR COVER See step 1 14. REMOVE LUGGAGE COMPARTMENT FLOOR MAT See step 1 15. REMOVE SPARE WHEEL COVER ASSEMBLY See step 2 16. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) See step 3 17. REMOVE REAR FLOOR FINISH PLATE See step 4 18. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Push the pin and remove the No. 1 luggage compartment trim hook.

Fig. 250: Identifying No. 1 Luggage Compartment Trim Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 19. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH See step 7 20. REMOVE FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Remove the screw.

Fig. 251: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 252: Identifying Fuel Lid Lock Open Lever Guide

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the fuel lid lock control cable sub-assembly and luggage door lock control cable subassembly and remove the fuel lid lock open lever sub-assembly.

Fig. 253: Disconnecting Fuel Lid Lock And Luggage Door Lock Control Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY a. Disengage the 2 clamps.

Fig. 254: Identifying Luggage Door Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a clip remover, disengage the clamp and disconnect the wire harness.

Fig. 255: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using a clip remover, disengage the 2 clamps and remove the 2 scuff plate clips.

Fig. 256: Identifying Scuff Plate Clip Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn back the floor carpet so that the luggage door lock control cable sub-assembly and fuel lid lock control cable sub-assembly can be removed. e. Disengage the guide as shown in the illustration.

Fig. 257: Disconnecting Luggage Door Lock Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disconnect the luggage door lock control cable sub-assembly.

Fig. 258: Identifying The Luggage Door Lock Control Cable End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disengage the clamp and disconnect the luggage door lock control cable sub-assembly.

Fig. 259: Identifying Luggage Door Lock Control Cable Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and the guides , and then pull the fuel filler opening lid lock retainer.

Fig. 260: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

i. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and guides , and then pull the fuel filler opening lid lock retainer.

Fig. 261: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

j. Pull out the fuel filler opening lid lock retainer with both guides and aligned with the cutouts.

Fig. 262: Removing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLRemoving Fuel Filler Opening Lid Lock RetainerUSTRATION *1 Cutout Guide *2

Guide *3

k. Disengage the 2 claws and remove the fuel filler opening lid lock retainer.

Fig. 263: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Disengage the 10 clamps and remove the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly.

Fig. 264: Identifying Fuel Lid Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Fuel Lid Door Lock Lock Control *1 *2 Control Cable Cable SubSubassembly assembly m. Using a knife, cut off the clamp as shown in the illustration.

Fig. 265: Identifying Clamp To Be Cut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tape - *a Cut - NOTE:

Be careful not to damage the vehicle fuel lid lock control cable subassembly and luggage door lock control cable sub-assembly.

n. Remove the clamp. o. Remove the 3 pieces of tape and fuel lid lock control cable sub-assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY a. Install the luggage door lock control cable sub-assembly to the fuel lid lock control cable subassembly with the new clamp (A) and the 3 pieces of tape as shown in the illustration.

Fig. 266: Identifying Luggage Door Lock Control Cable Clamp And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clamp *1 *2 Clamp (A) Luggage Fuel Lid Door Lock Lock Control *3 Control *4 Cable Cable SubSubassembly assembly *5 Tape - REFERENCE MEASUREMENT Area Measurement Area Measurement 295 to 305 880 to 900 a mm (11.6 to b mm (2.29 to 12.0 in.) 2.95 ft.) 2090 to 2110 2970 to 2990 c mm (6.86 to d mm (8.86 to 6.92 ft.) 9.81 ft.) 5.0 mm (0.197 e - in.) or less NOTE:

 

Wrap tape around the designated position 1 to 3 times. Make sure that the fuel lid lock control cable sub-assembly and

luggage door lock control cable sub-assembly are not kinked. b. Engage the 10 clamps and install the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly. c. Align the cutouts and guides , and then insert the fuel filler opening lid lock retainer.

Fig. 267: Installing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

d. Engage the 2 claws to install the fuel filler opening lid lock retainer.

Fig. 268: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Claw e. Engage the 2 claws to install the fuel lid lock control cable sub-assembly.

Fig. 269: Identifying Fuel Lid Lock Control Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Engage the clamp and connect the luggage door lock control cable sub-assembly. g. Connect the luggage door lock control cable sub-assembly. h. Engage the guide as shown in the illustration.

Fig. 270: Connecting Luggage Door Lock Control Cable Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Return the floor carpet to the original position. j. Engage the 2 clamps and install the 2 scuff plate clips.

k. Engage the 3 clamps to connect the wire harness. 2. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Connect the fuel lid lock control cable sub-assembly and luggage door lock control cable subassembly to the fuel lid lock open lever sub-assembly.

Fig. 271: Connecting Fuel Lid Lock And Luggage Door Lock Control Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Door Lock *1 Control Cable Subassembly Fuel Lid Lock Control *2 Cable Subassembly b. Engage the guide and install the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 272: Identifying Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the screw. 3. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH See step 6 4. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Engage the pin to install the No. 1 luggage compartment trim hook.

Fig. 273: Identifying No. 1 Luggage Compartment Trim Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 5. 6. 7. 8. 9. 10. 11. 12.

INSTALL REAR FLOOR FINISH PLATE See step 10 INSTALL BAGGAGE HOLDER NET (w/ Partition Net) See step 11 INSTALL SPARE WHEEL COVER ASSEMBLY See step 12 INSTALL LUGGAGE COMPARTMENT FLOOR MAT See step 13 INSTALL LUGGAGE COMPARTMENT DOOR COVER See step 10 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 23 CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6

13. INSTALL LAP BELT OUTER ANCHOR COVER . Refer to INSTALLATION - Step 7 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 15. INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 27 16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 17. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 18. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 19. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 20. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to INSTALLATION 21. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to INSTALLATION

LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH COMPONENTS ILLUSTRATION

Fig. 274: Identifying Luggage Compartment Door Opener Outer Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL - Step 2 2. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Remove the luggage door opening switch assembly.

Fig. 275: Identifying Luggage Door Opening Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 276: Inspecting Luggage Door Opening Switch Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Luggage door opening 2 (E) - 3 10 kohms switch (UL) or higher assembly not pushed Luggage door 2 (E) - 3 opening Below 1 (UL) switch ohms assembly pushed TEXT IN ILLUSTRATION Component without *a harness connected (Luggage

Door Opening Switch Assembly) INSTALLATION INSTALLATION

1. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Install the luggage door opening switch assembly. 2. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION - Step 4

FUEL LID LOCK CONTROL CABLE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 277: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 278: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 279: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 280: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to REMOVAL 2. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to REMOVAL 3. 4. 5. 6. 7.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5

8. REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 19 9. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 7 10. REMOVE LAP BELT OUTER ANCHOR COVER . Refer to REMOVAL - Step 8 11. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 9 12. REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 23 13. REMOVE LUGGAGE COMPARTMENT DOOR COVER See step 1 14. REMOVE LUGGAGE COMPARTMENT FLOOR MAT See step 1 15. REMOVE SPARE WHEEL COVER ASSEMBLY See step 2 16. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) See step 3 17. REMOVE REAR FLOOR FINISH PLATE See step 4 18. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK See step 18 19. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH See step 7 20. REMOVE FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY See step 20 21. REMOVE FUEL LID LOCK CONTROL CABLE SUB-ASSEMBLY a. Disengage the 2 clamps.

Fig. 281: Identifying Luggage Door Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a clip remover, disengage the clamp and disconnect the wire harness.

Fig. 282: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 2 clamps and remove the 2 scuff plate clips.

Fig. 283: Identifying Scuff Plate Clip Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Turn back the floor carpet so that the luggage door lock control cable sub-assembly and fuel lid lock control cable sub-assembly can be removed. e. Disengage the guide as shown in the illustration.

Fig. 284: Disconnecting Luggage Door Lock Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disconnect the luggage door lock control cable sub-assembly.

Fig. 285: Identifying The Luggage Door Lock Control Cable End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disengage the clamp and disconnect the luggage door lock control cable sub-assembly.

Fig. 286: Identifying Luggage Door Lock Control Cable Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and the guides , and then pull the fuel filler opening lid lock retainer.

Fig. 287: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

i. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and guides , and then pull the fuel filler opening lid lock retainer.

Fig. 288: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

j. Pull out the fuel filler opening lid lock retainer with both guides and aligned with the cutouts.

Fig. 289: Removing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

Guide *3

k. Disengage the 2 claws and remove the fuel filler opening lid lock retainer.

Fig. 290: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Disengage the 10 clamps and remove the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly.

Fig. 291: Identifying Fuel Lid Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Fuel Lid Door Lock Lock Control *1 *2 Control Cable Cable SubSubassembly assembly m. Using a knife, cut off the clamp as shown in the illustration.

Fig. 292: Identifying Clamp To Be Cut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tape - *a Cut - NOTE:

Be careful not to damage the vehicle fuel lid lock control cable subassembly and luggage door lock control cable sub-assembly.

n. Remove the clamp. o. Remove the 3 pieces of tape and fuel lid lock control cable sub-assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL LID LOCK CONTROL CABLE SUB-ASSEMBLY a. Install the fuel lid lock control cable sub-assembly to the luggage door lock control cable subassembly with the new clamp and the 3 pieces of tape as shown in the illustration.

Fig. 293: Identifying Fuel Lid Lock Control Cable Clamp And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clamp *1 *2 Clamp (A) Luggage Fuel Lid Door Lock Lock Control *3 Control *4 Cable Cable SubSubassembly assembly *5 Tape - REFERENCE MEASUREMENT Area Measurement Area Measurement 295 to 305 880 to 900 a mm (11.6 to b mm (2.29 to 12.0 in.) 2.95 ft.) 2090 to 2110 2970 to 2990 c mm (6.86 to d mm (8.86 to 6.92 ft.) 9.81 ft.) 5.0 mm (0.197 e - in.) or less NOTE:

 

Wrap tape around the designated position 1 to 3 times. Make sure that the fuel lid lock control cable sub-assembly and

luggage door lock control cable sub-assembly are not kinked. b. Engage the 10 clamps and install the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly. c. Align the cutouts and guides , and then insert the fuel filler opening lid lock retainer.

Fig. 294: Installing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

d. Engage the 2 claws to install the fuel filler opening lid lock retainer.

Fig. 295: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Claw e. Engage the 2 claws to install the fuel lid lock control cable sub-assembly.

Fig. 296: Identifying Fuel Lid Lock Control Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Engage the clamp and connect the luggage door lock control cable sub-assembly. g. Connect the luggage door lock control cable sub-assembly. h. Engage the guide as shown in the illustration.

Fig. 297: Connecting Luggage Door Lock Control Cable Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Return the floor carpet to the original position. j. Engage the 2 clamps and install the 2 scuff plate clips.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

k. Engage the 3 clamps to connect the wire harness. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY See step 2 INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH See step 6 INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK See step 4 INSTALL REAR FLOOR FINISH PLATE See step 10 INSTALL BAGGAGE HOLDER NET (w/ Partition Net) See step 11 INSTALL SPARE WHEEL COVER ASSEMBLY See step 12 INSTALL LUGGAGE COMPARTMENT FLOOR MAT See step 13 INSTALL LUGGAGE COMPARTMENT DOOR COVER See step 10 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 23 CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 INSTALL LAP BELT OUTER ANCHOR COVER . Refer to INSTALLATION - Step 7 INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 27 INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) Refer to INSTALLATION

21. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) Refer to INSTALLATION

2012-2017 ACCESSORIES & EQUIPMENT Door / Hood (Service Information) (Except Hybrid) - Camry

HOOD ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT HOOD SUB-ASSEMBLY a. Check that the clearance measurements of areas a through d are within each standard range.

Fig. 1: Inspecting Hood Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 2.45 to 6.45 3.55 to 7.55 a mm (0.0965 b mm (0.140 to to 0.254 in.) 0.297 in.) 2.0 to 5.0 mm -1.5 to 1.5 c (0.0787 to d mm (-0.0591 0.197 in.) to 0.0591 in.)

DISASSEMBLY DISASSEMBLY

1. REMOVE HOOD TO RADIATOR SUPPORT SEAL a. Using a clip remover, disengage the 8 clips and remove the hood to radiator support seal.

Fig. 2: Identifying Hood To Radiator Support Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE HOOD INSULATOR a. Using a clip remover, remove the 7 clips.

Fig. 3: Identifying Hood Insulator Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides and remove the hood insulator. 3. REMOVE WASHER NOZZLE SUB-ASSEMBLY . Refer to REMOVAL - Step 1 . 4. DISCONNECT WASHER HOSE ASSEMBLY a. Disengage the 6 clamps and disconnect the washer hose assembly.

Fig. 4: Identifying Washer Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE HOOD SUPPORT ASSEMBLY LH . See step 1. 6. REMOVE HOOD SUPPORT ASSEMBLY RH HINT: Use the same procedure as for the LH side. ADJUSTMENT ADJUSTMENT

Fig. 5: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT: 



Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT HOOD SUB-ASSEMBLY . See step 1. 2. ADJUST HOOD SUB-ASSEMBLY a. Horizontally and vertically adjust the hood. 1. Loosen the 4 hinge bolts of the hood.

Fig. 6: Adjusting Hood Horizontally And Vertically Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust the clearance between the hood and front fender by moving the hood. 3. Tighten the 4 hinge bolts after the adjustment.

Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) b. Adjust the height of the front end of the hood using the cushion rubbers. 1. Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.

Fig. 7: Adjusting Height Of Hood Using Cushion Rubbers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Raise or lower the front end of the hood by turning the 2 cushion rubbers. c. Remove the radiator grille sub-assembly. Refer to REMOVAL . d. Adjust the hood lock. 1. Loosen the 3 bolts.

Fig. 8: Adjusting The Hood Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust the hood lock and tighten the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 3. Check that the striker can engage with the hood lock smoothly. e. Install the radiator grille sub-assembly. Refer to INSTALLATION . REASSEMBLY REASSEMBLY

1. INSTALL HOOD SUPPORT ASSEMBLY LH . See step 1. 2. INSTALL HOOD SUPPORT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 3. CONNECT WASHER HOSE ASSEMBLY a. Engage the 6 clamps to connect the washer hose assembly.

Fig. 9: Identifying Washer Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL WASHER NOZZLE SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 . 5. INSPECT WASHER NOZZLE SUB-ASSEMBLY . Refer to ON-VEHICLE INSPECTION - Step 1. 6. ADJUST WASHER NOZZLE SUB-ASSEMBLY . Refer to ADJUSTMENT - Step 2 . 7. INSTALL HOOD INSULATOR a. Engage the 2 guides.

Fig. 10: Identifying Hood Insulator Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the hood insulator with the 7 new clips. 8. INSTALL HOOD TO RADIATOR SUPPORT SEAL a. Engage the 8 clips to install the hood to radiator support seal.

Fig. 11: Identifying Hood To Radiator Support Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HOOD SUPPORT COMPONENTS ILLUSTRATION

Fig. 12: Identifying Hood Support Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE HOOD SUPPORT ASSEMBLY NOTE:







Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing. Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks. In order to prevent the piston rod from deforming, do not apply any horizontal load to the door stay.

a. Using a screwdriver, remove the 2 stop rings as indicated by the arrows, in the order shown in the illustration.

Fig. 13: Removing Hood Support Stop Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. b. Release the ball joint and remove the hood support assembly. NOTE:

Remove the hood support assembly while supporting the hood by hand.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL HOOD SUPPORT ASSEMBLY NOTE:







Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing. Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks. In order to prevent the piston rod from deforming, do not apply any horizontal load to the door stay.

a. When reusing the hood support assembly: 1. Install the 2 stop rings to the hood support assembly.

Fig. 14: Identifying Hood Support Stop Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the hood support assembly.

Fig. 15: Identifying Hood Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Install the hood support assembly while supporting the hood by hand.

c. Check that the hood support assembly is engaged in the ball joint and it cannot be pulled out. DISPOSAL DISPOSAL

1. DISPOSE OF HOOD SUPPORT ASSEMBLY a. Horizontally hold the hood support in a vise with the piston-rod pulled out. b. Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a metal

saw to release the gas.

Fig. 16: Identifying Hood Support Assembly Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Measurement 100 mm (3.94 A-B in.) NOTE:

Although the gas inside the hood support is colorless, odorless and harmless, there is a possibility that metal debris could scatter. Therefore, cover it with a piece of cloth or other material.

HOOD LOCK CONTROL CABLE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 17: Identifying Hood Lock Control Cable Assembly Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 18: Identifying Hood Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY Refer to REMOVAL . 2. REMOVE FRONT WHEEL LH 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 2 . 4. REMOVE FRONT FENDER LINER LH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 5. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4 . 7. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 . 8. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Disconnect the hood lock control cable assembly and remove the hood lock control lever subassembly.

Fig. 19: Identifying Hood Lock Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE HOOD LOCK ASSEMBLY a. w/ Engine Hood Courtesy Switch: 1. Disconnect the connector.

Fig. 20: Identifying Hood Lock Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts.

Fig. 21: Identifying Hood Lock Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the hood lock control cable assembly and remove the hood lock assembly.

Fig. 22: Identifying Hood Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY a. Using a screwdriver, disengage 5 clamps and hood cable grommet as shown in the illustration.

Fig. 23: Locating Hood Lock Control Cable Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hood Hood Lock *1 *2 Cable Control Grommet Cable Hood Lock Washer *3 *4 Control Hose Cable Clamp HINT: Tape the screwdriver tip before use. b. Pull the hood lock control cable assembly from the engine compartment and remove it. INSTALLATION

INSTALLATION

1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY a. Pass the hood lock control cable assembly into the engine compartment. b. Pass the cable through the upper radiator support. c. Engage the hood cable grommet. d. Engage the 5 clamps and install the hood lock control cable assembly. 2. INSTALL HOOD LOCK ASSEMBLY a. Apply MP grease to the sliding areas of the lock.

Fig. 24: Identifying Sliding Areas To Apply Grease Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the hood lock control cable assembly. c. Install the hood lock assembly with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) d. w/ Engine Hood Courtesy Switch: 1. Connect the connector. 3. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Connect the hood lock control cable assembly and install the hood lock control lever sub-assembly. 4. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 41 .

5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 43 . 6. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 . 7. INSTALL FRONT FENDER LINER LH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 3 . 8. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 4 . 9. INSTALL FRONT WHEEL LH . Refer to INSTALLATION - Step 13 . 10. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION . 11. ADJUST HOOD SUB-ASSEMBLY Refer to ADJUSTMENT.

FRONT DOOR COMPONENTS ILLUSTRATION

Fig. 25: Identifying Front Door Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 26: Identifying Front Door Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 27: Identifying Front Door Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 28: Identifying Front Door Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY

DISASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG a. Using a moulding remover, disengage the 3 claws and remove the front door inside handle bezel plug as shown in the illustration.

Fig. 29: Identifying Front Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH a. Disengage the 3 clips and remove the front door lower frame bracket garnish.

Fig. 30: Identifying Front Door Lower Frame Bracket Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 31: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector and remove the power window regulator master switch assembly with front door armrest base panel. 6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 32: Identifying Power Window Regulator Switch Clips, Claws And Guides (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector and remove the power window regulator switch assembly with front door armrest base panel. 7. REMOVE FRONT ARMREST ASSEMBLY a. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the front armrest assembly.

Fig. 33: Identifying Front Armrest Assembly Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 . 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY a. Put protective tape around the front door panel.

Fig. 34: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 screws.

Fig. 35: Identifying Front Door Trim Board Screws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 10 clips. d. Pull out the front door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

Fig. 36: Pulling Out Front Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference

*1 Boss Front Door *2 Inner Glass Weatherstrip e. Disengage the reference boss from the front door panel. f. Raise the front door trim board sub-assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip. g. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.

Fig. 37: Disconnecting Front Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY a. Disengage the 2 claws and guides, and remove the front door inside handle sub-assembly.

Fig. 38: Identifying Front Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP a. Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.

Fig. 39: Identifying Front Door Inner Glass Weatherstrip Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 12. 13. 14. 15.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 10 . REMOVE FRONT NO. 1 SPEAKER ASSEMBLY . Refer to REMOVAL - Step 9 . REMOVE OUTER REAR VIEW MIRROR ASSEMBLY . Refer to REMOVAL - Step 9 . REMOVE FRONT DOOR SERVICE HOLE COVER a. Remove the bolt.

Fig. 40: Locating Front Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect each connector. c. Disengage the 5 clamps. d. Remove the front door service hole cover. HINT: Remove any remaining butyl tape from the door. 16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY a. Remove the grommet.

Fig. 41: Identifying Front Door Grommet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the cable to the negative (-) battery terminal. c. Connect the power window regulator master switch assembly and move the front door glass subassembly so that the door glass bolts can be seen. d. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

e. Disconnect the power window regulator master switch assembly. f. Remove the 2 bolts.

Fig. 42: Identifying Front Door Glass Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

After the bolts are removed, do not allow the door glass to fall.

g. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.

Fig. 43: Removing The Front Door Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the door glass.

17. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY a. Loosen the temporary bolt.

Fig. 44: Identifying Front Door Window Regulator Temporary Bolt And Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt NOTE:

Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and cause damage.

b. Remove the 5 bolts. c. Remove the front door window regulator assembly. d. Remove the temporary bolt from the front door window regulator assembly. 18. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.

Fig. 45: Identifying Front Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION a. Remove the 2 bolts.

Fig. 46: Identifying No. 2 Front Door Stiffener Cushion Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape b. Disengage the 2 guides and remove the No. 2 front door stiffener cushion. 20. REMOVE FRONT DOOR GLASS RUN a. Remove the front door glass run.

Fig. 47: Identifying Front Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY a. Remove the 2 bolts.

Fig. 48: Identifying Front Door Front Lower Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration. 22. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY a. Remove the 2 bolts.

Fig. 49: Identifying Front Door Rear Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration. 23. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) a. Remove the hole plug.

Fig. 50: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.

Fig. 51: Identifying Front Door Outside Handle Cover w/ Lock Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the front door outside handle frame subassembly. 24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Front Passenger Side) a. w/ Front Door Lock Cylinder: HINT: Use the same procedure for front passenger side and driver side. 25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) a. Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover as shown in the illustration.

Fig. 52: Removing Front Door Outside Handle Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) a. w/ Front Door Lock Cylinder: HINT:

Use the same procedure for the front passenger side and the driver side. b. w/o Front Door Lock Cylinder: 1. Remove the hole plug.

Fig. 53: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.

Fig. 54: Identifying Front Door Outside Handle Cover w/o Front Door Lock Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly. 27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY a. w/ Smart Key System: 1. Disengage the 2 claws. 2. Using a screwdriver, disconnect the connector.

Fig. 55: Identifying Front Door Outside Handle Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front door outside handle assembly as shown in the illustration.

Fig. 56: Removing Front Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

28. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD a. Disengage the 3 claws and remove the front door front outside handle pad.

Fig. 57: Identifying Front Door Front Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD a. Disengage the 2 claws and remove the front door rear outside handle pad.

Fig. 58: Identifying Front Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 59: Identifying Front Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod b. Slide the front door lock with motor assembly downward, and remove the front door lock with motor assembly and cables as a unit. c. When reusing the front door lock with motor assembly: 1. Remove the door lock wiring harness seal from the front door lock with motor assembly.

Fig. 60: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Remove the front door lock remote control cable assembly.

Fig. 61: Removing Front Door Lock Remote Control Cable

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY a. Using a screwdriver, disengage the 3 claws.

Fig. 62: Identifying Front Door Inside Locking Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front door inside locking cable assembly.

Fig. 63: Removing Front Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. w/ Smart Key System: 1. Disconnect the connector.

Fig. 64: Identifying Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disengage the 3 clamps. b. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

Fig. 65: Identifying Front Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

c. Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it. 34. REMOVE FRONT DOOR WIRE (w/ Smart Key System) a. Disengage the 3 clamps and remove the front door wire.

Fig. 66: Identifying Front Door Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE FRONT DOOR LOCK OPEN ROD a. Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

Fig. 67: Removing Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE FRONT DOOR CHECK ASSEMBLY a. Remove the 3 bolts and front door check assembly.

Fig. 68: Identifying Front Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE FRONT DOOR WEATHERSTRIP a. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.

Fig. 69: Identifying Front Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE DOOR FRAME GARNISH a. Disengage the clip and remove the door frame garnish.

Fig. 70: Identifying Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This garnish needs to be replaced with a new one because the clip will break when removing it. 39. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP a. Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.

Fig. 71: Identifying Front Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE FRONT DOOR PANEL CUSHION a. Disengage the 2 claws and remove the 2 front door panel cushions.

Fig. 72: Identifying Front Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 41. REMOVE DOOR DUST PROOF SEAL a. Remove the door dust proof seal.

Fig. 73: Identifying Door Dust Proof Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY . Refer to REMOVAL - Step 7 . 43. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING . Refer to REMOVAL - Step 11 . 44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING . Refer to REMOVAL - Step 12 . 45. REMOVE FRONT DOOR STRIPE . Refer to REMOVAL - Step 11 . 46. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE . Refer to REMOVAL - Step 12 . ADJUSTMENT ADJUSTMENT

Fig. 74: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT:   



Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT FRONT DOOR a. Check that the clearance measurements of areas a through p are within each standard range.

Fig. 75: Checking Front Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 3.35 to 6.35 9.0 to 12.0 a mm (0.132 to b mm (0.354 to 0.250 in.) 0.472 in.) 3.35 to 6.35 1.7 to 4.7 mm c mm (0.132 to d (0.0669 to 0.250 in.) 0.185 in.) 3.35 to 6.35 1.0 to 4.0 mm e mm (0.132 to f (0.0394 to 0.250 in.) 0.157 in.) 2.3 to 6.3 mm 2.96 to 4.64 g (0.0906 to h mm (0.115 to 0.248 in.) 0.182 in.)

-0.84 to 0.84 mm (-0.0331 to 0.0331 in.) -0.84 to 0.84 k mm (-0.0331 to 0.0331 in.) 2.3 to 4.7 mm m (0.0906 to 0.185 in.) 2.3 to 4.7 mm o (0.0906 to 0.185 in.) i

2.96 to 4.64 mm (0.115 to 0.182 in.) 2.9 to 7.1 mm l (0.114 to 0.280 in.) -1.2 to 1.2 n mm (-0.0472 to 0.0472 in.) -1.2 to 1.2 p mm (-0.0472 to 0.0472 in.) j

2. REMOVE FRONT WHEEL 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 2 . 4. REMOVE FRONT FENDER LINER HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 5. REMOVE FRONT FENDER SEAL a. Disengage the 3 clips and remove the front fender seal.

Fig. 76: Identifying Front Fender Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. ADJUST FRONT DOOR NOTE:

Make sure that the turn the ignition switch off when adjusting door lock strikers.

a. Using SST, loosen the hinge bolts on the vehicle body and adjust the door position.  SST: 09812-00010

Fig. 77: Adjusting The Door Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the hinge bolts on the vehicle body after adjustment.

Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) c. Loosen the hinge bolts on the door and adjust the door position. d. Tighten the hinge bolts on the door after adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) e. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 78: Adjusting Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using a brass bar and a hammer, hit the striker to adjust its position. g. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 7. INSTALL FRONT FENDER SEAL a. Install the front fender seal with new 3 clips.

Fig. 79: Identifying Front Fender Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL FRONT FENDER LINER HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 3 . 9. INSTALL FRONT WHEEL OPENING EXTENSION PAD HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 4 . 10. INSTALL FRONT WHEEL . Refer to INSTALLATION - Step 13 .

REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

REPAIR INSTRUCTION . Refer to INSTALLATION - Step 2 . INSTALL FRONT DOOR LOWER OUTSIDE STRIPE . Refer to INSTALLATION - Step 3 . INSTALL FRONT DOOR STRIPE . Refer to INSTALLATION - Step 4 . INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING . Refer to INSTALLATION Step 2 . 6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING . Refer to INSTALLATION Step 3 . 7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY . Refer to INSTALLATION - Step 2 . 8. INSTALL DOOR DUST PROOF SEAL a. Install door dust proof seal.

2. 3. 4. 5.

Fig. 80: Identifying Door Dust Proof Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL FRONT DOOR PANEL CUSHION a. Engage the 2 claws to install 2 new front door panel cushions.

Fig. 81: Identifying Front Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP a. Engage the 8 clips to install the front door No. 2 weatherstrip.

Fig. 82: Identifying Front Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL DOOR FRAME GARNISH a. Engage the clip to install a new door frame garnish.

Fig. 83: Identifying Door Frame Garnish Clip

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL FRONT DOOR WEATHERSTRIP a. Engage the 19 clips and install the front door weatherstrip.

Fig. 84: Identifying Front Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. INSTALL FRONT DOOR CHECK ASSEMBLY a. Apply MP grease to the sliding areas of the front door check assembly. b. Apply adhesive to the threads of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

c. Install the front door check assembly with the 3 bolts.

Fig. 85: Identifying Front Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt (A) Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) Bolt (B) Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 14. INSTALL FRONT DOOR LOCK OPEN ROD a. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

Fig. 86: Installing Front Door Lock Open Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL FRONT DOOR WIRE (w/ Smart Key System) a. Engage the 3 clamps to install the front door wire.

Fig. 87: Identifying Front Door Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly. b. Engage the claw.

Fig. 88: Identifying Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

c. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw and door handle nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) d. w/ Smart Key System: 1. Engage the 3 clamps.

Fig. 89: Identifying Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Connect the connector. 17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY a. Install the front door inside locking cable assembly.

Fig. 90: Installing Front Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws.

Fig. 91: Identifying Front Door Inside Locking Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Install the front door lock remote control cable assembly.

Fig. 92: Installing Front Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY NOTE:







When reusing the removed front door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock with motor assembly.

a. Apply MP grease to the sliding parts of the front door lock with motor assembly. b. When reusing the front door lock with motor assembly: 1. Install a new door lock wiring harness seal to the front door lock with motor assembly.

Fig. 93: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the front door lock open rod to the front door lock with motor assembly.

Fig. 94: Identifying Front Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door *1 Lock Open Rod d. Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD a. Engage the 2 claws to install the front door rear outside handle pad.

Fig. 95: Identifying Front Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD a. Engage the 3 claws to install the front door front outside handle pad.

Fig. 96: Identifying Front Door Front Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY a. Insert the front end of the front door outside handle assembly into the front door outside handle frame.

Fig. 97: Installing Front Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the rear end of the front door outside handle assembly into the front door outside handle frame, then slide the front door outside handle assembly toward the front of the vehicle to install it. c. w/ Smart Key System: 1. Connect the connector.

Fig. 98: Identifying Front Door Outside Handle Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Engage the 2 claws. 23. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) a. Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.

Fig. 99: Installing Front Door Outside Handle Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) a. w/o Front Door Lock Cylinder: 1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

Fig. 100: Identifying Front Door Outside Handle Cover w/o Front Door Lock Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 2. Install the hole plug.

Fig. 101: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Front Door Lock Cylinder: HINT: Use the same procedures for the front passenger side and the driver side. 25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) a. Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.

Fig. 102: Identifying Front Door Outside Handle Cover w/ Lock Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) b. Install the hole plug.

Fig. 103: Identifying Front Door Hole Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Front Passenger Side) a. w/ Front Door Lock Cylinder: HINT: Use the same procedures for the front passenger side and the driver side. 27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY a. Engage the guide as shown in the illustration.

Fig. 104: Identifying Front Door Rear Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front door rear lower frame sub-assembly with the 2 bolts. 28. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY a. Engage the guide as shown in the illustration.

Fig. 105: Identifying Front Door Front Lower Frame Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front door front lower frame sub-assembly with the 2 bolts. 29. INSTALL FRONT DOOR GLASS RUN a. Install the front door glass run.

Fig. 106: Identifying Front Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION a. Clean the front door panel sub-assembly. b. Engage the 2 guides.

Fig. 107: Identifying No. 2 Front Door Stiffener Cushion Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape c. Install a new No. 2 front door stiffener cushion with the 2 bolts. 31. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY NOTE:

The regulator arm must be below the intermediate position when installing the power window regulator motor.

a. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly

with the 3 screws.

Fig. 108: Identifying Front Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted. 32. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY a. Apply MP grease to the sliding parts of the front door window regulator assembly. b. Install the temporary bolt to the front door window regulator assembly. c. Temporarily install the front door window regulator assembly.

Fig. 109: Identifying Front Door Window Regulator Temporary Bolt And Assembly Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt d. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly. HINT: Tighten the bolts in the order shown in the illustration. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 33. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY a. Connect the cable to the negative (-) battery terminal. b. Connect the power window regulator master switch assembly and move the front door glass subassembly so that the door glass bolts can be seen. c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

d. Disconnect the power window regulator master switch assembly. e. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.

Fig. 110: Installing The Front Door Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the front door glass sub-assembly with the 2 bolts.

Fig. 111: Identifying Front Door Glass Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) g. Install the grommet.

Fig. 112: Identifying Front Door Grommet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. INSTALL FRONT DOOR SERVICE HOLE COVER a. Apply new butyl tape to the front door panel. b. Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.

Fig. 113: Locating Front Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *1 Point

c. Attach the front door service hole cover according to the reference points on the front door panel. NOTE:

Securely install the front door service hole cover preventing wrinkles and air bubbles.

d. Engage the 5 clamps. e. Install the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

35. 36. 37. 38.

f. Connect each connector. INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 . INSTALL OUTER REAR VIEW MIRROR ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL FRONT NO. 1 SPEAKER ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP a. Install the front door inner glass weatherstrip.

Fig. 114: Identifying Front Door Inner Glass Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY a. Engage the 2 claws and guide, and install the front door inside handle sub-assembly to the front door trim board sub-assembly.

Fig. 115: Identifying Front Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY a. Connect the front door lock remote control cable assembly and front door inside locking cable assembly.

Fig. 116: Connecting Front Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Door Inside *1 Locking Cable Assembly Front Door Lock *2 Remote Control Cable Assembly b. Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Fig. 117: Engaging Front Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference

*1 Boss c. Engage the 10 clips and install to front door trim board sub-assembly.

Fig. 118: Identifying Front Door Trim Board Screws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the 3 screws. e. If protective tape has been applied, remove it. 41. INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 . 42. INSTALL FRONT ARMREST ASSEMBLY a. Engage the 2 guides, 3 clips and 7 claws, and install the front armrest assembly.

Fig. 119: Identifying Front Armrest Assembly Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) a. Connect each connector. b. Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator master switch assembly with front door armrest base panel.

Fig. 120: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 44. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) a. Connect each connector. b. Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator switch assembly with front door armrest base panel.

Fig. 121: Identifying Power Window Regulator Switch Clips, Claws And Guides (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 45. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH a. Engage the 3 clips to install the front door lower frame bracket garnish.

Fig. 122: Identifying Front Door Lower Frame Bracket Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 46. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG a. Engage the 3 claws to install the front door inside handle bezel plug.

Fig. 123: Identifying Front Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

48. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION . 49. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK . 50. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR DOOR COMPONENTS ILLUSTRATION

Fig. 124: Identifying Rear Door Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 125: Identifying Rear Door Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 126: Identifying Rear Door Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 127: Identifying Rear Door Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG a. Using a moulding remover, disengage the 3 claws and remove the rear door inside handle bezel plug as shown in the illustration.

Fig. 128: Identifying Rear Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL a. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

Fig. 129: Identifying Rear Power Window Regulator Switch Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the rear power window regulator switch assembly with rear door armrest base panel. 5. REMOVE REAR ARMREST ASSEMBLY a. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the rear armrest assembly.

Fig. 130: Identifying Rear Armrest Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY a. Put protective tape around the rear door panel.

Fig. 131: Identifying Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 screws.

Fig. 132: Identifying Rear Door Trim Board Sub-Assembly Clips And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 8 clips. d. Pull out the rear door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

Fig. 133: Pulling Out Rear Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Reference Boss Rear Door *2 Inner Glass Weatherstrip *1

e. Disengage the reference boss from the rear door panel. f. Raise the rear door trim board sub-assembly to remove the rear door trim board sub-assembly together with the rear door inner glass weatherstrip. g. Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

Fig. 134: Disconnecting Rear Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Using a screwdriver, disengage the claw and remove the No. 1 door scuff plate clamp from the rear door trim board sub-assembly as shown in the illustration.

Fig. 135: Disengaging No. 1 Door Scuff Plate Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 7. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY a. Disengage the 2 claws and guide, and remove the rear door inside handle sub-assembly.

Fig. 136: Identifying Rear Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP a. Using a screwdriver, disengage the 3 claws and remove the rear door inner glass weatherstrip from the rear door trim board sub-assembly as shown in the illustration.

Fig. 137: Disengaging Rear Door Inner Glass Weatherstrip Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Screwdriver 9. REMOVE REAR DOOR SERVICE HOLE COVER a. Disconnect the connector and remove the rear door service hole cover.

Fig. 138: Locating Rear Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Remove any remaining butyl tape from the door. 10. REMOVE REAR DOOR CHECK ASSEMBLY a. Remove the bolt and 2 nuts, and rear door check assembly.

Fig. 139: Identifying Rear Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE REAR DOOR WEATHERSTRIP a. Using a clip remover, disengage the 20 clips and remove the rear door weatherstrip.

Fig. 140: Identifying Rear Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE REAR DOOR GLASS RUN a. Remove the rear door glass run.

Fig. 141: Identifying Rear Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY a. Remove the 2 bolts and screw, and rear door lower window frame sub-assembly.

Fig. 142: Identifying Rear Door Lower Window Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When the rear door lower window frame sub-assembly is removed, do not allow the rear door quarter window glass to fall.

14. REMOVE REAR DOOR QUARTER WINDOW GLASS a. Remove the rear door quarter window glass with the rear door quarter window weatherstrip as shown in the illustration.

Fig. 143: Removing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door quarter window glass from the rear door quarter window weatherstrip. 15. REMOVE REAR DOOR GLASS SUB-ASSEMBLY a. Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration.

Fig. 144: Removing Rear Door Glass From Rear Door Window Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the door glass.

16. REMOVE REAR DOOR FRAME GARNISH a. Disengage the clip and remove the rear door frame garnish.

Fig. 145: Identifying Rear Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This garnish needs to be replaced with a new one because the clip will break when removing it. 17. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY a. Remove the 4 screws.

Fig. 146: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear door inside panel reinforce sub-assembly. 18. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY a. Disconnect the connector.

Fig. 147: Identifying Rear Door Window Regulator Temporary Bolt And Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt b. Loosen the temporary bolt. NOTE:

Do not remove the temporary bolt. If the temporary bolt is removed, the rear door window regulator assembly may fall and cause damage.

c. Remove the 3 bolts. d. Remove the rear door window regulator assembly. e. Remove the temporary bolt from the rear door window regulator assembly. 19. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 3 screws and rear power window regulator motor assembly.

Fig. 148: Identifying Rear Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the 3 screws.

Fig. 149: Identifying Rear Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate b. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame. c. When reusing the rear door lock with motor assembly: 1. Remove the door lock wiring harness seal from the rear door lock with motor assembly.

Fig. 150: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Using a screwdriver, disengage the claw.

Fig. 151: Removing Rear Door Lock Remote Control Cable Cover Claw

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door lock remote control cable assembly.

Fig. 152: Removing Rear Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY a. Using a screwdriver, disengage the 3 claws.

Fig. 153: Identifying Rear Door Inside Locking Cable Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear door inside locking cable assembly.

Fig. 154: Removing Rear Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

23. REMOVE REAR DOOR OUTSIDE HANDLE COVER a. Using a T30 "TORX" socket wrench, loosen the screw.

Fig. 155: Identifying Rear Door Outside Handle Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The screw cannot be removed because it is integrated into the rear door outside handle frame subassembly. b. Disengage the claw and remove the rear door outside handle cover. 24. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY a. Pull and hold the release plate of the rear door outside handle frame sub-assembly as shown in the illustration.

Fig. 156: Pulling Rear Door Outside Handle Frame Release Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

The release plate may interfere with the rear door outside handle assembly and may be damaged when removing the rear door outside handle assembly, unless the release plate of the rear door outside handle frame sub-assembly is pulled and held.

b. Remove the rear door outside handle assembly as shown in the illustration.

Fig. 157: Removing Rear Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD a. Disengage the 3 claws and remove the rear door front outside handle pad.

Fig. 158: Identifying Rear Door Front Outside Handle Pad Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD a. Disengage the 2 claws and remove the rear door rear outside handle pad.

Fig. 159: Identifying Rear Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

Fig. 160: Identifying Rear Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

b. Slide the rear door outside handle frame sub-assembly to disengage the claw of the rear door outside handle frame sub-assembly, and then remove it. 28. REMOVE REAR DOOR NO. 2 WEATHERSTRIP a. Using a clip remover, disengage the 5 clips and remove the rear door No. 2 weatherstrip.

Fig. 161: Identifying Rear Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE REAR DOOR PANEL CUSHION a. Disengage the 2 claws and remove the 2 rear door panel cushions.

Fig. 162: Identifying Rear Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE REAR DOOR BELT MOULDING ASSEMBLY . Refer to REMOVAL - Step 15 . 31. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING . Refer to REMOVAL - Step 16 . 32. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING . Refer to REMOVAL - Step 17 . 33. REMOVE REAR DOOR OUTSIDE STRIPE . Refer to REMOVAL - Step 16 . 34. REMOVE REAR DOOR LOWER OUTSIDE STRIPE . Refer to REMOVAL - Step 17 . ADJUSTMENT ADJUSTMENT

Fig. 163: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT:   



Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS .

1. INSPECT REAR DOOR a. Check that the clearance measurements of areas a through r are within each standard range.

Fig. 164: Checking Rear Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 3.35 to 6.35 0.6 to 3.6 mm a mm (0.132 to b (0.0236 to 0.250 in.) 0.142 in.) 3.35 to 6.35 0.9 to 3.9 mm c mm (0.132 to d (0.0354 to 0.250 in.) 0.154 in.) 3.35 to 6.35 1.5 to 4.5 mm e mm (0.132 to f (0.0591 to 0.250 in.) 0.177 in.) 3.35 to 6.35 5.4 to 8.4 mm g mm (0.132 to h (0.213 to 0.250 in.) 0.331 in.)

i

k

m

o

q

-1.5 to 1.5 mm (-0.0591 to 0.0591 in.) 2.0 to 5.0 mm (0.0787 to 0.197 in.) 2.9 to 7.1 mm (0.114 to 0.280 in.) -0.84 to 0.84 mm (-0.0331 to 0.0331 in.) -0.84 to 0.84 mm (-0.0331 to 0.0331 in.)

2.0 to 5.0 mm (0.0787 to 0.197 in.) -1.5 to 1.5 l mm (-0.0591 to 0.0591 in.) 2.96 to 4.64 n mm (0.115 to 0.182 in.) 2.96 to 4.64 p mm (0.115 to 0.182 in.) 2.3 to 6.3 mm r (0.0906 to 0.248 in.) j

2. ADJUST REAR DOOR NOTE:

Make sure that the turn the ignition switch off when adjusting door lock strikers.

a. Using SST, loosen the hinge bolts on the vehicle body and adjust the door position.  SST: 09812-00010

Fig. 165: Adjusting The Door Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the hinge bolts on the vehicle body after the adjustment.

Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) c. Loosen the hinge bolts on the door and adjust the door position. d. Tighten the hinge bolts on the door after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) e. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 166: Adjusting Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using a brass bar and a hammer, hit the striker to adjust its position. g. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REPAIR INSTRUCTION . Refer to INSTALLATION - Step 2 .

2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE . Refer to INSTALLATION - Step 2 . 3. INSTALL REAR DOOR OUTSIDE STRIPE . Refer to INSTALLATION - Step 3 . 4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING . Refer to INSTALLATION Step 1 . 5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING . Refer to INSTALLATION Step 2 . 6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY . Refer to INSTALLATION - Step 1 . 7. INSTALL REAR DOOR PANEL CUSHION a. Engage the 2 claws to install 2 new rear door panel cushions.

Fig. 167: Identifying Rear Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

a. Engage the 5 clips to install the rear door No. 2 weatherstrip.

Fig. 168: Identifying Rear Door No. 2 Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY a. Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly. b. Engage the claw.

Fig. 169: Identifying Rear Door Outside Handle Frame Screw And Door Handle Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Door

Handle Nut *a Outside *b Inside *1

c. Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw and door handle nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD a. Engage the 2 claws to install the rear door rear outside handle pad.

Fig. 170: Identifying Rear Door Rear Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD a. Engage the 3 claws to install the rear door front outside handle pad.

Fig. 171: Identifying Rear Door Front Outside Handle Pad Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY a. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

Fig. 172: Installing Rear Door Outside Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

b. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it. 13. INSTALL REAR DOOR OUTSIDE HANDLE COVER a. Engage the claw and install the rear door outside handle cover.

Fig. 173: Identifying Rear Door Outside Handle Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY a. Install the rear door inside locking cable assembly.

Fig. 174: Installing Rear Door Inside Locking Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws.

Fig. 175: Identifying Rear Door Inside Locking Cable Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY a. Install the rear door lock remote control cable assembly.

Fig. 176: Installing Rear Door Lock Remote Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the claw.

Fig. 177: Installing Rear Door Lock Remote Control Cable Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY NOTE:







When reusing the removed rear door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock with motor assembly.

a. Apply MP grease to the sliding parts of the rear door lock with motor assembly. b. When reusing the rear door lock with motor assembly: 1. Install a new door lock wiring harness seal to the rear door lock with motor assembly.

Fig. 178: Identifying Door Lock Wiring Harness Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.

Fig. 179: Identifying Rear Door Lock With Motor Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Release *1 Plate d. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock with motor assembly. e. Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTE:

The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.

a. Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

Fig. 180: Identifying Rear Power Window Regulator Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted. 18. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY a. Apply MP grease to the sliding parts of the rear door window regulator assembly. b. Install the temporary bolt to the rear door window regulator assembly. c. Temporarily install the rear door window regulator assembly.

Fig. 181: Identifying Rear Door Window Regulator Temporary Bolt And Assembly Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Temporary *1 Bolt d. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly. HINT: Tighten the bolts in the order shown in the illustration. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 19. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY a. Engage the guide.

Fig. 182: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install a new rear door inside panel reinforce sub-assembly with the 4 screws. 20. INSTALL REAR DOOR FRAME GARNISH a. Engage the clip to install a new rear door frame garnish.

Fig. 183: Identifying Rear Door Frame Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY a. Slide the rear door glass sub-assembly to install it as shown in the illustration.

Fig. 184: Installing Rear Door Glass From Rear Door Window Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. INSTALL REAR DOOR QUARTER WINDOW GLASS a. Install the rear door quarter window glass to the rear door quarter window weatherstrip. b. Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

Fig. 185: Installing Rear Door Quarter Window Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY a. Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

Fig. 186: Identifying Rear Door Lower Window Frame Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL REAR DOOR GLASS RUN a. Install the rear door glass run.

Fig. 187: Identifying Rear Door Glass Run Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. INSTALL REAR DOOR WEATHERSTRIP a. Engage the 20 clips to install the rear door weatherstrip.

Fig. 188: Identifying Rear Door Weatherstrip Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. INSTALL REAR DOOR CHECK ASSEMBLY a. Apply MP grease to the sliding parts of the rear door check assembly. b. Apply adhesive to the threads of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent c. Install the rear door check assembly with the 2 nuts and bolt.

Fig. 189: Identifying Rear Door Check Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) Nut Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 27. INSTALL REAR DOOR SERVICE HOLE COVER a. Apply new butyl tape to the rear door panel. b. Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector through a new rear door service hole cover.

Fig. 190: Locating Rear Door Service Hole Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Reference *1 Point c. Attach the rear door service hole cover according to the reference points on the rear door panel. NOTE:

Securely install the rear door service hole cover preventing wrinkles and air bubbles.

d. Connect the connector. 28. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP a. Install the rear door inner glass weatherstrip.

Fig. 191: Identifying Rear Door Inner Glass Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY a. Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

Fig. 192: Identifying Rear Door Inside Handle Sub-Assembly Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY a. Install the No. 1 door scuff plate clamp as shown in the illustration.

Fig. 193: Identifying No. 1 Door Scuff Plate Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

Fig. 194: Connecting Rear Door Lock Remote Control And Inside Locking Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Door Inside *1 Locking Cable Assembly Rear Door Lock *2 Remote Control Cable Assembly c. Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Fig. 195: Engaging Rear Door Trim Board Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

Reference Boss

d. Engage the 8 clips and install the rear door trim board sub-assembly.

Fig. 196: Identifying Rear Door Trim Board Sub-Assembly Clips And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the 3 screws. f. If protective tape has been applied, remove it. 31. INSTALL REAR ARMREST ASSEMBLY a. Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

Fig. 197: Identifying Rear Armrest Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL a. Connect the connector. b. Engage the 4 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

Fig. 198: Identifying Rear Power Window Regulator Switch Clips, Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG a. Engage the 3 claws to install the rear door inside handle bezel plug.

Fig. 199: Identifying Rear Door Inside Handle Bezel Plug Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

35. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK .

LUGGAGE COMPARTMENT DOOR COMPONENTS ILLUSTRATION

Fig. 200: Identifying Luggage Compartment Door Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 201: Identifying Luggage Compartment Door Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY DISASSEMBLY

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER a. Remove the 13 clips and luggage compartment door cover.

Fig. 202: Identifying Luggage Compartment Door Cover Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE LUGGAGE COMPARTMENT DOOR CUSHION a. Disengage the 2 claws and remove the 2 luggage compartment door panel cushions.

Fig. 203: Identifying Luggage Compartment Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) . Refer to REMOVAL - Step 2 . 4. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to REMOVAL - Step 3 . 5. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (w/o Wireless Door Lock Control System) a. Disconnect the luggage door lock control cable sub-assembly.

Fig. 204: Identifying Luggage Door Lock Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and luggage compartment door lock cylinder assembly.

Fig. 205: Identifying Luggage Compartment Door Lock Cylinder Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. REMOVE REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) . Refer to REMOVAL - Step 2 . 7. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY . Refer to REMOVAL - Step 3 . 8. REMOVE REAR TELEVISION CAMERA ASSEMBLY (w/ Rear Monitor) . Refer to REMOVAL - Step 2 . 9. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH . Refer to REMOVAL - Step 2 . 10. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. 11. REMOVE REAR LIGHT ASSEMBLY LH . Refer to REMOVAL - Step 2 . 12. REMOVE REAR LIGHT ASSEMBLY RH HINT: Use the same procedure as for the LH side. ADJUSTMENT ADJUSTMENT

Fig. 206: Identifying Centering Bolt And Standard Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 *2

Centering Bolt Standard Bolt

HINT: 



1. 2. 3. 4. 5.

Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with the centering bolts installed. Substitute the centering bolts with standard bolts when making adjustments. Specified torque for standard bolts is shown in the standard bolt chart. Refer to SPECIFIED TORQUE FOR STANDARD BOLTS . REMOVE LUGGAGE COMPARTMENT DOOR COVER . See step 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT . See step 1. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . See step 3. REMOVE REAR FLOOR FINISH PLATE . See step 4. ADJUST LUGGAGE COMPARTMENT DOOR a. Loosen the door side hinge bolts to adjust the door horizontally and vertically.

Fig. 207: Adjusting Luggage Compartment Door Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)

b. Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

Fig. 208: Adjusting Luggage Compartment Door Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brass bar and a hammer, hit the striker to adjust its position. d. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 6. 7. 8. 9. 10.

INSTALL REAR FLOOR FINISH PLATE . See step 9. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . See step 10. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . See step 12. INSTALL LUGGAGE COMPARTMENT DOOR COVER . See step 12. INSPECT LUGGAGE COMPARTMENT DOOR a. Check that the clearance measurements of areas a through d are within each standard range.

Fig. 209: Checking Luggage Compartment Door Clearance Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD CLEARANCE Area Measurement Area Measurement 2.0 to 5.0 mm 6.4 mm (0.252 a b (0.0787 to in.) 0.197 in.) -1.0 to 2.0 3.85 to 7.85 c mm (-0.0394 d mm (0.152 to to 0.0787 in.) 0.309 in.) REASSEMBLY REASSEMBLY

1. INSTALL REAR LIGHT ASSEMBLY LH . Refer to INSTALLATION - Step 1 . 2. INSTALL REAR LIGHT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 3. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH . Refer to INSTALLATION - Step 2 . 4. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH

HINT: Use the same procedure as for the LH side. 5. INSTALL REAR TELEVISION CAMERA ASSEMBLY (w/ Rear Monitor) . Refer to INSTALLATION - Step 1 . 6. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY . Refer to INSTALLATION - Step 5 . 7. INSTALL REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) . Refer to INSTALLATION - Step 4. 8. INSTALL LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (w/o Wireless Door Lock Control System) a. Install the luggage compartment door lock cylinder assembly with the 2 nuts.

Fig. 210: Identifying Luggage Compartment Door Lock Cylinder Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the luggage door lock control cable sub-assembly.

Fig. 211: Identifying Luggage Door Lock Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) . Refer to INSTALLATION - Step 1 . 10. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to INSTALLATION - Step 3 . 11. INSTALL LUGGAGE COMPARTMENT DOOR CUSHION a. Engage the 2 claws and install the 2 new luggage compartment door panel cushions.

Fig. 212: Identifying Luggage Compartment Door Panel Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL LUGGAGE COMPARTMENT DOOR COVER a. Install the luggage compartment door cover with the 13 clips.

Fig. 213: Identifying Luggage Compartment Door Cover Clips

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. ADJUST REAR TELEVISION CAMERA ASSEMBLY OPTICAL AXIS (w/ Parking Assist Monitor System) Refer to CALIBRATION .

LUGGAGE DOOR HINGE TORSION BAR COMPONENTS ILLUSTRATION

Fig. 214: Identifying Luggage Door Hinge Torsion Bar Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

After installing the torsion bar, use your hand to open and close the luggage

door. Make sure the luggage door can open and close smoothly. 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT a. Remove the luggage compartment floor mat. 2. REMOVE SPARE WHEEL COVER ASSEMBLY a. Remove the spare wheel cover assembly. 3. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) a. Remove the baggage holder net. 4. REMOVE REAR FLOOR FINISH PLATE a. Remove the 5 clips.

Fig. 215: Identifying Rear Floor Finish Plate Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and remove the rear floor finish plate.

Fig. 216: Removing Rear Floor Finish Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Push the 2 pins and remove the 2 No. 1 luggage compartment trim hooks.

Fig. 217: Locating No. 1 Luggage Compartment Trim Hook Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 6. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH a. Remove the clip .

Fig. 218: Locating Luggage Compartment Inner Trim Cover LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Remove the 2 clips . c. Disengage the fastener and remove the luggage compartment inner trim cover LH.

Fig. 219: Locating Luggage Compartment Inner Trim Cover LH Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER RH a. Remove the clip .

Fig. 220: Locating Luggage Compartment Inner Trim Cover RH Clips

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Remove the 2 clips . c. Disengage the fastener and remove the luggage compartment inner trim cover RH.

Fig. 221: Locating Luggage Compartment Inner Trim Cover RH Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE LUGGAGE COMPARTMENT DOOR HINGE COVER LH a. Disengage the 4 claws and remove the luggage compartment door hinge cover LH.

Fig. 222: Identifying Luggage Compartment Door Hinge Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE LUGGAGE COMPARTMENT DOOR HINGE COVER RH HINT: Use the same procedure as for the LH side. 10. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH a. Disengage the hook in the order indicated in the illustration and disconnect the rear seatback lock assembly LH (rear seat lock control cable LH).

Fig. 223: Removing Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure as for the LH side and RH side. b. Put protective tape around the luggage door hinge.

Fig. 224: Identifying Protective Tape Around Luggage Door Hinge LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape c. Using SST, disconnect the luggage door hinge torsion bar LH from the luggage door hinge and the left side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 225: Disconnecting Luggage Door Hinge Torsion Bar LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 claws as shown in the illustration.

Fig. 226: Disengaging Luggage Door Hinge Torsion Bar LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the luggage door hinge torsion bar LH from the luggage compartment door torsion bar support as shown in the illustration.

Fig. 227: Disconnecting Luggage Door Hinge Torsion Bar LH From Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the luggage door hinge torsion bar LH from the right side of the vehicle body as shown in the illustration.

Fig. 228: Removing Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH a. Put protective tape around the luggage door hinge.

Fig. 229: Identifying Protective Tape Around Luggage Door Hinge RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using SST, disconnect the luggage door hinge torsion bar RH from the luggage door hinge and the right side of the vehicle body as shown in the illustration.



SST: 09804-24010

Fig. 230: Disconnecting Luggage Door Hinge Torsion Bar RH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the luggage door hinge torsion bar RH from the luggage compartment door torsion bar support as shown in the illustration.

Fig. 231: Disconnecting Luggage Door Hinge Torsion Bar RH From Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the luggage door hinge torsion bar RH from the left side of the vehicle body as shown in the illustration.

Fig. 232: Removing Luggage Door Hinge Torsion Bar RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT a. Remove the luggage compartment door torsion bar support as shown in the illustration.

Fig. 233: Removing Luggage Compartment Door Torsion Bar Support

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure to replace the luggage compartment door torsion bar support with a new one.

INSTALLATION INSTALLATION

NOTE:

After installing the torsion bar, use your hand to open and close the luggage door. Make sure the luggage door can open and close smoothly.

1. INSTALL LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT a. Install a new luggage compartment door torsion bar support as shown in the illustration.

Fig. 234: Installing Luggage Compartment Door Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL LUGGAGE DOOR HINGE TORSION BAR RH a. Check the identification mark on the luggage door hinge torsion bar RH. w/o Rear Spoiler Green w/ Rear Spoiler

Pink b. Set the tip of the luggage door hinge torsion bar RH in the center installation hole. The upper and lower installation holes are used for adjustment.

Fig. 235: Identifying Upper And Lower Installation Holes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Installation *a Hole Installation *b Hole (For Adjustment) c. Connect the luggage door hinge torsion bar RH to the left side of the vehicle body as shown in the illustration.

Fig. 236: Connecting Luggage Door Hinge Torsion Bar RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the luggage door hinge torsion bar RH to the luggage compartment door torsion bar support as shown in the illustration.

Fig. 237: Connecting Luggage Door Hinge Torsion Bar RH To Luggage Compartment Door

Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, install the luggage door hinge torsion bar RH to the luggage door hinge and the right side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 238: Installing Luggage Door Hinge Torsion Bar RH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the protective tape. 3. INSTALL LUGGAGE DOOR HINGE TORSION BAR LH

a. Check the identification mark on the luggage door hinge torsion bar RH. w/o Rear Spoiler White w/ Rear Spoiler Yellow b. Set the tip of the luggage door hinge torsion bar LH in the center installation hole. The upper and lower installation holes are used for adjustment.

Fig. 239: Identifying Upper And Lower Installation Holes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Installation *a Hole Installation *b Hole (For Adjustment) c. Connect the luggage door hinge torsion bar LH to the right side of the vehicle body as shown in the illustration.

Fig. 240: Connecting Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the luggage door hinge torsion bar LH to the luggage compartment door torsion bar support as shown in the illustration.

Fig. 241: Connecting Luggage Door Hinge Torsion Bar LH To Luggage Compartment Door

Torsion Bar Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, install the luggage door hinge torsion bar LH to the luggage door hinge and the left side of the vehicle body as shown in the illustration.  SST: 09804-24010

Fig. 242: Installing Luggage Door Hinge Torsion Bar LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Engage the 2 claws as shown in the illustration.

Fig. 243: Engaging Luggage Door Hinge Torsion Bar LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Connect the rear seatback lock assembly LH (rear seat lock control cable LH) and engage the hook in the order indicated in the illustration.

Fig. 244: Installing Luggage Door Hinge Torsion Bar LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure as for the LH side and RH side. h. Remove the protective tape. 4. INSTALL LUGGAGE COMPARTMENT DOOR HINGE COVER LH a. Engage the 4 claws and install the luggage compartment door hinge cover LH. 5. INSTALL LUGGAGE COMPARTMENT DOOR HINGE COVER RH HINT: Use the same procedure as for the LH side.

6. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH a. Install the clip .

Fig. 245: Locating Luggage Compartment Inner Trim Cover LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Install the 2 clips . c. Engage the fastener and install the luggage compartment inner trim cover LH. 7. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER RH a. Install the clip .

Fig. 246: Locating Luggage Compartment Inner Trim Cover RH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1

Clip *2

b. Install the 2 clips . c. Engage the fastener and install the luggage compartment inner trim cover RH. 8. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Engage the 2 pins to install the 2 No. 1 luggage compartment trim hooks.

Fig. 247: Locating No. 1 Luggage Compartment Trim Hook Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 9. INSTALL REAR FLOOR FINISH PLATE a. Engage the 4 clips and install the rear floor finish plate.

Fig. 248: Installing Rear Floor Finish Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 5 clips. 10. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) a. Install the baggage holder net. 11. INSTALL SPARE WHEEL COVER ASSEMBLY a. Install the spare wheel cover assembly. 12. INSTALL LUGGAGE COMPARTMENT FLOOR MAT a. Install the luggage compartment floor mat.

LUGGAGE DOOR LOCK CONTROL CABLE ASSEMBLY COMPONENTS

ILLUSTRATION

Fig. 249: Identifying Luggage Door Lock Control Cable Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 250: Identifying Luggage Door Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 251: Identifying Luggage Door Lock Control Cable Assembly Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 252: Identifying Luggage Door Lock Control Cable Assembly Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to REMOVAL . 4. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to REMOVAL . 5. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to REMOVAL . 6. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to REMOVAL . 7. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 4 . REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 18 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 . REMOVE LAP BELT OUTER ANCHOR COVER . Refer to REMOVAL - Step 7 . DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 8 .

16. 17. 18. 19. 20. 21. 22.

REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 22 . REMOVE LUGGAGE COMPARTMENT DOOR COVER . See step 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT . See step 1. REMOVE SPARE WHEEL COVER ASSEMBLY . See step 2. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . See step 3. REMOVE REAR FLOOR FINISH PLATE . See step 4. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Push the pin and remove the No. 1 luggage compartment trim hook.

Fig. 253: Locating No. 1 Luggage Compartment Trim Hook Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin

23. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH . See step 6. 24. REMOVE FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Remove the screw.

Fig. 254: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 255: Disengaging Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the fuel lid lock control cable sub-assembly and luggage door lock control cable subassembly and remove the fuel lid lock open lever sub-assembly.

Fig. 256: Identifying Fuel Lid Lock And Luggage Door Lock Control Cables

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY a. Disengage the 2 clamps.

Fig. 257: Identifying Luggage Door Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a clip remover, disengage the clamp and disconnect the wire harness.

Fig. 258: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 2 clamps and remove the 2 scuff plate clips.

Fig. 259: Identifying Scuff Plate Clip Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Turn back the floor carpet so that the luggage door lock control cable sub-assembly and fuel lid lock control cable sub-assembly can be removed. e. w/o Wireless Door Lock Control System: 1. Disconnect the luggage door lock control cable sub-assembly.

Fig. 260: Identifying Luggage Door Lock Control Cable w/o Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disengage the 3 clamps and disconnect luggage door lock control cable sub-assembly.

Fig. 261: Identifying Luggage Door Lock Control Cable Clamps w/o Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Wireless Door Lock Control System: 1. Disengage the guide as shown in the illustration.

Fig. 262: Disconnecting Luggage Door Lock Cover w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect the luggage door lock control cable sub-assembly.

Fig. 263: Identifying Luggage Door Lock Control Cable w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Disengage the clamp and disconnect the luggage door lock control cable sub-assembly.

Fig. 264: Identifying Luggage Door Lock Control Cable Clamp w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and the guides , and then pull the fuel filler opening lid lock retainer.

Fig. 265: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

h. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and guides , and then pull the fuel filler opening lid lock retainer.

Fig. 266: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

i. Pull out the fuel filler opening lid lock retainer with both guides aligned with the cutouts.

Fig. 267: Removing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

Guide *3

j. Disengage the 2 claws and remove the fuel filler opening lid lock retainer.

Fig. 268: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. k. Disengage the 10 clamps and remove the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly.

Fig. 269: Identifying Fuel Lid Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Fuel Lid Door Lock Lock Control *1 *2 Control Cable Cable SubSubassembly assembly l. Using a knife, cut off the clamp as shown in the illustration.

Fig. 270: Identifying Clamp To Be Cut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tape - *a Cut - NOTE:

Be careful not to damage the vehicle fuel lid lock control cable subassembly and luggage door lock control cable sub-assembly.

m. Remove the clamp. n. Remove the 3 pieces of tape and fuel lid lock control cable sub-assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY a. Install the luggage door lock control cable sub-assembly to the fuel lid lock control cable subassembly with the new clamp (A) and the 3 pieces of tape as shown in the illustration.

Fig. 271: Identifying Luggage Door Lock Control Cable Clamp And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clamp *1 *2 Clamp (A) Luggage Fuel Lid Door Lock Lock Control *3 Control *4 Cable Cable SubSubassembly assembly *5 Tape - REFERENCE MEASUREMENT Area Measurement Area Measurement 295 to 305 880 to 900 a mm (11.6 to b mm (2.29 to 12.0 in.) 2.95 ft.) 2090 to 2110 2970 to 2990 c mm (6.86 to d mm (8.86 to 6.92 ft.) 9.81 ft.) 5.0 mm (0.197 e - in.) or less NOTE:

 

Wrap tape around the designated position 1 to 3 times. Make sure that the fuel lid lock control cable sub-assembly and

luggage door lock control cable sub-assembly are not kinked. b. Engage the 10 clamps and install the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly. c. Align the cutouts and guides, and then insert the fuel filler opening lid lock retainer.

Fig. 272: Installing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout *2 Guide d. Engage the 2 claws and install the fuel filler opening lid lock retainer.

Fig. 273: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Claw e. Engage the 2 claws and install the fuel lid lock control cable sub-assembly.

Fig. 274: Identifying Fuel Lid Lock Control Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Wireless Door Lock Control System: 1. Engage the clamp and connect the luggage door lock control cable sub-assembly. 2. Connect the luggage door lock control cable sub-assembly. 3. Engage the guide as shown in the illustration.

Fig. 275: Connecting Luggage Door Lock Control Cable Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. w/o Wireless Door Lock Control System: 1. Engage the 3 clamps and connect the luggage door lock control cable sub-assembly.

2. Connect the luggage door lock control cable sub-assembly to the luggage compartment door lock cylinder assembly h. Return the floor carpet to the original position. i. Engage the 2 clamps and install the 2 scuff plate clips. j. Engage the 3 clamps and connect the wire harness. 2. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY a. Connect the fuel lid lock control cable sub-assembly and luggage door lock control cable subassembly to the fuel lid lock open lever sub-assembly.

Fig. 276: Identifying Fuel Lid Lock And Luggage Door Lock Control Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Door Lock *1 Control Cable Subassembly Fuel Lid Lock Control *2 Cable Subassembly

b. Engage the guide and install the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 277: Engaging Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the screw. 3. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH . See step 6. 4. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK a. Engage the pin to install the No. 1 luggage compartment trim hook.

Fig. 278: Locating No. 1 Luggage Compartment Trim Hook Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin 5. 6. 7. 8. 9. 10. 11. 12.

INSTALL REAR FLOOR FINISH PLATE . See step 9. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . See step 10. INSTALL SPARE WHEEL COVER ASSEMBLY . See step 11. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . See step 12. INSTALL LUGGAGE COMPARTMENT DOOR COVER . See step 12. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 22 . CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 .

13. INSTALL LAP BELT OUTER ANCHOR COVER . Refer to INSTALLATION - Step 7 . 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 15. INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 26 . 16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 . 17. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 . 18. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 19. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 20. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to INSTALLATION . 21. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to INSTALLATION . 22. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to INSTALLATION . 23. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to INSTALLATION . 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

25. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH COMPONENTS ILLUSTRATION

Fig. 279: Identifying Luggage Compartment Door Opener Outer Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL . 2. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Remove the luggage door opening switch assembly.

Fig. 280: Identifying Luggage Door Opening Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 281: Inspecting Luggage Door Opening Switch Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Luggage door opening 2 (E) - 3 10 kohms switch (UL) or higher assembly not pushed Luggage door 2 (E) - 3 opening Below 1 (UL) switch ohms assembly pushed TEXT IN ILLUSTRATION Component without *a harness connected (Luggage

Door Opening Switch Assembly) INSTALLATION INSTALLATION

1. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY a. Install the luggage door opening switch assembly. 2. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION .

FUEL LID LOCK CONTROL CABLE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 282: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 283: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 284: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 285: Identifying Fuel Lid Lock Control Cable Assembly Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to REMOVAL . 4. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to REMOVAL . 5. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to REMOVAL . 6. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to REMOVAL . 7. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 4 . REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 18 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 . REMOVE LAP BELT OUTER ANCHOR COVER . Refer to REMOVAL - Step 7 . DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 8 .

16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 22 . REMOVE LUGGAGE COMPARTMENT DOOR COVER . See step 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT . See step 1. REMOVE SPARE WHEEL COVER ASSEMBLY . See step 2. REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . See step 3. REMOVE REAR FLOOR FINISH PLATE . See step 4. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . See step 22. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH . See step 6. REMOVE FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY . See step 24. REMOVE FUEL LID LOCK CONTROL CABLE SUB-ASSEMBLY a. Disengage the 2 clamps.

Fig. 286: Identifying Luggage Door Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a clip remover, disengage the clamp and disconnect the wire harness.

Fig. 287: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a clip remover, disengage the 2 clamps and remove the 2 scuff plate clips.

Fig. 288: Identifying Scuff Plate Clip Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Turn back the floor carpet so that the luggage door lock control cable sub-assembly and fuel lid lock control cable sub-assembly can be removed. e. w/o Wireless Door Lock Control System: 1. Disconnect the luggage door lock control cable sub-assembly.

Fig. 289: Identifying Luggage Door Lock Control Cable w/o Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disengage the 3 clamps and disconnect the luggage door lock control cable sub-assembly.

Fig. 290: Identifying Luggage Door Lock Control Cable Clamps w/o Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Wireless Door Lock Control System: 1. Disengage the guide as shown in the illustration.

Fig. 291: Disconnecting Luggage Door Lock Cover w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect the luggage door lock control cable sub-assembly.

Fig. 292: Identifying Luggage Door Lock Control Cable w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Disengage the clamp and disconnect the luggage door lock control cable sub-assembly.

Fig. 293: Identifying Luggage Door Lock Control Cable Clamp w/ Wireless Door Lock Control System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and the guides , and then pull the fuel filler opening lid lock retainer.

Fig. 294: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

h. Rotate the fuel filler opening lid lock retainer as shown in the illustration to align the cutouts and guides , and then pull the fuel filler opening lid lock retainer.

Fig. 295: Rotating Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

i. Pull out the fuel filler opening lid lock retainer with both guides aligned with the cutouts.

Fig. 296: Removing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout Guide *2

Guide *3

j. Disengage the 2 claws and remove the fuel filler opening lid lock retainer.

Fig. 297: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. k. Disengage the 10 clamps and remove the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly.

Fig. 298: Identifying Fuel Lid Lock Control Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Luggage Fuel Lid Door Lock Lock Control *1 *2 Control Cable Cable SubSubassembly assembly l. Using a knife, cut off the clamp as shown in the illustration.

Fig. 299: Identifying Clamp To Be Cut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tape - *a Cut - NOTE:

Be careful not to damage the vehicle fuel lid lock control cable subassembly and luggage door lock control cable sub-assembly.

m. Remove the clamp. n. Remove the 3 pieces of tape and fuel lid lock control cable sub-assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL LID LOCK CONTROL CABLE SUB-ASSEMBLY a. Install the fuel lid lock control cable sub-assembly to the luggage door lock control cable subassembly with the new clamp and the 3 pieces of tape as shown in the illustration.

Fig. 300: Identifying Fuel Lid Lock Control Cable Clamp And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clamp *1 *2 Clamp (A) Luggage Fuel Lid Door Lock Lock Control *3 Control *4 Cable Cable SubSubassembly assembly *5 Tape - REFERENCE MEASUREMENT Area Measurement Area Measurement 295 to 305 880 to 900 a mm (11.6 to b mm (2.29 to 12.0 in.) 2.95 ft.) 2090 to 2110 2970 to 2990 c mm (6.86 to d mm (8.86 to 6.92 ft.) 9.81 ft.) 5.0 mm (0.197 e - in.) or less NOTE:

 

Wrap tape around the designated position 1 to 3 times. Make sure that the fuel lid lock control cable sub-assembly and

luggage door lock control cable sub-assembly are not kinked. b. Engage the 10 clamps and install the fuel lid lock control cable sub-assembly and luggage door lock control cable sub-assembly. c. Align the cutouts and guides, and then insert the fuel filler opening lid lock retainer.

Fig. 301: Installing Fuel Filler Opening Lid Lock Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout *2 Guide d. Engage the 2 claws and install the fuel filler opening lid lock retainer.

Fig. 302: Identifying Fuel Filler Opening Lid Lock Retainer Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Claw e. Engage the 2 claws and install the fuel lid lock control cable sub-assembly.

Fig. 303: Identifying Fuel Lid Lock Control Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Wireless Door Lock Control System: 1. Engage the clamp and connect the luggage door lock control cable sub-assembly. 2. Connect the luggage door lock control cable sub-assembly. 3. Engage the guide as shown in the illustration.

Fig. 304: Connecting Luggage Door Lock Control Cable Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. w/o Wireless Door Lock Control System: 1. Engage the 3 clamps and connect the luggage door lock control cable sub-assembly.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

2. Connect the luggage door lock control cable sub-assembly to the luggage compartment door lock cylinder assembly h. Return the floor carpet to the original position. i. Engage the 2 clamps and install the 2 scuff plate clips. j. Engage the 3 clamps and connect the wire harness. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY . See step 2. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH . See step 6. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . See step 4. INSTALL REAR FLOOR FINISH PLATE . See step 9. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . See step 10. INSTALL SPARE WHEEL COVER ASSEMBLY . See step 11. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . See step 12. INSTALL LUGGAGE COMPARTMENT DOOR COVER . See step 12. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 22 . CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 . INSTALL LAP BELT OUTER ANCHOR COVER . Refer to INSTALLATION - Step 7 . INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 26 . INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 . INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 . INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat) Refer to INSTALLATION .

21. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat) Refer to INSTALLATION . 22. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat) Refer to INSTALLATION . 23. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat) Refer to INSTALLATION .

24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

25. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 DRIVELINE/AXLES Drive Axle (Inspection) (Hybrid)

AXLE SYSTEM PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. AXLE SYSTEM Symptom

Wander or pulls

Front wheel shimmy

Suspected Area Tires (worn or improperly inflated) Front wheel alignment (incorrect) Rear wheel alignment (incorrect) Steering intermediate shaft (loose or worn) Front axle hub bearings (loose or worn) Rear axle hub bearings (loose or worn) Steering gear (broken) Suspension parts (worn out) Tires (worn or improperly inflated) Wheels (out of balance) Front shock absorber (worn out) Front wheel alignment (incorrect) Lower ball joint (worn) Axle hub bearings (loose or worn) Steering intermediate shaft (loose or worn) Steering gear (broken) Tires (worn or improperly

See Refer to INSPECTION Refer to ADJUSTMENT Refer to ADJUSTMENT Refer to REMOVAL Refer to ON-VEHICLE INSPECTION Refer to ON-VEHICLE INSPECTION Refer to REMOVAL Refer to INSPECTION Refer to INSPECTION Refer to INSPECTION Refer to ADJUSTMENT Refer to REMOVAL Refer to ON-VEHICLE INSPECTION Refer to REMOVAL Refer to REMOVAL

Rear wheel shimmy

inflated) Wheels (out of balance) Rear shock absorber (worn out) Axle hub bearings (loose or worn) Rear wheel alignment (incorrect)

Refer to INSPECTION Refer to INSPECTION Refer to INSPECTION Refer to ON-VEHICLE INSPECTION Refer to ADJUSTMENT

2012-2017 DRIVELINE/AXLES Drive Axle (Inspection) - Camry (Except Hybrid)

AXLE SYSTEM PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. AXLE SYSTEM Symptom

Wander or pulls

Front wheel shimmy

Suspected Area Tires (worn or improperly inflated) Front wheel alignment (incorrect) Rear wheel alignment (incorrect) Steering intermediate shaft (loose or worn) Front axle hub bearings (loose or worn) Rear axle hub bearings (loose or worn) Steering gear (broken) Suspension parts (worn out) Tires (worn or improperly inflated) Wheels (out of balance) Front shock absorber (worn out) Front wheel alignment (incorrect) Lower ball joint (worn) Axle hub bearings (loose or worn) Steering intermediate shaft (loose or worn) Steering gear (broken) Tires (worn or improperly

See Refer to INSPECTION Refer to ADJUSTMENT Refer to ADJUSTMENT Refer to REMOVAL Refer to ON-VEHICLE INSPECTION Refer to ON-VEHICLE INSPECTION Refer to REMOVAL Refer to INSPECTION Refer to INSPECTION Refer to INSPECTION Refer to ADJUSTMENT Refer to REMOVAL Refer to ON-VEHICLE INSPECTION Refer to REMOVAL Refer to REMOVAL

Rear wheel shimmy

inflated) Wheels (out of balance) Rear shock absorber (worn out) Axle hub bearings (loose or worn) Rear wheel alignment (incorrect)

Refer to INSPECTION Refer to INSPECTION Refer to INSPECTION Refer to ON-VEHICLE INSPECTION Refer to ADJUSTMENT

2012-2017 DRIVELINE/AXLES Drive Shaft (Service Information) (Hybrid)

FRONT DRIVE SHAFT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Drive Shaft Assembly Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Front Drive Shaft Assembly Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Front Drive Shaft Assembly Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Front Drive Shaft Assembly Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Identifying Front Drive Shaft Assembly Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

1. 2. 3. 4. 5. 6. 7. 8. 9.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN HYBRID TRANSAXLE FLUID . Refer to ADJUSTMENT - Step 1 REMOVE FRONT AXLE SHAFT NUT a. Using SST and a hammer, release the staked part of the front axle shaft nut.

Fig. 6: Releasing Staked Part Of Front Axle Shaft Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09930-00010

NOTE:

Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

10. 11. 12. 13. 14. 15.

b. While applying the brakes, remove the front axle shaft nut. SEPARATE FRONT STABILIZER LINK ASSEMBLY . Refer to REMOVAL - Step 4 SEPARATE FRONT SPEED SENSOR . Refer to REMOVAL - Step 5 SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to REMOVAL - Step 10 SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE FRONT DRIVE SHAFT ASSEMBLY LH a. Using SST, remove the front drive shaft assembly LH.

Fig. 7: Removing Front Drive Shaft Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09520-00031 SST: 09520-01010

NOTE:



 

Do not damage the hybrid vehicle transaxle assembly type T oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly LH.

16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH a. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

Fig. 8: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket. NOTE:



 

Do not damage the hybrid vehicle transaxle assembly type T oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly RH.

c. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH. 17. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH a. Using a screwdriver, remove the front drive shaft hole snap ring LH.

Fig. 9: Removing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Using needle-nose pliers, remove the front No. 2 axle inboard joint boot clamp.

Fig. 10: Removing Front No. 2 Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP a. Using pliers, remove the front axle inboard joint boot clamp.

Fig. 11: Removing Front Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. SEPARATE FRONT AXLE INBOARD JOINT BOOT a. Separate the front axle inboard joint boot from the front drive inboard joint assembly. 4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY a. Remove the old grease from the front drive inboard joint assembly. b. Put matchmarks on the front drive inboard joint assembly and front drive outboard joint shaft assembly.

Fig. 12: Identifying Matchmarks On Front Drive Inboard Joint Assembly And Front Drive Outboard Joint Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a Matchmark NOTE:

Do not use a punch for the marks.

c. Remove the front drive inboard joint assembly from the front drive outboard joint shaft assembly. d. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

e. Using a snap ring expander, remove the shaft snap ring from the front drive outboard joint shaft assembly.

Fig. 13: Identifying Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Put matchmarks on the front drive outboard joint shaft assembly and tripod joint.

Fig. 14: Identifying Front Axle Outboard Joint Shaft Assembly And Tripod Joint Matchmark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Do not use a punch for the marks.

g. Using a brass bar and a hammer, tap out the tripod joint from the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Do not drop the tripod joint.

5. REMOVE FRONT AXLE INBOARD JOINT BOOT a. Remove the front No. 2 axle inboard joint boot clamp, front axle inboard joint boot and front axle inboard joint boot clamp. 6. REMOVE FRONT DRIVE SHAFT DAMPER a. Using pliers, remove the front drive shaft damper clamp.

Fig. 15: Removing Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front drive shaft damper. 7. REMOVE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Using pliers, remove the front No. 2 axle outboard joint boot clamp.

Fig. 16: Removing Outboard Joint Boot No. 2 Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP HINT: Perform the same procedure as for the front No. 2 axle outboard joint boot clamp. 9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT a. Remove the front axle outboard joint boot clamp, front axle outboard joint boot and front No. 2 axle outboard joint boot clamp from the front drive outboard joint shaft assembly. b. Remove the grease from the outboard joint. 10. REMOVE FRONT DRIVE SHAFT DUST COVER LH a. Using SST and a press, remove the front drive shaft dust cover LH.

Fig. 17: Pressing Drive Shaft Dust Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

11. REMOVE FRONT DRIVE SHAFT DUST COVER RH a. Using a press, remove the front drive shaft dust cover RH.

Fig. 18: Identifying Drive Shaft Dust Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to drop the front drive inboard joint assembly.

12. REMOVE FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST and a press, remove the front drive shaft dust cover.

Fig. 19: Removing Drive Shaft Dust Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

13. REMOVE FRONT DRIVE SHAFT BEARING (for RH Side) a. Using a snap ring expander, remove the drive shaft hole snap ring.

Fig. 20: Removing Drive Shaft Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a press, remove the front drive shaft bearing.

Fig. 21: Removing Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09527-10011

NOTE:

Be careful not to drop the front drive inboard joint assembly.

INSPECTION INSPECTION

1. INSPECT FRONT DRIVE SHAFT ASSEMBLY a. Check that there is no excessive play in the radial direction of the outboard joint.

Fig. 22: Checking Excessive Play In Outboard Joint And Inboard Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Check that the inboard joint slides smoothly in the thrust direction. Check that there is no excessive play in the radial direction of the inboard joint. Check the boots for damage. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 23: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side NOTE:

Keep the drive shaft assembly level during inspection.

Dimension (A) Dimension (A) LH Side 581.5 mm (1.90 ft.)

RH Side 914.9 mm (3.00 ft.) REASSEMBLY REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft bearing.

Fig. 24: Install A New Front Drive Shaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09527-10011

NOTE:

The bearing should be completely installed.

b. Using a snap ring expander, install a new drive shaft hole snap ring.

Fig. 25: Removing Drive Shaft Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft dust cover.

Fig. 26: Installing Front Drive Shaft Dust Cover (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09726-40010

Dimension (A) 26.6 to 27.6 mm (1.05 to 1.08 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover.

3. INSTALL FRONT DRIVE SHAFT DUST COVER RH a. Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

Fig. 27: Installing Front Drive Shaft Dust Cover To Proper Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate Dimension (A)

110.0 to 111.0 mm (4.33 to 4.37 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover RH.

4. INSTALL FRONT DRIVE SHAFT DUST COVER LH a. Using a steel plate and a press, install a new front drive shaft dust cover LH.

Fig. 28: Installing Front Drive Shaft Dust Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover LH.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT a. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

Fig. 29: Wrapping Spline Of Drive Shaft With Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 30: Identifying Front Drive Outboard Joint Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Drive Outboard *1 Joint Shaft Assembly Front No. 2 Axle Outboard *2 Joint Boot Clamp Front Axle *3 Outboard Joint Boot Front Axle Outboard *4 Joint Boot Clamp

Outboard Joint Side Inboard Joint Side 1. Front No. 2 axle outboard joint boot clamp 2. Front axle outboard joint boot 3. Front axle outboard joint boot clamp c. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease. Standard grease capacity 164 to 184 g (5.78 to 6.48 oz.) d. Install the front axle outboard joint boot onto the front drive outboard joint shaft assembly groove. NOTE:





Do not allow grease to adhere to the boot clamp track of the outboard joint boot. Keep the inside of the outboard joint boot free of foreign matter.

6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot. c. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 31: Tightening No. 2 Front Axle Outboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 d. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

e. Remove SST. f. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.

Fig. 32: Measuring Clearance Of Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP a. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot. b. Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 33: Installing Front Axle Outboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 c. Tighten SST so that the front axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

d. Remove SST. e. Using SST, measure the clearance of the front axle outboard joint boot clamp.

Fig. 34: Measuring Clearance Of Front Axle Outboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 8. INSTALL FRONT DRIVE SHAFT DAMPER a. Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

Fig. 35: Installing Front Drive Shaft Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Set the dimension as specified below. Dimension (A) 223.4 to 227.4 mm (8.80 to 8.95 in.) c. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

d. Install a new front drive shaft damper clamp onto the front drive shaft damper. NOTE:

Be sure to install the clamp in the correct position.

e. Place SST onto the front drive shaft damper clamp, press it against the boot and slightly tighten SST.

Fig. 36: Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 f. Tighten SST so that the front drive shaft damper clamp is pinched. 

NOTE:

Do not overtighten SST.

g. Remove SST. h. Using SST, measure the clearance of the front drive shaft damper clamp.

Fig. 37: Measuring Clearance Of Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY a. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 38: Identifying Installation Order Of Front Axle Outboard Joint Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Axle Inboard *1 Joint Boot Clamp Front Axle *2 Inboard Joint Boot Front No. 2 Axle Inboard *3 Joint Boot Clamp Protective *4 Tape Outboard Joint Side Inboard Joint Side

1. Front axle inboard joint boot clamp 2. Front axle inboard joint boot 3. Front No. 2 axle inboard joint boot clamp b. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

c. Remove the protective tape. d. Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.

Fig. 39: Identifying Tripod Joint And Front Axle Outboard Joint Shaft Assembly Matchmark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark e. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Keep the tripod joint free of foreign matter.

f. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

Fig. 40: Identifying Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Pack the front drive inboard joint assembly and front axle inboard boot with grease. Standard grease capacity 135 to 155 g (4.76 to 5.46 oz.) h. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

Fig. 41: Identifying Matchmarks On Front Drive Inboard Joint Assembly And Front Drive Outboard Joint Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark 10. INSTALL FRONT AXLE INBOARD JOINT BOOT a. Install the front axle inboard joint boot to the front drive inboard joint assembly. b. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 42: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side Dimension (A) Dimension (A) LH Side 581.5 mm (1.90 ft.) RH Side 914.9 mm (3.00 ft.)

11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot. c. Place SST onto the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 43: Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 d. Tighten SST so that the front axle inboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

e. Remove SST. f. Using SST, measure the clearance of the front axle inboard joint boot clamp.

Fig. 44: Front Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot. b. Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.

Fig. 45: Removing Front No. 2 Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the front axle inboard joint boot.

13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH a. Install a new front drive shaft hole snap ring LH. NOTE:

Face the end gap of the front drive shaft hole snap ring downward.

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY See step 1 INSTALLATION INSTALLATION

1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease. c. Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

Fig. 46: Installing Drive Shaft Assembly LH With Brass Bar And Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





 

Face the end gap of the front drive shaft hole snap ring LH downward. Do not damage the hybrid vehicle transaxle assembly type T oil seal. Do not damage the front axle inboard joint boot. Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

HINT: Confirm whether the drive shaft is securely driven in by checking the reaction force and sound. d. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

Fig. 47: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. e. Align the matchmarks and install the front drive shaft assembly LH to the front axle hub subassembly.

Fig. 48: Identifying Matchmarks On Front Drive Shaft Assembly LH To Front Axle Hub Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease. c. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH. d. Install the front drive shaft assembly RH. NOTE:



 

Do not damage the hybrid vehicle transaxle assembly type T oil seal. Do not damage the front axle inboard joint boot. When inserting the front drive shaft assembly RH, keep it level.

e. Install the bearing bracket hole snap ring and a new bolt.

Fig. 49: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 32 N*m (330 kgf*cm, 24 ft.*lbf) f. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

Fig. 50: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. g. Align the matchmarks and install the front drive shaft assembly RH to the front axle hub subassembly.

Fig. 51: Identifying Matchmarks On Front Drive Shaft Assembly RH To Front Axle Hub Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

3. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 4. CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 5. INSTALL FRONT SPEED SENSOR . Refer to INSTALLATION - Step 19 6. INSTALL FRONT STABILIZER LINK ASSEMBLY . Refer to INSTALLATION - Step 10 7. INSTALL FRONT AXLE SHAFT NUT a. Clean the threaded parts on the front drive shaft assembly and a new axle shaft nut using a nonresidue solvent. NOTE:

 

Be sure to perform this work even when using a new drive shaft. Keep the threaded parts free of oil and foreign matter.

b. Using a socket wrench (30 mm), install the front axle shaft nut.

Fig. 52: Staking Front Axle Shaft Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 294 N*m (2998 kgf*cm, 217 ft.*lbf) c. Using a chisel and a hammer, stake the front axle shaft nut. 8. INSTALL FRONT WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 9. ADD HYBRID TRANSAXLE FLUID . Refer to ADJUSTMENT - Step 2

10. 11. 12. 13. 14. 15. 16. 17.

INSPECT HYBRID TRANSAXLE FLUID . Refer to ADJUSTMENT - Step 3 INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT

18. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

2012-2017 DRIVELINE/AXLES Drive Shaft (Service Information) (Except Hybrid) - Camry

FRONT DRIVE SHAFT ASSEMBLY (FOR 2AR-FE) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Drive Shaft Assembly (For 2AR-FE) Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Front Drive Shaft Assembly (For 2AR-FE) Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Front Drive Shaft Assembly (For 2AR-FE) Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Front Drive Shaft Assembly (For 2AR-FE) Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 5: Identifying Front Drive Shaft Assembly (For 2AR-FE) Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

1. 2. 3. 4. 5. 6. 7. 8. 9.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN AUTOMATIC TRANSAXLE FLUID . Refer to REPLACEMENT - Step 1 . REMOVE FRONT AXLE SHAFT NUT a. Using SST and a hammer, release the staked part of the front axle shaft nut.

Fig. 6: Releasing Staked Part Of Front Axle Shaft Nut LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09930-00010

NOTE:

Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

10. 11. 12. 13. 14. 15.

b. While applying the brakes, remove the front axle shaft nut. SEPARATE FRONT STABILIZER LINK ASSEMBLY . Refer to REMOVAL - Step 4 . SEPARATE FRONT SPEED SENSOR . Refer to REMOVAL - Step 3 . SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 . SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to REMOVAL - Step 8 . SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 7 . REMOVE FRONT DRIVE SHAFT ASSEMBLY LH a. Using SST, remove the front drive shaft assembly LH.

Fig. 7: Removing Front Drive Shaft Assembly LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09520-00031 SST: 09520-01010

NOTE:

  

Do not damage the transaxle case oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly LH.

16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH a. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

Fig. 8: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket. NOTE:

  

Do not damage the front transaxle case oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly RH.

c. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH. 17. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH a. Using a screwdriver, remove the front drive shaft hole snap ring LH.

Fig. 9: Removing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Using needle-nose pliers, remove the front No. 2 axle inboard joint boot clamp.

Fig. 10: Remove/Install Front No. 2 Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP HINT: Perform the same procedure as for the front No. 2 axle inboard joint boot clamp. 3. SEPARATE FRONT AXLE INBOARD JOINT BOOT a. Separate the front axle inboard joint boot from the front drive inboard joint assembly. 4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY a. Remove the old grease from the front drive inboard joint assembly. b. Put matchmarks on the front drive inboard joint assembly and front drive outboard joint shaft assembly.

Fig. 11: Identifying Front Drive Inboard & Outboard Joint Shaft Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Do not use a punch for the marks.

c. Remove the front drive inboard joint assembly from the front drive outboard joint shaft assembly. d. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

e. Using a snap ring expander, remove the shaft snap ring from the front drive outboard joint shaft assembly.

Fig. 12: Remove/Install Front Axle Outboard Joint Shaft Assembly Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Put matchmarks on the front drive outboard joint shaft assembly and tripod joint.

Fig. 13: Placing Matchmarks On Front Drive Outboard Joint Shaft Assembly And Tripod Joint

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Do not use a punch for the marks.

g. Using a brass bar and a hammer, tap out the tripod joint from the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Do not drop the tripod joint.

5. REMOVE FRONT AXLE INBOARD JOINT BOOT a. Remove the front No. 2 axle inboard joint boot clamp, front axle inboard joint boot and front axle inboard joint boot clamp. 6. REMOVE FRONT DRIVE SHAFT DAMPER a. Using needle-nose pliers, remove the front drive shaft damper clamp.

Fig. 14: Remove/Install Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front drive shaft damper. 7. REMOVE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Using pliers, remove the front No. 2 axle outboard joint boot clamp.

Fig. 15: Removing Outboard Joint Boot No. 2 Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP HINT: Perform the same procedure as for the front No. 2 axle outboard joint boot clamp. 9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT a. Remove the front axle outboard joint boot clamp, front axle outboard joint boot and front No. 2 axle outboard joint boot clamp from the front drive outboard joint shaft assembly. b. Remove the grease from the outboard joint. 10. REMOVE FRONT DRIVE SHAFT DUST COVER LH a. Using SST and a press, remove the front drive shaft dust cover LH.

Fig. 16: Pressing Drive Shaft Dust Cover LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

11. REMOVE FRONT DRIVE SHAFT DUST COVER RH a. Using a press, remove the front drive shaft dust cover RH.

Fig. 17: Removing Drive Shaft Dust Cover RH Using Press Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to drop the front drive inboard joint assembly.

12. REMOVE FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST and a press, remove the front drive shaft dust cover.

Fig. 18: Removing Drive Shaft Dust Cover Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

13. REMOVE FRONT DRIVE SHAFT BEARING (for RH Side) a. Using a snap ring expander, remove the drive shaft hole snap ring.

Fig. 19: Removing/Installing Drive Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a press, remove the front drive shaft bearing.

Fig. 20: Removing Bearing Using SST And Press Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09527-10011

NOTE:

Be careful not to drop the front drive inboard joint assembly.

INSPECTION INSPECTION

1. INSPECT FRONT DRIVE SHAFT ASSEMBLY a. Check that there is no excessive play in the radial direction of the outboard joint.

Fig. 21: Inspecting Front Drive Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Check that the inboard joint slides smoothly in the thrust direction. Check that there is no excessive play in the radial direction of the inboard joint. Check the boots for damage. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 22: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side NOTE:

Keep the drive shaft assembly level during inspection.

Dimension (A) Dimension (A) LH Side 587.4 mm (1.93 ft.)

RH Side 906.6 mm (2.97 ft.) REASSEMBLY REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft bearing.

Fig. 23: Installing Front Drive Shaft Bearing (For RH Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09527-10011

NOTE:

The bearing should be completely installed.

b. Using a snap ring expander, install a new drive shaft hole snap ring.

Fig. 24: Removing/Installing Drive Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft dust cover.

Fig. 25: Installing Front Drive Shaft Dust Cover (For RH Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09726-40010

Dimension (A) 26.6 to 27.6 mm (1.05 to 1.08 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover.

3. INSTALL FRONT DRIVE SHAFT DUST COVER RH a. Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

Fig. 26: Installing Front Drive Shaft Dust Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate Dimension (A)

110.0 to 111.0 mm (4.33 to 4.37 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover RH.

4. INSTALL FRONT DRIVE SHAFT DUST COVER LH a. Using a steel plate and a press, install a new front drive shaft dust cover LH.

Fig. 27: Installing Front Drive Shaft Dust Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover LH.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT a. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

Fig. 28: Wrapping Spline Of Drive Shaft With Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 29: Identifying Front Drive Outboard Joint Shaft Assembly Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Drive Outboard *1 Joint Shaft Assembly Front No. 2 Axle Outboard *2 Joint Boot Clamp Front Axle *3 Outboard Joint Boot Front Axle Outboard *4 Joint Boot Clamp

Outboard Joint Side Inboard Joint Side 1. Front No. 2 axle outboard joint boot clamp 2. Front axle outboard joint boot 3. Front axle outboard joint boot clamp c. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease. Standard grease capacity 100 to 120 g (3.53 to 4.23 oz.) d. Install the front axle outboard joint boot onto the front drive outboard joint shaft assembly groove. NOTE:





Do not allow grease to adhere to the boot clamp track of the outboard joint boot. Keep the inside of the outboard joint boot free of foreign matter.

6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot. c. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 30: Tightening No. 2 Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 d. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

e. Remove SST. f. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.

Fig. 31: Measuring Clearance Of Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 1.2 to 4.0 mm (0.0472 to 0.157 in.) If the clearance is outside the specified range, retighten SST. 7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP a. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot. b. Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 32: Tightening Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 c. Tighten SST so that the front axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

d. Remove SST. e. Using SST, measure the clearance of the front axle outboard joint boot clamp.

Fig. 33: Measuring Clearance Of Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 1.2 to 4.0 mm (0.0472 to 0.157 in.) If the clearance is outside the specified range, retighten SST. 8. INSTALL FRONT DRIVE SHAFT DAMPER a. Install a new front drive shaft damper clamp onto the front drive outboard joint shaft assembly. b. Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

Fig. 34: Identifying Front Drive Shaft Damper Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Drive *1 Shaft Damper Front Drive *2 Shaft Damper Clamp c. Set the dimension as specified below. Dimension (A) 223.4 to 227.4 mm (8.80 to 8.95 in.) d. Install the front drive shaft damper clamp onto the front drive shaft damper. NOTE:

Be sure to install the clamp in the correct position.

e. Using needle nose pliers, install the front drive shaft damper clamp.

Fig. 35: Remove/Install Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY a. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 36: Identifying Front Drive Inboard Joint Assembly Installation Sequence

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Axle Inboard *1 Joint Boot Clamp Front Axle *2 Inboard Joint Boot Front No. 2 Axle Inboard *3 Joint Boot Clamp Protective *4 Tape Outboard Joint Side Inboard Joint Side 1. Front axle inboard joint boot clamp 2. Front axle inboard joint boot 3. Front No. 2 axle inboard joint boot clamp b. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

c. Remove the protective tape. d. Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.

Fig. 37: Aligning Matchmarks And Installing Tripod Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark e. Align the matchmarks placed before removal. f. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Keep the tripod joint free of foreign matter.

g. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

Fig. 38: Remove/Install Front Axle Outboard Joint Shaft Assembly Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Pack the front drive inboard joint assembly and front axle inboard boot with grease. Standard grease capacity (LH Side) 150 to 170 g (5.29 to 5.99 oz.) Standard grease capacity (RH Side) 155 to 175 g (5.47 to 6.17 oz.) i. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

Fig. 39: Identifying Front Drive Inboard & Outboard Joint Shaft Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark 10. INSTALL FRONT AXLE INBOARD JOINT BOOT a. Install the front axle inboard joint boot to the front drive inboard joint assembly. b. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 40: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side Dimension (A) Dimension (A) LH Side 587.4 mm (1.93 ft.) RH Side 906.6 mm (2.97 ft.)

11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP a. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot. b. Using needle nose pliers, install the front axle inboard joint boot clamp.

Fig. 41: Installing Front Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the front axle inboard joint boot.

12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot. b. Using needle nose pliers, install the front No. 2 axle inboard joint boot clamp.

Fig. 42: Remove/Install Front No. 2 Axle Inboard Joint Boot Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the front axle inboard joint boot.

13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH a. Install a new front drive shaft hole snap ring LH. NOTE:

Face the end gap of the front drive shaft hole snap ring downward.

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY . See step 1. INSTALLATION INSTALLATION

1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the transaxle case oil seal with MP grease. c. Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

Fig. 43: Installing Drive Shaft Assembly LH With Brass Bar And Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  

Face the end gap of the front drive shaft hole snap ring LH downward. Do not damage the transaxle case oil seal. Do not damage the front axle inboard joint boot. Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

HINT: Confirm whether the drive shaft is securely driven in by checking the reaction force and sound. d. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

Fig. 44: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. e. Align the matchmarks and install the front drive shaft assembly LH to the front axle hub subassembly.

Fig. 45: Aligning Matchmarks To Front Drive Shaft Assembly LH To Front Axle Hub SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the front transaxle case oil seal with MP grease. c. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH. d. Install the front drive shaft assembly RH. NOTE:

  

Do not damage the front transaxle case oil seal. Do not damage the front axle inboard joint boot. When inserting the front drive shaft assembly RH, keep it level.

e. Install the bearing bracket hole snap ring and a new bolt.

Fig. 46: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 32 N*m (330 kgf*cm, 24 ft.*lbf) f. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

Fig. 47: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. g. Align the matchmarks and install the front drive shaft assembly RH to the front axle hub subassembly.

Fig. 48: Aligning Matchmarks To Front Drive Shaft Assembly RH To Front Axle Hub SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

3. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 . 4. CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 . 5. INSTALL FRONT SPEED SENSOR . Refer to INSTALLATION - Step 19 . 6. INSTALL FRONT STABILIZER LINK ASSEMBLY . Refer to INSTALLATION - Step 10 . 7. INSTALL FRONT AXLE SHAFT NUT a. Clean the threaded parts on the front drive shaft assembly and a new axle shaft nut using a nonresidue solvent. NOTE:

 

Be sure to perform this work even when using a new drive shaft. Keep the threaded parts free of oil and foreign matter.

b. Using a socket wrench (30 mm), install the front axle shaft nut.

Fig. 49: Staking Front Axle Shaft Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 294 N*m (2998 kgf*cm, 217 ft.*lbf) c. Using a chisel and hammer, stake the front axle shaft nut. 8. INSTALL FRONT WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 9. ADD AUTOMATIC TRANSAXLE FLUID

Refer to ADJUSTMENT . 10. 11. 12. 13. 14. 15. 16.

INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT .

17. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE .

FRONT DRIVE SHAFT ASSEMBLY (FOR 2GR-FE) COMPONENTS ILLUSTRATION

Fig. 50: Identifying Front Drive Shaft Assembly (For 2GR-FE) Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 51: Identifying Front Drive Shaft Assembly (For 2GR-FE) Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 52: Identifying Front Drive Shaft Assembly (For 2GR-FE) Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 53: Identifying Front Drive Shaft Assembly (For 2GR-FE) Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 54: Identifying Front Drive Shaft Assembly (For 2GR-FE) Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT:  

1. 2. 3. 4. 5. 6. 7. 8. 9.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN AUTOMATIC TRANSAXLE FLUID . Refer to REPLACEMENT - Step 1 . REMOVE FRONT AXLE SHAFT NUT a. Using SST and a hammer, release the staked part of the front axle shaft nut.

Fig. 55: Releasing Staked Part Of Front Axle Shaft Nut LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09930-00010

NOTE:

Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

10. 11. 12. 13. 14. 15.

b. While applying the brakes, remove the front axle shaft nut. SEPARATE FRONT STABILIZER LINK ASSEMBLY . Refer to REMOVAL - Step 4 . SEPARATE FRONT SPEED SENSOR . Refer to REMOVAL - Step 3 . SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 . SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to REMOVAL - Step 8 . SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 7 . REMOVE FRONT DRIVE SHAFT ASSEMBLY LH a. Using SST, remove the front drive shaft assembly LH.

Fig. 56: Removing Front Drive Shaft Assembly LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09520-00031 SST: 09520-01010

NOTE:

  

Do not damage the transaxle case oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly LH.

16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH a. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

Fig. 57: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket. NOTE:

  

Do not damage the front transaxle case oil seal. Do not damage the front axle inboard joint boot. Do not drop the front drive shaft assembly RH.

c. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH. 17. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH a. Using a screwdriver, remove the front drive shaft hole snap ring LH.

Fig. 58: Removing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Using pliers, remove the front No. 2 axle inboard joint boot clamp.

Fig. 59: Removing Inboard Joint Boot No. 2 Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP HINT: Perform the same procedure as for the front No. 2 axle inboard joint boot clamp. 3. SEPARATE FRONT AXLE INBOARD JOINT BOOT a. Separate the front axle inboard joint boot from the front drive inboard joint assembly. 4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY a. Remove the old grease from the front drive inboard joint assembly. b. Put matchmarks on the front drive inboard joint assembly and front drive outboard joint shaft assembly.

Fig. 60: Identifying Matchmarks On Front Drive Inboard Joint Assembly And Front Drive Outboard Joint Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Do not use a punch for the marks.

c. Remove the front drive inboard joint assembly from the front drive outboard joint shaft assembly. d. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

e. Using a snap ring expander, remove the shaft snap ring from the front drive outboard joint shaft assembly.

Fig. 61: Remove/Install Shaft Snap Ring Using Snap Ring Expander Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Put matchmarks on the front drive outboard joint shaft assembly and tripod joint.

Fig. 62: Identifying Front Axle Outboard Joint Shaft Assembly And Tripod Joint Matchmark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Matchmark NOTE:

Do not use a punch for the marks.

g. Using a brass bar and a hammer, tap out the tripod joint from the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Do not drop the tripod joint.

5. REMOVE FRONT AXLE INBOARD JOINT BOOT a. Remove the front No. 2 axle inboard joint boot clamp, front axle inboard joint boot and front axle inboard joint boot clamp. 6. REMOVE FRONT DRIVE SHAFT DAMPER a. Using pliers, remove the front drive shaft damper clamp.

Fig. 63: Removing Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front drive shaft damper. 7. REMOVE FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Using pliers, remove the front No. 2 axle outboard joint boot clamp.

Fig. 64: Removing Outboard Joint Boot No. 2 Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP HINT: Perform the same procedure as for the front No. 2 axle outboard joint boot clamp. 9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT a. Remove the front axle outboard joint boot clamp, front axle outboard joint boot and front No. 2 axle outboard joint boot clamp from the front drive outboard joint shaft assembly. b. Remove the grease from the outboard joint. 10. REMOVE FRONT DRIVE SHAFT DUST COVER LH a. Using SST and a press, remove the front drive shaft dust cover LH.

Fig. 65: Pressing Drive Shaft Dust Cover LH Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

11. REMOVE FRONT DRIVE SHAFT DUST COVER RH a. Using a press, remove the front drive shaft dust cover RH.

Fig. 66: Removing Drive Shaft Dust Cover RH Using Press Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to drop the front drive inboard joint assembly.

12. REMOVE FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST and a press, remove the front drive shaft dust cover.

Fig. 67: Removing Drive Shaft Dust Cover Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-00020

NOTE:

 

Be careful not to drop the front drive inboard joint assembly. Do not overtighten SST.

13. REMOVE FRONT DRIVE SHAFT BEARING (for RH Side) a. Using a snap ring expander, remove the drive shaft hole snap ring.

Fig. 68: Removing/Installing Drive Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a press, remove the front drive shaft bearing.

Fig. 69: Removing Bearing Using SST And Press Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09527-10011

NOTE:

Be careful not to drop the front drive inboard joint assembly.

INSPECTION INSPECTION

1. INSPECT FRONT DRIVE SHAFT ASSEMBLY a. Check that there is no excessive play in the radial direction of the outboard joint.

Fig. 70: Inspecting Front Drive Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Check that the inboard joint slides smoothly in the thrust direction. Check that there is no excessive play in the radial direction of the inboard joint. Check the boots for damage. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 71: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side NOTE:

Keep the drive shaft assembly level during inspection.

Dimension (A) Dimension (A) LH Side 587.5 mm (1.93 ft.)

RH Side 906.4 mm (2.97 ft.) REASSEMBLY REASSEMBLY

1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft bearing.

Fig. 72: Installing Front Drive Shaft Bearing (For RH Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09527-10011

NOTE:

The bearing should be completely installed.

b. Using a snap ring expander, install a new drive shaft hole snap ring.

Fig. 73: Removing/Installing Drive Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT DRIVE SHAFT DUST COVER (for RH Side) a. Using SST, a steel plate and a press, install a new front drive shaft dust cover.

Fig. 74: Installing Front Drive Shaft Dust Cover (For RH Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Steel *1 Plate 

SST: 09726-40010

Dimension (A) 26.6 to 27.6 mm (1.05 to 1.08 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover.

3. INSTALL FRONT DRIVE SHAFT DUST COVER RH a. Using a steel plate and a press, install a new front drive shaft dust cover RH until dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

Fig. 75: Installing Front Drive Shaft Dust Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate Dimension (A)

110.0 to 111.0 mm (4.33 to 4.37 in.) NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover RH.

4. INSTALL FRONT DRIVE SHAFT DUST COVER LH a. Using a steel plate and a press, install a new front drive shaft dust cover LH.

Fig. 76: Installing Front Drive Shaft Dust Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Steel *1 Plate NOTE:

 

The dust cover should be completely installed. Be careful not to damage the front drive shaft dust cover LH.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT a. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

Fig. 77: Wrapping Spline Of Drive Shaft With Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 78: Identifying Front Drive Outboard Joint Shaft Assembly Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Drive Outboard *1 Joint Shaft Assembly Front No. 2 Axle Outboard *2 Joint Boot Clamp Front Axle *3 Outboard Joint Boot Front Axle Outboard *4 Joint Boot Clamp

Outboard Joint Side Inboard Joint Side 1. Front No. 2 axle outboard joint boot clamp 2. Front axle outboard joint boot 3. Front axle outboard joint boot clamp c. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease. Standard grease capacity 164 to 184 g (5.78 to 6.48 oz.) d. Install the front axle outboard joint boot onto the front drive outboard joint shaft assembly groove. NOTE:





Do not allow grease to adhere to the boot clamp track of the outboard joint boot. Keep the inside of the outboard joint boot free of foreign matter.

6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Install the front No. 2 axle outboard joint boot clamp onto the front axle outboard joint boot. c. Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 79: Tightening No. 2 Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 d. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

e. Remove SST. f. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.

Fig. 80: Measuring Clearance Of Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP a. Install the front axle outboard joint boot clamp onto the front axle outboard joint boot. b. Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 81: Tightening Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 c. Tighten SST so that the front axle outboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

d. Remove SST. e. Using SST, measure the clearance of the front axle outboard joint boot clamp.

Fig. 82: Measuring Clearance Of Front Axle Outboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 8. INSTALL FRONT DRIVE SHAFT DAMPER a. Install the front drive shaft damper onto the front drive outboard joint shaft assembly.

Fig. 83: Identifying Front Drive Shaft Damper Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Set the dimension as specified below. Dimension (A) 228.0 to 232.0 mm (8.98 to 9.13 in.) c. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

d. Install a new front drive shaft damper clamp onto the front drive shaft damper. NOTE:

Be sure to install the clamp in the correct position.

e. Place SST onto the front drive shaft damper clamp, press it against the boot and slightly tighten SST.

Fig. 84: Tightening Drive Shaft Damper Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 f. Tighten SST so that the front drive shaft damper clamp is pinched. 

NOTE:

Do not overtighten SST.

g. Remove SST. h. Using SST, measure the clearance of the front drive shaft damper clamp.

Fig. 85: Measuring Clearance Of Front Drive Shaft Damper Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY a. Install new parts onto the front drive outboard joint shaft assembly in the following order:

Fig. 86: Identifying Front Drive Inboard Joint Assembly Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Axle Inboard *1 Joint Boot Clamp Front Axle *2 Inboard Joint Boot Front No. 2 Axle Inboard *3 Joint Boot Clamp Protective *4 Tape Outboard Joint Side Inboard Joint Side

1. Front axle inboard joint boot clamp 2. Front axle inboard joint boot 3. Front No. 2 axle inboard joint boot clamp b. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

c. Remove the protective tape. d. Align the matchmarks and install the tripod joint onto the front drive outboard joint shaft assembly.

Fig. 87: Identifying Tripod Joint And Front Axle Outboard Joint Shaft Assembly Matchmark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark e. Align the matchmarks placed before removal. f. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly. NOTE:

 

Do not tap the rollers. Keep the tripod joint free of foreign matter.

g. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

Fig. 88: Remove/Install Shaft Snap Ring Using Snap Ring Expander Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Pack the front drive inboard joint assembly and front axle inboard boot with grease. Standard grease capacity 155 to 175 g (5.47 to 6.17 oz.) i. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

Fig. 89: Identifying Front Drive Inboard & Outboard Joint Shaft Assembly Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark 10. INSTALL FRONT AXLE INBOARD JOINT BOOT a. Install the front axle inboard joint boot to the front drive inboard joint assembly. b. Check whether the drive shaft dimensions (A) are within the following specifications.

Fig. 90: Checking Drive Shaft Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH *A Side RH *B Side Dimension (A) Dimension (A) LH Side 587.5 mm (1.93 ft.) RH Side 906.4 mm (2.97 ft.)

11. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP a. Hold the drive shaft in a vise between aluminum plates. NOTE:

Do not overtighten the vise.

b. Install the front axle inboard joint boot clamp onto the front axle inboard joint boot. c. Place SST onto the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 91: Tightening Inboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 d. Tighten SST so that the front axle inboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

e. Remove SST. f. Using SST, measure the clearance of the front axle inboard joint boot clamp.

Fig. 92: Measuring Front Axle Inboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 12. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP a. Install the front No. 2 axle inboard joint boot clamp onto the front axle inboard joint boot. b. Place SST onto the front No. 2 axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

Fig. 93: Tightening No. 2 Front Axle Inboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09521-24010 c. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched. 

NOTE:

Do not overtighten SST.

d. Remove SST. e. Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.

Fig. 94: Measuring Clearance Of No. 2 Front Axle Inboard Joint Boot Clamp Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09240-00020

Clearance 0.5 to 1.5 mm (0.0197 to 0.0591 in.) If the clearance is outside the specified range, retighten SST. 13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH a. Install a new front drive shaft hole snap ring LH. NOTE:

Face the end gap of the front drive shaft hole snap ring downward.

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY . See step 1. INSTALLATION INSTALLATION

1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the transaxle case oil seal with MP grease. c. Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

Fig. 95: Installing Drive Shaft Assembly LH With Brass Bar And Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  

Face the end gap of the front drive shaft hole snap ring LH downward. Do not damage the transaxle case oil seal. Do not damage the front axle inboard joint boot. Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

HINT: Confirm whether the drive shaft is securely driven in by checking the reaction force and sound. d. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

Fig. 96: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. e. Align the matchmarks and install the front drive shaft assembly LH to the front axle hub subassembly.

Fig. 97: Aligning Matchmarks To Front Drive Shaft Assembly LH To Front Axle Hub SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH a. Coat the spline of the front drive inboard joint assembly with ATF. b. Coat the lip of the front transaxle case oil seal with MP grease. c. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH. d. Install the front drive shaft assembly RH. NOTE:

  

Do not damage the front transaxle case oil seal. Do not damage the front axle inboard joint boot. When inserting the front drive shaft assembly RH, keep it level.

e. Install the bearing bracket hole snap ring and a new bolt.

Fig. 98: Identifying Bearing Bracket Hole Snap Ring And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 32 N*m (330 kgf*cm, 24 ft.*lbf) f. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

Fig. 99: Identifying Front Axle Hub Bearing Mineral Oil Base Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mineral Oil Base Grease HINT: Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area. g. Align the matchmarks and install the front drive shaft assembly RH to the front axle hub subassembly.

Fig. 100: Aligning Matchmarks To Front Drive Shaft Assembly RH To Front Axle Hub SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Matchmark NOTE:

Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

3. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 . 4. CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 . 5. INSTALL FRONT SPEED SENSOR . Refer to INSTALLATION - Step 19 . 6. INSTALL FRONT STABILIZER LINK ASSEMBLY . Refer to INSTALLATION - Step 10 . 7. INSTALL FRONT AXLE SHAFT NUT a. Clean the threaded parts on the front drive shaft assembly and a new axle shaft nut using a nonresidue solvent. NOTE:

 

Be sure to perform this work even when using a new drive shaft. Keep the threaded parts free of oil and foreign matter.

b. Using a socket wrench (30 mm), install the front axle shaft nut.

Fig. 101: Staking Front Axle Shaft Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 294 N*m (2998 kgf*cm, 217 ft.*lbf) c. Using a chisel and a hammer, stake the front axle shaft nut. 8. INSTALL FRONT WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 9. ADD AUTOMATIC TRANSAXLE FLUID

Refer to ADJUSTMENT . 10. 11. 12. 13. 14. 15. 16.

INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT .

17. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE .

2012-2017 DTC INDEX Camry

AUDIO / VIDEO DTCS

(Hybrid)

AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITH INTUITIVE PARKING ASSIST SYSTEM) AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITH INTUITIVE PARKING ASSIST SYSTEM) DTC IDENTIFICATION DTC Code Description B1579 Voice Recognition Microphone Disconnected B1585 USB Media Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B5 DVD Changer Malfunction B15B7 Bluetooth Module Malfunction B15B8 Harddisk Malfunction B15C3 Speaker Output Short B15D3 Stereo Component Amplifier Disconnected B15E7 Harddisk Reading/Writing Malfunction(Low Temperature) B15E8 Harddisk Reading/Writing Malfunction(High Temperature) B15F5 A/C ECU Vehicle Information Reading/Writing Processor Malfunction B15F6 Main Body ECU Vehicle Information Reading/Writing Process Malfunction B15F7 Certification ECU Vehicle Information Reading/Writing Process Malfunction U0073 Sending Malfunction (Navigation to APGS) U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Brake System Control Module U0140 Lost Communication with Body Control Module U0155 Meter ECU Communication U0293 Lost Communication with HV ECU AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITHOUT INTUITIVE PARKING ASSIST SYSTEM) AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITHOUT INTUITIVE PARKING ASSIST SYSTEM) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1579 Voice Recognition Microphone Disconnected

B1585 B15A0 B15A3 B15B0 B15B3 B15B4 B15B7 B15BA B15C3 B15D3 B15F6 B15FE B15FF U0073 U0100 U0129 U0140 U0155 U0293

USB Device Malfunction LAN Master Malfunction Stereo Component Amplifier Malfunction Display Screen Malfunction Radio Tuner Malfunction CD Changer Malfunction Bluetooth Module Malfunction XM Tuner Malfunction Speaker Output Short Stereo Component Amplifier Disconnected Main Body ECU Vehicle Information Reading/Writing Process Malfunction XM Tuner Antenna Disconnected XM Tuner Antenna Short Sending Malfunction (Navigation to APGS) Lost Communication with ECM / PCM "A" Lost Communication with Brake System Control Module Lost Communication with Body Control Module Meter ECU Communication Lost Communication with HV ECU

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS DTCS ELECTRONICALLY CONTROLLED BRAKE SYSTEM ABS DTC IDENTIFICATION DTC Code Description 42 Electronically Controlled Brake System Malfunction C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH C1243/43 Acceleration Sensor Stuck Malfunction C1244/44 Open or Short in Acceleration Sensor Circuit C1245/45 Acceleration Sensor Output Malfunction C1336/98 Zero Point Calibration of Acceleration Sensor Undone C1381/97 Acceleration Sensor Power Supply Voltage Malfunction C1442/44 Invalid Data Received from Acceleration Sensor C1464/31 Front Speed Sensor RH Circuit C1465/32 Front Speed Sensor LH Circuit C1466/33 Rear Speed Sensor RH Circuit C1467/34 Rear Speed Sensor LH Circuit

U0124/95

Lost Communication with Lateral Acceleration Sensor Module

VSC DTC IDENTIFICATION DTC Code Description 43 ABS Control System Malfunction 45 Electronically Controlled Brake System Malfunction C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone C1231/31 Steering Angle Sensor Circuit Malfunction C1234/34 Yaw Rate Sensor Malfunction C1290/66 Steering Angle Sensor Zero Point Malfunction C1310/51 Malfunction in HV system C1380/64 Stop Light Control Relay Malfunction C1439/66 Steering Angle Sensor Initialization Incomplete C1440/98 Unusual Bank Angle Detected C1443/34 Invalid Data Received from Yaw Rate Sensor C1445/66 Vehicle Driven with Steering Angle Sensor not Initialized U0123/62 Lost Communication with Yaw Rate Sensor Module U0126/63 Lost Communication with Steering Angle Sensor Module ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC IDENTIFICATION DTC Code Description 36 ABS Control System Malfunction C1202/68 Master Reservoir Level Malfunction C1203/95 ECM Communication Circuit Malfunction C1211/25 SLA Linear Solenoid C1212/26 SLR Linear Solenoid C1214/62 Hydraulic Control System Malfunction C1225/31 SA1 Solenoid Circuit C1226/32 SA2 Solenoid Circuit C1227/33 SA3 Solenoid Circuit C1228/34 STR Solenoid Circuit C1242/42 Open in IG1 / IG2 Power Source Circuit C1246/46 Master Cylinder Pressure Sensor Malfunction C1247/47 Stroke Sensor Malfunction C1249/49 Open in Stop Light Switch Circuit C1252/52 Brake Booster Pump Motor on Time Abnormally Long C1253/53 Pump Motor Relay Malfunction C1256/56 Accumulator Low Pressure C1257/57 Power Supply Drive Circuit C1259/58 HV System Regenerative Malfunction C1300 Skid Control ECU Malfunction

C1311/11 C1312/12 C1345/66 C1352/21 C1353/23 C1356/22 C1357/24 C1364/61 C1365/54 C1368/67 C1391/69 C1392/48 C1451/72 U0073/94 U0293/59

Open in Main Relay 1 Circuit Short in Main Relay 1 Circuit Linear Solenoid Valve Offset Learning Undone FR Solenoid RR Solenoid FL Solenoid RL Solenoid Wheel Cylinder Pressure Sensor Malfunction Accumulator Pressure Sensor Malfunction Linear Solenoid Valve Offset Malfunction Accumulator Leak Malfunction Stroke Sensor Zero Point Calibration Undone Motor Drive Permission Malfunction Control Module Communication Bus OFF Communication Error from HV ECU

ABS AND ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC IDENTIFICATION DTC Code Description C1241/41 Low Battery Positive Voltage ABS TEST MODE DTC IDENTIFICATION DTC Code Description C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) ELECTRONICALLY CONTROLLED BRAKE SYSTEM TEST MODE DTC IDENTIFICATION DTC Code Description C1346/71 Stroke Sensor Zero Point Learning Malfunction (Test Mode DTC)

CELLULAR COMMUNICATION DTCS SAFETY CONNECT SYSTEM SAFETY CONNECT SYSTEM DTC IDENTIFICATION

DTC Code B1570 B1571 B1572 B1573 B15CB B1583 B15A8 B15C0 B15C1 B15C4 B15C5 B15CC B15EC

Description Manual (SOS) Switch Red Indicator Malfunction Manual (SOS) Switch Green Indicator Malfunction Telephone Microphone Error Short in Telephone Antenna Circuit Telematics Transceiver Antenna Disconnected GPS Signal Unreceived Telematics Transceiver Malfunction Short in GPS Antenna Open in GPS Antenna Airbag Signal Malfunction/Not Input Manual Button Malfunction Backup Battery Failure Backup Battery Degradation

CRUISE CONTROL DTCS CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description P0571 Brake Switch "A" Circuit P0575 Cruise Control Input Circuit P1578 Brake System Malfunction U0122 Lost Communication with Vehicle Dynamics Control Module

DOOR LOCK DTCS WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description B1242 Wireless Door Lock Tuner Circuit Malfunction

ENGINE CONTROL DTCS SFI SYSTEM SFI SYSTEM DTC IDENTIFICATION DTC Code Description P0010 Camshaft Position "A" Actuator Circuit (Bank 1) P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1)

P0012 P0016 P0031 P0032 P0037 P0038 P0101 P0102 P0103 P0106 P0107 P0108 P0111 P0112 P0113 P0115 P0116 P0117 P0118 P011B P0120 P0121 P0122 P0123 P0125 P0128 P0136 P0137 P0138 P0139 P0141 P014C P014D P015A P015B P0171 P0172 P0220 P0222

Camshaft Position "A" - Timing Over-Retarded (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) Mass Air Flow Circuit Range / Performance Problem Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance Problem Manifold Absolute Pressure / Barometric Pressure Circuit Low Input Manifold Absolute Pressure / Barometric Pressure Circuit High Input Intake Air Temperature Sensor Gradient Too High Intake Air Temperature Circuit Low Input Intake Air Temperature Circuit High Input Engine Coolant Temperature Circuit Malfunction Engine Coolant Temperature Circuit Range / Performance Problem Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature Circuit High Input Engine Coolant Temperature / Intake Air Temperature Correlation Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input Throttle / Pedal Position Sensor / Switch "A" Circuit High Input Insufficient Coolant Temperature for Closed Loop Fuel Control Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 2) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) A/F Sensor Slow Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Slow Response - Lean to Rich Bank 1 Sensor 1 A/F Sensor Delayed Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Delayed Response - Lean to Rich Bank 1 Sensor 1 System Too Lean (Bank 1) System Too Rich (Bank 1) Throttle / Pedal Position Sensor / Switch "B" Circuit Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input

P0223 P0300 P0301 P0302 P0303 P0304 P0327 P0328 P0335 P0340 P0342 P0343 P0351 P0352 P0353 P0354 P0401 P0403 P0420 P043E P043F P0441 P0451 P0452 P0453 P0455 P0456 P0505 P050A P050B P0560 P0604 P0606 P0607 P060A P060B P060E P062F P0630 P0657 P101D P102D

Throttle / Pedal Position Sensor / Switch "B" Circuit High Input Random / Multiple Cylinder Misfire Detected Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) Crankshaft Position Sensor "A" Circuit Camshaft Position Sensor Circuit Malfunction Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) Ignition Coil "A" Primary / Secondary Circuit Ignition Coil "B" Primary / Secondary Circuit Ignition Coil "C" Primary / Secondary Circuit Ignition Coil "D" Primary / Secondary Circuit Exhaust Gas Recirculation Flow Insufficient Detected Exhaust Gas Recirculation Control Circuit Catalyst System Efficiency Below Threshold (Bank 1) Evaporative Emission System Leak Detection Reference Orifice Low Flow Evaporative Emission System Reference Orifice High Flow Evaporative Emission Control System Incorrect Purge Flow Evaporative Emission Control System Pressure Sensor Range / Performance Evaporative Emission Control System Pressure Sensor / Switch Low Input Evaporative Emission Control System Pressure Sensor / Switch High Input Evaporative Emission Control System Leak Detected (Gross Leak) Evaporative Emission Control System Leak Detected (Very Small Leak) Idle Control System Malfunction Cold Start Idle Air Control System Performance Cold Start Ignition Timing Performance System Voltage Random Access Memory (RAM) ECM / PCM Processor Control Module Performance Internal Control Module Monitoring Processor Performance Internal Control Module A/D Processing Performance Internal Control Module Throttle Position Performance Internal Control Module EEPROM Error VIN not Programmed or Mismatch - ECM / PCM Actuator Supply Voltage Circuit / Open A/F Sensor Heater Circuit Performance Bank 1 Sensor 1 Stuck ON

P106A P148F P1604 P1605 P2102 P2103 P2109 P2111 P2112 P2118 P2119 P2135 P2195 P2196 P219A P2237 P2238 P2239 P2252 P2253 P2401 P2402 P2419 P2420 P2610 P261B P261C P261D P3190 P3191 P3193 U0293

O2 Sensor Heater Circuit Performance Bank 1 Sensor 2 Stuck ON Evaporative Emission System Pressure Sensor - Manifold Absolute Pressure Correlation Engine Coolant Pump Over Revolution Startability Malfunction Rough Idling Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle / Pedal Position Sensor "A" Minimum Stop Performance Throttle Actuator Control System - Stuck Open Throttle Actuator Control System - Stuck Closed Throttle Actuator Control Motor Current Range / Performance Throttle Actuator Control Throttle Body Range / Performance Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Bank 1 Air-Fuel Ratio Imbalance Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Evaporative Emission Leak Detection Pump Stuck OFF Evaporative Emission Leak Detection Pump Stuck ON Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High ECM / PCM Internal Engine Off Timer Performance Engine Coolant Pump "B" Control Malfunction Engine Coolant Pump "B" Control Circuit Low Engine Coolant Pump "B" Control Circuit High Poor Engine Power Engine does not Start Fuel Run Out Lost Communication with HV ECU

HEATING / AIR CONDITIONING DTCS AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM DTC IDENTIFICATION DTC Code Description B1411/11 Room Temperature Sensor Circuit

B1412/12 B1413/13 B1423/23 B1441/41 B1442/42 B1443/43 B1446/46 B1462/62 B1471/71 B1472/72 B1473/73 B1474/74 B1475/75 B1476/76 B1477/77 B1497/97 B1498/98 B14A2 B14A3 B14A8 B14A9 B14B2 B14B8 U0131 U0142 U0155 U0293

Ambient Temperature Sensor Circuit Evaporator Temperature Sensor Circuit Pressure Sensor Circuit Air Mix Damper Control Servo Motor Circuit (Passenger Side) Air Inlet Damper Control Servo Motor Circuit Air Outlet Damper Control Servo Motor Circuit Air Mix Damper Control Servo Motor Circuit (Driver Side) Room Humidity Sensor Circuit A/C Inverter High Voltage Power Resource System Malfunction A/C Inverter High Voltage Output System Malfunction A/C Inverter Start-up Signal System Malfunction A/C Inverter Malfunction A/C Inverter Cooling / Heating System Malfunction A/C Inverter Load System Malfunction A/C Inverter Low Voltage Power Resource System Malfunction BUS IC Communication Malfunction Communication Malfunction (A/C Inverter Local) Driver Side Solar Sensor Short Circuit Front Passenger Side Solar Sensor Short Circuit Glass Temperature Sensor Circuit Glass Surroundings Temperature Sensor Circuit Lost Communication with Front Panel LIN Refrigerant Shortage Lost Communication with Electric Power Steering ECU Lost Communication with Main Body ECU Lost Communication with Combination Meter Lost Communication with HV ECU

HYBRID CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description P0AA6-611 Hybrid Battery Voltage System Isolation Fault

HYBRID / BATTERY CONTROL DTCS HYBRID BATTERY SYSTEM HYBRID BATTERY SYSTEM DTC IDENTIFICATION DTC Code Description P0A7F-123 Hybrid Battery Pack Deterioration P0A80-123 Replace Hybrid Battery Pack P0A82-123 Hybrid Battery Pack Cooling Fan 1 Performance / Stuck OFF P0A84-123 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low

P0A85-123 P0A95-123 P0A9C-123 P0A9D-123 P0A9E-123 P0AAE-123 P0AAF-123 P0ABF-123 P0AC0-123 P0AC1-123 P0AC2-123 P0AC6-123 P0AC7-123 P0AC8-123 P0ACB-123 P0ACC-123 P0ACD-123 P0AFC-123 P0B3D-123 P0B42-123 P0B47-123 P0B4C-123 P0B51-123 P0B56-123 P0B5B-123 P0B60-123 P0B65-123 P0B6A-123 P0B6F-123 P0B74-123 P0B79-123 P0B7E-123 P0B83-123 P0B88-123 P0B8D-123 P0B92-123 P3011-123 P3012-123 P3013-123 P3014-123 P3015-123 P3016-123

Hybrid Battery Pack Cooling Fan 1 Control Circuit High High Voltage Fuse Hybrid Battery Temperature Sensor "A" Range / Performance Hybrid Battery Temperature Sensor "A" Circuit Low Hybrid Battery Temperature Sensor "A" Circuit High Hybrid Battery Pack Air Temperature Sensor "A" Circuit Low Hybrid Battery Pack Air Temperature Sensor "A" Circuit High Hybrid Battery Pack Current Sensor Circuit Hybrid Battery Pack Current Sensor Circuit Range / Performance Hybrid Battery Pack Current Sensor Circuit Low Hybrid Battery Pack Current Sensor Circuit High Hybrid Battery Temperature Sensor "B" Range / Performance Hybrid Battery Temperature Sensor "B" Circuit Low Hybrid Battery Temperature Sensor "B" Circuit High Hybrid Battery Temperature Sensor "C" Range / Performance Hybrid Battery Temperature Sensor "C" Circuit Low Hybrid Battery Temperature Sensor "C" Circuit High Hybrid Battery Pack Sensor Module Hybrid Battery Voltage Sensor "A" Circuit Low Hybrid Battery Voltage Sensor "B" Circuit Low Hybrid Battery Voltage Sensor "C" Circuit Low Hybrid Battery Voltage Sensor "D" Circuit Low Hybrid Battery Voltage Sensor "E" Circuit Low Hybrid Battery Voltage Sensor "F" Circuit Low Hybrid Battery Voltage Sensor "G" Circuit Low Hybrid Battery Voltage Sensor "H" Circuit Low Hybrid Battery Voltage Sensor "I" Circuit Low Hybrid Battery Voltage Sensor "J" Circuit Low Hybrid Battery Voltage Sensor "K" Circuit Low Hybrid Battery Voltage Sensor "L" Circuit Low Hybrid Battery Voltage Sensor "M" Circuit Low Hybrid Battery Voltage Sensor "N" Circuit Low Hybrid Battery Voltage Sensor "O" Circuit Low Hybrid Battery Voltage Sensor "P" Circuit Low Hybrid Battery Voltage Sensor "Q" Circuit Low Hybrid Battery Voltage Sensor "R" Circuit Low Battery Block 1 Becomes Weak Battery Block 2 Becomes Weak Battery Block 3 Becomes Weak Battery Block 4 Becomes Weak Battery Block 5 Becomes Weak

P3017-123 P3018-123 P3019-123 P3020-123 P3021-123 P3022-123 P3023-123 P3024-123 P3025-123 P3026-123 P3027-123 P3065-123 P308A-123 U029A-123

Battery Block 6 Becomes Weak Battery Block 7 Becomes Weak Battery Block 8 Becomes Weak Battery Block 9 Becomes Weak Battery Block 10 Becomes Weak Battery Block 11 Becomes Weak Battery Block 12 Becomes Weak Battery Block 13 Becomes Weak Battery Block 14 Becomes Weak Battery Block 15 Becomes Weak Battery Block 16 Becomes Weak Battery Block 17 Becomes Weak Hybrid Battery Temperature Sensor Range/Performance Stuck "A" Hybrid Battery Voltage Sensor All Circuits Low Lost Communication with Hybrid Battery Pack Sensor Module

HYBRID CONTROL SYSTEM HYBRID CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description P0069-273 Manifold Absolute Pressure - Barometric Pressure Correlation P0340-886 Camshaft Position Sensor "A" Circuit P0343-747 Camshaft Position Sensor "A" Circuit High Input P0516-769 Battery Temperature Sensor Circuit Low P0517-770 Battery Temperature Sensor Circuit High P060B-134 Internal Control Module A/D Processing Performance P060B-135 Internal Control Module A/D Processing Performance P060B-570 Internal Control Module A/D Processing Performance P062F-143 Internal Control Module EEPROM Error P062F-165 Internal Control Module EEPROM Error P06A4-209 Sensor Reference Voltage "D" Circuit Low P06A5-210 Sensor Reference Voltage "D" Circuit High P0705-757 Transmission Range Sensor Circuit P0705-758 Transmission Range Sensor Circuit P0851-775 Park / Neutral Switch Input Circuit Low P0A01-726 Motor Electronics Coolant Temperature Sensor Circuit Range / Performance P0A02-719 Motor Electronics Coolant Temperature Sensor Circuit Low P0A03-720 Motor Electronics Coolant Temperature Sensor Circuit High P0A04-725 Motor Electronics Coolant Temperature Sensor Circuit Intermittent P0A08-264 DC / DC Converter Status Circuit P0A09-265 DC / DC Converter Status Circuit Low Input

P0A09-591 P0A0D-350 P0A0D-351 P0A0F-204 P0A0F-205 P0A0F-206 P0A0F-238 P0A0F-524 P0A0F-525 P0A10-263 P0A10-592 P0A1A-151 P0A1A-155 P0A1A-156 P0A1A-166 P0A1A-200 P0A1A-658 P0A1A-659 P0A1A-791 P0A1A-792 P0A1A-793 P0A1B-163 P0A1B-164 P0A1B-168 P0A1B-192 P0A1B-193 P0A1B-198 P0A1B-511 P0A1B-512 P0A1B-661 P0A1B-786 P0A1B-794 P0A1B-795 P0A1B-796 P0A1D-144 P0A1D-148 P0A1D-162 P0A1D-187 P0A1D-721 P0A1D-722 P0A1D-723 P0A1D-787

DC / DC Converter Status Circuit Low Input High Voltage System Inter-Lock Circuit High High Voltage System Inter-Lock Circuit High Engine Failed to Start Engine Failed to Start Engine Failed to Start Engine Failed to Start Engine Failed to Start Engine Failed to Start DC / DC Converter Status Circuit High Input DC / DC Converter Status Circuit High Input Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Generator Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Drive Motor "A" Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module

P0A1D-818 P0A1D-821 P0A1D-822 P0A1D-823 P0A2B-250 P0A2C-247 P0A2D-249 P0A2E-248 P0A37-260 P0A38-257 P0A39-259 P0A3A-258 P0A3F-243 P0A40-500 P0A41-245 P0A4B-253 P0A4C-513 P0A4D-255 P0A51-174 P0A60-288 P0A60-290 P0A60-294 P0A60-501 P0A63-296 P0A63-298 P0A63-302 P0A63-502 P0A72-326 P0A72-328 P0A72-333 P0A72-515 P0A75-334 P0A75-336 P0A75-341 P0A75-516 P0A78-113 P0A78-121 P0A78-128 P0A78-202 P0A78-266 P0A78-267

Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Hybrid Powertrain Control Module Drive Motor "A" Temperature Sensor Circuit Range / Performance Drive Motor "A" Temperature Sensor Circuit Low Drive Motor "A" Temperature Sensor Circuit High Drive Motor "A" Temperature Sensor Circuit Intermittent Generator Temperature Sensor Circuit Range / Performance Generator Temperature Sensor Circuit Low Generator Temperature Sensor Circuit High Generator Temperature Sensor Circuit Intermittent Drive Motor "A" Position Sensor Circuit Drive Motor "A" Position Sensor Circuit Range / Performance Drive Motor "A" Position Sensor Circuit Low Generator Position Sensor Circuit Generator Position Sensor Circuit Range / Performance Generator Position Sensor Circuit Low Drive Motor "A" Current Sensor Circuit Drive Motor "A" Phase V Current Drive Motor "A" Phase V Current Drive Motor "A" Phase V Current Drive Motor "A" Phase V Current Drive Motor "A" Phase W Current Drive Motor "A" Phase W Current Drive Motor "A" Phase W Current Drive Motor "A" Phase W Current Generator Phase V Current Generator Phase V Current Generator Phase V Current Generator Phase V Current Generator Phase W Current Generator Phase W Current Generator Phase W Current Generator Phase W Current Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance

P0A78-279 P0A78-282 P0A78-284 P0A78-286 P0A78-287 P0A78-306 P0A78-503 P0A78-504 P0A78-505 P0A78-506 P0A78-565 P0A78-586 P0A78-806 P0A78-807 P0A78-808 P0A7A-122 P0A7A-130 P0A7A-203 P0A7A-322 P0A7A-324 P0A7A-325 P0A7A-344 P0A7A-517 P0A7A-518 P0A7A-809 P0A7A-810 P0A7A-811 P0A90-251 P0A90-509 P0A92-261 P0A92-521 P0A93-346 P0A94-127 P0A94-172 P0A94-442 P0A94-547 P0A94-548 P0A94-549 P0A94-550 P0A94-553 P0A94-554

Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Generator Inverter Performance Drive Motor "A" Performance Drive Motor "A" Performance Hybrid Generator Performance Hybrid Generator Performance Inverter Cooling System Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance

P0A94-555 P0A94-556 P0A94-557 P0A94-564 P0A94-585 P0A94-587 P0A94-589 P0A94-590 P0AA1-231 P0AA1-233 P0AA4-232 P0AA6-526 P0AA6-611 P0AA6-612 P0AA6-613 P0AA6-614 P0AA7-727 P0AC0-817 P0ADB-227 P0ADC-226 P0ADF-229 P0AE0-228 P0AE2-773 P0AE6-225 P0AE7-224 P0AEE-277 P0AEF-275 P0AF0-274 P0AF1-276 P0AFC-129 P0AFC-150 P0BCD-315 P0BCE-313 P0BCF-312 P0BD0-314 P0C30-390 P0C39-626 P0C3A-621 P0C3B-622 P0C3C-625 P0C3E-628

DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance DC / DC Converter Performance Hybrid Battery Positive Contactor Circuit Stuck Closed Hybrid Battery Positive Contactor Circuit Stuck Closed Hybrid Battery Negative Contactor Circuit Stuck Closed Hybrid Battery Voltage System Isolation Fault Hybrid Battery Voltage System Isolation Fault Hybrid Battery Voltage System Isolation Fault Hybrid Battery Voltage System Isolation Fault Hybrid Battery Voltage System Isolation Fault Hybrid Battery Voltage Isolation Sensor Circuit Hybrid Battery Pack Current Sensor Circuit Range / Performance Hybrid Battery Positive Contactor Control Circuit Low Hybrid Battery Positive Contactor Control Circuit High Hybrid Battery Negative Contactor Control Circuit Low Hybrid Battery Negative Contactor Control Circuit High Hybrid Battery Precharge Contactor Circuit Stuck Closed Hybrid Battery Precharge Contactor Control Circuit Low Hybrid Battery Precharge Contactor Control Circuit High Motor Inverter Temperature Sensor "A" Circuit Range / Performance Drive Motor Inverter Temperature Sensor "A" Circuit Low Drive Motor Inverter Temperature Sensor "A" Circuit High Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic Hybrid Battery Pack Sensor Module Hybrid Battery Pack Sensor Module Generator Inverter Temperature Sensor Circuit Range / Performance Generator Inverter Temperature Sensor Circuit Low Generator Inverter Temperature Sensor Circuit High Generator Inverter Temperature Sensor Circuit Intermittent / Erratic Hybrid Battery Pack State of Charge High DC / DC Converter Temperature Sensor "A" Range / Performance DC / DC Converter Temperature Sensor "A" Low DC / DC Converter Temperature Sensor "A" High DC / DC Converter Temperature Sensor "A" Intermittent / Erratic

P0C3F-623 P0C40-624 P0C41-627 P0C73-776 P0C76-523 P1606-308 P1606-317 P2120-152 P2121-106 P2122-104 P2123-105 P2125-153 P2126-109 P2127-107 P2128-108 P2138-110 P2138-154 P2228-268 P2229-269 P2511-149 P2532-772 P3000-388 P3000-389 P3000-603 P3004-131 P3004-132 P3004-133 P3004-800 P3004-801 P3004-803 P3107-213 P3107-214 P3107-215 P3108-536 P3110-223 P3147-239 P3147-240 P3147-241 P3147-242 P314A-828 P321E-318

DC / DC Converter Temperature Sensor "B" Range / Performance DC / DC Converter Temperature Sensor "B" Low DC / DC Converter Temperature Sensor "B" High DC / DC Converter Temperature Sensor "B" Intermittent / Erratic Motor Electronics Coolant Pump "A" Control Performance Hybrid Battery System Discharge Time Too Long Collision has been detected or Collision Sensor Connection (Open) Collision has been detected or Collision Sensor Connection (Open) Throttle / Pedal Position Sensor / Switch "D" Circuit Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input Throttle / Pedal Position Sensor / Switch "D" Circuit High Input Throttle / Pedal Position Sensor / Switch "E" Circuit Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input Throttle / Pedal Position Sensor / Switch "E" Circuit High Input Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Barometric Pressure Sensor "A" Circuit Low Barometric Pressure Sensor "A" Circuit High HV CPU Power Relay Sense Circuit Intermittent No Continuity Ignition Switch Run Position Circuit High Battery Control System Battery Control System Battery Control System High Voltage Power Resource High Voltage Power Resource High Voltage Power Resource High Voltage Power Resource High Voltage Power Resource High Voltage Power Resource Lost Communication with Airbag System Control Module Lost Communication with Airbag System Control Module Lost Communication with Airbag System Control Module Lost Communication with A/C System Control Module HV Main Relay Transmission system Transmission system Transmission system Transmission system Inverter Coolant Pump Speed Signal

P321F-319 P324E-788 U0100-211 U0100-212 U0100-530 U0110-159 U0110-160 U0110-656 U0110-657 U0129-220 U0129-222 U0129-527 U0129-528 U0140-146 U0151-763 U0164-594 U0164-827 U0424-537 U1107-436

All HV Gate Blocking Range/Performance Part of HV Gate Blocking Range/Performance MG-ECU Power Relay Intermittent Circuit Lost Communication with ECM / PCM "A" Lost Communication with ECM / PCM "A" Lost Communication with ECM / PCM "A" Lost Communication with Drive Motor Control Module "A" Lost Communication with Drive Motor Control Module "A" Lost Communication with Drive Motor Control Module "A" Lost Communication with Drive Motor Control Module "A" Lost Communication with Brake System Control Module Lost Communication with Brake System Control Module Lost Communication with Brake System Control Module Lost Communication with Brake System Control Module Communication Error from Body ECU to HV ECU Communication Error from Airbag ECU to HV ECU Communication Error from A/C ECU to HV ECU Communication Error from A/C ECU to HV ECU Invalid Data Received from HVAC Control Module Lost Communication with Power Management Module

LIGHTING (EXT) DTCS AUTOMATIC HEADLIGHT BEAM LEVEL CONTROL SYSTEM AUTOMATIC HEADLIGHT BEAM LEVEL CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description B2416 Height Control Sensor Malfunction B241A Rear Height Control Sensor B2420 HL AutoLeveling ECU Failure B2450 Initialization has not been Performed B2451 Vehicle Specifications have not been Stored B2452 Height Control Sensor Data Out of Range When Initializing B2453 Variation Error LIGHTING SYSTEM LIGHTING SYSTEM DTC IDENTIFICATION DTC Code Description B1244 Light Sensor Circuit Malfunction

METER / GAUGE / DISPLAY DTCS

METER / GAUGE SYSTEM METER / GAUGE SYSTEM DTC IDENTIFICATION DTC Code Description B1500 Fuel Sender Open Detected B1507 Open in Turn Signal Circuit B1508 Short in Turn Signal / Hazard Flasher Circuit U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Skid Control ECU U0131 Lost Communication with Power Steering Control Module U0142 Lost Communication with Main Body ECU U0151 Lost Communication with Airbag ECU

NAVIGATION / MULTI INFO DISPLAY DTCS NAVIGATION SYSTEM (FOR NAVIGATION RECEIVER TYPE) NAVIGATION SYSTEM (FOR NAVIGATION RECEIVER TYPE) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1579 Voice Recognition Microphone Disconnected B1585 USB Media Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15AD Navigation Processor Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B5 DVD Changer Malfunction B15B7 Bluetooth Module Malfunction B15B8 Harddisk Malfunction B15BA XM Tuner Malfunction B15C0 Short in GPS Antenna B15C1 Open in GPS Antenna B15C2 Speed Signal Malfunction B15C3 Speaker Output Short B15D3 Stereo Component Amplifier Disconnected B15E7 Harddisk Reading/Writing Malfunction(Low Temperature) B15E8 Harddisk Reading/Writing Malfunction(High Temperature) B15F5 A/C ECU Vehicle Information Reading/Writing Processor Malfunction B15F6 Main Body ECU Vehicle Information Reading/Writing Process Malfunction B15F7 Certification ECU Vehicle Information Reading/Writing Process Malfunction B15FE XM Tuner Antenna Disconnected

B15FF U0073 U0100 U0129 U0140 U0155 U0293

XM Tuner Antenna Short Sending Malfunction (Navigation to APGS) Lost Communication with ECM / PCM "A" Lost Communication with Brake System Control Module Lost Communication with Body Control Module Meter ECU Communication Lost Communication with HV ECU

NAVIGATION SYSTEM (FOR RADIO AND DISPLAY TYPE) NAVIGATION SYSTEM (FOR RADIO AND DISPLAY TYPE) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1552 Extension Module Malfunction B156C Extension Module Disconnected B1579 Voice Recognition Microphone Disconnected B157E Bluetooth Antenna Disconnected B1585 USB Device Malfunction B158A Extension Module Noise Adjustment Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B4 CD Changer Malfunction B15B7 Bluetooth Module Malfunction B15BA XM Tuner Malfunction B15C0 Short in GPS Antenna B15C1 Open in GPS Antenna B15C3 Speaker Output Short B15D3 Stereo Component Amplifier Disconnected B15F6 Main Body ECU Vehicle Information Reading/Writing Process Malfunction B15FE XM Tuner Antenna Disconnected B15FF XM Tuner Antenna Short U0073 Sending Malfunction (Navigation to APGS) U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Brake System Control Module U0140 Lost Communication with Body Control Module U0155 Meter ECU Communication U0293 Lost Communication with HV ECU

NETWORKING DTCS

CAN COMMUNICATION SYSTEM SUB BUS 15 (MALFUNCTION OF SUB BUS 15) DTC IDENTIFICATION DTC Code Description U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Brake System Control Module U0293 Lost Communication with HV ECU SUB BUS 15 (OPEN IN SUB BUS BRANCH, COMMUNICATION STOP) DTC IDENTIFICATION DTC Code Description U0129 Lost Communication with Brake System Control Module SUB BUS 11 (POWER MANAGEMENT CONTROL ECU OUTPUT DTCS (TECHSTREAM DISPLAY: PM1 GATEWAY)) DTC IDENTIFICATION DTC Code Description U0232 Lost Communication with Blind Spot Monitor Slave Module U0233 Lost Communication with Blind Spot Monitor Master Module U1002 Lost Communication with Gateway Module LIN COMMUNICATION SYSTEM MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) DTC IDENTIFICATION DTC Code Description B126A Remote Engine Starter ECU Communication Stop B1273 Sliding Roof ECU Communication Stop B2321 Driver Side Door ECU Communication Stop B2325 LIN Communication Bus Malfunction CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) DTC IDENTIFICATION DTC Code Description B2785 Communication Malfunction between ECUs Connected by LIN B2786 No Response from Steering Lock ECU B2789 No Response from ID BOX B278C Lost Communication with Power Source Control POWER MANAGEMENT CONTROL ECU DTC IDENTIFICATION DTC Code Description B2287 LIN Communication Master Malfunction

PARK ASSIST / MONITORING DTCS BLIND SPOT MONITOR SYSTEM

BLIND SPOT MONITOR SYSTEM DTC IDENTIFICATION DTC Code Description C1A45 Vehicle Speed Sensor C1A47 Steering Angle Sensor C1AB0 Short to +B in Outer Mirror Indicator(Master) C1AB1 Short to +B in Outer Mirror Indicator(Slave) C1AB2 Short to GND in Outer Mirror Indicator(Master) C1AB3 Short to GND in Outer Mirror Indicator(Slave) C1AB4 Open in Outer Mirror Indicator(Master) C1AB5 Open in Outer Mirror Indicator(Slave) C1AB6 Blind Spot Monitor Master Module C1AB7 Blind Spot Monitor Slave Module C1AB8 Destination Information Undefined C1ABA Blind Spot Monitor Slave Module Connection Incorrect C1ABB Blind Spot Monitor Master Module Beam Axis Inspection Incomplete C1ABC Blind Spot Monitor Slave Module Beam Axis Inspection Incomplete U0126 Lost Communication with Steering Angle Sensor Module U0129 Lost Communication with Brake System Control Module U0142 Lost Communication with Body Control Module "B" U0232 Lost Communication with Blind Spot Monitor Slave Module U0233 Lost Communication with Blind Spot Monitor Master Module U0293 Lost Communication with HV ECU U1331 Software Incompatibility with Body Control Module "B" INTUITIVE PARKING ASSIST SYSTEM INTUITIVE PARKING ASSIST SYSTEM DTC IDENTIFICATION DTC Code Description C1AE1 Front Left Sensor Malfunction C1AE4 Front Right Sensor Malfunction C1AE6 Rear Left Sensor Malfunction C1AE7 Rear Left Center Sensor Malfunction C1AE8 Rear Right Center Sensor Malfunction C1AE9 Rear Right Sensor Malfunction C1AEC Front Sensor Communication Malfunction C1AED Rear Sensor Communication Malfunction U0100 Lost Communication with ECM / PCM "A" U0101 Lost Communication with TCM U0142 Lost Communication with Body Control Module "B" U0155 Lost Communication with Instrument Panel Cluster Control Module (Combination Meter)

PARKING ASSIST MONITOR SYSTEM PARKING ASSIST MONITOR SYSTEM DTC IDENTIFICATION DTC Code Description C1622 Open or Short Circuit in Back Camera Signal C1625 Open or Short in Steering Angle Sensor +B C1626 Steering Angle Sensor Failure C1691 Back Camera Initialization Incomplete C1694 Steering Angle Initialization Incomplete U0126 Lost Communication with Steering Angle Sensor Module U0140 Lost Communication with Body Control Module

POWER ASSIST SYSTEMS DTCS POWER STEERING SYSTEM POWER STEERING SYSTEM DTC IDENTIFICATION DTC Code Description C1511/11 Torque Sensor 1 Malfunction C1512/11 Torque Sensor 2 Malfunction C1513/11 Torque Sensor Deviation Excessive C1514/11 Torque Sensor Power Supply Voltage Malfunction C1521/25 Short in Motor Circuit C1524/24 Motor Circuit Malfunction C1528/12 Motor Rotation Angle Sensor Malfunction C1531/25 ECU Malfunction C1532/25 ECU Malfunction C1533/25 Temperature Sensor Circuit is Low or High C1534/25 EEPROM Malfunction C1541/13 Vehicle Speed Signal C1551/25 IG Power Supply Voltage Malfunction C1552/22 PIG Power Supply Voltage Malfunction C1554/23 Power Supply Relay Failure C1555/25 Motor Relay Welding Failure C1581/26 Assist Map Number Un-Writing C1582/26 Assist Map Number Mismatch U0129/42 Lost Communication with Brake System Control Module U0293/41 Lost Communication with Hybrid Control Module

SLIDING ROOF / DTCS SLIDING ROOF SYSTEM

SLIDING ROOF SYSTEM DTC IDENTIFICATION DTC Code Description B2341 Sensor (Motor) Failure B2342 Switch Failure B2343 Position Initialization Incomplete B2344 Position Failure

STEERING COLUMN DTCS STEERING LOCK SYSTEM STEERING LOCK SYSTEM DTC IDENTIFICATION DTC Code Description B2781 Open / Short in Steering Lock ECU B2782 Power Source Control ECU Malfunction B2788 IG2 Signal Malfunction

SUPPLEMENTAL RESTRAINT SYSTEMS DTCS AIRBAG SYSTEM (FOR BUILT-IN TYPE YAW RATE SENSOR) AIRBAG SYSTEM (FOR BUILT-IN TYPE YAW RATE SENSOR) DTC IDENTIFICATION DTC Code Description B1000/31 Center Airbag Sensor Assembly Malfunction B1610/13 Front Airbag Sensor RH Malfunction B1612/83 Lost Communication with Front Airbag Sensor RH B1613/83 Front Airbag Sensor RH Initialization Incomplete B1615/14 Front Airbag Sensor LH Malfunction B1617/84 Lost Communication with Front Airbag Sensor LH B1618/84 Front Airbag Sensor LH Initialization Incomplete B161A/8A Lost Communication with Front Satellite Sensor Bus B1620/21 Side Airbag Sensor RH Circuit Malfunction B1622/81 Lost communication with Side Airbag Sensor RH B1623/81 Side Airbag Sensor Assembly RH Initialization Incomplete B1625/22 Side Airbag Sensor LH Circuit Malfunction B1627/82 Lost communication with Side Airbag Sensor LH B1628/82 Side Airbag Sensor Assembly LH Initialization Incomplete B1630/23 Rear Airbag Sensor RH Circuit Malfunction B1632/81 Lost Communication with Rear Airbag Sensor RH B1633/81 Rear Airbag Sensor Assembly RH Initialization Incomplete B1635/24 Rear Airbag Sensor LH Circuit Malfunction B1637/82 Lost Communication with Rear Airbag Sensor LH

B1638/82 B1642/81 B1647/82 B1650/32 B1656/38 B1660/43 B1690/15 B1692/81 B1693/81 B1695/16 B1697/82 B1698/82 B1800/51 B1801/51 B1802/51 B1803/51 B1805/52 B1806/52 B1807/52 B1808/52 B1810/53 B1811/53 B1812/53 B1813/53 B1815/54 B1816/54 B1817/54 B1818/54 B1820/55 B1821/55 B1822/55 B1823/55 B1825/56 B1826/56 B1827/56 B1828/56 B1830/57 B1831/57 B1832/57 B1833/57 B1835/58 B1836/58

Rear Airbag Sensor Assembly LH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus RH Lost Communication with Side Satellite Sensor Bus LH Occupant Classification System Malfunction Seat Belt Buckle Switch LH Circuit Malfunction Passenger Airbag ON/OFF Indicator Circuit Malfunction Door Side Airbag Sensor RH Malfunction Lost Communication with Door Side Airbag Sensor RH Door Side Airbag Sensor RH Initialization Incomplete Door Side Airbag Sensor LH Malfunction Lost Communication with Door Side Airbag Sensor LH Door Side Airbag Sensor LH Initialization Incomplete Short in Driver Side Squib Circuit Open in Driver Side Squib Circuit Short to GND in Driver Side Squib Circuit Short to B+ in Driver Side Squib Circuit Short in Front Passenger Side Squib Circuit Open in Front Passenger Side Squib Circuit Short to GND in Front Passenger Side Squib Circuit Short to B+ in Front Passenger Side Squib Circuit Short in Driver Side Squib 2nd Step Circuit Open in Driver Side Squib 2nd Step Circuit Short to GND in Driver Side Squib 2nd Step Circuit Short to B+ in Driver Side Squib 2nd Step Circuit Short in Front Passenger Side Squib 2nd Step Circuit Open in Front Passenger Side Squib 2nd Step Circuit Short to GND in Front Passenger Side Squib 2nd Step Circuit Short to B+ in Front Passenger Side Squib 2nd Step Circuit Short in Side Squib RH Circuit Open in Side Squib RH Circuit Short to GND in Side Squib RH Circuit Short to B+ in Side Squib RH Circuit Short in Side Squib LH Circuit Open in Side Squib LH Circuit Short to GND in Side Squib LH Circuit Short to B+ in Side Squib LH Circuit Short in Curtain Shield Squib RH Circuit Open in Curtain Shield Squib RH Circuit Short to GND in Curtain Shield Squib RH Circuit Short to B+ in Curtain Shield Squib RH Circuit Short in Curtain Shield Squib LH Circuit

B1837/58 B1838/58 B1850/62 B1851/62 B1852/62 B1853/62 B1855/63 B1856/63 B1857/63 B1858/63 B1860/64 B1861/64 B1862/64 B1863/64 B1865/65 B1866/65 B1867/65 B1868/65 B1900/73 B1901/73 B1902/73 B1903/73 B1905/74 B1906/74 B1907/74 B1908/74

Open in Curtain Shield Squib LH Circuit Short to GND in Curtain Shield Squib LH Circuit Short to B+ in Curtain Shield Squib LH Circuit Short in Rear Side Squib RH Circuit Open in Rear Side Squib RH Circuit Short to GND in Rear Side Squib RH Circuit Short to B+ in Rear Side Squib RH Circuit Short in Rear Side Squib LH Circuit Open in Rear Side Squib LH Circuit Short to GND in Rear Side Squib LH Circuit Short to B+ in Rear Side Squib LH Circuit Short in Driver Side Knee Airbag Squib Circuit Open in Driver Side Knee Airbag Squib Circuit Short to GND in Driver Side Knee Airbag Squib Circuit Short to B+ in Driver Side Knee Airbag Squib Circuit Short in Front Passenger Side Knee Airbag Squib Circuit Open in Front Passenger Side Knee Airbag Squib Circuit Short to GND in Front Passenger Side Knee Airbag Squib Circuit Short to B+ in Front Passenger Side Knee Airbag Squib Circuit Short in Front Pretensioner Squib RH Circuit Open in Front Pretensioner Squib RH Circuit Short to GND in Front Pretensioner Squib RH Circuit Short to B+ in Front Pretensioner Squib RH Circuit Short in Front Pretensioner Squib LH Circuit Open in Front Pretensioner Squib LH Circuit Short to GND in Front Pretensioner Squib LH Circuit Short to B+ in Front Pretensioner Squib LH Circuit

AIRBAG SYSTEM (FOR SEPARATE TYPE YAW RATE SENSOR) AIRBAG SYSTEM (FOR SEPARATE TYPE YAW RATE SENSOR) DTC IDENTIFICATION DTC Code Description B1000/31 Center Airbag Sensor Assembly Malfunction B1603/83 Front Satellite Sensor Bus RH Initialization Incomplete B1608/84 Front Satellite Sensor Bus LH Initialization Incomplete B1610/13 Front Airbag Sensor RH Malfunction B1612/83 Lost Communication with Front Airbag Sensor RH B1613/83 Front Airbag Sensor RH Initialization Incomplete B1615/14 Front Airbag Sensor LH Malfunction B1617/84 Lost Communication with Front Airbag Sensor LH B1618/84 Front Airbag Sensor LH Initialization Incomplete

B1620/21 B1622/81 B1623/81 B1625/22 B1627/82 B1628/82 B1630/23 B1632/81 B1633/81 B1635/24 B1637/82 B1638/82 B1642/81 B1643/81 B1647/82 B1648/82 B1650/32 B1656/38 B1660/43 B1690/15 B1692/81 B1693/81 B1695/16 B1697/82 B1698/82 B1800/51 B1801/51 B1802/51 B1803/51 B1805/52 B1806/52 B1807/52 B1808/52 B1810/53 B1811/53 B1812/53 B1813/53 B1815/54 B1816/54 B1817/54 B1818/54 B1820/55

Side Airbag Sensor RH Circuit Malfunction Lost communication with Side Airbag Sensor RH Side Airbag Sensor Assembly RH Initialization Incomplete Side Airbag Sensor LH Circuit Malfunction Lost communication with Side Airbag Sensor LH Side Airbag Sensor Assembly LH Initialization Incomplete Rear Airbag Sensor RH Circuit Malfunction Lost Communication with Rear Airbag Sensor RH Rear Airbag Sensor Assembly RH Initialization Incomplete Rear Airbag Sensor LH Circuit Malfunction Lost Communication with Rear Airbag Sensor LH Rear Airbag Sensor Assembly LH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus RH Side Satellite Sensor Bus RH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus LH Side Satellite Sensor Bus LH Initialization Incomplete Occupant Classification System Malfunction Seat Belt Buckle Switch LH Circuit Malfunction Passenger Airbag ON/OFF Indicator Circuit Malfunction Door Side Airbag Sensor RH Malfunction Lost Communication with Door Side Airbag Sensor RH Door Side Airbag Sensor RH Initialization Incomplete Door Side Airbag Sensor LH Malfunction Lost Communication with Door Side Airbag Sensor LH Door Side Airbag Sensor LH Initialization Incomplete Short in Driver Side Squib Circuit Open in Driver Side Squib Circuit Short to GND in Driver Side Squib Circuit Short to B+ in Driver Side Squib Circuit Short in Front Passenger Side Squib Circuit Open in Front Passenger Side Squib Circuit Short to GND in Front Passenger Side Squib Circuit Short to B+ in Front Passenger Side Squib Circuit Short in Driver Side Squib 2nd Step Circuit Open in Driver Side Squib 2nd Step Circuit Short to GND in Driver Side Squib 2nd Step Circuit Short to B+ in Driver Side Squib 2nd Step Circuit Short in Front Passenger Side Squib 2nd Step Circuit Open in Front Passenger Side Squib 2nd Step Circuit Short to GND in Front Passenger Side Squib 2nd Step Circuit Short to B+ in Front Passenger Side Squib 2nd Step Circuit

B1821/55 B1822/55 B1823/55 B1825/56 B1826/56 B1827/56 B1828/56 B1830/57 B1831/57 B1832/57 B1833/57 B1835/58 B1836/58 B1837/58 B1838/58 B1850/62 B1851/62 B1852/62 B1853/62 B1855/63 B1856/63 B1857/63 B1858/63 B1860/64 B1861/64 B1862/64 B1863/64 B1865/65 B1866/65 B1867/65 B1868/65 B1900/73 B1901/73 B1902/73 B1903/73 B1905/74 B1906/74 B1907/74 B1908/74

Short in Side Squib RH Circuit Open in Side Squib RH Circuit Short to GND in Side Squib RH Circuit Short to B+ in Side Squib RH Circuit Short in Side Squib LH Circuit Open in Side Squib LH Circuit Short to GND in Side Squib LH Circuit Short to B+ in Side Squib LH Circuit Short in Curtain Shield Squib RH Circuit Open in Curtain Shield Squib RH Circuit Short to GND in Curtain Shield Squib RH Circuit Short to B+ in Curtain Shield Squib RH Circuit Short in Curtain Shield Squib LH Circuit Open in Curtain Shield Squib LH Circuit Short to GND in Curtain Shield Squib LH Circuit Short to B+ in Curtain Shield Squib LH Circuit Short in Rear Side Squib RH Circuit Open in Rear Side Squib RH Circuit Short to GND in Rear Side Squib RH Circuit Short to B+ in Rear Side Squib RH Circuit Short in Rear Side Squib LH Circuit Open in Rear Side Squib LH Circuit Short to GND in Rear Side Squib LH Circuit Short to B+ in Rear Side Squib LH Circuit Short in Driver Side Knee Airbag Squib Circuit Open in Driver Side Knee Airbag Squib Circuit Short to GND in Driver Side Knee Airbag Squib Circuit Short to B+ in Driver Side Knee Airbag Squib Circuit Short in Front Passenger Side Knee Airbag Squib Circuit Open in Front Passenger Side Knee Airbag Squib Circuit Short to GND in Front Passenger Side Knee Airbag Squib Circuit Short to B+ in Front Passenger Side Knee Airbag Squib Circuit Short in Front Pretensioner Squib RH Circuit Open in Front Pretensioner Squib RH Circuit Short to GND in Front Pretensioner Squib RH Circuit Short to B+ in Front Pretensioner Squib RH Circuit Short in Front Pretensioner Squib LH Circuit Open in Front Pretensioner Squib LH Circuit Short to GND in Front Pretensioner Squib LH Circuit Short to B+ in Front Pretensioner Squib LH Circuit

OCCUPANT CLASSIFICATION SYSTEM OCCUPANT CLASSIFICATION SYSTEM DTC IDENTIFICATION DTC Code Description B1771 Passenger Side Buckle Switch Circuit Malfunction B1782 Rear Occupant Classification Sensor LH Circuit Malfunction B1783 Rear Occupant Classification Sensor RH Circuit Malfunction B1787 Rear Occupant Classification Sensor LH Collision Detection B1788 Rear Occupant Classification Sensor RH Collision Detection B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction B1793 Occupant Classification Sensor Power Supply Circuit Malfunction B1794 Open in Occupant Classification ECU Battery Positive Line B1795 Occupant Classification ECU Malfunction B1796 Sleep Operation Failure of Occupant Classification ECU

THEFT DETERRENT / KEYLESS ENTRY DTCS ENGINE IMMOBILISER SYSTEM CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) DTC IDENTIFICATION DTC Code Description B2779 Engine Starter Communication Malfunction B2784 Antenna Coil Open / Short B278A Short to GND in Immobiliser System Power Source Circuit B278D Malfunction of ID-BOX Recognition POWER MANAGEMENT CONTROL ECU DTC IDENTIFICATION DTC Code Description B2799 Engine Immobiliser System Malfunction B279A Theft Deterrent System Communication Line High Fixation B279C Theft Deterrent System Presence Detection SMART KEY SYSTEM (FOR ENTRY FUNCTION) SMART KEY SYSTEM (FOR ENTRY FUNCTION) DTC IDENTIFICATION DTC Code Description B27A1 Open in Driver Side Electrical Antenna Circuit B27A2 Open in Front Passenger Side Electrical Antenna Circuit B27A5 Open in Front Floor Electrical Key Oscillator Circuit B27A6 Open in Rear Floor Electrical Key Oscillator Circuit B27A7 Open in Inside Luggage Compartment Electrical Key Oscillator Circuit B27A8 Open in Outside Luggage Compartment Electrical Key Antenna Circuit

SMART KEY SYSTEM (FOR START FUNCTION) SMART KEY SYSTEM (FOR START FUNCTION) DTC IDENTIFICATION DTC Code Description B2271 Ignition Hold Monitor Malfunction B2274 ACC Monitor Malfunction B2275 STSW Monitor Malfunction B2277 Detecting Vehicle Submersion B2282 Vehicle Speed Signal Malfunction B2283 Vehicle Speed Sensor Malfunction B2284 Brake Signal Malfunction B2285 Steering Lock Position Signal Circuit Malfunction B2286 Runnable Signal Malfunction U0100 Lost Communication with ECM U0140 Lost Communication with Main Body ECU U0142 Lost Communication with Main Body ECU U0155 Lost Communication with Combination Meter U0293 Lost Communication with HV ECU U0293 Lost Communication with HV ECU

TIRE PRESSURE MONITORING DTCS TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING ECU AND RECEIVER DTC IDENTIFICATION DTC Code Description C2111/11 Transmitter ID1 Operation Stop C2112/12 Transmitter ID2 Operation Stop C2113/13 Transmitter ID3 Operation Stop C2114/14 Transmitter ID4 Operation Stop C2121/21 No Signal from Transmitter ID1 C2122/22 No Signal from Transmitter ID2 C2123/23 No Signal from Transmitter ID3 C2124/24 No Signal from Transmitter ID4 C2126/26 Transmitter ID not Received in Main Mode C2141/41 Transmitter ID1 Error C2142/42 Transmitter ID2 Error C2143/43 Transmitter ID3 Error C2144/44 Transmitter ID4 Error C2171/71 Transmitter ID not Registered C2176/76 Receiver Error C2177/77 Initialization not Completed

C2179/79 C2181/81 C2182/82 C2183/83 C2184/84 C2198/98

Tire Pressure Monitor ECU Communication Stop Transmitter ID1 not Received (Test Mode DTC) Transmitter ID2 not Received (Test Mode DTC) Transmitter ID3 not Received (Test Mode DTC) Transmitter ID4 not Received (Test Mode DTC) Initialization Switch (for Test Mode DTC)

MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) DTC IDENTIFICATION DTC Code Description B1247 Tire Pressure Monitor Receiver Communication Stop

WINDOW / GLASS DTCS POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description B2311 Power Window Motor Malfunction B2312 Power Window Switch Malfunction B2313 Glass Position Initialization Incomplete

2012-2017 DTC INDEX Camry (Except Hybrid)

AUDIO / VIDEO DTCS AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITH INTUITIVE PARKING ASSIST SYSTEM) AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITH INTUITIVE PARKING ASSIST SYSTEM) DTC IDENTIFICATION DTC Code Description B1579 Voice Recognition Microphone Disconnected B1585 USB Media Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B5 DVD Changer Malfunction B15B7 Bluetooth Module Malfunction B15B8 Harddisk Malfunction B15C3 Speaker Output Short B15D3 Stereo Component Amplifier Disconnected B15E7 Harddisk Reading/Writing Malfunction (Low Temperature) B15E8 Harddisk Reading/Writing Malfunction (High Temperature) B15F5 A/C ECU Vehicle Information Reading/Writing Processor Malfunction B15F6 Main Body ECU Vehicle Information Reading/Writing Process Malfunction B15F7 Certification ECU Vehicle Information Reading/Writing Process Malfunction U0073 Sending Malfunction (Navigation to APGS) U0100 Lost Communication with ECM U0140 Lost Communication with Body Control Module U0155 Meter ECU Communication AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITHOUT INTUITIVE PARKING ASSIST SYSTEM) AUDIO AND VISUAL SYSTEM (FOR RADIO AND DISPLAY TYPE WITHOUT INTUITIVE PARKING ASSIST SYSTEM) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1579 Voice Recognition Microphone Disconnected B1585 USB Device Malfunction B15A0 LAN Master Malfunction

B15A3 B15B0 B15B3 B15B4 B15B7 B15BA B15C3 B15D3 B15F6 B15FE B15FF U0073 U0100 U0140 U0155

Stereo Component Amplifier Malfunction Display Screen Malfunction Radio Tuner Malfunction CD Changer Malfunction Bluetooth Module Malfunction XM Tuner Malfunction Speaker Output Short Stereo Component Amplifier Disconnected Main Body ECU Vehicle Information Reading/Writing Process Malfunction XM Tuner Antenna Disconnected XM Tuner Antenna Short Sending Malfunction (Navigation to APGS) Lost Communication with ECM Lost Communication with Body Control Module Meter ECU Communication

AUTOMATIC TRANSAXLE DTCS AUTOMATIC TRANSAXLE SYSTEM (U660E) AUTOMATIC TRANSAXLE SYSTEM DTC IDENTIFICATION DTC Code Description P0500 Vehicle Speed Sensor "A" P0560 System Voltage P0617 Starter Relay Circuit High P062F Internal Control Module EEPROM Error P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) P0711 Transmission Fluid Temperature Sensor "A" Performance P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input P0715 Input / Turbine Speed Sensor Circuit Malfunction P0717 Input Speed Sensor Circuit No Signal P0724 Brake Switch "B" Circuit High P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve SL) P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) P0791 Intermediate Shaft Speed Sensor "A" Circuit P0793 Intermediate Shaft Speed Sensor "A" P0796 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3)

P0798 P0989 P0990 P2714 P2716 P2757 P2759 P2769 P2770 P2808 P2810 U0100

Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) Transmission Fluid Pressure Sensor / Switch "E" Circuit Low Transmission Fluid Pressure Sensor / Switch "E" Circuit High Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) Short in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) Open in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) Pressure Control Solenoid "G" Performance (Shift Solenoid Valve SL4) Pressure Control Solenoid "G" Electrical (Shift Solenoid Valve SL4) Lost Communication with ECM / PCM "A"

AUTOMATIC TRANSAXLE SYSTEM (U760E) AUTOMATIC TRANSAXLE SYSTEM DTC IDENTIFICATION DTC Code Description P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) P0711 Transmission Fluid Temperature Sensor "A" Performance P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input P0715 Input / Turbine Speed Sensor Circuit Malfunction P0717 Input Speed Sensor Circuit No Signal P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve SL) P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) P0791 Intermediate Shaft Speed Sensor "A" Circuit P0793 Intermediate Shaft Speed Sensor "A" P0796 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3) P0798 Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) P2769 Short in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) P2770 Open in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL)

P2808 P2810 U0100

Pressure Control Solenoid "G" Performance (Shift Solenoid Valve SL4) Pressure Control Solenoid "G" Electrical (Shift Solenoid Valve SL4) Lost Communication with ECM / PCM "A"

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS DTCS VEHICLE STABILITY CONTROL SYSTEM ABS DTC IDENTIFICATION DTC Code Description C1225 SM Solenoid Circuit C1226 SA2 Solenoid Circuit C1227 SA3 Solenoid Circuit C1228 STR Solenoid Circuit C1237 Speed Sensor Rotor Faulty C1241 Low Power Supply Voltage Malfunction C1246 Master Cylinder Pressure Sensor Malfunction C1249 Open in Stop Light Switch Circuit C1300 Skid Control ECU Malfunction C1330 Open in Front Speed Sensor RH C1331 Open in Front Speed Sensor LH C1332 Open in Rear Speed Sensor RH C1333 Open in Rear Speed Sensor LH C1417 High Power Supply Voltage Malfunction C1425 Open in Stop Light Switch Circuit C1426 Stop Light Switch OFF Stuck Malfunction C1428 Motor Circuit Malfunction C1429 Open or Short in Brake Pedal Load Sensing Switch C1430 Brake Pedal Load Sensing Switch OFF Stuck Malfunction C1431 Brake Pedal Load Sensing Switch ON Stuck Malfunction C1464 Front Speed Sensor RH C1465 Front Speed Sensor LH C1466 Rear Speed Sensor RH C1467 Rear Speed Sensor LH C1468 SFR Solenoid Circuit C1469 SFL Solenoid Circuit C146A SRR Solenoid Circuit C146B SRL Solenoid Circuit C146C Open in ABS Motor Relay Circuit C146E Open in ABS Solenoid Relay Circuit U0073 Control Module Communication Bus OFF

VSC DTC IDENTIFICATION DTC Code Description C1201 Engine Control System Malfunction C1224 NE Signal C1234 Yaw Rate Sensor C1288 Error in Matching of ECUs C1381 Acceleration Sensor Power Supply Voltage Malfunction C1419 Acceleration Sensor Internal Circuit C1420 Acceleration Sensor Malfunction C1432 Steering Angle Sensor Power Source Voltage Malfunction C1433 Steering Angle Sensor Internal Circuit C1434 Steering Angle Sensor Output Malfunction C1435 Yaw Rate Sensor Internal Circuit C1436 Yaw Rate Sensor Malfunction C1439 Steering Angle Sensor Initialization Incomplete C1445 Vehicle Driven with Steering Angle Sensor not Initialized C1472 Acceleration Sensor U0100 Lost Communication with ECM / PCM U0123 Lost Communication with Yaw Rate Sensor Module U0126 Lost Communication with Steering Angle Sensor Module ABS TEST MODE DTC IDENTIFICATION DTC Code Description C1271 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) C1272 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) C1273 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) C1274 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) C1275 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) C1276 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) C1277 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) C1278 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) C1281 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC)

CELLULAR COMMUNICATION DTCS SAFETY CONNECT SYSTEM SAFETY CONNECT SYSTEM DTC IDENTIFICATION DTC Code Description B1570 Manual (SOS) Switch Red Indicator Malfunction B1571 Manual (SOS) Switch Green Indicator Malfunction B1572 Telephone Microphone Error

B1573 B15CB B1583 B15A8 B15C0 B15C1 B15C4 B15C5 B15CC B15EC

Short in Telephone Antenna Circuit Telematics Transceiver Antenna Disconnected GPS Signal Unreceived Telematics Transceiver Malfunction Short in GPS Antenna Open in GPS Antenna Airbag Signal Malfunction/Not Input Manual Button Malfunction Backup Battery Failure Backup Battery Degradation

CRUISE CONTROL DTCS CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description P0500 Vehicle Speed Sensor Malfunction P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High P0571 Brake Switch "A" Circuit P0575 Cruise Control Input Circuit

DOOR LOCK DTCS WIRELESS DOOR LOCK CONTROL SYSTEM (W/ SMART KEY SYSTEM) WIRELESS DOOR LOCK CONTROL SYSTEM (W/ SMART KEY SYSTEM) DTC IDENTIFICATION DTC Code Description B1242 Wireless Door Lock Tuner Circuit Malfunction

ENGINE CONTROL DTCS SFI SYSTEM (2AR-FE) SFI SYSTEM DTC IDENTIFICATION DTC Code Description P0010 Camshaft Position "A" Actuator Circuit (Bank 1) P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) P0013 Camshaft Position "B" Actuator Circuit / Open (Bank 1) P0014 Camshaft Position "B" - Timing Over-Advanced or System Performance (Bank 1)

P0015 P0016 P0017 P0031 P0032 P0037 P0038 P0101 P0102 P0103 P0111 P0112 P0113 P0115 P0116 P0117 P0118 P011B P0120 P0121 P0122 P0123 P0125 P0128 P0136 P0137 P0138 P0139 P0141 P014C P014D P015A P015B P0171 P0172 P0220 P0222 P0223 P0300 P0301

Camshaft Position "B" - Timing Over-Retarded (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B) Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) Mass Air Flow Circuit Range / Performance Problem Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Intake Air Temperature Sensor Gradient Too High Intake Air Temperature Circuit Low Input Intake Air Temperature Circuit High Input Engine Coolant Temperature Circuit Malfunction Engine Coolant Temperature Circuit Range / Performance Problem Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature Circuit High Input Engine Coolant Temperature / Intake Air Temperature Correlation Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input Throttle / Pedal Position Sensor / Switch "A" Circuit High Input Insufficient Coolant Temperature for Closed Loop Fuel Control Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 2) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) A/F Sensor Slow Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Slow Response - Lean to Rich Bank 1 Sensor 1 A/F Sensor Delayed Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Delayed Response - Lean to Rich Bank 1 Sensor 1 System Too Lean (Bank 1) System Too Rich (Bank 1) Throttle / Pedal Position Sensor / Switch "B" Circuit Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input Throttle / Pedal Position Sensor / Switch "B" Circuit High Input Random / Multiple Cylinder Misfire Detected Cylinder 1 Misfire Detected

P0302 P0303 P0304 P0327 P0328 P0335 P0339 P0340 P0342 P0343 P0351 P0352 P0353 P0354 P0365 P0367 P0368 P0420 P043E P043F P0441 P0451 P0452 P0453 P0455 P0456 P0500 P0504 P0505 P050A P050B P0560 P0604 P0606 P0607 P060A P060B P060D P060E P0617 P062F P0630

Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) Crankshaft Position Sensor "A" Circuit Crankshaft Position Sensor "A" Circuit Intermittent Camshaft Position Sensor Circuit Malfunction Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) Ignition Coil "A" Primary / Secondary Circuit Ignition Coil "B" Primary / Secondary Circuit Ignition Coil "C" Primary / Secondary Circuit Ignition Coil "D" Primary / Secondary Circuit Camshaft Position Sensor "B" Circuit (Bank 1) Camshaft Position Sensor "B" Circuit Low Input (Bank 1) Camshaft Position Sensor "B" Circuit High Input (Bank 1) Catalyst System Efficiency Below Threshold (Bank 1) Evaporative Emission System Leak Detection Reference Orifice Low Flow Evaporative Emission System Reference Orifice High Flow Evaporative Emission Control System Incorrect Purge Flow Evaporative Emission Control System Pressure Sensor Range / Performance Evaporative Emission Control System Pressure Sensor / Switch Low Input Evaporative Emission Control System Pressure Sensor / Switch High Input Evaporative Emission Control System Leak Detected (Gross Leak) Evaporative Emission Control System Leak Detected (Very Small Leak) Vehicle Speed Sensor "A" Brake Switch "A" / "B" Correlation Idle Control System Malfunction Cold Start Idle Air Control System Performance Cold Start Ignition Timing Performance System Voltage Random Access Memory (RAM) ECM / PCM Processor Control Module Performance Internal Control Module Monitoring Processor Performance Internal Control Module A/D Processing Performance Internal Control Module Accelerator Pedal Position Performance Internal Control Module Throttle Position Performance Starter Relay Circuit High Internal Control Module EEPROM Error

P0657 P0724 P101D P102D P1603 P1604 P1605 P1607 P2004 P2006 P2009 P2010 P2014 P2016 P2017 P2102 P2103 P2109 P2111 P2112 P2118 P2119 P2120 P2121 P2122 P2123 P2125 P2127 P2128 P2135 P2138 P2195 P2196 P219A P2237 P2238 P2239 P2252 P2253 P2401 P2402

VIN not Programmed or Mismatch - ECM / PCM Actuator Supply Voltage Circuit / Open Brake Switch "B" Circuit High A/F Sensor Heater Circuit Performance Bank 1 Sensor 1 Stuck ON O2 Sensor Heater Circuit Performance Bank 1 Sensor 2 Stuck ON Engine Stall History Startability Malfunction Rough Idling Cruise Control Input Processor Intake Manifold Runner Control Stuck Open (Bank 1) Intake Manifold Runner Control Stuck Closed (Bank 1) Intake Manifold Runner Control Circuit Low (Bank 1) Intake Manifold Runner Control Circuit High (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle / Pedal Position Sensor "A" Minimum Stop Performance Throttle Actuator Control System - Stuck Open Throttle Actuator Control System - Stuck Closed Throttle Actuator Control Motor Current Range / Performance Throttle Actuator Control Throttle Body Range / Performance Throttle / Pedal Position Sensor / Switch "D" Circuit Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input Throttle / Pedal Position Sensor / Switch "D" Circuit High Input Throttle / Pedal Position Sensor / Switch "E" Circuit Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input Throttle / Pedal Position Sensor / Switch "E" Circuit High Input Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Bank 1 Air-Fuel Ratio Imbalance Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Evaporative Emission Leak Detection Pump Stuck OFF

P2419 P2420 P2610 P2A00 U0101

Evaporative Emission Leak Detection Pump Stuck ON Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High ECM / PCM Internal Engine Off Timer Performance A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) Lost Communication with TCM

SFI SYSTEM (2GR-FE) SFI SYSTEM DTC IDENTIFICATION DTC Code Description P0010 Camshaft Position "A" Actuator Circuit (Bank 1) P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) P0013 Camshaft Position "B" Actuator Circuit / Open (Bank 1) P0014 Camshaft Position "B" - Timing Over-Advanced or System Performance (Bank 1) P0015 Camshaft Position "B" - Timing Over-Retarded (Bank 1) P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B) P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) P0019 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor B) P0020 Camshaft Position "A" Actuator Circuit (Bank 2) P0021 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 2) P0022 Camshaft Position "A" - Timing Over-Retarded (Bank 2) P0023 Camshaft Position "B" Actuator Circuit / Open (Bank 2) P0024 Camshaft Position "B" - Timing Over-Advanced or System Performance (Bank 2) P0025 Camshaft Position "B" - Timing Over-Retarded (Bank 2) P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) P0101 Mass Air Flow Circuit Range / Performance Problem P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input P0111 Intake Air Temperature Sensor 1 Circuit Range / Performance P0112 Intake Air Temperature Circuit Low Input P0113 Intake Air Temperature Circuit High Input

P0115 P0116 P0117 P0118 P011B P0120 P0121 P0122 P0123 P0125 P0128 P0136 P0137 P0138 P0139 P0141 P014C P014D P014E P014F P0156 P0157 P0158 P0159 P015A P015B P015C P015D P0161 P0171 P0172 P0174 P0175 P0220 P0222 P0223 P0300 P0301 P0302 P0303

Engine Coolant Temperature Circuit Malfunction Engine Coolant Temperature Circuit Range / Performance Problem Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature Circuit High Input Engine Coolant Temperature / Intake Air Temperature Correlation Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input Throttle / Pedal Position Sensor / Switch "A" Circuit High Input Insufficient Coolant Temperature for Closed Loop Fuel Control Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 2) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) A/F Sensor Slow Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Slow Response - Lean to Rich Bank 1 Sensor 1 A/F Sensor Slow Response - Rich to Lean Bank 2 Sensor 1 A/F Sensor Slow Response - Lean to Rich Bank 2 Sensor 1 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) Oxygen Sensor Circuit Slow Response (Bank 2 Sensor 2) A/F Sensor Delayed Response - Rich to Lean Bank 1 Sensor 1 A/F Sensor Delayed Response - Lean to Rich Bank 1 Sensor 1 A/F Sensor Delayed Response - Rich to Lean Bank 2 Sensor 1 A/F Sensor Delayed Response - Lean to Rich Bank 2 Sensor 1 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 1) System Too Lean (Bank 2) System Too Rich (Bank 2) Throttle / Pedal Position Sensor / Switch "B" Circuit Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input Throttle / Pedal Position Sensor / Switch "B" Circuit High Input Random / Multiple Cylinder Misfire Detected Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected

P0304 P0305 P0306 P0327 P0328 P0332 P0333 P0335 P0339 P0340 P0342 P0343 P0345 P0347 P0348 P0351 P0352 P0353 P0354 P0355 P0356 P0365 P0367 P0368 P0390 P0392 P0393 P0420 P0430 P043E P043F P0441 P0443 P0451 P0452 P0453 P0455 P0456 P0500 P0504 P0505 P050A

Cylinder 4 Misfire Detected Cylinder 5 Misfire Detected Cylinder 6 Misfire Detected Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) Knock Sensor 2 Circuit Low Input (Bank 2) Knock Sensor 2 Circuit High Input (Bank 2) Crankshaft Position Sensor "A" Circuit Crankshaft Position Sensor "A" Circuit Intermittent Camshaft Position Sensor Circuit Malfunction Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) Camshaft Position Sensor "A" Circuit (Bank 2) Camshaft Position Sensor "A" Circuit Low Input (Bank 2) Camshaft Position Sensor "A" Circuit High Input (Bank 2) Ignition Coil "A" Primary / Secondary Circuit Ignition Coil "B" Primary / Secondary Circuit Ignition Coil "C" Primary / Secondary Circuit Ignition Coil "D" Primary / Secondary Circuit Ignition Coil "E" Primary / Secondary Circuit Ignition Coil "F" Primary / Secondary Circuit Camshaft Position Sensor "B" Circuit (Bank 1) Camshaft Position Sensor "B" Circuit Low Input (Bank 1) Camshaft Position Sensor "B" Circuit High Input (Bank 1) Camshaft Position Sensor "B" Circuit (Bank 2) Camshaft Position Sensor "B" Circuit Low Input (Bank 2) Camshaft Position Sensor "B" Circuit High Input (Bank 2) Catalyst System Efficiency Below Threshold (Bank 1) Catalyst System Efficiency Below Threshold (Bank 2) Evaporative Emission System Leak Detection Reference Orifice Low Flow Evaporative Emission System Reference Orifice High Flow Evaporative Emission Control System Incorrect Purge Flow Evaporative Emission Control System Purge Control Valve Circuit Evaporative Emission Control System Pressure Sensor Range / Performance Evaporative Emission Control System Pressure Sensor / Switch Low Input Evaporative Emission Control System Pressure Sensor / Switch High Input Evaporative Emission Control System Leak Detected (Gross Leak) Evaporative Emission Control System Leak Detected (Very Small Leak) Vehicle Speed Sensor "A" Brake Switch "A" / "B" Correlation Idle Control System Malfunction

P050B P0560 P0604 P0606 P0607 P060A P060B P060D P060E P0617 P062F P0630 P0657 P0705 P0724 P101D P102D P103D P105D P1603 P1604 P1605 P1607 P2102 P2103 P2109 P2111 P2112 P2118 P2119 P2120 P2121 P2122 P2123 P2125 P2127 P2128 P2135 P2138 P2195 P2196

Cold Start Idle Air Control System Performance Cold Start Ignition Timing Performance System Voltage Internal Control Module Random Access Memory (RAM) Error ECM / PCM Processor Control Module Performance Internal Control Module Monitoring Processor Performance Internal Control Module A/D Processing Performance Internal Control Module Accelerator Pedal Position Performance Internal Control Module Throttle Position Performance Starter Relay Circuit High Internal Control Module EEPROM Error VIN not Programmed or Mismatch - ECM / PCM Actuator Supply Voltage Circuit / Open Transmission Range Sensor Circuit Malfunction (PRNDL Input) Brake Switch "B" Circuit High A/F Sensor Heater Circuit Performance Bank 1 Sensor 1 Stuck ON O2 Sensor Heater Circuit Performance Bank 1 Sensor 2 Stuck ON A/F Sensor Heater Circuit Performance Bank 2 Sensor 1 Stuck ON O2 Sensor Heater Circuit Performance Bank 2 Sensor 2 Stuck ON Engine Stall History Startability Malfunction Rough Idling Cruise Control Input Processor Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle / Pedal Position Sensor "A" Minimum Stop Performance Throttle Actuator Control System - Stuck Open Throttle Actuator Control System - Stuck Closed Throttle Actuator Control Motor Current Range / Performance Throttle Actuator Control Throttle Body Range / Performance Throttle / Pedal Position Sensor / Switch "D" Circuit Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input Throttle / Pedal Position Sensor / Switch "D" Circuit High Input Throttle / Pedal Position Sensor / Switch "E" Circuit Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input Throttle / Pedal Position Sensor / Switch "E" Circuit High Input Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1)

P2197 P2198 P219A P219B P2237 P2238 P2239 P2240 P2241 P2242 P2252 P2253 P2255 P2256 P2401 P2402 P2419 P2420 P2610 U0101

Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) Bank 1 Air-Fuel Ratio Imbalance Bank 2 Air-Fuel Ratio Imbalance Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 2 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) Evaporative Emission Leak Detection Pump Stuck OFF Evaporative Emission Leak Detection Pump Stuck ON Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High ECM / PCM Internal Engine Off Timer Performance Lost Communication with TCM

HEATING / AIR CONDITIONING DTCS AIR CONDITIONING SYSTEM (FOR AUTOMATIC AIR CONDITIONING SYSTEM) AIR CONDITIONING SYSTEM (FOR AUTOMATIC AIR CONDITIONING SYSTEM) DTC IDENTIFICATION DTC Code Description B1411 Room Temperature Sensor Circuit B1412 Ambient Temperature Sensor Circuit B1413 Evaporator Temperature Sensor Circuit B1422 Compressor Lock Sensor Circuit B1423 Pressure Sensor Circuit B1441 Air Mix Damper Control Servo Motor Circuit (Passenger Side) B1442 Air Inlet Damper Control Servo Motor Circuit B1443 Air Outlet Damper Control Servo Motor Circuit B1446 Air Mix Damper Control Servo Motor Circuit (Driver Side) B1451 Compressor Solenoid Circuit B1479 Flow Sensor Circuit B1497 BUS IC Communication Malfunction B14A2 Driver Side Solar Sensor Short Circuit

B14A3 B14B2 B14B8 U0100 U0131 U0142 U0155

Front Passenger Side Solar Sensor Short Circuit Lost Communication with Front Panel LIN Refrigerant Shortage Lost Communication with ECM Lost Communication with Electric Power Steering ECU Lost Communication with Main Body ECU Lost Communication with Combination Meter

AIR CONDITIONING SYSTEM (FOR MANUAL AIR CONDITIONING SYSTEM) AIR CONDITIONING SYSTEM (FOR MANUAL AIR CONDITIONING SYSTEM) DTC IDENTIFICATION DTC Code Description B1412 Ambient Temperature Sensor Circuit B1413 Evaporator Temperature Sensor Circuit B1422 Compressor Lock Sensor Circuit B1423 Pressure Sensor Circuit B1441 Air Mix Damper Control Servo Motor Circuit (Passenger Side) B1442 Air Inlet Damper Control Servo Motor Circuit B1443 Air Outlet Damper Control Servo Motor Circuit B1451 Compressor Solenoid Circuit B1479 Flow Sensor Circuit B1497 Communication Malfunction (Bus Ic) B14B2 Lost Communication with Front Panel LIN B14B8 Refrigerant Shortage U0100 Lost Communication with ECM U0131 Lost Communication with Electric Power Steering ECU U0142 Lost Communication with Main Body ECU U0155 Lost Communication with Combination Meter

LIGHTING (EXT) DTCS AUTOMATIC HEADLIGHT BEAM LEVEL CONTROL SYSTEM AUTOMATIC HEADLIGHT BEAM LEVEL CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description B2416 Height Control Sensor Malfunction B241A Rear Height Control Sensor B2420 HL AutoLeveling ECU Failure B2450 Initialization has not been Performed B2451 Vehicle Specifications have not been Stored B2452 Height Control Sensor Data Out of Range When Initializing

B2453

Variation Error

LIGHTING SYSTEM LIGHTING SYSTEM DTC IDENTIFICATION DTC Code Description B1244 Light Sensor Circuit Malfunction

METER / GAUGE / DISPLAY DTCS METER / GAUGE SYSTEM METER / GAUGE SYSTEM DTC IDENTIFICATION DTC Code Description B1500 Fuel Sender Open Detected B1507 Open in Turn Signal Circuit B1508 Short in Turn Signal / Hazard Flasher Circuit U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Skid Control ECU U0131 Lost Communication with Power Steering Control Module U0142 Lost Communication with Main Body ECU U0151 Lost Communication with Airbag ECU

NAVIGATION / MULTI INFO DISPLAY DTCS NAVIGATION SYSTEM (FOR NAVIGATION RECEIVER TYPE) NAVIGATION SYSTEM (FOR NAVIGATION RECEIVER TYPE) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1579 Voice Recognition Microphone Disconnected B1585 USB Media Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15AD Navigation Processor Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B5 DVD Changer Malfunction B15B7 Bluetooth Module Malfunction B15B8 Harddisk Malfunction B15BA XM Tuner Malfunction B15C0 Short in GPS Antenna

B15C1 B15C2 B15C3 B15D3 B15E7 B15E8 B15F5 B15F6 B15F7 B15FE B15FF U0073 U0100 U0140 U0155

Open in GPS Antenna Speed Signal Malfunction Speaker Output Short Stereo Component Amplifier Disconnected Harddisk Reading/Writing Malfunction (Low Temperature) Harddisk Reading/Writing Malfunction (High Temperature) A/C ECU Vehicle Information Reading/Writing Processor Malfunction Main Body ECU Vehicle Information Reading/Writing Process Malfunction Certification ECU Vehicle Information Reading/Writing Process Malfunction XM Tuner Antenna Disconnected XM Tuner Antenna Short Sending Malfunction (Navigation to APGS) Lost Communication with ECM Lost Communication with Body Control Module Meter ECU Communication

NAVIGATION SYSTEM (FOR RADIO AND DISPLAY TYPE) NAVIGATION SYSTEM (FOR RADIO AND DISPLAY TYPE) DTC IDENTIFICATION DTC Code Description B1551 HD Radio Tuner Malfunction B1552 Extension Module Malfunction B156C Extension Module Disconnected B1579 Voice Recognition Microphone Disconnected B157E Bluetooth Antenna Disconnected B1585 USB Device Malfunction B158A Extension Module Noise Adjustment Malfunction B15A0 LAN Master Malfunction B15A3 Stereo Component Amplifier Malfunction B15B0 Display Screen Malfunction B15B3 Radio Tuner Malfunction B15B4 CD Changer Malfunction B15B7 Bluetooth Module Malfunction B15BA XM Tuner Malfunction B15C0 Short in GPS Antenna B15C1 Open in GPS Antenna B15C3 Speaker Output Short B15D3 Stereo Component Amplifier Disconnected B15F6 Main Body ECU Vehicle Information Reading/Writing Process Malfunction B15FE XM Tuner Antenna Disconnected B15FF XM Tuner Antenna Short

U0073 U0100 U0140 U0155

Sending Malfunction (Navigation to APGS) Lost Communication with ECM Lost Communication with Body Control Module Meter ECU Communication

NETWORKING DTCS CAN COMMUNICATION SYSTEM CAN COMMUNICATION SYSTEM DTC IDENTIFICATION DTC Code Description U0232 Lost Communication with Blind Spot Monitor Slave Module U0233 Lost Communication with Blind Spot Monitor Master Module U1002 Lost Communication with Gateway Module LIN COMMUNICATION SYSTEM MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) DTC IDENTIFICATION DTC Code Description B1273 Sliding Roof ECU Communication Stop B2321 Driver Side Door ECU Communication Stop B2325 LIN Communication Bus Malfunction CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) DTC IDENTIFICATION DTC Code Description B2785 Communication Malfunction between ECUs Connected by LIN B2786 No Response from Steering Lock ECU B2789 No Response from ID BOX B278C Lost Communication with Power Source Control

PARK ASSIST / MONITORING DTCS BLIND SPOT MONITOR SYSTEM BLIND SPOT MONITOR SYSTEM DTC IDENTIFICATION DTC Code Description C1A45 Vehicle Speed Sensor C1A47 Steering Angle Sensor C1AB0 Short to +B in Outer Mirror Indicator (Master) C1AB1 Short to +B in Outer Mirror Indicator (Slave) C1AB2 Short to GND in Outer Mirror Indicator (Master) C1AB3 Short to GND in Outer Mirror Indicator (Slave)

C1AB4 C1AB5 C1AB6 C1AB7 C1AB8 C1ABA C1ABB C1ABC U0100 U0126 U0129 U0142 U0232 U0233 U1331

Open in Outer Mirror Indicator (Master) Open in Outer Mirror Indicator (Slave) Blind Spot Monitor Master Module Blind Spot Monitor Slave Module Destination Information Undefined Blind Spot Monitor Slave Module Connection Incorrect Blind Spot Monitor Master Module Beam Axis Inspection Incomplete Blind Spot Monitor Slave Module Beam Axis Inspection Incomplete Lost Communication with ECM / PCM "A" Lost Communication with Steering Angle Sensor Module Lost Communication with Brake System Control Module Lost Communication with Body Control Module "B" Lost Communication with Blind Spot Monitor Slave Module Lost Communication with Blind Spot Monitor Master Module Software Incompatibility with Body Control Module "B"

INTUITIVE PARKING ASSIST SYSTEM INTUITIVE PARKING ASSIST SYSTEM DTC IDENTIFICATION DTC Code Description C1AE1 Front Left Sensor Malfunction C1AE4 Front Right Sensor Malfunction C1AE6 Rear Left Sensor Malfunction C1AE7 Rear Left Center Sensor Malfunction C1AE8 Rear Right Center Sensor Malfunction C1AE9 Rear Right Sensor Malfunction C1AEC Front Sensor Communication Malfunction C1AED Rear Sensor Communication Malfunction U0100 Lost Communication with ECM / PCM "A" U0101 Lost Communication with TCM U0142 Lost Communication with Body Control Module "B" U0155 Lost Communication with Instrument Panel Cluster Control Module (Combination Meter) PARKING ASSIST MONITOR SYSTEM PARKING ASSIST MONITOR SYSTEM DTC IDENTIFICATION DTC Code Description C1622 Open or Short Circuit in Back Camera Signal C1625 Open or Short in Steering Angle Sensor +B C1626 Steering Angle Sensor Failure C1691 Back Camera Initialization Incomplete

C1694 U0126 U0140

Steering Angle Initialization Incomplete Lost Communication with Steering Angle Sensor Module Lost Communication with Body Control Module

POWER ASSIST SYSTEMS DTCS POWER STEERING SYSTEM (FOR 2AR-FE WITH WIRELESS DOOR LOCK) POWER STEERING SYSTEM (FOR 2AR-FE WITH WIRELESS DOOR LOCK) DTC IDENTIFICATION DTC Code Description C1511 Torque Sensor Circuit Malfunction C1512 Torque Sensor Circuit Malfunction C1513 Torque Sensor Circuit Malfunction C1514 Torque Sensor Power Supply Abnormal C1515 Torque Sensor Zero Point Adjustment Undone C1516 Torque Sensor Zero Point Adjustment Incomplete C1517 Torque Hold Abnormal C1521 Motor Circuit Malfunction C1522 Motor Circuit Malfunction C1523 Motor Circuit Malfunction C1524 Motor Circuit Malfunction C1528 Motor Rotation Angle Sensor Malfunction C1531 ECU Malfunction C1532 ECU Malfunction C1533 ECU Malfunction C1534 ECU Malfunction C1541 Vehicle Speed Signal Malfunction C1551 IG Power Supply Voltage Malfunction C1552 PIG Power Supply Voltage Malfunction C1554 Power Supply Relay Failure C1555 Motor Relay Welding Failure C1581 Assist Map Number Un-Writing C1582 Assist Map Number Mismatch U0100 Lost Communication with ECM / PCM "A" U0129 Lost Communication with Brake System Control Module POWER STEERING SYSTEM (FOR 2AR-FE WITHOUT WIRELESS DOOR LOCK) POWER STEERING SYSTEM (FOR 2AR-FE WITHOUT WIRELESS DOOR LOCK) DTC IDENTIFICATION DTC Code Description

C1511 C1512 C1513 C1514 C1515 C1516 C1517 C1524 C1531 C1532 C1533 C1534 C1535 C1541 C1551 C1552 C1554 C1555 C1581 U0100 U0129

Torque Sensor Circuit Malfunction Torque Sensor Circuit Malfunction Torque Sensor Circuit Malfunction Torque Sensor Power Supply Abnormal Torque Sensor Zero Point Adjustment Undone Torque Sensor Zero Point Adjustment Incomplete Torque Hold Abnormal Motor Circuit Malfunction ECU Malfunction ECU Malfunction ECU Malfunction ECU Malfunction ECU Malfunction Vehicle Speed Signal Malfunction IG Power Supply Voltage Malfunction PIG Power Supply Voltage Malfunction Power Supply Relay Failure Motor Relay Welding Failure Assist Map Number Un-Writing Lost Communication with ECM / PCM "A" Lost Communication with Brake System Control Module

POWER STEERING SYSTEM (FOR 2GR-FE) POWER STEERING SYSTEM (FOR 2GR-FE) DTC IDENTIFICATION DTC Code Description C1511 Torque Sensor Circuit Malfunction C1512 Torque Sensor Circuit Malfunction C1513 Torque Sensor Circuit Malfunction C1514 Torque Sensor Power Supply Abnormal C1521 Motor Circuit Malfunction C1524 Motor Circuit Malfunction C1528 Motor Rotation Angle Sensor Malfunction C1531 ECU Malfunction C1532 ECU Malfunction C1533 ECU Malfunction C1534 ECU Malfunction C1541 Vehicle Speed Signal Malfunction C1551 IG Power Supply Voltage Malfunction C1552 PIG Power Supply Voltage Malfunction C1554 Power Supply Relay Failure

C1555 C1581 C1582 U0100 U0129

Motor Relay Welding Failure Assist Map Number Un-Writing Assist Map Number Mismatch Lost Communication with ECM / PCM "A" Lost Communication with Brake System Control Module

SLIDING ROOF DTCS SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM DTC IDENTIFICATION DTC Code Description B2341 Sensor (Motor) Failure B2342 Switch Failure B2343 Position Initialization Incomplete B2344 Position Failure

STEERING COLUMN DTCS STEERING LOCK SYSTEM STEERING LOCK SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION DTC Code Description B2781 Open / Short in Steering Lock ECU B2782 Power Source Control ECU Malfunction B2788 IG2 Signal Malfunction

SUPPLEMENTAL RESTRAINT SYSTEMS DTCS AIRBAG SYSTEM (FOR BUILT-IN TYPE YAW RATE SENSOR) AIRBAG SYSTEM (FOR BUILT-IN TYPE YAW RATE SENSOR) DTC IDENTIFICATION DTC Code Description B1000 Center Airbag Sensor Assembly Malfunction B1610 Front Airbag Sensor RH Malfunction B1612 Lost Communication with Front Airbag Sensor RH B1613 Front Airbag Sensor RH Initialization Incomplete B1615 Front Airbag Sensor LH Malfunction B1617 Lost Communication with Front Airbag Sensor LH B1618 Front Airbag Sensor LH Initialization Incomplete B161A Lost Communication with Front Satellite Sensor Bus B1620 Side Airbag Sensor RH Circuit Malfunction

B1622 B1623 B1625 B1627 B1628 B1630 B1632 B1633 B1635 B1637 B1638 B1642 B1647 B1650 B1656 B1660 B1690 B1692 B1693 B1695 B1697 B1698 B1800 B1801 B1802 B1803 B1805 B1806 B1807 B1808 B1810 B1811 B1812 B1813 B1815 B1816 B1817 B1818 B1820 B1821 B1822 B1823

Lost communication with Side Airbag Sensor RH Side Airbag Sensor Assembly RH Initialization Incomplete Side Airbag Sensor LH Circuit Malfunction Lost communication with Side Airbag Sensor LH Side Airbag Sensor Assembly LH Initialization Incomplete Rear Airbag Sensor RH Circuit Malfunction Lost Communication with Rear Airbag Sensor RH Rear Airbag Sensor Assembly RH Initialization Incomplete Rear Airbag Sensor LH Circuit Malfunction Lost Communication with Rear Airbag Sensor LH Rear Airbag Sensor Assembly LH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus RH Lost Communication with Side Satellite Sensor Bus LH Occupant Classification System Malfunction Seat Belt Buckle Switch LH Circuit Malfunction Passenger Airbag ON/OFF Indicator Circuit Malfunction Door Side Airbag Sensor RH Malfunction Lost Communication with Door Side Airbag Sensor RH Door Side Airbag Sensor RH Initialization Incomplete Door Side Airbag Sensor LH Malfunction Lost Communication with Door Side Airbag Sensor LH Door Side Airbag Sensor LH Initialization Incomplete Short in Driver Side Squib Circuit Open in Driver Side Squib Circuit Short to GND in Driver Side Squib Circuit Short to B+ in Driver Side Squib Circuit Short in Front Passenger Side Squib Circuit Open in Front Passenger Side Squib Circuit Short to GND in Front Passenger Side Squib Circuit Short to B+ in Front Passenger Side Squib Circuit Short in Driver Side Squib 2nd Step Circuit Open in Driver Side Squib 2nd Step Circuit Short to GND in Driver Side Squib 2nd Step Circuit Short to B+ in Driver Side Squib 2nd Step Circuit Short in Front Passenger Side Squib 2nd Step Circuit Open in Front Passenger Side Squib 2nd Step Circuit Short to GND in Front Passenger Side Squib 2nd Step Circuit Short to B+ in Front Passenger Side Squib 2nd Step Circuit Short in Side Squib RH Circuit Open in Side Squib RH Circuit Short to GND in Side Squib RH Circuit

B1825 B1826 B1827 B1828 B1830 B1831 B1832 B1833 B1835 B1836 B1837 B1838 B1850 B1851 B1852 B1853 B1855 B1856 B1857 B1858 B1860 B1861 B1862 B1863 B1865 B1866 B1867 B1868 B1900 B1901 B1902 B1903 B1905 B1906 B1907 B1908

Short to B+ in Side Squib RH Circuit Short in Side Squib LH Circuit Open in Side Squib LH Circuit Short to GND in Side Squib LH Circuit Short to B+ in Side Squib LH Circuit Short in Curtain Shield Squib RH Circuit Open in Curtain Shield Squib RH Circuit Short to GND in Curtain Shield Squib RH Circuit Short to B+ in Curtain Shield Squib RH Circuit Short in Curtain Shield Squib LH Circuit Open in Curtain Shield Squib LH Circuit Short to GND in Curtain Shield Squib LH Circuit Short to B+ in Curtain Shield Squib LH Circuit Short in Rear Side Squib RH Circuit Open in Rear Side Squib RH Circuit Short to GND in Rear Side Squib RH Circuit Short to B+ in Rear Side Squib RH Circuit Short in Rear Side Squib LH Circuit Open in Rear Side Squib LH Circuit Short to GND in Rear Side Squib LH Circuit Short to B+ in Rear Side Squib LH Circuit Short in Driver Side Knee Airbag Squib Circuit Open in Driver Side Knee Airbag Squib Circuit Short to GND in Driver Side Knee Airbag Squib Circuit Short to B+ in Driver Side Knee Airbag Squib Circuit Short in Front Passenger Side Knee Airbag Squib Circuit Open in Front Passenger Side Knee Airbag Squib Circuit Short to GND in Front Passenger Side Knee Airbag Squib Circuit Short to B+ in Front Passenger Side Knee Airbag Squib Circuit Short in Front Pretensioner Squib RH Circuit Open in Front Pretensioner Squib RH Circuit Short to GND in Front Pretensioner Squib RH Circuit Short to B+ in Front Pretensioner Squib RH Circuit Short in Front Pretensioner Squib LH Circuit Open in Front Pretensioner Squib LH Circuit Short to GND in Front Pretensioner Squib LH Circuit Short to B+ in Front Pretensioner Squib LH Circuit

AIRBAG SYSTEM (FOR SEPARATE TYPE YAW RATE SENSOR) AIRBAG SYSTEM (FOR SEPARATE TYPE YAW RATE SENSOR) DTC IDENTIFICATION

DTC Code B1000 B1603 B1608 B1610 B1612 B1613 B1615 B1617 B1618 B1620 B1622 B1623 B1625 B1627 B1628 B1630 B1632 B1633 B1635 B1637 B1638 B1642 B1643 B1647 B1648 B1650 B1656 B1660 B1690 B1692 B1693 B1695 B1697 B1698 B1800 B1801 B1802 B1803 B1805 B1806 B1807

Description Center Airbag Sensor Assembly Malfunction Front Satellite Sensor Bus RH Initialization Incomplete Front Satellite Sensor Bus LH Initialization Incomplete Front Airbag Sensor RH Malfunction Lost Communication with Front Airbag Sensor RH Front Airbag Sensor RH Initialization Incomplete Front Airbag Sensor LH Malfunction Lost Communication with Front Airbag Sensor LH Front Airbag Sensor LH Initialization Incomplete Side Airbag Sensor RH Circuit Malfunction Lost communication with Side Airbag Sensor RH Side Airbag Sensor Assembly RH Initialization Incomplete Side Airbag Sensor LH Circuit Malfunction Lost communication with Side Airbag Sensor LH Side Airbag Sensor Assembly LH Initialization Incomplete Rear Airbag Sensor RH Circuit Malfunction Lost Communication with Rear Airbag Sensor RH Rear Airbag Sensor Assembly RH Initialization Incomplete Rear Airbag Sensor LH Circuit Malfunction Lost Communication with Rear Airbag Sensor LH Rear Airbag Sensor Assembly LH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus RH Side Satellite Sensor Bus RH Initialization Incomplete Lost Communication with Side Satellite Sensor Bus LH Side Satellite Sensor Bus LH Initialization Incomplete Occupant Classification System Malfunction Seat Belt Buckle Switch LH Circuit Malfunction Passenger Airbag ON/OFF Indicator Circuit Malfunction Door Side Airbag Sensor RH Malfunction Lost Communication with Door Side Airbag Sensor RH Door Side Airbag Sensor RH Initialization Incomplete Door Side Airbag Sensor LH Malfunction Lost Communication with Door Side Airbag Sensor LH Door Side Airbag Sensor LH Initialization Incomplete Short in Driver Side Squib Circuit Open in Driver Side Squib Circuit Short to GND in Driver Side Squib Circuit Short to B+ in Driver Side Squib Circuit Short in Front Passenger Side Squib Circuit Open in Front Passenger Side Squib Circuit

B1808 B1810 B1811 B1812 B1813 B1815 B1816 B1817 B1818 B1820 B1821 B1822 B1823 B1825 B1826 B1827 B1828 B1830 B1831 B1832 B1833 B1835 B1836 B1837 B1838 B1850 B1851 B1852 B1853 B1855 B1856 B1857 B1858 B1860 B1861 B1862 B1863 B1865 B1866 B1867 B1868

Short to GND in Front Passenger Side Squib Circuit Short to B+ in Front Passenger Side Squib Circuit Short in Driver Side Squib 2nd Step Circuit Open in Driver Side Squib 2nd Step Circuit Short to GND in Driver Side Squib 2nd Step Circuit Short to B+ in Driver Side Squib 2nd Step Circuit Short in Front Passenger Side Squib 2nd Step Circuit Open in Front Passenger Side Squib 2nd Step Circuit Short to GND in Front Passenger Side Squib 2nd Step Circuit Short to B+ in Front Passenger Side Squib 2nd Step Circuit Short in Side Squib RH Circuit Open in Side Squib RH Circuit Short to GND in Side Squib RH Circuit Short to B+ in Side Squib RH Circuit Short in Side Squib LH Circuit Open in Side Squib LH Circuit Short to GND in Side Squib LH Circuit Short to B+ in Side Squib LH Circuit Short in Curtain Shield Squib RH Circuit Open in Curtain Shield Squib RH Circuit Short to GND in Curtain Shield Squib RH Circuit Short to B+ in Curtain Shield Squib RH Circuit Short in Curtain Shield Squib LH Circuit Open in Curtain Shield Squib LH Circuit Short to GND in Curtain Shield Squib LH Circuit Short to B+ in Curtain Shield Squib LH Circuit Short in Rear Side Squib RH Circuit Open in Rear Side Squib RH Circuit Short to GND in Rear Side Squib RH Circuit Short to B+ in Rear Side Squib RH Circuit Short in Rear Side Squib LH Circuit Open in Rear Side Squib LH Circuit Short to GND in Rear Side Squib LH Circuit Short to B+ in Rear Side Squib LH Circuit Short in Driver Side Knee Airbag Squib Circuit Open in Driver Side Knee Airbag Squib Circuit Short to GND in Driver Side Knee Airbag Squib Circuit Short to B+ in Driver Side Knee Airbag Squib Circuit Short in Front Passenger Side Knee Airbag Squib Circuit Open in Front Passenger Side Knee Airbag Squib Circuit Short to GND in Front Passenger Side Knee Airbag Squib Circuit

B1900 B1901 B1902 B1903 B1905 B1906 B1907 B1908

Short to B+ in Front Passenger Side Knee Airbag Squib Circuit Short in Front Pretensioner Squib RH Circuit Open in Front Pretensioner Squib RH Circuit Short to GND in Front Pretensioner Squib RH Circuit Short to B+ in Front Pretensioner Squib RH Circuit Short in Front Pretensioner Squib LH Circuit Open in Front Pretensioner Squib LH Circuit Short to GND in Front Pretensioner Squib LH Circuit Short to B+ in Front Pretensioner Squib LH Circuit

OCCUPANT CLASSIFICATION SYSTEM OCCUPANT CLASSIFICATION SYSTEM DTC IDENTIFICATION DTC Code Description B1771 Passenger Side Buckle Switch Circuit Malfunction B1782 Rear Occupant Classification Sensor LH Circuit Malfunction B1783 Rear Occupant Classification Sensor RH Circuit Malfunction B1787 Rear Occupant Classification Sensor LH Collision Detection B1788 Rear Occupant Classification Sensor RH Collision Detection B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction B1793 Occupant Classification Sensor Power Supply Circuit Malfunction B1794 Open in Occupant Classification ECU Battery Positive Line B1795 Occupant Classification ECU Malfunction B1796 Sleep Operation Failure of Occupant Classification ECU

THEFT DETERRENT / KEYLESS ENTRY DTCS ENGINE IMMOBILISER SYSTEM (W/ SMART KEY SYSTEM) CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) DTC IDENTIFICATION DTC Code Description B2784 Antenna Coil Open / Short B278A Short to GND in Immobiliser System Power Source Circuit B278D Malfunction of ID-BOX Recognition ECM DTC IDENTIFICATION DTC Code Description B2799 Engine Immobiliser System Malfunction B279A Theft Deterrent System Communication Line High Fixation B279C Theft Deterrent System Presence Detection ENGINE IMMOBILISER SYSTEM (W/O SMART KEY SYSTEM)

TRANSPONDER KEY ECU ASSEMBLY DTC IDENTIFICATION DTC Code Description B2780 Push Switch / Key Unlock Warning Switch Malfunction B2784 Antenna Coil Open / Short B2793 Transponder Chip Malfunction B2794 Unmatched Encryption Code B2795 Unmatched Key Code B2796 No Communication in Immobiliser System B2797 Communication Malfunction No. 1 B2798 Communication Malfunction No. 2 ECM DTC IDENTIFICATION DTC Code Description B2799 Engine Immobiliser System Malfunction B279A Theft Deterrent System Communication Line High Fixation B279C Theft Deterrent System Presence Detection REMOTE ENGINE STARTER SYSTEM MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) DTC IDENTIFICATION DTC Code Description B126A Remote Engine Starter ECU Communication Stop REMOTE ENGINE STARTER ECU DTC IDENTIFICATION DTC Code Description B2334 Remote Engine Starter ECU Internal Relay B2335 Lost Communication with Immobiliser System B2336 Immobiliser Communication ID Unmatched CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) DTC IDENTIFICATION DTC Code Description B2779 Engine Starter Communication Malfunction SMART KEY SYSTEM (FOR ENTRY FUNCTION) SMART KEY SYSTEM (FOR ENTRY FUNCTION) DTC IDENTIFICATION DTC Code Description B27A1 Open in Driver Side Electrical Antenna Circuit B27A2 Open in Front Passenger Side Electrical Antenna Circuit B27A5 Open in Front Floor Electrical Key Oscillator Circuit B27A6 Open in Rear Floor Electrical Key Oscillator Circuit B27A7 Open in Inside Luggage Compartment Electrical Key Oscillator Circuit

B27A8

Open in Outside Luggage Compartment Electrical Key Antenna Circuit

SMART KEY SYSTEM (FOR START FUNCTION) SMART KEY SYSTEM (FOR START FUNCTION) DTC IDENTIFICATION DTC Code Description B2271 Ignition Hold Monitor Malfunction B2274 ACC Monitor Malfunction B2277 Detecting Vehicle Submersion B2282 Vehicle Speed Signal Malfunction B2283 Vehicle Speed Sensor Malfunction B2284 Brake Signal Malfunction B2285 Steering Lock Position Signal Circuit Malfunction B2286 Runnable Signal Malfunction P0335 Crankshaft Position Sensor Circuit Malfunction (NE Signal) U0100 Lost Communication with ECM / PCM U0140 Lost Communication with Main Body ECU U0142 Lost Communication with Main Body ECU U0155 Lost Communication with Combination Meter

TIRE PRESSURE MONITORING DTCS TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING ECU AND RECEIVER DTC IDENTIFICATION DTC Code Description C2111 Transmitter ID1 Operation Stop C2112 Transmitter ID2 Operation Stop C2113 Transmitter ID3 Operation Stop C2114 Transmitter ID4 Operation Stop C2121 No Signal from Transmitter ID1 C2122 No Signal from Transmitter ID2 C2123 No Signal from Transmitter ID3 C2124 No Signal from Transmitter ID4 C2126 Transmitter ID not Received in Main Mode C2141 Transmitter ID1 Error C2142 Transmitter ID2 Error C2143 Transmitter ID3 Error C2144 Transmitter ID4 Error C2171 Transmitter ID not Registered C2176 Receiver Error C2177 Initialization not Completed

C2179 C2181 C2182 C2183 C2184 C2198

Tire Pressure Monitor ECU Communication Stop Transmitter ID1 not Received (Test Mode DTC) Transmitter ID2 not Received (Test Mode DTC) Transmitter ID3 not Received (Test Mode DTC) Transmitter ID4 not Received (Test Mode DTC) Initialization Switch (for Test Mode DTC)

MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) DTC IDENTIFICATION DTC Code Description B1247 Tire Pressure Monitor Receiver Communication Stop

WINDOW / GLASS DTCS POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM DTC IDENTIFICATION DTC Code Description B2311 Power Window Motor Malfunction B2312 Power Window Switch Malfunction B2313 Glass Position Initialization Incomplete

2012-2017 ENGINE PERFORMANCE Emission Control System (Service Information) - Camry (2AR-FE)

CANISTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Canister Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Canister Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL TANK ASSEMBLY Refer to REMOVAL 2. REMOVE CHARCOAL CANISTER ASSEMBLY a. Disconnect the purge line hose.

Fig. 3: Identifying Charcoal Canister Assembly Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector from the charcoal canister leak detection pump sub-assembly. c. Disconnect the air line tube. TEXT IN ILLUSTRATION Tube *1 Connector *2 O-ring Pipe (charcoal *3 canister leak detection

pump subassembly) *a Pinch *b Push NOTE:





  



Remove any dirt or foreign matter on the tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the tube connector has an O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the air line tube. Protect the disconnected parts by covering them with plastic bags after disconnecting the air line tube. If the tube connector and pipe are stuck, push and pull on them to release.

1. Push the air line tube firmly toward the charcoal canister side. 2. Pinch the air line tube as shown in the illustration. 3. Pull out the air line tube. d. Remove the 3 bolts and guide.

Fig. 4: Identifying Charcoal Canister Assembly Bolts And Guide

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Separate the clip from the body to remove the charcoal canister assembly. 3. REMOVE CHARCOAL CANISTER BASE BRACKET a. Disengage the claw and remove the charcoal canister base bracket.

Fig. 5: Removing Charcoal Canister Base Bracket Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE CHARCOAL CANISTER SUPPORT BRACKET a. Disengage the claw and remove the charcoal canister support bracket.

Fig. 6: Removing Charcoal Canister Support Bracket Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Before removing the charcoal canister leak detection pump sub-assembly, clean the canister by blowing air into it to ensure that the canister is free of foreign matter. NOTE:

 

Make sure to clean the canister using only air. Do not use gasoline, thinners or solvents.

b. While disengaging the 2 claws as shown in the illustration, push the charcoal canister leak detection pump sub-assembly upwards using a screwdriver to remove it.

Fig. 7: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check if the canister contains foreign matter such as mud or water. 1. Visually check that the inside of the canister is free of foreign matter.

Fig. 8: Identifying Canister Contains Foreign Matter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Hold the canister upside down to make sure that the canister is free of foreign matter. If the canister contains foreign matter, replace the canister. INSPECTION INSPECTION

1. INSPECT CHARCOAL CANISTER ASSEMBLY a. Visually check the charcoal canister assembly. 1. Visually check the charcoal canister assembly for cracks or damage.

Fig. 9: Identifying Charcoal Canister Assembly For Cracks Or Damage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracks or damage are found, replace the charcoal canister assembly. b. Check canister operation. 1. With the purge port closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into the vent line port, and check that air flows from the air line port.

Fig. 10: Identifying Air Flows From Air Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vent *a Line Port Air *b Line Port Purge *c Line Port *d Air If the result is not as specified, replace the charcoal canister assembly. 2. With the vent port closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into the air line port, and check that air flows from the purge line port.

Fig. 11: Identifying Air Flows From Purge Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vent *a Line Port Air *b Line Port Purge *c Line Port *d Air If the result is not as specified, replace the charcoal canister assembly. c. Check for air leaks. 1. Connect a pressure gauge to the vent line port of the charcoal canister assembly.

Fig. 12: Connecting Pressure Gauge To Vent Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressure *1 Gauge Vent *a Line Port Air *b Line Port Purge *c Line Port

2. With the purge line port and the air line port closed, apply 20 kPa (150 mmHg, 5.91 in.Hg) of pressurized air into the vent line port, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the charcoal canister assembly. d. Check the charcoal canister leak detection pump sub-assembly. 1. Connect a positive (+) lead from the battery to terminal 5 and a negative (-) lead to terminal 1.

Fig. 13: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check that a clicking sound is heard from the charcoal canister leak detection pump subassembly. If the result is not as specified, replace the charcoal canister leak detection pump sub-

assembly. INSTALLATION INSTALLATION

1. INSTALL CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Engage the 2 claws to install a new charcoal canister leak detection pump sub-assembly to the canister.

Fig. 14: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Do not allow foreign matter such as grease, oil or water to adhere to the O-rings.



Ensure that the claws are engaged properly.

2. INSTALL CHARCOAL CANISTER SUPPORT BRACKET a. Engage the claw to install the charcoal canister support bracket. 3. INSTALL CHARCOAL CANISTER BASE BRACKET a. Engage the claw to install the charcoal canister base bracket. 4. INSTALL CHARCOAL CANISTER ASSEMBLY a. Connect the clip to install the charcoal canister assembly. b. Install the 3 bolts and guide. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Connect the air line tube. NOTE:





Check that there are no scratches or foreign matter around the connected part of the tube connector and pipe before performing this work. After connecting the air line tube, check that the air line tube is securely connected by pulling on the tube connector and the charcoal canister.

d. Connect the purge line hose. e. Connect the connector to the charcoal canister leak detection pump sub-assembly. 5. INSTALL FUEL TANK ASSEMBLY Refer to INSTALLATION

PURGE VALVE COMPONENTS ILLUSTRATION

Fig. 15: Identifying Purge Valve Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE PURGE VSV a. Disconnect the connector and 2 fuel vapor feed hoses.

Fig. 16: Identifying Purge VSV Connector And Fuel Vapor Feed Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the purge VSV. INSPECTION INSPECTION

1. INSPECT PURGE VSV a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 23 to 26 1-2 F) ohms If the result is not as specified, replace the purge VSV. b. Apply battery voltage between the terminals of the purge VSV and check that the following occurs when blowing air into port E. OK

Measurement Specified Condition Condition Battery voltage Air flows applied from port between F. terminals 1 and 2 Battery voltage not applied Air does between not flow. terminals 1 and 2

Fig. 17: Inspecting Purge VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the purge VSV. INSTALLATION INSTALLATION

1. INSTALL PURGE VSV a. Install the purge VSV. b. Connect the connector and 2 fuel vapor feed hoses.

FUEL TANK CAP INSPECTION INSPECTION

1. INSPECT FUEL TANK CAP ASSEMBLY a. Visually check that the cap and gasket are not deformed or damaged. If the result is not as specified, replace the fuel tank cap assembly.

Fig. 18: Inspecting Fuel Tank Cap Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Gasket

PCV VALVE COMPONENTS ILLUSTRATION

Fig. 19: Identifying PCV Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL 2. REMOVE VENTILATION VALVE SUB-ASSEMBLY a. Disconnect the No. 2 ventilation hose from the ventilation valve sub-assembly.

Fig. 20: Locating No. 2 Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly.

Fig. 21: Identifying Ventilation Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 19 mm Deep *1 Socket Wrench INSPECTION INSPECTION

1. INSPECT VENTILATION VALVE SUB-ASSEMBLY a. Install a clean hose to the ventilation valve sub-assembly. b. Check ventilation valve sub-assembly operation. 1. Blow air into the cylinder block side, and check that air passes through easily.

Fig. 22: Identifying Air Passes Through Easily Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Cylinder *a Block Side *b Air WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. If the result is not as specified, replace the ventilation valve sub-assembly. 2. Blow air into the intake manifold side, and check that air passes through with difficulty.

Fig. 23: Identifying Air Passes Through With Difficulty Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Intake *a Manifold Side *b Air WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. If the result is not as specified, replace the ventilation valve sub-assembly. c. Remove the clean hose from the ventilation valve sub-assembly. INSTALLATION INSTALLATION

1. INSTALL VENTILATION VALVE SUB-ASSEMBLY a. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

Adhesive Toyota genuine adhesive 1324, three bond 1324 or equivalent b. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) c. Connect the No. 2 ventilation hose to the ventilation valve sub-assembly. 2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION

2012-2017 ENGINE PERFORMANCE Emission Control System (Service Information) - Camry (2GR-FE)

CANISTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Canister Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Canister Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL TANK ASSEMBLY Refer to REMOVAL 2. REMOVE CHARCOAL CANISTER ASSEMBLY a. Disconnect the purge line hose.

Fig. 3: Identifying Charcoal Canister Assembly Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector from the charcoal canister leak detection pump sub-assembly. c. Disconnect the air line tube. TEXT IN ILLUSTRATION Tube *1 Connector *2 O-ring Pipe (charcoal *3 canister leak detection

pump subassembly) *a Pinch *b Push NOTE:





  



Remove any dirt or foreign matter on the tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the tube connector has an O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the air line tube. Protect the disconnected parts by covering them with plastic bags after disconnecting the air line tube. If the tube connector and pipe are stuck, push and pull on them to release.

1. Push the air line tube firmly toward the charcoal canister side. 2. Pinch the air line tube as shown in the illustration. 3. Pull out the air line tube. d. Remove the 3 bolts and guide.

Fig. 4: Identifying Charcoal Canister Assembly Bolts And Guide

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Separate the clip from the body to remove the charcoal canister assembly. 3. REMOVE CHARCOAL CANISTER BASE BRACKET a. Disengage the claw and remove the charcoal canister base bracket.

Fig. 5: Removing Charcoal Canister Base Bracket Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE CHARCOAL CANISTER SUPPORT BRACKET a. Disengage the claw and remove the charcoal canister support bracket.

Fig. 6: Removing Charcoal Canister Support Bracket Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Before removing the charcoal canister leak detection pump sub-assembly, clean the canister by blowing air into it to ensure that the canister is free of foreign matter. NOTE:

 

Make sure to clean the canister using only air. Do not use gasoline, thinners or solvents.

b. While disengaging the 2 claws as shown in the illustration, push the charcoal canister leak detection pump sub-assembly upwards using a screwdriver to remove it.

Fig. 7: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check if the canister contains foreign matter such as mud or water. 1. Visually check that the inside of the canister is free of foreign matter.

Fig. 8: Identifying Canister Contains Foreign Matter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Hold the canister upside down to make sure that the canister is free of foreign matter. If the canister contains foreign matter, replace the canister. INSPECTION INSPECTION

1. INSPECT CHARCOAL CANISTER ASSEMBLY a. Visually check the charcoal canister assembly. 1. Visually check the charcoal canister assembly for cracks or damage.

Fig. 9: Identifying Charcoal Canister Assembly For Cracks Or Damage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracks or damage are found, replace the charcoal canister assembly. b. Check canister operation. 1. With the purge port closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into the vent line port, and check that air flows from the air line port.

Fig. 10: Identifying Air Flows From Air Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vent *a Line Port Air *b Line Port Purge *c Line Port *d Air If the result is not as specified, replace the charcoal canister assembly. 2. With the vent port closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into the air line port, and check that air flows from the purge line port.

Fig. 11: Identifying Air Flows From Purge Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vent *a Line Port Air *b Line Port Purge *c Line Port *d Air If the result is not as specified, replace the charcoal canister assembly. c. Check for air leaks. 1. Connect a pressure gauge to the vent line port of the charcoal canister assembly.

Fig. 12: Connecting Pressure Gauge To Vent Line Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressure *1 Gauge Vent *a Line Port Air *b Line Port Purge *c Line Port

2. With the purge line port and the air line port closed, apply 20 kPa (150 mmHg, 5.91 in.Hg) of pressurized air into the vent line port, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the charcoal canister assembly. d. Check the charcoal canister leak detection pump sub-assembly. 1. Connect a positive (+) lead from the battery to terminal 5 and a negative (-) lead to terminal 1.

Fig. 13: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check that a clicking sound is heard from the charcoal canister leak detection pump subassembly. If the result is not as specified, replace the charcoal canister leak detection pump sub-

assembly. INSTALLATION INSTALLATION

1. INSTALL CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Engage the 2 claws to install a new charcoal canister leak detection pump sub-assembly to the canister.

Fig. 14: Identifying Charcoal Canister Leak Detection Pump Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Do not allow foreign matter such as grease, oil or water to adhere to the O-rings.



Ensure that the claws are engaged properly.

2. INSTALL CHARCOAL CANISTER SUPPORT BRACKET a. Engage the claw to install the charcoal canister support bracket. 3. INSTALL CHARCOAL CANISTER BASE BRACKET a. Engage the claw to install the charcoal canister base bracket. 4. INSTALL CHARCOAL CANISTER ASSEMBLY a. Connect the clip to install the charcoal canister assembly. b. Install the 3 bolts and guide. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Connect the air line tube. NOTE:





Check that there are no scratches or foreign matter around the connected part of the tube connector and pipe before performing this work. After connecting the air line tube, check that the air line tube is securely connected by pulling on the tube connector and the charcoal canister.

d. Connect the purge line hose. e. Connect the connector to the charcoal canister leak detection pump sub-assembly. 5. INSTALL FUEL TANK ASSEMBLY Refer to INSTALLATION

PURGE VALVE COMPONENTS ILLUSTRATION

Fig. 15: Identifying Purge Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 2. REMOVE PURGE VSV a. Disconnect the connector and wire harness clamp.

Fig. 16: Identifying Purge VSV Connector And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 fuel vapor feed hoses. c. Remove the bolt and purge VSV.

Fig. 17: Identifying Purge VSV Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT PURGE VSV a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 23 to 26 1-2 F) ohms If the result is not as specified, replace the purge VSV. b. Apply battery voltage between the terminals of the purge VSV and check that the following occurs when blowing air into port E. OK Measurement Specified Condition Condition Battery voltage Air flows applied from port between F terminals 1 and 2 Battery voltage not applied Air does between not flow terminals 1 and 2

Fig. 18: Identifying Air Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the purge VSV. INSTALLATION INSTALLATION

1. INSTALL PURGE VSV a. Install the purge VSV with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Connect the 2 fuel vapor feed hoses. c. Connect the wire harness clamp and connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82

FUEL TANK CAP INSPECTION INSPECTION

1. INSPECT FUEL TANK CAP ASSEMBLY a. Visually check that the cap and gasket are not deformed or damaged. If the result is not as specified, replace the fuel tank cap assembly.

Fig. 19: Inspecting Fuel Tank Cap Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Gasket

PCV VALVE COMPONENTS ILLUSTRATION

Fig. 20: Identifying PCV Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 2. REMOVE VENTILATION VALVE SUB-ASSEMBLY a. Disconnect the ventilation hose from the ventilation valve sub-assembly.

Fig. 21: Identifying Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly.

Fig. 22: Locating Ventilation Valve Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT VENTILATION VALVE SUB-ASSEMBLY a. Install a clean hose to the ventilation valve sub-assembly. b. Check ventilation valve sub-assembly operation. 1. Blow air into the cylinder head cover side, and check that air passes through easily.

Fig. 23: Identifying Air Passes Through Easily Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Cylinder Head *a Cover Side *b Air WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health.

If the result is not as specified, replace the ventilation valve sub-assembly. 2. Blow air into the intake air surge tank side, and check that air passes through with difficulty.

Fig. 24: Identifying Air Passes Through With Difficulty Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Intake Air *a Surge Tank Side *b Air WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. If the result is not as specified, replace the ventilation valve sub-assembly. c. Remove the clean hose from the ventilation valve sub-assembly.

INSTALLATION INSTALLATION

1. INSTALL VENTILATION VALVE SUB-ASSEMBLY a. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly. Adhesive Toyota genuine adhesive 1324, three bond 1324 or equivalent b. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) c. Connect the ventilation hose to the ventilation valve sub-assembly. 2. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82

2012-2017 ENGINE PERFORMANCE Emission Control System (Service Information) (Hybrid)

EGR VALVE COMPONENTS ILLUSTRATION

Fig. 1: Identifying EGR Valve Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying EGR Valve Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4.

DRAIN COOLANT (for Engine) . Refer to REPLACEMENT - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE EGR VALVE ASSEMBLY a. Disconnect the connector.

Fig. 3: Identifying EGR Valve Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 water by-pass hoses.

Fig. 4: Identifying Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using a 10 mm deep socket wrench, remove the bolt.

Fig. 5: Identifying EGR Tube Stud Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a 12 mm deep socket wrench, remove the 2 nuts. e. Using an E8 "TORX" socket wrench, remove the 2 stud bolts. f. Remove the 4 bolts and EGR valve assembly.

Fig. 6: Identifying EGR Valve Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the 2 gaskets.

Fig. 7: Identifying EGR Valve Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT EGR VALVE ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 8: EGR Valve Assembly Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 5 (+B2) - 4 20°C (68° 18 to 22 (EGR1) F) ohms 5 (+B2) - 6 20°C (68° 18 to 22 (EGR3) F) ohms 2 (+B1) - 1 20°C (68° 18 to 22 (EGR4) F) ohms 2 (+B1) - 3 20°C (68° 18 to 22 (EGR2) F) ohms If the result is not as specified, replace the EGR valve assembly. INSTALLATION

INSTALLATION

1. INSTALL EGR VALVE ASSEMBLY HINT: After replacing the EGR valve assembly, perform the "Inspection After Repairs". Refer to INITIALIZATION . a. Install 2 new gaskets. b. Temporarily install the EGR valve assembly with the 4 bolts. c. Using an E8 "TORX" socket wrench, install the 2 stud bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) d. Temporarily install the 2 nuts. e. Tighten the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) f. Using a 12 mm deep socket wrench, tighten the 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) g. Using a 10 mm deep socket wrench, install the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

2. 3. 4. 5.

h. Connect the 2 water by-pass hoses. i. Connect the connector. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86 ADD COOLANT (for Engine) . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1

EGR COOLER COMPONENTS ILLUSTRATION

Fig. 9: Identifying EGR Cooler Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE EGR COOLER ASSEMBLY a. Disconnect the water by-pass hose.

Fig. 10: Disconnecting Water By-Pass Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and nut.

Fig. 11: Identifying EGR Cooler Tube Bolt, Nut And Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using an E8 "TORX" socket wrench, remove the stud bolt. d. Remove the 2 bolts.

Fig. 12: Identifying EGR Cooler Tube Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the bolt, nut, EGR cooler and 2 gaskets.

Fig. 13: Identifying EGR Cooler Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL EGR COOLER ASSEMBLY a. Temporarily install 2 new gaskets and the EGR cooler assembly with the bolt (A) and nut (A).

Fig. 14: Identifying EGR Cooler Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an E8 "TORX" socket wrench, install the stud bolt.

Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) c. Temporarily install the bolt (B) and nut (B). d. Temporarily install the 2 bolts (C). e. Tighten the 4 bolts and 2 nuts. Bolt (A) and Nut (A) Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Bolt (B) and Nut (B) Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Bolt (C) Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Make sure that all installation surfaces of the EGR cooler assembly are in even contact when tightening the bolts and nuts.

f. Connect the water by-pass hose. 2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Refer to INSTALLATION

VACUUM SENSOR COMPONENTS ILLUSTRATION

Fig. 15: Identifying Vacuum Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR a. Disconnect the connector.

Fig. 16: Identifying Manifold Absolute Pressure Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the vacuum hose.

Fig. 17: Identifying Manifold Absolute Pressure Sensor Vacuum Hose And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the bolt and manifold absolute pressure sensor. INSTALLATION INSTALLATION

1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR a. Install the manifold absolute pressure sensor with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) b. Connect the vacuum hose and connector. 2. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86

CANISTER COMPONENTS ILLUSTRATION

Fig. 18: Identifying Canister Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 19: Identifying Canister Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL TANK ASSEMBLY Refer to REMOVAL 2. REMOVE CHARCOAL CANISTER ASSEMBLY a. Disconnect the connector from the charcoal canister leak detection pump sub-assembly.

Fig. 20: Identifying Charcoal Canister Leak Detection Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the air line tube. TEXT IN ILLUSTRATION Tube *1 Connector *2 O-ring Pipe (charcoal canister *3 leak detection pump sub-

assembly) *a Pinch *b Push NOTE:





  



Remove any dirt or foreign matter on the tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the tube connector has an O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the air line tube. Protect the disconnected parts by covering them with plastic bags after disconnecting the air line tube. If the tube connector and pipe are stuck, push and pull on them to release.

1. Push the air line tube firmly toward the charcoal canister side. 2. Pinch the air line tube as shown in the illustration. 3. Pull out the air line tube. c. Disconnect the 2 tube clamps.

Fig. 21: Identifying Air Line Tube Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disconnect the purge line hose.

Fig. 22: Disconnecting Purge Line Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the 4 bolts and guide.

Fig. 23: Identifying Charcoal Canister Assembly Bolts And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Separate the clip from the body to remove the charcoal canister assembly. 3. REMOVE CHARCOAL CANISTER SUPPORT BRACKET a. Remove the 4 bolts and charcoal canister support bracket.

Fig. 24: Identifying Charcoal Canister Support Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 1 CHARCOAL CANISTER FILTER a. Disengage the 2 claws and remove the cap.

Fig. 25: Identifying No. 1 Charcoal Canister Filter Cap And Vent Hose Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the vent hose. TEXT IN ILLUSTRATION Tube *1 Connector *2 O-ring Pipe (charcoal *3 canister assembly) *a Pinch *b Push

NOTE:

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

  



Remove any dirt or foreign matter on the tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the tube connector has an O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the vent hose. Protect the disconnected parts by covering them with plastic bags after disconnecting the vent hose. If the tube connector and pipe are stuck, push and pull on them to release.

1. Push the vent hose firmly toward the charcoal canister side. 2. Pinch the vent hose as shown in the illustration. 3. Pull out the vent hose. 5. REMOVE CHARCOAL CANISTER BASE BRACKET a. Remove the 2 bolts and charcoal canister base bracket.

Fig. 26: Identifying Charcoal Canister Base Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Before removing the charcoal canister leak detection pump sub-assembly, clean the canister by blowing air into it to ensure that the canister is free of foreign matter.

NOTE:

 

Make sure to clean the canister using only air. Do not use gasoline, thinners or solvents.

b. While disengaging the 2 claws as shown in the illustration, push the charcoal canister leak detection pump sub-assembly upwards using a screwdriver to remove it.

Fig. 27: Removing Charcoal Canister Leak Detection Pump Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. c. Check if the canister contains foreign matter such as mud or water. 1. Visually check that the inside of the canister is free of foreign matter.

Fig. 28: Canister Is Free Of Foreign Matter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Hold the canister upside down to make sure that the canister is free of foreign matter. If the canister contains foreign matter, replace the canister. INSPECTION INSPECTION

1. INSPECT CHARCOAL CANISTER ASSEMBLY a. Visually check the charcoal canister assembly. 1. Visually check the charcoal canister assembly for cracks or damage.

Fig. 29: Inspecting Charcoal Canister Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracks or damage are found, replace the charcoal canister assembly. b. Check canister operation. 1. With port C closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into port A, and check that air flows from port B.

Fig. 30: Checking Canister Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the charcoal canister assembly. 2. With port A closed, blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into port B, and check that air flows from port C.

Fig. 31: Checking Canister Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the charcoal canister assembly. c. Check for air leaks. 1. Connect a pressure gauge to port A of the charcoal canister assembly.

Fig. 32: Checking Charcoal Canister Assembly For Air Leaks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressure *1 Gauge 2. With port C and port B closed, apply 20 kPa (150 mmHg, 5.91 in.Hg) of pressurized air into port A, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the charcoal canister assembly. 2. INSPECT NO. 1 CHARCOAL CANISTER FILTER a. Visually check the No. 1 charcoal canister filter. 1. Visually check the No. 1 charcoal canister filter for cracks or damage.

Fig. 33: Inspecting No. 1 Charcoal Canister Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracks or damage are found, replace the No. 1 charcoal canister filter. b. Check canister operation. 1. Blow 5 kPa (0.1 kgf/cm2 , 0.7 psi) of air into port A, and check that air flows from port B.

Fig. 34: Checking No. 1 Charcoal Canister Filter Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the No. 1 charcoal canister filter. c. Check for air leaks. 1. Connect a pressure gauge to port A of the No. 1 charcoal canister filter.

Fig. 35: Checking No. 1 Charcoal Canister Filter For Air Leaks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressure *1 Gauge 2. With port B closed, apply 20 kPa (150 mmHg, 5.91 in.Hg) of pressurized air into port A, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the No. 1 charcoal canister filter. d. Check the charcoal canister leak detection pump sub-assembly. 1. Connect a positive (+) lead from the auxiliary battery to terminal 5 and a negative (-) lead to terminal 1.

Fig. 36: Charcoal Canister Leak Detection Pump Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check that a clicking sound is heard from the leak detection pump. If the result is not as specified, replace the charcoal canister leak detection pump subassembly. INSTALLATION INSTALLATION

1. INSTALL CHARCOAL CANISTER LEAK DETECTION PUMP SUB-ASSEMBLY a. Engage the 2 claws to install a new charcoal canister leak detection pump sub-assembly to the canister.

Fig. 37: Identifying Charcoal Canister Leak Detection Pump Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

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Do not allow foreign matter such as grease, oil or water to adhere to the O-rings. Ensure that the claws are engaged properly.

2. INSTALL CHARCOAL CANISTER BASE BRACKET a. Install the charcoal canister base bracket with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL NO. 1 CHARCOAL CANISTER FILTER a. Connect the vent hose. NOTE:





Check that there are no scratches or foreign matter around the connected part of the tube connector and pipe before performing this work. After connecting the vent hose, check that the vent hose is securely connected by pulling on the tube connector and the charcoal canister.

b. Engage the 2 claws to install the cap. 4. INSTALL CHARCOAL CANISTER SUPPORT BRACKET a. Install the charcoal canister support bracket with the 4 bolts.

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 5. INSTALL CHARCOAL CANISTER ASSEMBLY a. Connect the clip to install the charcoal canister assembly. b. Install the 4 bolts and guide. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Connect the purge line hose. d. Connect the 2 tube clamps. e. Connect the air line tube. NOTE:





Check that there are no scratches or foreign matter around the connected part of the tube connector and pipe before performing this work. After connecting the air line tube, check that the air line tube is securely connected by pulling on the tube connector and the charcoal canister.

f. Connect the connector to the charcoal canister leak detection pump sub-assembly. 6. INSTALL FUEL TANK ASSEMBLY Refer to INSTALLATION

PURGE VALVE COMPONENTS ILLUSTRATION

Fig. 38: Identifying Purge Valve Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE PURGE VSV a. Disconnect the connector and wire harness clamp.

Fig. 39: Identifying Purge VSV Connector And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 fuel vapor feed hoses.

Fig. 40: Identifying Fuel Vapor Feed Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Fuel Tube *2 Connector *3 Pipe *4 O-ring *a Pinch *b Pull NOTE:

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

 

Remove any dirt or foreign matter on the fuel tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an Oring that seals the pipe. Perform this work by hand. Do not use any tools. Protect the disconnected parts by covering them with plastic bags after disconnecting each fuel vapor feed hose.

c. Remove the purge VSV from the No. 1 air cleaner hose. d. Remove the fuel vapor feed hose from the purge VSV.

Fig. 41: Removing Fuel Vapor Feed Hose From Purge VSV

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT PURGE VSV a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 23 to 26 1-2 F) ohms If the result is not as specified, replace the purge VSV. b. Apply auxiliary battery voltage between the terminals of the purge VSV and check that the following occurs when blowing air into port E. OK Measurement Specified Condition Condition Auxiliary battery voltage Air flows applied from port between F terminals 1 and 2 Auxiliary battery voltage not Air does applied not flow between terminals 1 and 2

Fig. 42: Checking Air Flow Of Purge VSV Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Air If the result is not as specified, replace the purge VSV. INSTALLATION INSTALLATION

1. INSTALL PURGE VSV a. Install the fuel vapor feed hose to the purge VSV. b. Install the purge VSV to the No. 1 air cleaner hose. c. Connect the 2 fuel vapor feed hoses.

Fig. 43: Connecting Fuel Vapor Feed Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*a Push NOTE:

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



Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe before performing this work. Connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer. After connecting the fuel vapor feed hose to the fuel tube connector, check that the fuel vapor feed hose is securely connected by pulling on the fuel tube connector and the fuel vapor feed hose.

d. Connect the wire harness clamp and connector.

FUEL TANK CAP INSPECTION INSPECTION

1. INSPECT FUEL TANK CAP ASSEMBLY a. Visually check that the cap and gasket are not deformed or damaged.

Fig. 44: Identifying Fuel Tank Cap Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Gasket If the result is not as specified, replace the fuel tank cap assembly.

Fig. 45: Identifying Fuel Tank Cap ID Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION ID *a Mark NOTE:

PCV VALVE COMPONENTS ILLUSTRATION

Confirm that ID mark K is printed on the replacement fuel tank cap.

Fig. 46: Identifying PCV Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL 2. REMOVE VENTILATION VALVE SUB-ASSEMBLY a. Remove the No. 2 ventilation hose.

Fig. 47: Removing No. 2 Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly.

Fig. 48: Identifying Ventilation Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION 19 mm Deep *1 Socket Wrench INSPECTION INSPECTION

1. INSPECT VENTILATION VALVE SUB-ASSEMBLY a. Install a clean hose to the ventilation valve sub-assembly. b. Check ventilation valve sub-assembly operation. 1. Blow air into the cylinder block side, and check that air passes through easily.

Fig. 49: Inspecting Ventilation Valve Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Cylinder *a Block Side *b Air

WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. If the result is not as specified, replace the ventilation valve sub-assembly. 2. Blow air into the intake manifold side, and check that air passes through with difficulty.

Fig. 50: Inspecting Ventilation Valve Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clean *1 Hose Intake *a Manifold Side *b Air WARNING: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. If the result is not as specified, replace the ventilation valve sub-assembly.

c. Remove the clean hose from the ventilation valve sub-assembly. INSTALLATION INSTALLATION

1. INSTALL VENTILATION VALVE SUB-ASSEMBLY a. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly. Adhesive Toyota genuine adhesive 1324, three bond 1324 or equivalent b. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) c. Install the No. 2 ventilation hose. 2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION

2012-2017 ENGINE PERFORMANCE ENGINE CONTROL SYSTEM - Camry [2AR-FE,]

CAMSHAFT OIL CONTROL VALVE COMPONENTS ILLUSTRATION

Fig. 1: Identifying Camshaft Oil Control Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

a. b. c. d. e.

Connect the Techstream to the DLC3. Start the engine. Turn the Techstream on. Turn the A/C switch on. Inspect the camshaft timing oil control valve assembly (for intake camshaft). 1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1). 2. Check the engine speed while operating the camshaft timing oil control valve assembly (for intake camshaft) using the Techstream. Standard Condition Tester Specified Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls HINT: If the result is not acceptable, cool the engine (engine coolant temperature is 50°C (122°F) or less) and perform the Active Test again.

f. Inspect the camshaft timing oil control valve assembly (for exhaust camshaft). 1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Exhaust Linear (Bank 1). 2. Check the engine speed while operating the camshaft timing oil control valve assembly (for exhaust camshaft) using the Techstream. Standard Condition Tester Specified Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls

HINT: If the result is not acceptable, cool the engine (engine coolant temperature is 50°C (122°F) or less) and perform the Active Test again. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 2. SEPARATE ENGINE WIRE a. Remove the 2 nuts and separate the engine wire.

Fig. 2: Identifying Engine Cover Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Camshaft timing oil control valve assembly (for exhaust side) 1. Disconnect the oil control valve connector.

Fig. 3: Identifying Oil Control Valve Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove the bolt and oil control valve. 3. Remove the O-ring from the oil control valve.

Fig. 4: Identifying O-Ring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring b. Camshaft timing oil control valve assembly (for intake side) 1. Disconnect the oil control valve connector.

Fig. 5: Identifying Oil Control Valve Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove the bolt and oil control valve. 3. Remove the O-ring from the oil control valve.

Fig. 6: Identifying O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSPECTION INSPECTION

HINT: Use the same procedure for the intake side and exhaust side. 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 6.9 to 7.9 1-2 F) ohms If the result is not as specified, replace the oil control valve assembly.

b. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2, and check the movement of the valve.

Fig. 7: Identifying Oil Control Valve Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Valve Component without harness connected *a (Camshaft Timing Oil Control Valve) When *b applied When cut *c off OK Condition

Specified Condition

Battery

Valve

positive (+) voltage is applied

moves in left arrow direction shown in illustration Valve Battery moves in right positive arrow (+) voltage is direction cut off shown in illustration

NOTE:

Confirm that the valve moves freely and does not stick in any position.

If necessary, replace the camshaft timing oil control valve assembly. HINT: Accumulation of foreign matter can cause minor pressure leaks. Minor pressure leaks will cause the camshaft to advance or retard, and this will cause a DTC to be set. INSTALLATION INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Camshaft timing oil control valve assembly (for exhaust side) 1. Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

Fig. 8: Identifying O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION New *1 Oring 2. Install the oil control valve with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) NOTE:





Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with the cylinder head cover). Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

3. Connect the oil control valve connector. b. Camshaft timing oil control valve assembly (for intake side) 1. Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

Fig. 9: Identifying O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION New *1 Oring 2. Install the oil control valve with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) NOTE:





Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover). Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

3. Connect the oil control valve connector. 2. INSTALL ENGINE WIRE a. Install the engine wire with the 2 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) 3. INSPECT FOR OIL LEAK

4. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68

THROTTLE BODY COMPONENTS ILLUSTRATION

Fig. 10: Identifying Intake Manifold Replacement Components With Torque Specifications (1 of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 11: Identifying Engine Unit Replacement Components With Torque Specifications (1 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. CHECK THROTTLE WITH MOTOR BODY ASSEMBLY a. Check the throttle control motor operating sound. 1. Turn the ignition switch to ON. 2. When depressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises are emitted from the motor. If friction noises exist, replace the throttle with motor body assembly. b. Check the throttle position sensor. 1. Connect the Techstream to the DLC3. 2. Turn the ignition switch to ON. 3. Turn the Techstream on. 4. Perform the "Inspection After Repair" . Refer to INITIALIZATION . 5. Enter the following menus: Powertrain / Engine and ECT / Data List / Gas Throttle / Throttle Sensor Position. 6. Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of "Throttle Sensor Position" is within the specification. Standard throttle valve opening percentage 60% or more NOTE:

When checking the standard throttle valve opening percentage, make sure that the shift lever is in N.

If the percentage is less than 60%, replace the throttle with motor body assembly. REMOVAL REMOVAL

1. 2. 3. 4. 5. 6. 7.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 REMOVE AIR CLEANER CAP SUB-ASSEMBLY a. Disconnect the vacuum switching valve assembly from the air cleaner hose.

Fig. 12: Identifying Vacuum Switching Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the mass air flow meter connector and 2 wire harness clamps from the air cleaner cap sub-assembly.

Fig. 13: Identifying Mass Air Flow Meter Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Separate the fuel vapor feed hose from the air cleaner hose.

Fig. 14: Identifying Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the ventilation hose from the cylinder head cover.

Fig. 15: Identifying Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

Fig. 16: Identifying Hose Clamp

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Release the 2 clamps and remove the air cleaner cap sub-assembly.

Fig. 17: Identifying Air Cleaner Sub-Assembly Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY a. Disconnect the fuel tube from the clamp.

Fig. 18: Identifying Throttle Body Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the throttle body connector. c. Disconnect the water by-pass hose from the throttle with motor body assembly.

Fig. 19: Identifying Water By-pass Hoses

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the No. 2 water by-pass hose from the throttle with motor body assembly. e. Remove the 4 bolts and throttle with motor body assembly with fuel tube bracket.

Fig. 20: Locating Bolts And Throttle Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the bolt and fuel tube bracket.

Fig. 21: Locating Bolt And Fuel Tube Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the gasket from the intake manifold.

Fig. 22: Locating Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY a. Check that the throttle valve opens and closes smoothly. b. Check that there is no sludge accumulated around the throttle with motor body assembly.

c. Measure the resistance according to the value(s) in the table below.

Fig. 23: Inspecting Throttle Body Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 1 (M-) - 2 20°C (68° 0.3 to 100 (M+) F) ohms TEXT IN ILLUSTRATION Component without harness connected: *a (Throttle with Motor Body Assembly) If the result is not as specified, replace the throttle with motor body assembly. INSTALLATION INSTALLATION

1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY a. Install a new gasket to the intake manifold. b. Install the fuel tube bracket with the bolt. Torque: 13 N*m ( 132 kgf*cm, 10 ft.*lbf) c. Install the throttle with motor body assembly with the 4 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) d. Connect the throttle body connector. e. Connect the fuel tube to the clamp. f. Connect the No. 2 water by-pass hose to the throttle with motor body assembly. g. Connect the water by-pass hose to the throttle with motor body assembly. 2. INSTALL AIR CLEANER CAP SUB-ASSEMBLY a. Install the air cleaner cap sub-assembly with the 2 clamps. b. Install the air cleaner hose with the hose clamp. c. Connect the ventilation hose to the cylinder head cover. d. Install the fuel vapor feed hose to the air cleaner hose. e. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap subassembly.

3. 4. 5. 6. 7. 8. 9. 10.

f. Connect the vacuum switching valve assembly to the air cleaner hose. ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68 INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH PERFORM INITIALIZATION NOTE:





Be sure to perform this procedure after reassembling the throttle with motor body assembly or removing and reinstalling any throttle body component. Perform the following procedure after replacing the throttle with motor body assembly or any throttle body components. The following procedure should also be performed if the throttle body is cleaned.

a. Turn the ignition switch to ON without operating the accelerator pedal. NOTE:

If the accelerator pedal is operated, perform the above step again.

b. Connect the Techstream to the DLC3 and clear the DTCs . Refer to DTC CHECK / CLEAR . c. Perform the "Inspection After Repair" . Refer to INITIALIZATION . d. Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off. Standard Engine Condition Idle Speed A/C 610 to switched 710 off rpm NOTE:

 

Be sure to perform this step with all accessories off. Make sure that the shift lever is in N.

e. Enter the following menus: Powertrain / Engine and ECT / Data List / Gas Throttle / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more. f. Perform a road test and confirm that there are no abnormalities.

ECM COMPONENTS ILLUSTRATION

Fig. 24: Identifying ECM Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

Perform the Vehicle Identification Number (VIN) registration when replacing the ECM . Refer to REGISTRATION .

HINT: When removing only the ECM, it is not necessary to remove the cool air intake duct seal and battery. REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected . Refer to INITIALIZATION .

2. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 3. REMOVE BATTERY . Refer to REMOVAL - Step 23 4. REMOVE ECM a. Disconnect the 2 ECM connectors.

Fig. 25: Raising ECM Connector Levers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Push in the locks on the 2 levers, raise the levers, and disconnect the 2 ECM connectors. NOTE:

After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting part of

the connectors. b. Remove the nut.

Fig. 26: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. d. e. f.

Remove the screw (A). Loosen the screw (B) and remove the ECM. Remove the screw (B). Remove the 2 screws and No. 2 ECM bracket.

Fig. 27: Identifying No. 2 ECM Screws And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 ECM BRACKET a. Remove the nut.

Fig. 28: Identifying No. 1 ECM Bracket Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the wire harness clamp. c. Disconnect the wire harness clamp.

Fig. 29: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the nut and No. 1 ECM bracket.

Fig. 30: Identifying No. 1 ECM Bracket Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ECM BRACKET a. Install the No. 1 ECM bracket with the nut.

Fig. 31: Identifying No. 1 ECM Bracket Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf) b. Connect the wire harness clamp.

Fig. 32: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the wire harness clamp.

Fig. 33: Identifying No. 1 ECM Bracket Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the nut. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) 2. INSTALL ECM a. Install the No. 2 ECM bracket to the ECM with the 2 screws.

Fig. 34: Identifying No. 2 ECM Screws And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) b. Temporarily install the screw (B). c. Install the ECM with the nut.

Fig. 35: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf) d. Install the screw (A). Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) e. Tighten the screw (B). Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) f. Connect the 2 ECM connectors and lower the 2 levers.

Fig. 36: Raising ECM Connector Levers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other part. Make sure that the 2 levers are securely locked.

g. Connect the 2 wire harness clamps. 3. INSTALL BATTERY . Refer to INSTALLATION - Step 49 4. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected . Refer to INITIALIZATION .

6. PERFORM INITIALIZATION Refer to PRECAUTION

ACCELERATOR PEDAL COMPONENTS ILLUSTRATION

Fig. 37: Identifying Accelerator Pedal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. CHECK ACCELERATOR PEDAL SENSOR ASSEMBLY

a. Measure the voltage. 1. Connect the Techstream to the DLC3. 2. Turn the ignition switch to ON. 3. Turn the Techstream on. 4. Enter the following menus: Powertrain / Engine and ECT / Data List / Gas Throttle / Accel Sensor Out No. 1 and Accel Sensor Out No. 2. 5. Read the value displayed on the Techstream. Standard Voltage Accel Accel Accelerator Sensor Sensor Pedal Out Out Operation No. 1 No. 2 Fully 0.5 to 1.2 to Released 1.1 V 2.0 V Fully 2.6 to 3.4 to Depressed 4.5 V 4.98 V If the result is not as specified, check the accelerator pedal sensor assembly, wire harness or ECM. REMOVAL REMOVAL

1. REMOVE ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal assembly. Do not disassemble the accelerator pedal assembly.

a. Disconnect the accelerator pedal sensor connector.

Fig. 38: Identifying Accelerator Pedal Sensor Assembly Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and accelerator pedal sensor assembly. INSTALLATION INSTALLATION

1. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal assembly. Do not disassemble the accelerator pedal assembly.

a. Temporarily install the accelerator pedal sensor assembly with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 39: Identifying Bolt Tightening Order Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m ( 55 kgf*cm, 48 in.*lbf) c. Connect the accelerator pedal connector.

MASS AIR FLOW METER COMPONENTS ILLUSTRATION

Fig. 40: Identifying Mass Air Flow Meter Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

NOTE:





Perform the mass air flow meter inspection according to the procedure below. Only replace the mass air flow meter when the mass air flow value in the Data List (with the engine stopped) is not within the normal operating range or there is foreign matter on the mass air flow meter platinum hot

wire (heater). 1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY NOTE:







a. b. c. d. e.

Perform the inspection with the vehicle indoors and on a level surface. Perform the inspection of the mass air flow meter while it is installed to the air cleaner case (installed to the vehicle). During the test, do not use an exhaust air duct to perform suction on the exhaust pipe.

Connect the Techstream to the DLC3. Turn the ignition switch to ON (do not run the engine). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / MAF. Wait 30 seconds, and read the values on the Techstream. Standard Item Condition 



MAF

Specified Condition

Engine not running 30 seconds Less than 0.47g/sec. after turning ignition switch to ON

If the result is not as specified, replace the mass air flow meter sub-assembly. If the result is as specified, inspect the mass air flow meter sub-assembly . Refer to INSPECTION. REMOVAL REMOVAL

1. REMOVE MASS AIR FLOW METER SUB-ASSEMBLY a. Disconnect the mass air flow meter connector.

Fig. 41: Identifying Mass Air Flow Meter Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 screws and mass air flow meter sub-assembly. INSPECTION INSPECTION

1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY a. Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter sub-assembly shown in the illustration.

Fig. 42: Identifying Mass Air Flow Meter Platinum Hot Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Platinum Hot *1 Wire (Heater) OK There is no foreign matter. b. Check the intake air temperature sensor (built into the mass air flow meter sub-assembly). 1. Measure the resistance according to the value(s) in the table below.

Fig. 43: Identifying Mass Air Flow Meter Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Mass Air Flow Meter Subassembly) Standard Resistance Tester Specified Condition Connection Condition 13.6 to 1 (THA) - 2 -20°C (-4° 18.4 (E2) F) kohms 2.21 to 1 (THA) - 2 20°C (68° 2.69 (E2) F) kohms 0.49 to 1 (THA) - 2 60°C 0.67 (E2) (140°F) kohms

If the result is not as specified, replace the mass air flow meter sub-assembly. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly . Refer to INITIALIZATION . 1. INSTALL MASS AIR FLOW METER SUB-ASSEMBLY a. Install the mass air flow meter sub-assembly with the 2 screws. NOTE:

Make sure that the O-ring is not cracked or jammed when installing the mass air flow meter.

HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly . Refer to INITIALIZATION . b. Connect the mass air flow meter connector.

CAMSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 44: Identifying Camshaft Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18

2. REMOVE CAMSHAFT POSITION SENSOR a. Camshaft position sensor (for Exhaust Side) 1. Disconnect the sensor connector.

Fig. 45: Locating Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove the bolt and sensor. b. Camshaft position sensor (for Intake Side) 1. Disconnect the sensor connector.

Fig. 46: Identifying Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. Remove the bolt and sensor. INSTALLATION INSTALLATION

1. INSTALL CAMSHAFT POSITION SENSOR a. Camshaft position sensor (for Intake Side) 1. Clean and degrease the threads of the bolt for the camshaft position sensor. 2. Apply a light coat of engine oil to the O-ring of the sensor. NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

3. Apply adhesive to 2 or 3 threads of the bolt.

Fig. 47: Applying Adhesive To Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

4. Install the sensor with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) 5. Connect the sensor connector. b. Camshaft position sensor (for Exhaust Side) 1. Clean and degrease the threads of the bolt for the camshaft position sensor. 2. Apply a light coat of engine oil to the O-ring of the sensor. NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

3. Apply adhesive to 2 or 3 threads of the bolt.

Fig. 48: Applying Adhesive To Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. 4. Install the sensor with the bolt.

Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) 5. Connect the sensor connector. 2. INSPECT FOR OIL LEAK 3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68

CRANKSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 49: Identifying Crankshaft Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CRANKSHAFT POSITION SENSOR

Fig. 50: Locating Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Disconnect the sensor connector. b. Remove the bolt and sensor. INSPECTION INSPECTION

1. INSPECT CRANKSHAFT POSITION SENSOR a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 1630 to Cold 2740 ohms 1-2 2065 to Hot 3225 ohms HINT:

In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). If the result is not as specified, replace the crankshaft position sensor. INSTALLATION INSTALLATION

1. INSTALL CRANKSHAFT POSITION SENSOR a. Clean and degrease the threads of the bolt for the crankshaft position sensor. b. Apply a light coat of engine oil to the O-ring of the sensor.

Fig. 51: Identifying Crankshaft Position Sensor O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring c. Apply adhesive to 2 or 3 threads of the bolt.

Fig. 52: Applying Adhesive To Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. d. Install the sensor with the bolt. Torque: 6.5 N*m ( 66 kgf*cm, 58 in.*lbf) NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

e. Connect the sensor connector. 2. INSPECT FOR OIL LEAK

IGNITION COIL AND SPARK PLUG COMPONENTS ILLUSTRATION

Fig. 53: Identifying Ignition Coil And Spark Plug Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 2. REMOVE IGNITION COIL ASSEMBLY a. Disconnect the 4 ignition coil assembly connectors. b. Remove the 4 bolts and 4 ignition coil assemblies.

Fig. 54: Locating Bolts And Ignition Coil Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE SPARK PLUG a. Using a spark plug wrench, remove the 4 spark plugs.

Fig. 55: Installing Spark Plug

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the spark plug and ignition coil assembly . Refer to INITIALIZATION . 1. INSTALL SPARK PLUG a. Using a spark plug wrench, install the 4 spark plugs. Torque: 25 N*m ( 255 kgf*cm, 18 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the spark plug . Refer to INITIALIZATION . 2. INSTALL IGNITION COIL ASSEMBLY a. Install the 4 ignition coil assemblies with the 4 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the ignition coil assembly . Refer to INITIALIZATION . b. Connect the 4 ignition coil assembly connectors. 3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68

ENGINE COOLANT TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 56: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 57: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH

5. 6. 7. 8. 9.

DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 19 REMOVE ENGINE COOLANT TEMPERATURE SENSOR a. Disconnect the engine coolant temperature sensor connector.

Fig. 58: Identifying Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and disconnect the wire harness.

Fig. 59: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor.

Fig. 60: Removing Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Ball Joint *1 Lock Nut Wrench *2 Gasket d. Remove the gasket from the engine coolant temperature sensor. INSPECTION INSPECTION

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Fig. 61: Inspecting Engine Coolant Temperature Sensor With Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected Temperature *a *b (Engine °C (°F) Coolant Temperature Sensor) Resistance *c *d Acceptable ohms a. Partially immerse the sensor in water and warm up the water. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 2.32 to 20°C (68° 1-2 2.59 F) kohms 0.310 to 80°C 1-2 0.326 (176°F) kohms NOTE:

When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

If the result is not as specified, replace the engine coolant temperature sensor. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor . Refer to INITIALIZATION . 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR a. Install a new gasket to the engine coolant temperature sensor. b. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor. Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf) NOTE:

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench . Refer to PRECAUTION .

HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor . Refer to INITIALIZATION . c. Connect the engine coolant temperature sensor connector. d. Install the wire harness with the 2 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) 2. 3. 4. 5. 6. 7. 8. 9. 10.

INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 53 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68 INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

KNOCK SENSOR COMPONENTS

ILLUSTRATION

Fig. 62: Identifying Knock Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL 2. REMOVE KNOCK CONTROL SENSOR a. Disconnect the sensor connector.

Fig. 63: Locating Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and knock control sensor. INSPECTION INSPECTION

1. INSPECT KNOCK CONTROL SENSOR a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 120 to 280 1-2 F) kohms

If the result is not as specified, replace the knock control sensor. INSTALLATION INSTALLATION

Perform "Inspection After Repair" after replacing the knock control sensor . Refer to INITIALIZATION . 1. INSTALL KNOCK CONTROL SENSOR a. Install the sensor with the bolt so that the sensor is angled as shown in the illustration.

Fig. 64: Identifying Knock Control Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf)

TEXT IN ILLUSTRATION Front *a of Engine *b Up *c 7° *d 10° NOTE:

The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position.

HINT: Perform "Inspection After Repair" after replacing the knock control sensor . Refer to INITIALIZATION b. Connect the sensor connector. 2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION

AIR FUEL RATIO SENSOR COMPONENTS ILLUSTRATION

Fig. 65: Identifying Air Fuel Ratio Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 66: Identifying Air Fuel Ratio Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to REMOVAL - Step 8

2. REMOVE AIR FUEL RATIO SENSOR (except PZEV) a. Remove the hose clamp.

Fig. 67: Identifying Air Fuel Ratio Sensor Connector And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the air fuel ratio sensor connector. c. Using SST, remove the air fuel ratio sensor from the exhaust manifold.

Fig. 68: Removing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09224-00010 3. REMOVE AIR FUEL RATIO SENSOR (for PZEV) a. Disconnect the air fuel ratio sensor connector. 

Fig. 69: Identifying Air Fuel Ratio Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the air fuel ratio sensor from the exhaust manifold.

Fig. 70: Removing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT AIR FUEL RATIO SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 71: Identifying Air Fuel Ratio Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HA1A) - 20°C (68° 1.6 to 3.2 2 (+B) F) ohms 1 (HA1A) 10 kohms Always 4 (A1A-) or higher TEXT IN ILLUSTRATION Component without harness *a connected: (Air Fuel Ratio Sensor) If the result is not as specified, replace the air fuel ratio sensor. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to INITIALIZATION . 1. INSTALL AIR FUEL RATIO SENSOR (for PZEV) a. Using SST, install the air fuel ratio sensor to the exhaust manifold.

Fig. 72: Installing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length 30 mm Fulcrum *b Length

300 mm 

SST: 09224-00010

without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to INITIALIZATION . b. Connect the air fuel ratio sensor connector. 2. INSTALL AIR FUEL RATIO SENSOR (except PZEV) a. Using SST, install the air fuel ratio sensor to the exhaust manifold.

Fig. 73: Installing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length 30 mm Fulcrum *b Length 300 mm 

SST: 09224-00010

without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf)

with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to INITIALIZATION . b. Connect the air fuel ratio sensor connector. c. Install the hose clamp. 3. INSPECT FOR EXHAUST GAS LEAK 4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to INSTALLATION - Step 4

HEATED OXYGEN SENSOR COMPONENTS ILLUSTRATION

Fig. 74: Identifying Heated Oxygen Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HEATED OXYGEN SENSOR a. Disconnect the heated oxygen sensor connector.

Fig. 75: Identifying Heated Oxygen Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the heated oxygen sensor from the front exhaust pipe.

Fig. 76: Removing Heated Oxygen Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT OXYGEN SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 77: Identifying Heated Oxygen Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HT1B) - 20°C (68° 11 to 16 2 (+B) F) ohms 1 (HT1B) 10 kohms Always 4 (E2) or higher TEXT IN ILLUSTRATION Component *a without harness connected

(Oxygen Sensor) If the result is not as specified, replace the oxygen sensor. INSTALLATION INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR a. Using SST, install the heated oxygen sensor to the front exhaust pipe.

Fig. 78: Installing Heated Oxygen Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Fulcrum *a Length 30 mm Fulcrum *b Length 300 mm 

SST: 09224-00010

without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to PRECAUTION The "with SST" torque value is effective when SST is parallel to the torque wrench.

b. Connect the heated oxygen sensor connector. 2. INSPECT FOR EXHAUST GAS LEAK

INTEGRATION RELAY COMPONENTS ILLUSTRATION

Fig. 79: Identifying Integration Relay Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 RELAY BLOCK COVER 2. REMOVE NO. 1 INTEGRATION RELAY a. Disconnect the connector.

Fig. 80: Identifying No. 1 Integration Relay Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the No. 1 integration relay.

Fig. 81: Identifying No. 1 Integration Relay Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 4 connectors and remove the No. 1 integration relay.

Fig. 82: Identifying No. 1 Integration Relay Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT NO. 1 INTEGRATION RELAY

Fig. 83: No. 1 Integration Relay - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration - Relay a. EFI MAIN RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 84: Identifying IG2 Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1

*1

Integration Relay

Standard Resistance Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not 10 kohms relay 1B-1 - applied between or higher No. 1 integration terminals relay 1A-8 1C-7 and 1E-2 No. 1 integration relay 1B-1 No. 1 integration relay 1A-8 No. 1 integration relay 1B-1 No. 1 integration relay 1C-3 Battery No. 1 voltage is integration applied relay 1B-1 Below 1 between No. 1 ohms terminals integration 1C-7 and relay 1C-4 1E-2 No. 1 integration relay 1B-1 No. 1 integration relay 1C-9 No. 1 integration relay 1B-1 No. 1 integration relay 1C-10

If the resistance is not as specified, replace the No. 1 integration relay. b. EFI MAIN2 RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 85: Identifying IG2 Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration Relay Standard Resistance Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not relay 1A-6 - applied 10 kohms No. 1 between or higher integration terminals relay 1D-1 1A-8 and 1E-2 No. 1 integration relay 1A-6 Battery No. 1 integration voltage is relay 1D-1 applied Below 1 between ohms No. 1 terminals integration 1A-8 and relay 1A-7 - 1E-2 No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay. c. IG2 RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 86: Identifying IG2 Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1

*1

Integration Relay

Standard Resistance Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not 10 kohms relay 1A-1 - applied between or higher No. 1 integration terminals relay 1D-3 1C-8 and 1E-2 No. 1 integration relay 1A-1 No. 1 integration relay 1D-3 No. 1 integration relay 1A-3 No. 1 integration relay 1D-3 Battery No. 1 voltage is integration applied relay 1C-1 Below 1 between No. 1 ohms terminals integration 1C-8 and relay 1D-3 1E-2 No. 1 integration relay 1C-2 No. 1 integration relay 1D-3 No. 1 integration relay 1C-5 No. 1 integration relay 1D-3

If the resistance is not as specified, replace the No. 1 integration relay. d. C/OPN RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 87: Identifying IG2 Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration Relay Standard Resistance Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not relay 1A-6 - applied 10 kohms No. 1 between or higher integration terminals relay 1D-1 1A-1 and 1E-1 No. 1 integration relay 1A-6 Battery No. 1 integration voltage is relay 1D-1 applied Below 1 between ohms No. 1 terminals integration 1A-1 and relay 1A-7 - 1E-1 No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay. INSTALLATION INSTALLATION

1. INSTALL NO. 1 INTEGRATION RELAY a. Connect the 4 connectors. b. Attach the No. 1 integration relay to the engine room relay block. c. Connect the connector. 2. INSTALL NO. 1 RELAY BLOCK COVER

2012-2017 ENGINE PERFORMANCE Engine Control System (Service Information) - Camry (2GR-FE)

CAMSHAFT OIL CONTROL VALVE COMPONENTS ILLUSTRATION

Fig. 1: Identifying Camshaft Oil Control Valve Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Camshaft Oil Control Valve Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Connect the Techstream to the DLC3. b. Start the engine. c. Turn the Techstream on. d. Turn the A/C switch on. e. Inspect the oil control valve assembly (for intake camshaft). 1. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Linear (Bank 1). 2. Check the engine speed while operating the camshaft timing oil control valve assembly (for intake camshaft) using the Techstream. Standard Condition

Techstream Engine Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls If the operation is not as specified, check the oil control valve assembly, wire harness and ECM. 3. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Linear (Bank 2). 4. Check the engine speed while operating the camshaft timing oil control valve assembly (for intake camshaft) using the Techstream. Standard Condition Techstream Engine Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls If the operation is not as specified, check the oil control valve assembly, wire harness and ECM. f. Inspect the oil control valve assembly (for exhaust camshaft). 1. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Exhaust Linear (Bank 1). 2. Check the engine speed while operating the camshaft timing oil control valve assembly (for exhaust camshaft) using the Techstream. Standard Condition Techstream Engine Operation Condition 0%

Normal engine

100%

speed Engine idles roughly or stalls

If the operation is not as specified, check the oil control valve assembly, wire harness and ECM. 3. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Exhaust Linear (Bank 2). 4. Check the engine speed while operating the camshaft timing oil control valve assembly (for exhaust camshaft) using the Techstream. Standard Condition Techstream Engine Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls If the operation is not as specified, check the oil control valve assembly, wire harness and ECM. REMOVAL REMOVAL

1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to REMOVAL . 2. DISCONNECT ENGINE WIRE a. Disconnect the 3 wire harness clamps.

Fig. 3: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

Bank 2 for *b Bank 1 *a

b. Remove the 2 bolts and 2 wire harness brackets. 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Disconnect the 4 oil control valve connectors. b. Remove the 4 bolts and 4 oil control valves.

Fig. 4: Identifying Oil Control Valves, Connectors And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

Intake Side for *b Exhaust Side for *c Bank 2 for *d Bank 1 *a

c. Remove the O-ring from each oil control valve.

Fig. 5: Identifying Oil Control Valve O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSPECTION INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Measure the resistance according to the value(s) in the table below. Standard Resistance

Tester Specified Connection Condition 6.9 to 7.9 ohms at 1-2 20°C (68° F) If the result is not as specified, replace the oil control valve assembly. b. Check the operation.

Fig. 6: Connecting Battery Positive (+) Lead To Terminal 1 And Negative (-) Lead To Terminal 2 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Spool *1 Valve *2 Battery 1. Connect a battery positive (+) lead to terminal 1 and negative (-) lead to terminal 2, and check the movement of the spool valve. OK Condition

Specified Condition

Valve moves in Battery black voltage is arrow applied direction shown in illustration Valve moves in Battery white voltage is arrow not direction applied shown in illustration If the result is not as specified, replace the oil control valve. NOTE:

Accumulation of foreign matter can cause minor pressure leaks. Minor pressure leaks in the intake side oil control valve will cause the intake camshaft to advance. Minor pressure leaks in the exhaust side oil control valve will cause the exhaust camshaft to retard. The inappropriate camshaft timing that results from these leaks will cause a DTC to be set.

INSTALLATION INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Apply a light coat of engine oil to 4 new O-rings and install them to the 4 camshaft timing oil control valve assemblies.

Fig. 7: Identifying Oil Control Valve O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION New *1 Oring b. Install the 4 oil control valves with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Make sure that each O-ring is not cracked or does not jump out of position during installation.

c. Connect the 4 oil control valve connectors. 2. CONNECT ENGINE WIRE a. Install the 2 wire harness brackets with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 3 wire harness clamps. 3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to INSTALLATION .

THROTTLE BODY COMPONENTS ILLUSTRATION

Fig. 8: Identifying Throttle Body Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 9: Identifying Throttle Body Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY

a. Check the throttle control motor operating sound. 1. Turn the engine switch on (IG). 2. When depressing the accelerator pedal, check the operating sound of the motor. Make sure that no friction noises are emitted from the motor. If friction noise exists, replace the throttle with motor body assembly. b. Check the throttle position sensor. 1. Connect the Techstream to the DLC3. 2. Turn the engine switch on (IG). 3. Turn the Techstream on. 4. Enter the following menus: Powertrain / Engine / Data List / Gas Throttle / Throttle Sensor Position. 5. Depress the accelerator pedal. When the throttle valve is fully open, check that the Throttle Sensor Position value is within the specification. Standard Throttle Valve Opening Percentage Tester Specified Display Condition Throttle 60% or Sensor more Position NOTE:





When checking the throttle valve opening percentage, the shift lever should be in neutral. Fully depress the accelerator pedal.

If the percentage is less than 60%, replace the throttle with motor body assembly. REMOVAL REMOVAL

1. 2. 3. 4. 5. 6. 7.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE AIR CLEANER CAP SUB-ASSEMBLY a. Disconnect the mass air flow meter connector and wire harness clamp.

Fig. 10: Identifying Mass Air Flow Meter Connector And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 3 hoses.

Fig. 11: Identifying Air Cleaner Cap Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Separate the ventilation hose. d. Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.

Fig. 12: Identifying Air Cleaner Cap Sub-Assembly Hose Clamp And Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Release the 2 clamps and remove the air cleaner cap with hose. 8. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY a. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly.

Fig. 13: Locating Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the throttle body connector and wire harness clamp.

Fig. 14: Locating Bolts, Throttle Body And Wire Harness Clamp Stay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 4 bolts, throttle with motor body assembly and wire harness clamp stay. d. Remove the gasket from the intake air surge tank assembly. INSPECTION INSPECTION

1. INSPECT THROTTLE BODY a. Measure the resistance according to the value(s) in the table below.

Fig. 15: Identifying Throttle Body Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 1 (M-) - 2 20°C (68° 0.3 to 100 (M+) F) ohms TEXT IN ILLUSTRATION Component without harness *a connected (Throttle body) If the result is not as specified, replace the throttle body. INSTALLATION INSTALLATION

1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY a. Install a new gasket to the intake air surge tank assembly.

Fig. 16: Locating Intake Air Surge Tank Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the throttle with motor body assembly and wire harness clamp stay to the intake air surge tank assembly with the 4 bolts.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

2.

3. 4. 5. 6. 7. 8. 9. 10.

c. Connect the throttle body connector and wire harness clamp. d. Connect the 2 water by-pass hoses to the throttle with motor body assembly. INSTALL AIR CLEANER CAP SUB-ASSEMBLY a. Connect the air cleaner cap sub-assembly to the throttle with motor body assembly with the hose clamp. b. Install the air cleaner cap with hose to the air cleaner case with the 2 clamps. c. Connect the wire harness clamp and mass air flow meter connector. d. Connect the 3 hoses. e. Connect the ventilation hose. f. Connect the mass air flow meter connector and wire harness clamp. ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82 INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH PERFORM INITIALIZATION NOTE:





Be sure to perform this procedure after reassembling the throttle with motor body assembly or removing and reinstalling any throttle body component. Perform the following procedure after replacing the throttle with motor body assembly or any throttle body components. The following procedure should also be performed if the throttle body is cleaned.

a. Turn the engine switch on (IG) without operating the accelerator pedal. NOTE:

If the accelerator pedal is operated, perform the above steps again.

b. Connect the Techstream to the DLC3 and clear the DTCs. Refer to DTC CHECK / CLEAR . c. Perform the "Inspection After Repair". Refer to INITIALIZATION . d. Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off. Standard Engine

Idle Speed A/C 600 to switched 700 off rpm Condition

NOTE:

 

Be sure to perform this step with all accessories off. Make sure that the shift lever is in neutral.

e. Enter the following menus: Powertrain / Engine / Data List / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more. f. Perform a road test and confirm that there are no abnormalities.

VACUUM SWITCHING VALVE (FOR ENGINE MOUNTING) COMPONENTS ILLUSTRATION

Fig. 17: Identifying Vacuum Switching Valve Replacement Components With Torque Specifications (For Engine Mounting) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

2. 3. 4. 5. 6.

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. REMOVE DUTY VACUUM SWITCHING VALVE a. Disconnect the 2 vacuum hoses from the duty vacuum switching valve.

Fig. 18: Identifying Duty Vacuum Switching Valve Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hose. c. Remove the bolt and disconnect the duty vacuum switching valve connector.

Fig. 19: Identifying Duty Vacuum Switching Valve Connector And Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the vacuum hose to remove the duty vacuum switching valve. INSPECTION INSPECTION

1. INSPECT DUTY VACUUM SWITCHING VALVE (OPERATION) a. Check the operation of the duty vacuum switching valve when positive battery voltage is applied to its terminals.

Fig. 20: Inspecting Duty Vacuum Switching Valve Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Condition Specified Condition The air from pipe Battery G is voltage is flowing not out applied through pipes E and H. Condition

The air

from pipe F is Battery flowing voltage is out applied through pipes E and H. If the result is not as specified, replace the duty vacuum switching valve. 2. INSPECT DUTY VACUUM SWITCHING VALVE (RESISTANCE) a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 19 to 21 1-2 F) ohms If the resistance is not as specified, replace the duty vacuum switching valve. INSTALLATION INSTALLATION

1. INSTALL DUTY VACUUM SWITCHING VALVE a. Connect the vacuum hose and vacuum switching valve connector.

Fig. 21: Identifying Duty Vacuum Hose And Vacuum Switch Valve Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the duty vacuum switching valve with the bolt. HINT: Hose A: Large hose Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) c. Connect the 2 vacuum hoses to the duty vacuum switching valve.

Fig. 22: Identifying Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Hose B: Dummy hose (not used for ventilation, the other end is plugged) d. Connect the hose. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

3. 4. 5. 6.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

ACTIVE CONTROL ENGINE MOUNT COMPONENTS ILLUSTRATION

Fig. 23: Identifying Active Control Engine Mount Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 24: Identifying Active Control Engine Mount Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY a. Check the operation. 1. Connect the Techstream to DLC3. 2. Turn the engine switch on (IG). 3. Turn the Techstream on. 4. Enter the following menus: Powertrain / Engine / Active Test / Control the ACM Inhibit. Tester Test Control Diagnostic

Display Part Range Control the ON / ACM ACM OFF Inhibit

Note Test is possible while engine is idling

5. Check if the front engine mounting insulator assembly operates in accordance with tester operation. Result Condition "Control the ACM Inhibit" is OFF

"Control the ACM Inhibit" is ON

Specified Condition The engine does not move (insulator operation is normal). The engine moves in accordance with insulator operation.

HINT: While "Control the ACM Inhibit" is ON, the front engine mounting insulator assembly operates repeatedly. b. Inspect for vacuum leaks. 1. Disconnect the vacuum hose from the front engine mounting insulator assembly. 2. Using a vacuum pump, apply vacuum of 80 kPa (600 mmHg, 25 in.Hg) and wait for 1 minute.

Fig. 25: Inspecting For Vacuum Leaks Using Vacuum Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Check that there is no change in the needle movement of the vacuum pump gauge. OK Vacuum pressure holds. 4. Check that there is no fluid leakage caused by a break in the diaphragm. 5. Reconnect the vacuum hose. REMOVAL REMOVAL

1. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL . 2. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET HINT: Securely support the automatic transaxle using a jack. a. Remove the 2 bolts and separate the transmission oil cooler.

Fig. 26: Identifying Transmission Oil Cooler Boots Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and transverse engine mounting bracket.

Fig. 27: Identifying Engine Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY a. Disconnect the duty vacuum switching valve connector and 2 clamps.

Fig. 28: Identifying Duty Vacuum Switching Valve Connector And Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the hole plug. c. Remove the 3 nuts and front engine mounting insulator assembly.

Fig. 29: Identifying Front Engine Mounting Insulator Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY a. Install the front engine mounting insulator assembly with the 3 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) b. Install the hole plug. c. Connect the duty vacuum switching valve connector and 2 clamps. 2. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET a. Install the transverse engine mounting bracket with the 4 bolts.

Fig. 30: Identifying Transverse Engine Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt *1 A Bolt *2 B Bolt A Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Bolt B Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) b. Install the transmission oil cooler with the 2 bolts. Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 3. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION .

ECM

COMPONENTS ILLUSTRATION

Fig. 31: Identifying ECM Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

Perform the Vehicle Identification Number (VIN) registration when replacing the ECM. Refer to REGISTRATION .

HINT: When removing only the ECM, it is not necessary to remove the cool air intake duct seal and battery.

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

2. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 3. REMOVE BATTERY . Refer to REMOVAL - Step 22 4. REMOVE ECM a. Disconnect the 2 ECM connectors.

Fig. 32: Raising ECM Connector Levers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Push in the locks on the 2 levers, raise the levers, and disconnect the 2 ECM connectors. NOTE:

b. Remove the nut.

After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting part of the connectors.

Fig. 33: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. d. e. f.

Remove the screw (A). Loosen the screw (B) and remove the ECM. Remove the screw (B). Remove the 2 screws and No. 2 ECM bracket.

Fig. 34: Identifying No. 2 ECM Screws And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 ECM BRACKET a. Remove the nut.

Fig. 35: Identifying No. 1 ECM Bracket Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the wire harness clamp. c. Disconnect the wire harness clamp.

Fig. 36: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the nut and No. 1 ECM bracket.

Fig. 37: Identifying No. 1 ECM Bracket Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ECM BRACKET a. Install the No. 1 ECM bracket with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) b. Connect the 2 wire harness clamps. c. Install the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL ECM a. Install the No. 2 ECM bracket to the ECM with the 2 screws. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) b. Temporarily install the screw (B). c. Install the ECM with the nut.

Fig. 38: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) d. Install the screw (A). Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) e. Tighten the screw (B). Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) f. Connect the 2 ECM connectors and lower the 2 levers. NOTE:





When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other part. Make sure that the 2 levers are securely locked.

3. INSTALL BATTERY . Refer to INSTALLATION - Step 55 4. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. PERFORM INITIALIZATION Refer to PRECAUTION .

ACCELERATOR PEDAL COMPONENTS ILLUSTRATION

Fig. 39: Identifying Acceleration Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ACCELERATOR PEDAL SENSOR ASSEMBLY

a. b. c. d.

Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Data List / All Data / Accel Sensor Out No. 1 and Accel Sensor Out No. 2. e. Read the values displayed on the Techstream. Standard Voltage Accel Accel Accelerator Sensor Sensor Pedal Out Out Operation No. 1 No. 2 0.5 to 1.2 to Released 1.1 V 2.0 V 2.6 to 3.4 to Depressed 4.5 V 4.98 V If the result is not as specified, check the accelerator pedal sensor assembly, wire harness or ECM.

REMOVAL REMOVAL

1. REMOVE ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly.

a. Disconnect the accelerator pedal sensor assembly connector.

Fig. 40: Identifying Accelerator Pedal Sensor Assembly Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and accelerator pedal sensor assembly. INSTALLATION INSTALLATION

1. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly.

a. Temporarily install the accelerator pedal sensor assembly with the 2 bolts.

Fig. 41: Identifying Accelerator Pedal Sensor Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the 2 bolts in the order shown in the illustration. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) c. Connect the accelerator pedal sensor assembly connector.

MASS AIR FLOW METER COMPONENTS ILLUSTRATION

Fig. 42: Identifying Mass Air Flow Meter Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

NOTE:

 

Perform the MAF meter inspection according to the following procedure. Only replace the MAF meter when the MAF value in the Data List (with the engine stopped) is not within the normal operating range or there is foreign matter on the MAF meter platinum hot wire (heater).

1. INSPECT MASS AIR FLOW METER a. Read the values using the Techstream (MAF). NOTE:







Perform the inspection with the vehicle indoors and on a level surface. Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle). During the test, do not use an exhaust air duct on the exhaust

pipe. 1. 2. 3. 4.

Connect the Techstream to the DLC3. Turn the engine switch on (IG) (do not run the engine). Enter the following menus: Powertrain / Engine / Data List / Primary / MAF. Wait for 30 seconds, and read the values on the Techstream. Standard Condition Tester Specified Condition Display Condition 



MAF

Engine not running 30 0.49 seconds g/sec. or after less engine switch turned on (IG)

If the result is not as specified, replace the MAF meter. If the result is within the specified range, remove and inspect the MAF meter See step 1. REMOVAL REMOVAL

1. REMOVE MASS AIR FLOW METER SUB-ASSEMBLY a. Separate the mass air flow meter connector.

Fig. 43: Identifying Mass Air Flow Meter Connector And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 screws and mass air flow meter. INSPECTION INSPECTION

1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY a. Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration.

Fig. 44: Identifying Platinum Hot Wire (Heater) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Platinum Hot *a Wire (Heater) OK There is no foreign matter. If the result is not as specified, replace the mass air flow meter. b. Measure the resistance according to the value(s) in the table below.

Fig. 45: Identifying Mass Air Flow Meter Sub-Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 13.6 to 1 (THA) - 2 -20°C (-4° 18.4 (E2) F) kohms 2.21 to 1 (THA) - 2 20°C (68° 2.69 (E2) F) kohms 0.49 to 1 (THA) - 2 60°C 0.67 (E2) (140°F) kohms TEXT IN ILLUSTRATION Component without harness *a connected (Mass Air Flow Meter)

If the result is not as specified, replace the mass air flow meter. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly. Refer to INITIALIZATION . 1. INSTALL MASS AIR FLOW METER SUB-ASSEMBLY a. Install the mass air flow meter with the 2 screws. NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly. Refer to INITIALIZATION . b. Connect the mass air flow meter connector.

CAMSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 46: Identifying Camshaft Position Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 47: Identifying Camshaft Position Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to REMOVAL . 2. REMOVE VVT SENSOR a. Disconnect the 4 sensor connectors. b. Remove the 4 bolts and 4 sensors.

Fig. 48: Identifying VVT Sensor Connectors, Sensors And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

for Bank 1 for *b Bank 2 for *c Intake Side for *d Exhaust Side *a

INSTALLATION INSTALLATION

1. INSTALL VVT SENSOR a. Install the 4 sensors with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Connect the 4 sensor connectors. 2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to INSTALLATION .

CRANKSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 49: Identifying Crankshaft Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COMPRESSOR AND MAGNETIC CLUTCH a. Remove the compressor and magnetic clutch. Refer to REMOVAL . 2. REMOVE CRANK POSITION SENSOR a. Disconnect the crank position sensor connector.

Fig. 50: Locating Crank Position Sensor Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and crank position sensor. INSPECTION INSPECTION

1. INSPECT CRANK POSITION SENSOR a. Measure the resistance according to the value(s) in the table below. Standard Resistance Temperature Cold

Hot

Specified Condition 1630 to 2740 ohms 2065 to 3225 ohms

HINT: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10 to 50°C (14 to 122 °F) and "Hot" is from 50 to 100°C (122 to 212°F).

If the resistance is not as specified, replace the crank position sensor. INSTALLATION INSTALLATION

1. INSTALL CRANK POSITION SENSOR a. Apply a light coat of engine oil to the O-ring on the crank position sensor.

Fig. 51: Locating Crank Position Sensor O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring b. Install the crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) c. Connect the crank position sensor connector. 2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH a. Install the compressor and magnetic clutch. Refer to INSTALLATION .

IGNITION COIL AND SPARK PLUG

COMPONENTS ILLUSTRATION

Fig. 52: Identifying Ignition Coil And Spark Plug Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 53: Identifying Ignition Coil And Spark Plug Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to REMOVAL . 2. REMOVE NO. 1 SURGE TANK STAY . Refer to REMOVAL - Step 3 3. REMOVE IGNITION COIL ASSEMBLY a. Remove the nut.

Fig. 54: Identifying Ignition Coil Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 harness clamps. c. Disconnect the 6 ignition coil connectors.

Fig. 55: Locating Ignition Coil Connectors

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 6 bolts and 6 ignition coils.

Fig. 56: Installing Ignition Coils Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE SPARK PLUG a. Remove the 6 spark plugs.

Fig. 57: Locating Spark Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the spark plug and ignition coil assembly. Refer to INITIALIZATION . 1. INSTALL SPARK PLUG a. Install the 6 spark plugs.

Fig. 58: Installing Spark Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . 2. INSTALL IGNITION COIL ASSEMBLY a. Install the 6 ignition coils with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the ignition coil assembly. Refer to INITIALIZATION . b. Connect the 6 ignition coil connectors. c. Connect the 2 wire harness clamps. d. Install the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 3. INSTALL NO. 1 SURGE TANK STAY . Refer to INSTALLATION - Step 18

4. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to INSTALLATION .

ENGINE COOLANT TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 59: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (1 Of 2)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 60: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

2. 3. 4. 5. 6. 7. 8.

REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE ENGINE COOLANT TEMPERATURE SENSOR a. Disconnect the 2 engine wire clamps.

Fig. 61: Identifying Engine Coolant Temperature Sensor Engine Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the engine coolant temperature sensor connector. c. Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor.

Fig. 62: Identifying Ball Joint Lock Nut Wrench And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Ball Joint *1 Lock Nut Wrench *2 Gasket d. Remove the gasket from the engine coolant temperature sensor. INSPECTION INSPECTION

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 63: Inspecting Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition 2.32 to 1 (E2) - 2 20°C (68° 2.59 (THW) F) kohms 0.310 to 1 (E2) - 2 80°C 0.326 (THW) (176°F) kohms NOTE:

If checking the sensor in water, be careful not to allow water to contact the terminals. After checking, wipe the water off the sensor.

If the result is not as specified, replace the engine coolant temperature sensor. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor. Refer to INITIALIZATION . 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR a. Install a new gasket onto the engine coolant temperature sensor. b. Install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE:

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench. Refer to PRECAUTION .

HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor. Refer to INITIALIZATION . c. Connect the engine coolant temperature sensor connector. d. Connect the 2 engine wire clamps. 2. ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 3. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 4. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4

5. 6. 7. 8. 9.

INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82 INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

KNOCK SENSOR COMPONENTS ILLUSTRATION

Fig. 64: Identifying Knock Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL . 2. REMOVE KNOCK CONTROL SENSOR a. Disconnect the 2 knock control sensor connectors.

Fig. 65: Locating Knock Control Sensor Connectors And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and 2 knock control sensors. INSPECTION INSPECTION

1. INSPECT KNOCK CONTROL SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 66: Measuring Resistance Between Knock Control Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (Knock Control Sensor) Standard Resistance Tester Specified Condition Connection Condition 1 (Ground) 20°C (68° 120 to 280 - 2 (Output) F) kohms If the result is not as specified, replace the knock control sensor. INSTALLATION INSTALLATION

1. INSTALL KNOCK CONTROL SENSOR a. Install the 2 knock control sensors with the 2 bolts as shown in the illustration.

Fig. 67: Identifying Knock Control Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION for *a Bank 1 for *b Bank 2 Front *c of Vehicle NOTE:

Make sure that each knock control sensor is in the correct position.

b. Connect the 2 knock control sensor connectors. 2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION .

AIR FUEL RATIO SENSOR COMPONENTS ILLUSTRATION

Fig. 68: Identifying Air Fuel Ratio Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1

2. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 3. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) a. Disconnect the air fuel ratio sensor connector.

Fig. 69: Identifying Air Fuel Ratio Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Separate the wire harness clamp.

Fig. 70: Identifying Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, remove the air fuel ratio sensor from the exhaust manifold LH.

Fig. 71: Removing Air Fuel Ratio Sensor Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SST: 09224-00010 4. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

Refer to REMOVAL . 5. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) a. Disconnect the air fuel ratio sensor connector.

Fig. 72: Identifying Air Fuel Ratio Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the harness clamp. c. Using SST, remove the air fuel ratio sensor from the exhaust manifold RH.

Fig. 73: Removing Air Fuel Ratio Sensor Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT AIR FUEL RATIO SENSOR (for Bank 1) a. Measure the resistance according to the value(s) in the table below.

Fig. 74: Identifying Air Fuel Ratio Sensor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HA1A) - 20°C (68° 1.6 to 3.2 2 (+B) F) ohms 1 (HA1A) 10 kohms 4 (A1A-) or higher TEXT IN ILLUSTRATION Component without harness *a connected (Air Fuel Ratio Sensor) If the result is not as specified, replace the air fuel ratio sensor. 2. INSPECT AIR FUEL RATIO SENSOR (for Bank 2) a. Measure the resistance according to the value(s) in the table below.

Fig. 75: Identifying Air Fuel Ratio Sensor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HA2A) - 20°C (68° 1.6 to 3.2 2 (+B) F) ohms 1 (HA2A) 10 kohms 4 (A2A-) or higher TEXT IN ILLUSTRATION Component without harness *a connected (Air Fuel Ratio Sensor) If the result is not as specified, replace the air fuel ratio sensor. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor. Refer to INITIALIZATION . 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) a. Using SST, install the air fuel ratio sensor to the exhaust manifold RH.

Fig. 76: Identifying Fulcrum Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum Length *a 30 mm (1.18 in.) Fulcrum Length *b 180 mm (7.09 in.) 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)

with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor. Refer to INITIALIZATION . b. Connect the harness clamp. c. Connect the air fuel ratio sensor connector. 2. INSTALL FRONT EXHAUST PIPE ASSEMBLY Refer to INSTALLATION . 3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) a. Using SST, install the air fuel ratio sensor to the exhaust manifold LH.

Fig. 77: Identifying Fulcrum Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Fulcrum Length *a 30 mm (1.18 in.) Fulcrum Length *b 180 mm (7.09 in.) 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor. Refer to INITIALIZATION . b. Connect the air fuel ratio sensor connector. c. Install the wire harness clamp. 4. INSPECT FOR EXHAUST GAS LEAK 5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82 6. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4

HEATED OXYGEN SENSOR COMPONENTS ILLUSTRATION

Fig. 78: Identifying Heated Oxygen Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Refer to REMOVAL . 2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) a. Using SST, remove the heated oxygen sensor from the front exhaust pipe sub-assembly.

Fig. 79: Identifying Heated Oxygen Sensor And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09224-00010 3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) a. Using SST, remove the heated oxygen sensor from the front exhaust pipe assembly. 

Fig. 80: Identifying Heated Oxygen Sensor And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) a. Measure the resistance according to the value(s) in the table below.

Fig. 81: Identifying Heated Oxygen Sensor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HT1B) - 20°C (68° 11 to 16 2 (+B) F) ohms 1 (HT1B) 10 kohms 4 (E2) or higher TEXT IN ILLUSTRATION Component without harness *a connected (Heated Oxygen Sensor) If the resistance is not as specified, replace the heated oxygen sensor. 2. INSPECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) a. Measure the resistance according to the value(s) in the table below.

Fig. 82: Inspect No. 2 Oxygen Sensor (For Bank 2 Sensor 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HT2B) - 20°C (68° 11 to 16 2 (+B) F) ohms 1 (HT2B) 10 kohms 4 (E2) or higher TEXT IN ILLUSTRATION Component without harness *a connected (Heated Oxygen Sensor) If the resistance is not as specified, replace the heated oxygen sensor. INSTALLATION INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) a. Using SST, install the heated oxygen sensor to the front exhaust pipe assembly.

Fig. 83: Identifying Heated Oxygen Sensor And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum Length *a 30 mm (1.18 in.) Fulcrum *b Length 180 mm

(7.09 in.) 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) a. Using SST, install the heated oxygen sensor to the center exhaust pipe assembly.

Fig. 84: Identifying Fulcrum Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum Length *a 30 mm (1.18 in.) Fulcrum Length *b 180 mm (7.09 in.) 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

3. INSTALL FRONT EXHAUST PIPE ASSEMBLY Refer to INSTALLATION .

INTEGRATION RELAY COMPONENTS ILLUSTRATION

Fig. 85: Identifying Integration Relay Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 RELAY BLOCK COVER 2. REMOVE NO. 1 INTEGRATION RELAY a. Disconnect the connector.

Fig. 86: Identifying No. 1 Integration Relay Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the No. 1 integration relay.

Fig. 87: Identifying No. 1 Integration Relay Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 4 connectors and remove the No. 1 integration relay.

Fig. 88: Identifying No. 1 Integration Relay Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT NO. 1 INTEGRATION RELAY

Fig. 89: Identifying No. 1 Integration Relay Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration - Relay a. EFI MAIN RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 90: Identifying EFI Main Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not relay 1B-1 - applied 10 kohms No. 1 between or higher integration terminals relay 1A-8 1C-7 and 1E-2 No. 1 integration relay 1B-1 No. 1 integration relay 1A-8 No. 1 integration relay 1B-1 No. 1 integration relay 1C-3 No. 1 integration relay 1B-1 Battery No. 1 integration voltage is relay 1C-4 applied Below 1 between ohms No. 1 terminals integration 1C-7 and relay 1B-1 - 1E-2 No. 1 integration relay 1C-6 No. 1 integration relay 1B-1 No. 1 integration relay 1C-9 No. 1 integration relay 1B-1 No. 1 integration relay 1C-10

TEXT IN ILLUSTRATION No. 1 *1 Integration Relay If the resistance is not as specified, replace the No. 1 integration relay. b. A/F HTR RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 91: Identifying A/F HTR Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not relay 1A-6 - applied 10 kohms No. 1 between or higher integration terminals relay 1D-1 1A-8 and 1E-2 No. 1 integration relay 1A-6 Battery No. 1 integration voltage is relay 1D-1 applied Below 1 between ohms No. 1 terminals integration 1A-8 and relay 1A-7 - 1E-2 No. 1 integration relay 1D-1 TEXT IN ILLUSTRATION No. 1 *1 Integration Relay If the resistance is not as specified, replace the No. 1 integration relay. c. IG2 RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 92: Identifying IG2 Relay Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition Battery No. 1 voltage is integration not relay 1A-1 - applied 10 kohms No. 1 between or higher integration terminals relay 1D-3 1C-8 and 1E-2 No. 1 integration relay 1A-1 No. 1 integration relay 1D-3 No. 1 integration relay 1A-3 No. 1 integration relay 1D-3 No. 1 integration relay 1A-5 Battery No. 1 integration voltage is relay 1D-3 applied Below 1 between ohms No. 1 terminals integration 1C-8 and relay 1C-1 - 1E-2 No. 1 integration relay 1D-3 No. 1 integration relay 1C-2 No. 1 integration relay 1D-3 No. 1 integration relay 1C-5 No. 1 integration relay 1D-3

TEXT IN ILLUSTRATION No. 1 *1 Integration Relay If the resistance is not as specified, replace the No. 1 integration relay. INSTALLATION INSTALLATION

1. INSTALL NO. 1 INTEGRATION RELAY a. Connect the 4 connectors. b. Install the No. 1 integration relay to the engine room relay block and junction block assembly. c. Connect the connector. 2. INSTALL NO. 1 RELAY BLOCK COVER

2012-2017 ENGINE PERFORMANCE Engine Control System (Service Information) (Hybrid)

CAMSHAFT OIL CONTROL VALVE COMPONENTS ILLUSTRATION

Fig. 1: Identifying Camshaft Oil Control Valve Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Connect the tester to the DLC3. b. Start the engine. c. Turn the tester on. d. Turn the A/C switch on. e. Inspect the camshaft timing oil control valve assembly. 1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1). 2. Check the engine speed while operating the camshaft timing oil control valve assembly using the tester. Standard Condition Tester Specified Operation Condition Normal 0% engine speed Engine idles 100% roughly or stalls HINT: If the result is not acceptable, cool the engine (engine coolant temperature is 50°C (122°F) or less) and perform the Active Test again. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 2. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Disconnect the oil control valve connector.

Fig. 2: Identifying Oil Control Valve Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and oil control valve. c. Remove the O-ring from the oil control valve.

Fig. 3: Identifying O-Ring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSPECTION INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 6.9 to 7.9 1-2 F) ohms If the result is not as specified, replace the oil control valve assembly. b. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2, and check the movement of the valve.

Fig. 4: Identifying Oil Control Valve Connector Terminals

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Valve Component without harness connected *a (Camshaft Timing Oil Control Valve) When *b applied When cut *c off OK Condition Auxiliary battery positive (+) voltage is applied Auxiliary battery positive (+) voltage is cut off NOTE:

Specified Condition Valve moves in left arrow direction shown in illustration Valve moves in right arrow direction shown in illustration Confirm that the valve moves freely and does not stick in any position.

If necessary, replace the camshaft timing oil control valve assembly. HINT: Accumulation of foreign matter can cause minor pressure leaks. Minor pressure leaks will cause the camshaft to advance or retard, and this will cause a DTC to be set. INSTALLATION

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY a. Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

Fig. 5: Identifying O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION New *1 Oring b. Install the oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:





Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover). Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

c. Connect the oil control valve connector. 2. INSPECT FOR OIL LEAK 3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86

THROTTLE BODY COMPONENTS ILLUSTRATION

Fig. 6: Identifying Throttle Body Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Identifying Throttle Body Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. CHECK THROTTLE WITH MOTOR BODY ASSEMBLY

a. Check the throttle control motor operating sound. 1. Turn the power switch on (IG). 2. When depressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises are emitted from the motor. If friction noises exist, replace the throttle with motor body assembly. b. Check the throttle position sensor. 1. Connect the tester to the DLC3. 2. Turn the power switch on (IG). 3. Turn the tester on. 4. Perform the "Inspection After Repair". Refer to INITIALIZATION . 5. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Throttle Sensor Position. 6. Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of "Throttle Sensor Position" is within the specification. Standard throttle valve opening percentage 60% or more NOTE:

When checking the standard throttle valve opening percentage, make sure that the shift lever is in N.

If the percentage is less than 60%, replace the throttle with motor body assembly. REMOVAL REMOVAL

1. DRAIN COOLANT (for Engine) . Refer to REPLACEMENT - Step 1 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY a. Disconnect the mass air flow meter connector and wire harness clamp from the air cleaner cap subassembly.

Fig. 8: Identifying Mass Air Flow Meter Connector And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the ventilation hose from the cylinder head cover. c. Disconnect the connector and wire harness clamp. d. Release the 2 clamps and remove the air cleaner cap sub-assembly.

Fig. 9: Identifying Air Cleaner Cap Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the 2 fuel vapor feed hoses.

Fig. 10: Disconnecting Fuel Vapor Feed Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Retainer Fuel Tube *2 Connector *3 Pipe *4 O-ring *a Pinch *b Pull NOTE:





 

Remove any dirt or foreign matter on the fuel tube connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an Oring that seals the pipe. Perform this work by hand. Do not use any tools. Protect the disconnected parts by covering them with plastic bags after disconnecting each fuel vapor feed hose.

f. Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

Fig. 11: Identifying Air Cleaner Hose Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY a. Disconnect the 2 hoses.

Fig. 12: Identifying Throttle Body Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the throttle body connector.

Fig. 13: Identifying Throttle Body Connector And Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. d. Remove the 4 bolts and the throttle body with fuel tube bracket.

Fig. 14: Identifying Throttle Body Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the gasket from the intake manifold.

Fig. 15: Identifying Throttle Body Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY a. Check that the throttle valve opens and closes smoothly. b. Check that there is no sludge accumulated around the throttle with motor body assembly. c. Measure the resistance according to the value(s) in the table below.

Fig. 16: Identifying Resistance Between Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (M-) - 2 20°C (68° 0.3 to 100 (M+) F) ohms TEXT IN ILLUSTRATION Component without harness connected: *a (Throttle with Motor Body Assembly) If the result is not as specified, replace the throttle with motor body assembly. INSTALLATION INSTALLATION

1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

a. Install a new gasket to the intake manifold. b. Install the throttle with motor body assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) c. Connect the throttle body connector. d. Connect the 2 water by-pass hoses to the throttle with motor body assembly. e. Connect the 2 hoses. 2. INSTALL AIR CLEANER CAP SUB-ASSEMBLY a. Install the air cleaner hose with the hose clamp. b. Connect the 2 fuel vapor feed hoses.

Fig. 17: Connecting Fuel Vapor Feed Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*a Push NOTE:







Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe before performing this work. Connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer. After connecting the fuel vapor feed hose to the fuel tube connector, check that the fuel vapor feed hose is securely connected by pulling on the fuel tube connector and the fuel vapor feed hose.

c. Connect the 2 hinges of the air cleaner cap subassembly.

Fig. 18: Identifying Air Cleaner Cap Hinges Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hinge *b Clamp d. e. f. g.

Install the air cleaner cap sub-assembly with the 2 clamps. Connect the wire harness clamp and connector. Connect the ventilation hose to the cylinder head cover. Connect the mass air flow meter connector and wire harness clamp to the air cleaner cap sub-

3. 4. 5. 6.

assembly. ADD COOLANT (for Engine) . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86 PERFORM INITIALIZATION NOTE:





Be sure to perform this procedure after reassembling the throttle with motor body assembly or removing and reinstalling any throttle body components. Perform the following procedure after replacing the throttle with motor body assembly or any throttle body components. The following procedure should also be performed if the throttle body is cleaned.

a. Turn the power switch on (IG) without operating the accelerator pedal. NOTE:

If the accelerator pedal is operated, perform the above step again.

b. Connect the tester to the DLC3 and clear the DTCs. Refer to DTC CHECK / CLEAR . c. Perform the "Inspection After Repair". Refer to INITIALIZATION . d. Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off. Standard Engine Condition Idle Speed A/C 900 to switched 1050 off RPM NOTE:

 

Be sure to perform this step with all accessories off. Make sure that the shift lever is in N.

e. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data /Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more. f. Perform a road test and confirm that there are no abnormalities.

ECM COMPONENTS

ILLUSTRATION

Fig. 19: Identifying ECM Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 20: Identifying ECM Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE ECM a. Disconnect the 2 ECM connectors.

Fig. 21: Raising ECM Connector Levers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Push in the locks on the 2 levers, raise the levers, and disconnect the 2 ECM connectors. NOTE:

b. Remove the nut.

After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting part of the connectors.

Fig. 22: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. d. e. f.

Remove the screw (A). Loosen the screw (B) and remove the ECM. Remove the screw (B). Remove the 2 screws and No. 2 ECM bracket.

Fig. 23: Identifying No. 2 ECM Screws And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 1 RELAY BLOCK COVER 5. REMOVE NO. 1 ECM BRACKET a. Remove the nut.

Fig. 24: Identifying NO. 1 ECM Bracket Nut And Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Release the 2 clamps and disconnect the wire harness. c. Disconnect the wire harness clamp.

Fig. 25: Identifying ECM Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the nut and No. 1 ECM bracket.

Fig. 26: Identifying No. 1 ECM Bracket And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ECM BRACKET a. Install the No. 1 ECM bracket with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) b. Connect the wire harness clamp. c. Install the wire harness and 2 clamps. d. Install the nut. 2. INSTALL NO. 1 RELAY BLOCK COVER 3. INSTALL ECM a. Install the No. 2 ECM brackets to the ECM with the 2 screws.

Fig. 27: Identifying No. 2 ECM Screws And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) b. Temporarily install the screw (B). c. Install the ECM with the nut.

Fig. 28: Identifying ECM Screw, Nut And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) d. Install the screw (A). Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) e. Tighten the screw (B). Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) f. Connect the 2 ECM connectors and lower the 2 levers.

Fig. 29: Lowering ECM Connector Levers In Reverse Way Shown In Picture Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other part. Make sure that the 2 levers are securely locked.

g. Connect the 2 wire harness clamps. 4. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 6. PERFORM INITIALIZATION Refer to PRECAUTION

MASS AIR FLOW METER COMPONENTS ILLUSTRATION

Fig. 30: Identifying Mass Air Flow Meter Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

NOTE:





Perform the mass air flow meter inspection according to the procedure below. Only replace the mass air flow meter when the mass air flow value in the Data List (with the engine stopped) is not within the normal operating range or there is foreign matter on the mass air flow meter platinum hot wire (heater).

1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY NOTE:





Perform the inspection with the vehicle indoors and on a level surface. Perform the inspection of the mass air flow meter while it is installed to the air cleaner case (installed to the vehicle).



a. b. c. d. e.

During the test, do not use an exhaust air duct to perform suction on the exhaust pipe.

Connect the Techstream to the DLC3. Turn the power switch on (IG) (do not run the engine). Turn the tester on. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAF. Wait 30 seconds, and read the values on the tester. Standard Item Condition 



MAF

Specified Condition

Engine not running 30 seconds 0.50g/sec. or less after turning power switch on (IG)

If the result is not as specified, replace the mass air flow meter sub-assembly. If the result is as specified, inspect the mass air flow meter sub-assembly. Refer to INSPECTION. REMOVAL REMOVAL

1. REMOVE MASS AIR FLOW METER SUB-ASSEMBLY a. Disconnect the mass air flow meter connector.

Fig. 31: Identifying Mass Air Flow Meter Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 screws and mass air flow meter sub-assembly. INSPECTION INSPECTION

1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY a. Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter sub-assembly shown in the illustration.

Fig. 32: Identifying Mass Air Flow Meter Platinum Hot Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Platinum Hot *1 Wire (Heater) OK There is no foreign matter. b. Check the intake air temperature sensor (built into the mass air flow meter sub-assembly). 1. Measure the resistance according to the value(s) in the table below.

Fig. 33: Identifying Mass Air Flow Meter Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 13.6 to 1 (THA) - 2 -20°C (-4° 18.4 (E2) F) kohms 2.21 to 1 (THA) - 2 20°C (68° 2.69 (E2) F) kohms 0.49 to 1 (THA) - 2 60°C 0.67 (E2) (140°F) kohms TEXT IN ILLUSTRATION Component without harness connected *a (Mass Air Flow Meter Subassembly)

If the result is not as specified, replace the mass air flow meter sub-assembly. INSTALLATION INSTALLATION

1. INSTALL MASS AIR FLOW METER SUB-ASSEMBLY a. Install the mass air flow meter sub-assembly with the 2 screws. NOTE:

Make sure that the O-ring is not cracked or jammed when installing the mass air flow meter.

HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly. Refer to INITIALIZATION . b. Connect the mass air flow meter connector.

CAMSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 34: Identifying Camshaft Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector.

Fig. 35: Identifying Camshaft Position Sensor Connector And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and sensor. INSTALLATION INSTALLATION

1. INSTALL CAMSHAFT POSITION SENSOR a. Clean and degrease the threads of the bolt for the camshaft position sensor. b. Apply a light coat of engine oil to the O-ring of the sensor. NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

c. Apply adhesive to 2 or 3 threads of the bolt.

Fig. 36: Applying Adhesive To Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. d. Install the sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) e. Connect the sensor connector. 2. INSPECT FOR OIL LEAK 3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86

CRANKSHAFT POSITION SENSOR COMPONENTS ILLUSTRATION

Fig. 37: Identifying Crankshaft Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CRANKSHAFT POSITION SENSOR

Fig. 38: Locating Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Disconnect the sensor connector. b. Remove the bolt and sensor. INSPECTION INSPECTION

1. INSPECT CRANKSHAFT POSITION SENSOR a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 1630 to Cold 2740 ohms 1-2 2065 to Hot 3225 ohms HINT:

In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). If the result is not as specified, replace the crankshaft position sensor. INSTALLATION INSTALLATION

1. INSTALL CRANKSHAFT POSITION SENSOR a. Clean and degrease the threads of the bolt for the crankshaft position sensor. b. Apply a light coat of engine oil to the O-ring of the sensor.

Fig. 39: Identifying Crankshaft Position Sensor O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring c. Apply adhesive to 2 or 3 threads of the bolt.

Fig. 40: Applying Adhesive To Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. d. Install the sensor with the bolt. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) NOTE:

Make sure that the O-ring is not cracked or does not jump out of position during installation.

e. Connect the sensor connector. 2. INSPECT FOR OIL LEAK

IGNITION COIL AND SPARK PLUG COMPONENTS ILLUSTRATION

Fig. 41: Identifying Ignition Coil And Spark Plug Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 2. REMOVE IGNITION COIL ASSEMBLY a. Disconnect the 4 ignition coil assembly connectors.

Fig. 42: Identifying Ignition Coil Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and 4 ignition coil assemblies.

Fig. 43: Locating Bolts And Ignition Coil Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. REMOVE SPARK PLUG a. Using a spark plug wrench, remove the 4 spark plugs.

Fig. 44: Installing Spark Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL SPARK PLUG a. Using a spark plug wrench, install the 4 spark plugs. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . 2. INSTALL IGNITION COIL ASSEMBLY a. Install the 4 ignition coil assemblies with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT:

Perform "Inspection After Repair" after replacing the ignition coil assembly. Refer to INITIALIZATION . b. Connect the 4 ignition coil assembly connectors. 3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86

ENGINE COOLANT TEMPERATURE SENSOR COMPONENTS ILLUSTRATION

Fig. 45: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 46: Identifying Engine Coolant Temperature Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4.

DRAIN COOLANT (for Engine) . Refer to REPLACEMENT - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 25 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30

5. REMOVE ENGINE COOLANT TEMPERATURE SENSOR a. Disconnect the ventilation hose from the cylinder head cover.

Fig. 47: Identifying Cylinder Head Cover Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the engine coolant temperature sensor connector.

Fig. 48: Identifying Engine Coolant Temperature Sensor Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 bolts and disconnect the wire harness. d. Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor.

Fig. 49: Removing Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Ball Joint *1 Lock Nut Wrench *2 Gasket e. Remove the gasket from the engine coolant temperature sensor. INSPECTION INSPECTION

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Fig. 50: Inspecting Engine Coolant Temperature Sensor With Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected Temperature *a *b (Engine °C (°F) Coolant Temperature Sensor) Resistance *c *d Acceptable ohms a. Partially immerse the sensor in water and warm up the water. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 2.32 to 20°C (68° 1-2 2.59 F) kohms 0.310 to 80°C 1-2 0.326 (176°F) kohms NOTE:

When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

If the result is not as specified, replace the engine coolant temperature sensor. INSTALLATION INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR a. Install a new gasket to the engine coolant temperature sensor. b. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE:

Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench. Refer to PRECAUTION .

HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor. Refer to INITIALIZATION . c. Connect the engine coolant temperature sensor connector. d. Install the wire harness with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

2. 3. 4. 5. 6.

e. Connect the ventilation hose to the cylinder head cover. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 ADD COOLANT (for Engine) . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 86

KNOCK SENSOR COMPONENTS ILLUSTRATION

Fig. 51: Identifying Knock Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL 2. REMOVE KNOCK CONTROL SENSOR a. Disconnect the sensor connector.

Fig. 52: Locating Bolt And Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and knock control sensor. INSPECTION INSPECTION

1. INSPECT KNOCK CONTROL SENSOR a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 120 to 280 1-2 F) kohms If the result is not as specified, replace the knock control sensor. INSTALLATION INSTALLATION

1. INSTALL KNOCK CONTROL SENSOR a. Install the sensor with the bolt so that the sensor is angled as shown in the illustration.

Fig. 53: Identifying Knock Control Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION Front *a of Engine *b Up *c 7° *d 10° NOTE:

The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position.

HINT: Perform "Inspection After Repair" after replacing the knock control sensor. Refer to INITIALIZATION b. Connect the sensor connector. 2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION

AIR FUEL RATIO SENSOR COMPONENTS ILLUSTRATION

Fig. 54: Identifying Air Fuel Ratio Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to REMOVAL - Step 6 2. REMOVE AIR FUEL RATIO SENSOR a. Remove the hose clamp.

Fig. 55: Identifying Air Fuel Ratio Sensor Connector And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the air fuel ratio sensor connector. c. Using SST, remove the air fuel ratio sensor from the exhaust manifold.

Fig. 56: Removing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT AIR FUEL RATIO SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 57: Identifying Air Fuel Ratio Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HA1A) - 20°C (68° 1.6 to 3.2 2 (+B) F) ohms 1 (HA1A) 10 kohms Always 4 (A1A-) or higher TEXT IN ILLUSTRATION Component without harness *a connected: (Air Fuel Ratio Sensor) If the result is not as specified, replace the air fuel ratio sensor. INSTALLATION INSTALLATION

1. INSTALL AIR FUEL RATIO SENSOR a. Using SST, install the air fuel ratio sensor to the exhaust manifold.

Fig. 58: Installing Air Fuel Ratio Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length 30 mm Fulcrum *b Length 300 mm 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor. Refer to INITIALIZATION . b. Connect the air fuel ratio sensor connector. c. Install the hose clamp. 2. INSPECT FOR EXHAUST GAS LEAK 3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 8

HEATED OXYGEN SENSOR COMPONENTS ILLUSTRATION

Fig. 59: Identifying Heated Oxygen Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HEATED OXYGEN SENSOR a. Disconnect the heated oxygen sensor connector.

Fig. 60: Identifying Heated Oxygen Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the heated oxygen sensor from the front exhaust pipe.

Fig. 61: Removing Heated Oxygen Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



SST: 09224-00010

INSPECTION INSPECTION

1. INSPECT HEATED OXYGEN SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 62: Identifying Heated Oxygen Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (HT1B) - 20°C (68° 11 to 16 2 (+B) F) ohms 1 (HT1B) 10 kohms Always 4 (E2) or higher TEXT IN ILLUSTRATION Component *a without harness connected

(Heated Oxygen Sensor) If the result is not as specified, replace the heated oxygen sensor. INSTALLATION INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR a. Using SST, install the heated oxygen sensor to the front exhaust pipe.

Fig. 63: Installing Heated Oxygen Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Fulcrum *a Length 30 mm Fulcrum *b Length 300 mm 

SST: 09224-00010

without SST Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.). Refer to PRECAUTION The "with SST" torque value is effective when SST is parallel to the torque wrench.

b. Connect the heated oxygen sensor connector. 2. INSPECT FOR EXHAUST GAS LEAK

INTEGRATION RELAY COMPONENTS ILLUSTRATION

Fig. 64: Identifying Integration Relay Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 RELAY BLOCK COVER 2. REMOVE NO. 1 INTEGRATION RELAY a. Disconnect the connector.

Fig. 65: Identifying No. 1 Integration Relay Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the No. 1 integration relay.

Fig. 66: Disconnecting No. 1 Integration Relay

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 4 connectors and remove the No. 1 integration relay.

Fig. 67: Identifying No. 1 Integration Relay Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT NO. 1 INTEGRATION RELAY

Fig. 68: No. 1 Integration Relay - Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration - Relay a. EFI MAIN RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 69: Identifying No. 1 Integration Relay Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1

*1

Integration Relay

Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery No. 1 voltage is integration not relay 1B-1 10 kohms applied No. 1 or higher between integration terminals relay 1A-8 1C-7 and 1E-2 No. 1 integration relay 1B-1 No. 1 integration relay 1A-8 No. 1 integration relay 1B-1 No. 1 integration relay 1C-3 Auxiliary battery No. 1 integration voltage is relay 1B-1 - applied Below 1 No. 1 between ohms integration terminals relay 1C-4 1C-7 and 1E-2 No. 1 integration relay 1B-1 No. 1 integration relay 1C-9 No. 1 integration relay 1B-1 No. 1 integration relay 1C-10

If the resistance is not as specified, replace the No. 1 integration relay. b. EFI MAIN2 RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 70: Identifying No. 1 Integration Relay Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration Relay Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery No. 1 voltage is integration not relay 1A-6 10 kohms applied No. 1 or higher between integration terminals relay 1D-1 1A-8 and 1E-2 No. 1 integration relay 1A-6 - Auxiliary No. 1 battery integration voltage is relay 1D-1 applied Below 1 ohms between No. 1 integration terminals relay 1A-7 - 1A-8 and 1E-2 No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay. c. IG2 RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 71: Identifying No. 1 Integration Relay Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1

*1

Integration Relay

Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery No. 1 voltage is integration not relay 1A-1 10 kohms applied No. 1 or higher between integration terminals relay 1D-3 1C-8 and 1E-2 No. 1 integration relay 1A-1 No. 1 integration relay 1D-3 No. 1 integration relay 1A-3 No. 1 integration relay 1D-3 Auxiliary battery No. 1 integration voltage is relay 1C-1 - applied Below 1 No. 1 between ohms integration terminals relay 1D-3 1C-8 and 1E-2 No. 1 integration relay 1C-2 No. 1 integration relay 1D-3 No. 1 integration relay 1C-5 No. 1 integration relay 1D-3

If the resistance is not as specified, replace the No. 1 integration relay. d. C/OPN RELAY: 1. Measure the resistance according to the value(s) in the table below.

Fig. 72: Identifying No. 1 Integration Relay Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Integration Relay Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery No. 1 voltage is integration not relay 1A-6 10 kohms applied No. 1 or higher between integration terminals relay 1D-1 1A-1 and 1E-1 No. 1 integration relay 1A-6 - Auxiliary No. 1 battery integration voltage is relay 1D-1 applied Below 1 ohms between No. 1 integration terminals relay 1A-7 - 1A-1 and 1E-1 No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay. INSTALLATION INSTALLATION

1. INSTALL NO. 1 INTEGRATION RELAY a. Connect the 4 connectors. b. Attach the No. 1 integration relay to the engine room relay block. c. Connect the connector. 2. INSTALL NO. 1 RELAY BLOCK COVER

2012-2017 ENGINE Engine Cooling System (Service Information) - Camry (2AR-FE)

COOLANT REPLACEMENT REPLACEMENT

1. DRAIN ENGINE COOLANT NOTE:

Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

a. Loosen the radiator drain cock plug. b. Remove the radiator cap sub-assembly.

Fig. 1: Identifying Radiator Cap Sub-Assembly And Radiator Drain Cock Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator Radiator Cap Drain *1 *2 SubCock assembly Plug HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area. 2. ADD ENGINE COOLANT a. Tighten the radiator drain cock plug by hand. b. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). NOTE:

Never use water as a substitute for engine coolant.

Specified capacity 7.3 liters (7.7 US qts, 6.4 lmp. qts) HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids). c. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line. d. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. e. Install the radiator cap sub-assembly and reserve tank cap. f. Bleed air from the cooling system. NOTE:

  

Before starting the engine, turn the A/C switch off. Adjust the heater control to the maximum hot setting. Adjust the blower speed to the low setting.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. HINT: The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose. 2. Maintain the engine speed at 2500 to 3000 rpm. 3. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

WARNING: When squeezing the radiator hoses:   

NOTE:









Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the cooling fans.

Make sure that the radiator reserve tank assembly still has some coolant in it. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool. If there is not enough coolant, the engine may overheat or be seriously damaged. If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.

g. Stop the engine and wait until the engine coolant cools down. h. Add engine coolant to the full line on the radiator reserve tank assembly. 3. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

WATER PUMP COMPONENTS ILLUSTRATION

Fig. 2: Identifying Water Pump Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Water Pump Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. REMOVE V-RIBBED BELT

Refer to REMOVAL 2. INSPECT ENGINE WATER PUMP ASSEMBLY a. Visually check the drain hole for coolant leakage. If leakage is found, replace the engine water pump assembly. b. Turn the pulley and check that the engine water pump bearing moves smoothly without making a clicking noise. If the bearing does not move smoothly, replace the engine water pump assembly.

Fig. 4: Checking Water Pump Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL V-RIBBED BELT Refer to INSTALLATION REMOVAL REMOVAL

1. DRAIN ENGINE COOLANT See step 1 2. REMOVE V-RIBBED BELT Refer to REMOVAL 3. REMOVE GENERATOR ASSEMBLY Refer to REMOVAL 4. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY . Refer to DISASSEMBLY - Step 13 5. REMOVE ENGINE WATER PUMP ASSEMBLY

a. Remove the 7 bolts, engine water pump and gasket.

Fig. 5: Locating Bolts And Water Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ENGINE WATER PUMP ASSEMBLY a. Install a new gasket and the engine water pump with the 7 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY . Refer to REASSEMBLY - Step 48 3. INSTALL GENERATOR ASSEMBLY Refer to INSTALLATION 4. INSTALL V-RIBBED BELT Refer to INSTALLATION 5. ADD ENGINE COOLANT See step 2 6. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

THERMOSTAT COMPONENTS ILLUSTRATION

Fig. 6: Identifying Thermostat Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN ENGINE COOLANT See step 1 2. DISCONNECT NO. 2 RADIATOR HOSE . Refer to REMOVAL - Step 25 3. REMOVE WATER INLET a. Remove the 2 nuts and water inlet.

Fig. 7: Locating Water Inlet Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE THERMOSTAT a. Remove the thermostat. b. Remove the gasket from the thermostat. INSPECTION INSPECTION

1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat.

Fig. 8: Identifying Valve Opening Temperature Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Immerse the thermostat in water, and then gradually heat the water.

Fig. 9: Checking Valve Opening Temperature Of Thermostat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Check that the valve of the thermostat opens at the specified temperature. Standard valve opening temperature 80 to 84°C (176 to 183°F) If the valve does not open as specified, replace the thermostat. c. Check the valve lift.

Fig. 10: Identifying Valve Lift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *a Lift Standard valve lift 10 mm (0.394 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. d. Check that the valve is fully closed when the thermostat is at a low temperature (below 77°C (171° F)). If the valve is not fully closed, replace the thermostat.

INSTALLATION INSTALLATION

1. INSTALL THERMOSTAT a. Install a new gasket to the thermostat. b. Install the thermostat with the jiggle valve facing upward.

Fig. 11: Identifying Jiggle Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Jiggle *1 valve *a 10° HINT: The jiggle valve may be set to within 10° on either side of the prescribed position. 2. INSTALL WATER INLET a. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. CONNECT NO. 2 RADIATOR HOSE . Refer to INSTALLATION - Step 48

4. ADD ENGINE COOLANT See step 2 5. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

COOLING FAN MOTOR COMPONENTS ILLUSTRATION

Fig. 12: Identifying Cooling Fan Motor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. COOLING FAN MOTOR

a. Check that the motor operates smoothly when the battery is connected to the fan motor connector.

Fig. 13: Identifying Fan Motor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

Specified Condition

Battery Cooling voltage 5.8 to 7.4 fan applied at A motor 20°C (68° F) If the result is not as specified, replace the cooling fan motor.

2. NO. 2 COOLING FAN MOTOR a. Check that the motor operates smoothly when the battery is connected to the fan motor connector.

Fig. 14: Identifying No. 2 Cooling Fan Motor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (No. 2 Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

Specified Condition

Battery No. 2 voltage Cooling 5.8 to 7.4 applied at fan A 20°C (68° motor F)

If the result is not as specified, replace the No. 2 cooling fan motor. REMOVAL REMOVAL

1. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL 2. REMOVE FAN a. Remove the nut and fan.

Fig. 15: Identifying Fan And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE NO. 2 FAN a. Remove the nut and No. 2 fan.

Fig. 16: Identifying No. 2 Fan And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE COOLING FAN MOTOR a. Remove the 3 screws and cooling fan motor.

Fig. 17: Identifying Cooling Fan Motor Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 2 COOLING FAN MOTOR a. Disconnect the 4 clamps.

Fig. 18: Identifying No. Cooling Fan Motor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and No. 2 cooling fan motor.

Fig. 19: Identifying No. 2 Cooling Fan Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 COOLING FAN MOTOR a. Install the No. 2 cooling fan motor with the 3 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) b. Connect the 4 clamps. 2. INSTALL COOLING FAN MOTOR a. Install the cooling fan motor with the 3 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) 3. INSTALL NO. 2 FAN a. Install the No. 2 fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 4. INSTALL FAN a. Install the fan with the nut.

Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 5. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION

RADIATOR COMPONENTS ILLUSTRATION

Fig. 20: Identifying Radiator Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 21: Identifying Radiator Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 22: Identifying Radiator Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. CHECK RADIATOR CAP SUB-ASSEMBLY a. Measure the valve opening pressure.

Fig. 23: Locating Rubber Packings 1, 2, 3 And 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. 2. Check that rubber packings 1, 2 and 3 are not deformed, cracked or swollen. 3. Check that 3 and 4 are not stuck together. 4. Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. 5. When using the cap tester, tilt it upward 30° or more. 6. Pump the cap tester several times, and check the maximum pressure*1.

Fig. 24: Identifying Radiator Cap Tester And Radiator Cap Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator *1 Cap Tester Radiator Cap *2 Subassembly 30° or *a more Pumping speed 1 pump every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criterion Specified Condition 93.3 to 122.7 kPa Standard (0.95 to Item

value (for brandnew cap)

1.25 kgf/cm2 , 13.5 to 17.8 psi)

Minimum 78.5 kPa standard (0.8 value 2 (for used kgf/cm , 11.4 psi) cap) If the maximum pressure is less than the specified pressure for the minimum standard value, replace the radiator cap sub-assembly. REMOVAL REMOVAL

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7.

DRAIN ENGINE COOLANT See step 1 REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

8. 9. 10. 11.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 19 REMOVE RADIATOR GRILLE SUB-ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE RADIATOR RESERVE TANK ASSEMBLY a. Disconnect the radiator reserve tank hose.

Fig. 25: Identifying Radiator Reserve Tank Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and radiator reserve tank assembly. 12. DISCONNECT NO. 1 RADIATOR HOSE a. Disconnect the No. 1 radiator hose.

Fig. 26: Identifying No. 1 Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. DISCONNECT NO. 2 RADIATOR HOSE a. Disconnect the No. 2 radiator hose and clamp.

Fig. 27: Identifying No. 2 Radiator Hose And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 15. REMOVE UPPER RADIATOR SUPPORT a. Disconnect the 2 connectors.

Fig. 28: Identifying Upper Radiator Support Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hood lock control cable clamp and remove the 5 bolts and upper radiator support.

Fig. 29: Identifying Upper Radiator Support Hood Lock Control Cable Clamp, Bolts And Support Cushions

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 radiator support cushions. 16. REMOVE RADIATOR ASSEMBLY a. Disconnect the 2 clamps and 2 connectors.

Fig. 30: Identifying Radiator Assembly Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and separate the condenser assembly from the radiator assembly.

Fig. 31: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the radiator assembly with fan assembly.

Fig. 32: Removing Radiator Assembly With Fan Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not apply any excessive force to the cooler condenser assembly or pipe when removing the radiator assembly.

d. Remove the 2 lower radiator supports. e. Release the 3 claws and lift the fan assembly from the radiator.

Fig. 33: Identifying Fan Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL RADIATOR ASSEMBLY a. Install the fan assembly to the radiator with the 2 guides at the bottom and 3 claws on the top.

Fig. 34: Identifying Fan Assembly Guides And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide b. Install the 2 lower radiator supports to the radiator assembly. c. Install the radiator with fan assembly.

Fig. 35: Installing Radiator With Fan Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply any excessive force to the cooler condenser assembly or pipe when installing the radiator assembly.

d. Install the condenser assembly with the 4 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) e. Connect the 2 connectors and the 2 clamps. 2. INSTALL UPPER RADIATOR SUPPORT a. Install the 2 radiator support cushions to the radiator assembly. b. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

3. 4. 5. 6.

c. Connect the 2 connectors. INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 CONNECT NO. 2 RADIATOR HOSE a. Connect the No. 2 radiator hose and clamp. CONNECT NO. 1 RADIATOR HOSE a. Connect the No. 1 radiator hose. INSTALL RADIATOR RESERVE TANK ASSEMBLY

a. Install the radiator reserve tank with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) b. Connect the radiator reserve tank hose. 7. INSTALL RADIATOR GRILLE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 8. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 53 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

10. 11. 12. 13. 14. 15. 16.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

ADD ENGINE COOLANT See step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT FAN RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 36: Identifying Fan Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Battery voltage not Below 1 3-4 applied ohms between terminals 1 and 2 Battery voltage not 10 kohms 3-5 applied or higher between terminals 1 and 2 Battery voltage applied 10 kohms 3-4 between or higher terminals 1 and 2

3-5

Battery voltage Below 1 applied between ohms terminals 1 and 2 If the result is not as specified, replace the relay.

2012-2017 ENGINE Engine Cooling System (Service Information) - Camry (2GR-FE)

COOLANT REPLACEMENT REPLACEMENT

1. DRAIN ENGINE COOLANT NOTE:

Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

a. Loosen the radiator drain cock plug. b. Loosen the 2 cylinder block drain cock plugs. c. Remove the radiator cap sub-assembly.

Fig. 1: Identifying Radiator Cap Sub-Assembly, Cylinder Block Drain Cock Plug And Radiator Drain Cock Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator Cylinder *1 Cap *2 Block SubDrain

assembly

Cock Plug Radiator Air Drain Drain *3 *4 Cock Cock Plug Plug HINT: Collect the coolant in a container and dispose of it according to the regulations in your area. 2. ADD ENGINE COOLANT a. Tighten the radiator drain cock plug by hand. b. Close the 2 cylinder block drain cock plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) c. Loosen the air drain cock plug on the water inlet housing. d. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) e. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Specified capacity 9.1 liters (9.6 US qts, 8.0 lmp. qts) HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids). f. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line. g. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. h. Install the radiator cap sub-assembly and reserve tank cap. i. Bleed air from the cooling system.

NOTE:

  

Before starting the engine, turn the A/C switch off. Adjust the heater control to the maximum hot setting. Adjust the blower speed to the low setting.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. HINT: The thermostat open timing can be confirmed by squeezing the outlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose. 2. Maintain the engine speed at 2500 to 3000 rpm. 3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air. WARNING: When squeezing the radiator hoses:   

NOTE:









Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the radiator fans.

Make sure that the radiator reserve tank assembly still has some coolant in it. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool. If there is not enough coolant, the engine may overheat or be seriously damaged. If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.

j. Stop the engine, and wait until the engine coolant cools down. k. Add engine coolant to the full line on the radiator reserve tank assembly. 3. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

WATER PUMP COMPONENTS ILLUSTRATION

Fig. 2: Identifying Water Pump Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Water Pump Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. INSPECT FOR COOLANT LEAK HINT: Before performing this inspection, check that there is no coolant leaking from any parts other than the engine water pump assembly. If there are leaks, inspect those areas.  Perform this inspection when the engine is cold. a. Visually inspect the engine compartment for the following conditions: 1. There is a large amount of coolant in the engine compartment or on the underside of the hood near the V-ribbed belt. 2. Liquid coolant is dripping from around the engine water pump assembly. 3. The coolant level in the reserve tank assembly is below the low line and there are traces of leakage around the engine water pump assembly. 

If any of the above conditions exist, replace the engine water pump assembly. If none of the above conditions exist, perform the following inspection (inspection of the area around the engine water pump assembly). b. Remove the V-ribbed belt. Refer to REMOVAL . c. Separate the water pump pulley See step 11. HINT: Move the water pump pulley so that the drain plug can be reached. d. Inspect the area around the engine water pump assembly. HINT: Check for deposits around the drain plug of the engine water pump assembly. 1. Press a piece of paper towel against the drain plug or deposits on the lip of the drain plug and check that the paper towel is not wet.

Fig. 4: Identifying Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drain *1 Plug If the paper towel is wet, replace the engine water pump assembly. If the paper towel is not wet, thoroughly clean the area around the engine water pump assembly. e. Install the water pump pulley See step 2. 2. INSPECT ENGINE WATER PUMP ASSEMBLY a. Turn the pulley and check that the water pump bearing moves smoothly and quietly.

Fig. 5: Inspecting Engine Water Pump Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If necessary, replace the engine water pump assembly. b. Install the V-ribbed belt. Refer to INSTALLATION . REMOVAL REMOVAL

1. REMOVE V-RIBBED BELT Refer to REMOVAL 2. DRAIN ENGINE COOLANT See step 1 3. DISCONNECT OUTLET RADIATOR HOSE . Refer to REMOVAL - Step 32 4. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side) . Refer to REMOVAL - Step 25 5. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) . Refer to REMOVAL - Step 6 6. REMOVE ENGINE MOVING CONTROL ROD BRACKET . Refer to REMOVAL - Step 26 7. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH a. Using SST, remove the bolt.

Fig. 6: Identifying SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09961-00950

HINT: There is not enough clearance to completely remove the bolt from the front No. 1 engine mounting bracket LH. Remove the front No. 1 engine mounting bracket LH together with the bolt. b. Remove the 5 bolts and front No. 1 engine mounting bracket LH.

Fig. 7: Identifying No. 1 Engine Mounting Bracket Bolts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to REMOVAL - Step 16 9. REMOVE V-RIBBED BELT TENSIONER PULLEY a. Remove the 5 mm bi-hexagon wrench. b. Remove the bolt and V-ribbed belt tensioner pulley and dust shield.

Fig. 8: Locating Idler Pulley Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not turn the bolt labeled "L" counterclockwise. Store the V-ribbed belt tensioner pulley so that the bearing does not get damaged.

10. REMOVE WATER INLET HOUSING a. Disconnect the water hose.

Fig. 9: Identifying Water Hose And Water Inlet Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Water *1 hose Water *2 Inlet housing b. Remove the 2 bolts, nut and water inlet housing. c. Remove the 2 O-rings.

Fig. 10: Identifying O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. SEPARATE WATER PUMP PULLEY a. Using SST, hold the water pump pulley.

Fig. 11: Identifying Water Pump Pulley And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09960-10010 09962-01000 09963-00700 b. Using SST and union nut wrench, remove the 4 bolts and separate the water pump pulley from the engine water pump.  SST: 09961-00950 

HINT: There is not enough clearance to completely remove the water pump pulley from the water pump shaft. Remove the water pump pulley together with the engine water pump.

12. REMOVE ENGINE WATER PUMP ASSEMBLY a. Remove the 16 bolts, engine water pump assembly, water pump pulley and gasket.

Fig. 12: Identifying Engine Water Pump Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ENGINE WATER PUMP ASSEMBLY a. Install a new gasket and the engine water pump assembly together with the water pump pulley with the 16 bolts.

Fig. 13: Identifying Engine Water Pump Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Bolt B and C Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE:

 

Make sure that there is no oil on the threads of bolts A. Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

2. INSTALL WATER PUMP PULLEY a. Temporarily install the water pump pulley with the 4 bolts. b. Using SST, hold the water pump pulley.

Fig. 14: Identifying Water Pump Pulley And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09960-10010 09962-01000 09963-00700

TEXT IN ILLUSTRATION Union *1 Nut Wrench 170 *a mm c. Using SST and union nut wrench, tighten the 4 bolts.



SST: 09961-00950

without SST Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) with SST Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 170 mm (6.69 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

3. INSTALL WATER INLET HOUSING a. Install 2 new O-rings. b. Install the water inlet housing with the 2 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Be careful not to allow the O-ring to get caught between the parts.

c. Connect the water hose. 4. INSTALL V-RIBBED BELT TENSIONER PULLEY a. Install the V-ribbed belt tensioner pulley and dust shield with the bolt.

Fig. 15: Identifying V-Ribbed Belt Tensioner Pulley And Dust Shield With Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Dust

*1 Shield *2 Pulley *a Correct *b Incorrect NOTE:







Be careful when tightening the bolt because its thread is lefthanded. Install the dust shield in the direction shown in the illustration. Failure to do so may cause looseness. Make sure to use the removed bolt. (Do not use another bolt even if it is the same size.)

Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) b. Install the 5 mm bi-hexagon wrench. 5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to INSTALLATION - Step 7 6. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH a. Temporarily install the front No. 1 engine mounting bracket LH with the 6 bolts. b. Fully tighten the 5 bolts.

Fig. 16: Identifying Front No. 1 Engine Mounting Bracket Bolts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

c. Using SST, fully tighten the bolt.

Fig. 17: Tightening Bolt With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09961-00950

TEXT IN ILLUSTRATION 150 *a mm without SST Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) with SST Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) NOTE:





The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.905 in.) and a torque wrench with a fulcrum length of 260 mm (10.23 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench.

7. INSTALL ENGINE MOVING CONTROL ROD BRACKET . Refer to INSTALLATION - Step 51

8. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) . Refer to INSTALLATION - Step 16 9. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side) . Refer to INSTALLATION - Step 52 10. CONNECT OUTLET RADIATOR HOSE . Refer to INSTALLATION - Step 45 11. INSTALL V-RIBBED BELT Refer to INSTALLATION 12. ADD ENGINE COOLANT See step 2 13. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

THERMOSTAT COMPONENTS ILLUSTRATION

Fig. 18: Identifying Thermostat Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 19: Identifying Thermostat Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN ENGINE COOLANT See step 1 2. REMOVE V-RIBBED BELT Refer to REMOVAL 3. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to REMOVAL - Step 16 4. DISCONNECT OUTLET RADIATOR HOSE . Refer to REMOVAL - Step 32 5. REMOVE WATER INLET

a. Remove the 2 nuts and water inlet.

Fig. 20: Locating Water Inlet And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE THERMOSTAT a. Remove the thermostat from the water inlet housing. b. Remove the gasket from the thermostat. INSPECTION INSPECTION

1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat.

Fig. 21: Identifying Temperature Mark On Thermostat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Immerse the thermostat in water, and then gradually heat the water.

Fig. 22: Checking Valve Opening Temperature Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Check that the valve of the thermostat opens at the specified temperature. Valve opening temperature 80 to 84°C (176 to 183°F) If the valve does not open as specified, replace the thermostat. c. Check the valve lift.

Fig. 23: Identifying Valve Lift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *a Lift Valve lift 7.7 mm (0.3031 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104° F)). If it is not fully closed, replace the thermostat.

INSTALLATION INSTALLATION

1. INSTALL THERMOSTAT a. Install a new gasket to the thermostat. b. Install the thermostat with the jiggle valve facing up.

Fig. 24: Identifying Jiggle Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Jiggle *1 valve *a 10° HINT: The jiggle valve may be set within 10° on either side of the prescribed position. 2. INSTALL WATER INLET a. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. CONNECT OUTLET RADIATOR HOSE . Refer to INSTALLATION - Step 45

4. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to INSTALLATION - Step 7 5. INSTALL V-RIBBED BELT Refer to INSTALLATION 6. ADD ENGINE COOLANT See step 2 7. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

COOLING FAN MOTOR COMPONENTS ILLUSTRATION

Fig. 25: Identifying Cooling Fan Motor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. CHECK COOLING FAN MOTOR

a. Check that the motor operates smoothly when the battery is connected to the fan motor connector.

Fig. 26: Cooling Fan Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

Specified Condition

Battery Cooling voltage 7.3 to 9.3 fan applied at A motor 20°C (68° F) If the result is not as specified, replace the cooling fan motor.

2. CHECK NO. 2 COOLING FAN MOTOR a. Check that the motor operates smoothly when the battery is connected to the fan motor connector.

Fig. 27: No. 2 Cooling Fan Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (No. 2 Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

Specified Condition

Battery No. 2 voltage Cooling 7.3 to 9.3 applied at fan A 20°C (68° motor F)

If the result is not as specified, replace the No. 2 cooling fan motor. REMOVAL REMOVAL

1. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL 2. REMOVE FAN a. Remove the nut and fan.

Fig. 28: Identifying Fan Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE NO. 2 FAN a. Remove the nut and No. 2 fan.

Fig. 29: Identifying No. 2 Fan Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE COOLING FAN MOTOR a. Disconnect the clamp and connector.

Fig. 30: Identifying Cooling Fan Motor Clamp And Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and cooling fan motor.

Fig. 31: Identifying Cooling Fan Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 2 COOLING FAN MOTOR a. Disconnect the 4 clamps and connector.

Fig. 32: Identifying No. 2 Cooling Fan Motor Clamps And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and No. 2 cooling fan motor.

Fig. 33: Identifying No. 2 Cooling Fan Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION INSTALLATION

1. INSTALL NO. 2 COOLING FAN MOTOR a. Install the No. 2 cooling fan motor with the 3 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) b. Connect the 4 clamps and connector. 2. INSTALL COOLING FAN MOTOR a. Install the cooling fan motor with the 3 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) b. Connect the clamp and connector. 3. INSTALL NO. 2 FAN a. Install the No. 2 fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 4. INSTALL FAN a. Install the fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 5. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION

COOLING FAN ECU ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT COOLING FAN ECU a. Put the vehicle in the following conditions: 1. The engine switch is off. 2. The coolant temperature is less than 92°C (198°F). 3. The battery voltage is between 11 to 14 V. 4. The A/C switch is off. b. Connect the pickup of a clamp-on ammeter over one of the two wires for the cooling fan motor. c. Turn the engine switch on (IG) and wait for approximately 10 seconds. Check that the fan stops.

d. Start the engine. Check that the fan stops with the engine idling. HINT: Make sure that the radiator engine coolant temperature is less than 92°C (198°F).  Turn the A/C switch off. e. Check that the fan operates when the A/C switch is turned on. 

Standard Current Item

Specified Condition

Cooling 14.2 to fan 20.2 A motor No. 2 cooling 7.5 to 11.5 A fan motor HINT: The coolant temperature is less than 92°C (198°F). f. Check that the fan operates when the engine coolant temperature sensor connector is disconnected. Standard Current Item

Specified Condition

Cooling 14.2 to fan 20.2 A motor No. 2 cooling 7.5 to 11.5 fan A motor g. After the engine is warmed up, check that the fan operates as shown in the illustration.

Fig. 34: Identifying Fan Operation Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT:

  

RADIATOR COMPONENTS ILLUSTRATION

The coolant temperature at which the fan starts operating is approximately 94°C (201°F). This system can also be checked using the Techstream. Select the following menu items: Powertrain / Engine / Data List / Coolant Temp.

Fig. 35: Identifying Radiator Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 36: Identifying Radiator Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 37: Identifying Radiator Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. CHECK RADIATOR CAP SUB-ASSEMBLY a. Measure the valve opening pressure.

Fig. 38: Locating Rubber Packings 1, 2, 3 And 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. 2. Check that rubber packings 1, 2 and 3 are not deformed, cracked or swollen. 3. Check that 3 and 4 are not stuck together. 4. Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. 5. When using the cap tester, tilt it upward 30° or more. 6. Pump the cap tester several times, and check the maximum pressure *1.

Fig. 39: Identifying Radiator Cap Tester And Radiator Cap Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator *1 Cap Tester Radiator Cap *2 Subassembly 30° or *a more Pumping speed 1 pump every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criteria Specified Condition 93.3 to 122.7 kPa Standard (0.95 to Item

value 1.25 (for kgf/cm2 , brand13.5 to new cap) 17.8 psi) Minimum 78.5 kPa standard (0.8 value 2 (for used kgf/cm , 11.4 psi) cap) If the maximum pressure is less than the specified pressure for the minimum standard value, replace the radiator cap sub-assembly. REMOVAL REMOVAL

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7.

DRAIN ENGINE COOLANT See step 1 REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

8. 9. 10. 11. 12. 13.

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE BATTERY . Refer to REMOVAL - Step 22 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET NO. 2 AIR CLEANER . Refer to REMOVAL - Step 18 REMOVE INLET NO. 1 AIR CLEANER . Refer to REMOVAL - Step 23 REMOVE RADIATOR GRILLE SUB-ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE RADIATOR RESERVE TANK ASSEMBLY a. Disconnect the radiator reserve tank hose.

Fig. 40: Identifying Radiator Reserve Tank Hose And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and radiator reserve tank assembly. 14. DISCONNECT INLET RADIATOR HOSE a. Disconnect the inlet radiator hose.

Fig. 41: Identifying Inlet Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. DISCONNECT OUTLET RADIATOR HOSE a. Disconnect the outlet radiator hose and clamp.

Fig. 42: Identifying Outlet Radiator Hose And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 17. REMOVE UPPER RADIATOR SUPPORT a. Disconnect the 2 connectors.

Fig. 43: Identifying Upper Radiator Support Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hood lock control cable clamp and remove the 5 bolts and upper radiator support.

Fig. 44: Identifying Hood Lock Control Cable Clamp And Upper Radiator Support Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 2 radiator support cushions from the radiator assembly. 18. REMOVE RADIATOR ASSEMBLY a. Disconnect the 3 clamps and connector.

Fig. 45: Identifying Radiator Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and separate the condenser assembly from the radiator assembly.

Fig. 46: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the radiator assembly with fan assembly.

Fig. 47: Identifying Radiator Assembly With Fan Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not apply any excessive force to the cooler condenser assembly or pipe when removing the radiator assembly.

d. Remove the 2 lower radiator supports from the radiator assembly. e. Release the 3 claws and lift the fan assembly from the radiator.

Fig. 48: Identifying Fan Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL RADIATOR ASSEMBLY a. Install the fan assembly to the radiator with the 2 guides at the bottom and 3 claws on the top.

Fig. 49: Identifying Fan Assembly Guides And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide b. Install the 2 lower radiator supports to the radiator assembly. c. Install the radiator with fan assembly.

Fig. 50: Identifying Radiator Fan Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply any excessive force to the cooler condenser assembly or pipe when installing the radiator assembly.

d. Install the condenser assembly with the 4 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) e. Connect the 3 clamps and connector. 2. INSTALL UPPER RADIATOR SUPPORT a. Install the 2 radiator support cushions to the radiator assembly. b. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

3. 4. 5. 6.

c. Connect the 2 connectors. INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 CONNECT OUTLET RADIATOR HOSE a. Connect the outlet radiator hose and clamp. CONNECT INLET RADIATOR HOSE a. Connect the inlet radiator hose. INSTALL RADIATOR RESERVE TANK ASSEMBLY

a. Install the radiator reserve tank with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

7. 8. 9. 10. 11.

b. Connect the radiator reserve tank hose. INSTALL RADIATOR GRILLE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 INSTALL INLET NO. 1 AIR CLEANER . Refer to INSTALLATION - Step 54 INSTALL INLET NO. 2 AIR CLEANER . Refer to INSTALLATION - Step 59 INSTALL BATTERY . Refer to INSTALLATION - Step 55 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

12. 13. 14. 15. 16. 17. 18.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

ADD ENGINE COOLANT See step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT FAN RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 51: Fan Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Battery voltage is not 10 kohms 3-5 applied or higher between terminals 1 and 2 Apply battery voltage Below 1 3-5 between ohms terminals 1 and 2 If the result is not as specified, replace the relay.

2012-2017 ENGINE Engine Cooling System (Service Information) (Hybrid)

COOLANT (FOR ENGINE) REPLACEMENT REPLACEMENT

1. DRAIN COOLANT (for Engine) NOTE:

Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

a. Loosen the radiator drain cock plug. b. Remove the radiator cap sub-assembly.

Fig. 1: Identifying Radiator Drain Cock Plug And Radiator Cap Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator Radiator Cap Drain *1 *2 SubCock assembly Plug HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area. 2. ADD COOLANT (for Engine) a. Tighten the radiator drain cock plug by hand. b. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Item Capacity 7.2 liters Engine (7.6 US coolant qts, 6.3 Imp. qts) NOTE:

Never use water as a substitute for engine coolant.

HINT: TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids). c. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line. d. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. e. Install the radiator cap sub-assembly and reserve tank cap. f. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . g. Bleed air from the cooling system. NOTE:

  

Before starting the engine, turn the A/C switch off. Adjust the heater control to the maximum hot setting. Adjust the blower speed to the low setting.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. HINT: The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

2. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air. WARNING: When squeezing the radiator hoses:   

NOTE:









Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the cooling fans.

Make sure that the radiator reserve tank assembly still has some coolant in it. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool. If there is not enough coolant, the engine may overheat or be seriously damaged. If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.

h. Stop the engine and wait until the engine coolant cools down. i. Add engine coolant to the full line on the radiator reserve tank assembly. 3. INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1

WATER PUMP COMPONENTS ILLUSTRATION

Fig. 2: Identifying Water Pump Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN COOLANT (for Engine) See step 1 2. REMOVE ENGINE WATER PUMP ASSEMBLY a. Disconnect the clamp.

Fig. 3: Identifying Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector from the engine water pump assembly.

Fig. 4: Identifying Water Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 5 bolts and engine water pump assembly.

Fig. 5: Identifying Water Pump Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the gasket from the engine water pump assembly.

Fig. 6: Identifying Water Pump Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ENGINE WATER PUMP ASSEMBLY a. Install a new gasket to the engine water pump assembly. HINT: Be sure to clean the contact surfaces. b. Install the engine water pump assembly with the 5 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) c. Connect the connector to the engine water pump assembly. d. Connect the clamp. 2. ADD COOLANT (for Engine) See step 2 3. INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1

THERMOSTAT COMPONENTS ILLUSTRATION

Fig. 7: Identifying Thermostat Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4.

DRAIN COOLANT (for Engine) See step 1 REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to REMOVAL - Step 2 DISCONNECT NO. 2 RADIATOR HOSE . Refer to REMOVAL - Step 64 DISCONNECT NO. 6 WATER BY-PASS HOSE a. Disconnect the No. 6 water by-pass hose.

Fig. 8: Identifying No. 6 Water By-Pass Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY a. Remove the 2 bolts and water inlet with thermostat sub-assembly.

Fig. 9: Identifying Water Inlet Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the gasket from the water inlet with thermostat sub-assembly.

Fig. 10: Identifying Water Inlet Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

Fig. 11: Identifying Valve Opening Temperature Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The valve opening temperature is inscribed on the water inlet with thermostat sub-assembly. a. Immerse the water inlet with thermostat sub-assembly in water and then gradually heat the water. b. Check the valve opening temperature of the water inlet with thermostat sub-assembly. Valve opening temperature 80 to 84°C (176 to 183°F) HINT: If the valve opening temperature is not as specified, replace the water inlet with thermostat subassembly. c. Check the valve lift.

Fig. 12: Checking The Valve Lift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *a Lift Valve lift 10 to 11.3 mm (0.394 to 0.445 in.) at 95°C (203°F) HINT: If the valve lift is not as specified, replace the water inlet with thermostat sub-assembly. d. Check that the valve is fully closed when the water inlet with thermostat sub-assembly is at low temperatures (below 77°C (171°F)). HINT: If it is not fully closed, replace the water inlet with thermostat sub-assembly. INSTALLATION INSTALLATION

1. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

a. Install a new gasket on the water inlet with thermostat sub-assembly. b. Install the water inlet with thermostat sub-assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 2. CONNECT NO. 6 WATER BY-PASS HOSE a. Connect the No. 6 water by-pass hose. 3. CONNECT NO. 2 RADIATOR HOSE . Refer to INSTALLATION - Step 40 4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to INSTALLATION - Step 19 5. ADD COOLANT (for Engine) See step 2 6. INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1

COOLING FAN MOTOR COMPONENTS ILLUSTRATION

Fig. 13: Identifying Cooling Fan Motor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. CHECK COOLING FAN MOTOR

a. Check that the motor operates smoothly when the auxiliary battery is connected to the fan motor connector.

Fig. 14: Identifying Cooling Fan Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

Specified Condition

Auxiliary battery Cooling voltage 10.6 to fan applied at 16.6 A motor 20°C (68° F)

If the result is not as specified, replace the cooling fan motor. 2. CHECK NO. 2 COOLING FAN MOTOR a. Check that the motor operates smoothly when the auxiliary battery is connected to the fan motor connector.

Fig. 15: Identifying No. 2 Cooling Fan Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness *a connected (No. 2 Cooling Fan Motor) b. Measure the current while the motor is operating. Standard Current Item Condition

No. 2

Auxiliary battery

Specified Condition

Cooling voltage fan applied at 10.6 to motor 20°C (68° 16.6 A F) If the result is not as specified, replace the No. 2 cooling fan motor. REMOVAL REMOVAL

1. REMOVE RADIATOR ASSEMBLY Refer to REMOVAL 2. REMOVE COOLING FAN MOTOR INSULATOR a. Remove the 2 bolts and cooling fan motor insulator.

Fig. 16: Identifying Cooling Fan Motor Insulator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FAN a. Remove the nut and fan.

Fig. 17: Identifying Nut And Fan Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 2 FAN a. Remove the nut and No. 2 fan.

Fig. 18: Identifying Nut And No. 2 Fan

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE COOLING FAN MOTOR a. Disconnect the 2 clamps and connector.

Fig. 19: Identifying Cooling Fan Motor Clamps And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and cooling fan motor.

Fig. 20: Identifying Cooling Fan Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE NO. 2 COOLING FAN MOTOR a. Disconnect the 3 clamps and connector.

Fig. 21: Identifying NO. 2 Cooling Fan Motor Clamps And Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws and No. 2 cooling fan motor.

Fig. 22: Identifying NO. 2 Cooling Fan Motor Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 COOLING FAN MOTOR a. Install the No. 2 cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) b. Connect the 3 clamps and connector. 2. INSTALL COOLING FAN MOTOR a. Install the cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) b. Connect the 2 clamps and connector. 3. INSTALL NO. 2 FAN a. Install the No. 2 fan with the nut.

Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 4. INSTALL FAN a. Install the fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) 5. INSTALL COOLING FAN MOTOR INSULATOR a. Install the cooling fan motor insulator with the 2 bolts. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) 6. INSTALL RADIATOR ASSEMBLY Refer to INSTALLATION

COOLING FAN ECU ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT COOLING FAN ECU a. Put the vehicle in the following conditions: 1. The power switch is off. 2. The coolant temperature is less than 92°C (198°F). 3. The auxiliary battery voltage is between 11 to 14 V. 4. The A/C switch is off. b. Connect the pickup of a clamp-on ammeter over one of the two wires for the cooling fan motor. c. Turn the power switch on (IG) and wait for approximately 10 seconds. Check that the fan stops. d. Start the engine. Check that the fan stops with the engine idling. HINT: Make sure that the radiator engine coolant temperature is less than 92°C (198°F).  Turn the A/C switch off. e. Check that the fan operates when the A/C switch is turned on. 

Standard Current Item

Specified Condition

Cooling 10.6 to

fan 16.6 A motor No. 2 cooling 10.6 to 16.6 A fan motor HINT: The coolant temperature is less than 92°C (198°F). f. Check that the fan operates when the engine coolant temperature sensor connector is disconnected. Standard Current Item

Specified Condition

Cooling 10.6 to fan 16.6 A motor No. 2 cooling 10.6 to fan 16.6 A motor g. After the engine is warmed up, check that the fan operates as shown in the illustration.

Fig. 23: Checking Fan Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT:

  

The coolant temperature at which the fan starts operating is approximately 94°C (201°F). This system can also be checked using the Techstream. Select the following menu items: Powertrain / Engine and ECT / Data List / All Data / Coolant Temp.

RADIATOR COMPONENTS ILLUSTRATION

Fig. 24: Identifying Radiator Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 25: Identifying Radiator Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 26: Identifying Radiator Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 27: Identifying Radiator Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. CHECK RADIATOR CAP SUB-ASSEMBLY a. Measure the valve opening pressure.

Fig. 28: Locating Rubber Packings 1, 2, 3 And 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. 2. Check that rubber packings 1, 2 and 3 are not deformed, cracked or swollen. 3. Check that 3 and 4 are not stuck together. 4. Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. 5. When using the cap tester, tilt it upward 30° or more. 6. Pump the cap tester several times, and check the maximum pressure*1.

Fig. 29: Cap Tester & Maximum Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Radiator *1 Cap Tester Radiator Cap *2 Subassembly 30° or *a more Pumping speed 1 pump every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criterion Specified Condition 93.3 to Standard 122.7 kPa value (1.0 to 1.3 Item

(for kgf/cm2 , brand13.5 to new cap) 18.0 psi) Minimum 78.5 kPa standard (0.8 value 2 (for used kgf/cm , 11.4 psi) cap) If the maximum pressure is less than the specified pressure for the minimum standard value, replace the radiator cap sub-assembly. REMOVAL REMOVAL

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7. 8.

DRAIN COOLANT (for Engine) See step 1 REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

9. 10. 11. 12. 13.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 REMOVE RADIATOR GRILLE SUB-ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE NO. 5 INVERTER BRACKET . Refer to REMOVAL - Step 12 REMOVE RADIATOR RESERVE TANK ASSEMBLY a. Disconnect the radiator reserve tank hose.

Fig. 30: Identifying Radiator Reserve Tank Hose And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and radiator reserve tank assembly. 14. DISCONNECT NO. 1 RADIATOR HOSE a. Disconnect the No. 1 radiator hose.

Fig. 31: Disconnecting No. 1 Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. DISCONNECT NO. 2 RADIATOR HOSE a. Disconnect the No. 2 radiator hose and clamp.

Fig. 32: Disconnecting No. 2 Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. DISCONNECT NO. 1 INVERTER COOLING PIPE ASSEMBLY a. Remove the 2 bolts and disconnect the No. 1 inverter cooling pipe assembly.

Fig. 33: Identifying No. 1 Inverter Cooling Pipe Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 18. REMOVE UPPER RADIATOR SUPPORT a. Disconnect the 2 connectors.

Fig. 34: Identifying Horn Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hood lock control cable clamp and remove the 5 bolts and upper radiator support.

Fig. 35: Identifying Upper Radiator Support Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 radiator support cushions. 19. REMOVE RADIATOR ASSEMBLY a. Disconnect the 2 clamps.

Fig. 36: Identifying Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 clamps and connector.

Fig. 37: Identifying Radiator Clamps And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the clamp and No. 4 inverter cooling hose.

Fig. 38: Identifying No. 4 Inverter Cooling Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 4 bolts and separate the condenser assembly from the radiator assembly (for inverter coolant).

Fig. 39: Identifying Condenser Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the radiator assembly with the fan assembly.

Fig. 40: Removing The Radiator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not apply any excessive force to the radiator assembly (for inverter coolant), cooler condenser assembly or pipe when removing the radiator assembly.

f. Remove the 2 lower radiator supports. g. Release the 3 claws and lift the fan assembly from the radiator.

Fig. 41: Identifying Fan Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL RADIATOR ASSEMBLY a. Install the fan assembly to the radiator with the 2 guides at the bottom and 3 claws on the top.

Fig. 42: Identifying Fan Assembly Bottom Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Guide b. Install the 2 lower radiator supports to the radiator assembly. c. Install the radiator with fan assembly.

Fig. 43: Installing The Radiator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply any excessive force to the radiator assembly (for inverter coolant), cooler condenser assembly or pipe when installing the radiator assembly.

d. Install the radiator with fan assembly to the condenser assembly and radiator assembly (for inverter coolant) with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) e. Connect the No. 4 inverter cooling hose with the clamp. f. Connect the connector and the 2 clamps. g. Connect the 2 clamps. 2. INSTALL UPPER RADIATOR SUPPORT a. Install the 2 radiator support cushions to the radiator assembly. b. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) c. Connect the 2 connectors. 3. INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 4. CONNECT NO. 1 INVERTER COOLING PIPE ASSEMBLY

a. Temporarily install the bolt A.

Fig. 44: Identifying No. 1 Inverter Cooling Pipe Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the bolt B. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) c. Fully tighten the bolt A. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 5. CONNECT NO. 2 RADIATOR HOSE a. Connect the No. 2 radiator hose and clamp. 6. CONNECT NO. 1 RADIATOR HOSE a. Connect the No. 1 radiator hose. 7. INSTALL RADIATOR RESERVE TANK ASSEMBLY a. Install the radiator reserve tank with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) b. Connect the radiator reserve tank hose. 8. INSTALL NO. 5 INVERTER BRACKET . Refer to INSTALLATION - Step 26 9. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63

10. INSTALL RADIATOR GRILLE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

12. 13. 14. 15. 16. 17. 18. 19.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 ADD COOLANT (for Engine) See step 2 INSPECT FOR COOLANT LEAK (for Engine) . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT FAN RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 45: Fan Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Auxiliary battery voltage is not 10 kohms 3-5 applied or higher between terminals 1 and 2 Auxiliary battery voltage is Below 1 applied 3-5 ohms between terminals 1 and 2 If the result is not as specified, replace the relay.

2012-2017 ENGINE Engine Intake System (Inspection) - Camry (2GR-FE)

INTAKE SYSTEM PARTS LOCATION ILLUSTRATION

Fig. 1: Identifying Engine Intake System Components Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Identifying Engine Intake System Diagram (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

*3

*5

Throttle Valve

Air Cleaner Element Vacuum Switching Valve (for Intake Air Control System)

*2

Intake Air Control Valve (for Intake Air Control System)

*4

Resonator

*6

Intake Air Surge Tank

*7 *9 *a

Vacuum Tank ECM Engine Speed Signal

Diaphragm Chamber -

*8 *b

Air

Fig. 3: Identifying Engine Intake System Diagram (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

*3 *a

Throttle Valve

Actuator Engine Speed Signal

*2

*4 -

Intake Air Control Valve (for ACIS) ECM -

Fig. 4: Identifying Engine Intake System Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT INTAKE SYSTEM a. Check that there are no vacuum leaks at the points shown in the illustration.

Fig. 5: Inspecting Intake System For Vacuum Leaks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform "Inspection After Repair" after repairing air leaks in the intake system. Refer to INITIALIZATION .

2012-2017 ENGINE Engine Intake System (Inspection) (Hybrid)

INTAKE SYSTEM ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT INTAKE SYSTEM a. Check that there are no vacuum leaks at the points shown in the illustration.

Fig. 1: Identifying Intake System Check Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform "Inspection After Repair" after repairing air leaks in the intake system. Refer to INITIALIZATION .

2012-2017 ENGINE Engine Mechanical (Service Information) - Camry (2AR-FE)

ENGINE ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT Refer to ON-VEHICLE INSPECTION 2. INSPECT ENGINE OIL Refer to ON-VEHICLE INSPECTION 3. INSPECT BATTERY Refer to ON-VEHICLE INSPECTION 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY a. Remove the air cleaner filter element sub-assembly. b. Visually check that the air cleaner filter element sub-assembly is not excessively damaged or oily. If necessary, replace the air cleaner filter element sub-assembly. HINT: If there is any dirt or a blockage in the air cleaner filter element sub-assembly, clean it with compressed air.  If any dirt or a blockage remains even after cleaning the air cleaner filter element subassembly with compressed air, replace it. c. Install the air cleaner filter element sub-assembly. 5. INSPECT SPARK PLUG 

Refer to ON-VEHICLE INSPECTION 6. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOISE a. Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the inspection above again. If any defects or problems are found during the inspection above, perform a lash adjuster inspection. See step 2.

7. INSPECT IGNITION TIMING a. Warm up and stop the engine. b. When using the Techstream: 1. Connect the Techstream to the DLC3. NOTE:

When checking the ignition timing, the transmission should be in neutral.

2. Start the engine and idle it. 3. Turn the Techstream main switch on. 4. Enter the following menus: Powertrain / Engine / Data List / IGN Advance. Standard ignition timing BTDC 5 to 15 deg. at idle HINT: Refer to the Techstream operator's manual for further details. If the ignition timing is not as specified, check the valve timing. 5. Check that the ignition timing advances immediately when the engine speed is increased. 6. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1 / ON. 7. Monitor IGN Advance of the Data List. Standard ignition timing BTDC 8 to 12 deg. at idle HINT: Refer to the Techstream operator's manual for further details. If the ignition timing is not as specified, check the valve timing. 8. Enter the following menus: Connect the TC and TE1 / OFF. 9. Turn the ignition switch off. 10. Disconnect the Techstream from the DLC3. c. When not using the Techstream: 1. Remove the No. 1 engine cover sub-assembly. 2. Pull out the wire harness as shown in the illustration.

Fig. 1: Connecting Clip Of Timing Light To Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Connect the clip of a timing light to the wire harness. NOTE:

Use a timing light that detects primary signals.

4. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

Fig. 2: Identifying DLC3 Connector Terminals Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3



SST: 09843-18040

NOTE:





Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. When checking the ignition timing, the transmission should be in neutral.

5. Using a timing light, check the ignition timing. Standard ignition timing 8 to 12° BTDC at idle 6. Remove SST from the DLC3. 7. Check the ignition timing. Standard ignition timing 5 to 15° BTDC at idle If the ignition timing is not as specified, check the valve timing. 8. Check that the ignition timing advances immediately when the engine speed is increased. 9. Disconnect the timing light from the engine. 10. Install the No. 1 engine cover sub-assembly. 8. INSPECT ENGINE IDLE SPEED a. Warm up and stop the engine. b. When using the Techstream: 1. Connect the Techstream to the DLC3. NOTE:





Switch off all accessories and the A/C before connecting the Techstream. When checking the idle speed, the transmission should be in neutral.

2. Race the engine at 2500 rpm for approximately 90 seconds. 3. Turn the Techstream main switch on. 4. Enter the following menus: Powertrain / Engine / Data List / Engine Speed. Standard idle speed 610 to 710 rpm

HINT: Refer to the Techstream operator's manual for further details. If the idle speed is not as specified, check the air intake system. 5. Disconnect the Techstream from the DLC3. c. When not using the Techstream: 1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

Fig. 3: Identifying DLC3 Connector Terminals Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3 

SST: 09843-18030

NOTE:



  

Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components. Turn all electrical systems and the A/C off. Inspect the idle speed with the cooling fans off. When checking the idle speed, the transaxle should be in neutral.

2. Race the engine at 2500 rpm for approximately 90 seconds. 3. Check the idle speed. Standard idle speed 610 to 710 rpm If the speed is not as specified, check the air intake system. 4. Disconnect the tachometer probe from the DLC3. 9. INSPECT COMPRESSION a. Warm up and stop the engine. b. Check for DTCs. Refer to DTC CHECK / CLEAR . c. Remove the 4 spark plugs. Refer to REMOVAL - Step 3 . d. Disconnect the 4 fuel injector connectors. e. Insert a compression gauge into the spark plug hole.

Fig. 4: Measuring Compression Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Fully open the throttle. g. While cranking the engine, measure the compression pressure. Standard compression pressure

1450 kPa (14.8 kgf/cm2 , 210 psi) Minimum pressure 980 kPa (10.0 kgf/cm2 , 142 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2 , 15 psi) HINT: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. h. If the cylinder compression is low in one or more cylinders, pour a small amount of engine oil into the cylinder with low compression through its spark plug hole. Then inspect the cylinder compression pressure again. HINT: If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore is worn or damaged.  If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. i. Connect the 4 fuel injector connectors. j. Install the 4 spark plugs. Refer to INSTALLATION - Step 1 . k. Clear the DTCs. Refer to DTC CHECK / CLEAR . 10. INSPECT CO/HC 

HINT: This check determines whether or not the idle CO/HC complies with regulations. a. b. c. d.

Start the engine. Keep the engine speed at 2500 rpm for approximately 180 seconds. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling. Immediately check CO/HC concentration at idle and 2500 rpm. HINT: 



When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

1. Check the DTCs. Refer to DTC CHECK / CLEAR . 2. See the table below for possible causes, and then inspect and correct the applicable causes if necessary. CO

HC Symptom

Normal High Rough idle

Low

High

Rough idle (Fluctuating High HC reading)

Rough idle (Black High smoke from exhaust)

Causes 1. Faulty ignition  Incorrect timing  Plugs are contaminated or shorted, or gaps are defective 2. Leaky intake and exhaust valves 3. Leaky cylinder 1. Vacuum leaks  PCV hose  Intake manifold  Throttle body  Brake booster line 2. Lean mixture causing misfire 1. Restricted air filter 2. Faulty SFI system  Faulty pressure  Defective ECT sensor  Faulty ECM  Faulty injector  Faulty throttle position sensor



Faulty MAF sensor

DRIVE BELT COMPONENTS ILLUSTRATION

Fig. 5: Identifying Drive Belt Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT V-RIBBED BELT a. Check the belt for wear, cracks or other signs of damage.

Fig. 6: Inspecting V-Ribbed Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT If any of the following defects is found, replace the V-ribbed belt. The belt is cracked.  The belt is worn out to the extent that the cords are exposed.  The belt has chunks missing from the ribs. b. Check that the belt fits properly in the ribbed grooves. 

Fig. 7: Checking V Belt For Proper Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly. 2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY a. Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the V-ribbed belt tensioner. REMOVAL REMOVAL REMOVAL

1. 2. 3. 4.

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH

5. REMOVE V-RIBBED BELT a. Attach a wrench to the hexagonal portion of the belt tensioner as shown in the illustration, rotate the belt tensioner clockwise, and remove the V-ribbed belt.

Fig. 8: Removing V-Ribbed Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION INSTALLATION

1. INSTALL V-RIBBED BELT a. Set the V-ribbed belt onto each part as shown in the illustration except the water pump pulley.

Fig. 9: Identifying V-Ribbed Belt Routing Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Crankshaft *2 Tensioner *3 Generator Water *4 Pump Cooler *5 Compressor b. Loosen the V-ribbed belt by turning the belt tensioner clockwise. c. Set the V-ribbed belt onto the water pump pulley.

NOTE:

2. 3. 4. 5.

Make sure that the belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.

INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

CAMSHAFT COMPONENTS ILLUSTRATION

Fig. 10: Identifying Camshaft Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 11: Identifying Camshaft Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY See step 18 REMOVE INLET AIR CLEANER ASSEMBLY See step 19 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY See step 21 REMOVE AIR CLEANER CASE SUB-ASSEMBLY See step 22 REMOVE NO. 2 ENGINE MOUNTING STAY RH See step 32 REMOVE ENGINE MOVING CONTROL ROD See step 34 DISCONNECT ENGINE WIRE a. Disconnect the connectors and clamps.

Fig. 12: Identifying Connectors, Clamp, Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolts and nuts and disconnect the engine wire from the engine. 15. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2

16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 4 17. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 13: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Timing *b Mark Timing *c Notch b. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with each timing mark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration. c. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly. 18. REMOVE TIMING CHAIN COVER PLATE a. Remove the 4 bolts, timing chain cover plate and gasket.

Fig. 14: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY a. Turn the crankshaft approximately 10° clockwise.

Fig. 15: View Of Turning Crankshaft 10Degrees Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the crankshaft approximately 10° counterclockwise.

Fig. 16: Turning Crankshaft Approximately 10° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Align the holes of the stopper plate and tensioner, and insert a pin into the stopper plate hole to lock the tensioner.

Fig. 17: Aligning Holes Of Stopper Plate & Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin d. Turn the crankshaft approximately 10° clockwise.

Fig. 18: View Of Turning Crankshaft 10° Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the 2 bolts, chain tensioner and gasket.

Fig. 19: No. 1 Chain Tensioner Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Make sure not to drop the gasket inside the timing chain cover.

f. Turn the crankshaft approximately 10° counterclockwise.

Fig. 20: Turning Crankshaft Approximately 10° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE TIMING CHAIN GUIDE See step 13 21. REMOVE TIMING CHAIN COVER TIGHT PLUG See step 21 22. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt from the camshaft.

Fig. 21: Removing Camshaft Timing Gear Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

b. Separate the camshaft timing gear assembly from the camshaft.

Fig. 22: Identifying Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the timing chain from the camshaft timing gear assembly, and turn the camshaft timing gear assembly approximately 180°.

Fig. 23: Removing Timing Chain From Camshaft Timing Gear Assembly & Turn Camshaft Timing Gear Assembly Approximately 180 Degrees Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide d. Remove the camshaft timing gear assembly.

Fig. 24: Identifying Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the camshaft timing gear assembly.

23. REMOVE CAMSHAFT BEARING CAP a. Using several steps, remove the 11 bearing cap bolts in the sequence shown in the illustration.

Fig. 25: Identifying 11 Bearing Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using several steps, remove the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 26: Identifying 10 Bearing Cap Bolt Loosening Sequence (Second Step) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 5 bearing caps. HINT: Arrange the removed parts in the correct order. 24. REMOVE CAMSHAFT a. Remove the camshaft from the camshaft housing sub-assembly.

Fig. 27: Identifying Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

25. REMOVE NO. 2 CAMSHAFT a. Hold up the chain and remove the No. 2 camshaft from the camshaft housing sub-assembly.

Fig. 28: Identifying No. 2 Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Suspend the chain with a string or equivalent as shown in the illustration.

Fig. 29: Suspending Chain With A String Or Equivalent Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to drop the chain inside the timing chain cover.

26. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

a. Remove the flange bolt and camshaft timing exhaust gear assembly.

Fig. 30: Locating Camshaft Timing Exhaust Gear Assembly & Flange Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the camshaft timing exhaust gear assembly.

27. REMOVE OIL CONTROL VALVE FILTER See step 35 28. REMOVE NO. 1 CAMSHAFT BEARING See step 37 29. REMOVE NO. 2 CAMSHAFT BEARING See step 38 INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 1. 2. 3. 4.

INSTALL NO. 2 CAMSHAFT BEARING See step 18 INSTALL NO. 1 CAMSHAFT BEARING See step 17 INSTALL OIL CONTROL VALVE FILTER See step 19 INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY a. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing

exhaust gear assembly.

Fig. 31: Identifying Knock Pin And Knock Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Knock *a Pin Hole b. Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

Fig. 32: Checking Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft Timing *1 Exhaust Gear Assembly *2 Clearance Camshaft *3 Flange *a INCORRECT *b CORRECT *c No Clearance

c. Fix the camshaft timing exhaust gear assembly with the bolt.

Fig. 33: Locating Camshaft Timing Exhaust Gear Assembly & Flange Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:

Do not disassemble the camshaft timing exhaust gear assembly.

HINT: Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 5. SET TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 34: Setting TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *a Notch 6. INSTALL NO. 2 CAMSHAFT a. Make sure that the valve rocker arms are installed as shown in the illustration.

Fig. 35: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap b. Clean the camshaft journals. c. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. d. Hold up the chain and align the timing mark and the paint mark, and install the camshaft.

Fig. 36: Aligning Timing Mark And Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint

*a Mark Timing *b Mark HINT: Perform "Inspection After Repair" after replacing the No. 2 camshaft. Refer to INITIALIZATION . 7. INSTALL CAMSHAFT a. Make sure that the valve rocker arms are installed as shown in the illustration.

Fig. 37: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap

b. Clean the camshaft journals. c. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. d. Install the camshaft to the camshaft housing as shown in the illustration.

Fig. 38: Identifying Camshaft Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Knock Pin Approximately *a 17° HINT: Perform "Inspection After Repair" after replacing the camshaft. Refer to INITIALIZATION .

8. INSTALL CAMSHAFT BEARING CAP a. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

Fig. 39: Identifying Camshaft Bearing Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.

Fig. 40: Tightening 10 Bolts In The Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) c. Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

Fig. 41: Tightening 11 Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) d. Check the torque of each bolt again. 9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY a. Check the camshaft timing gear position.

Fig. 42: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Advanced

*a Position Retarded *b Position Knock Pin *c Hole Alignment *d Mark NOTE:





If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation. If the camshaft timing gear has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear to the most advanced position before tightening the camshaft timing gear.

b. Install the camshaft timing gear assembly as shown in the illustration.

Fig. 43: Identifying Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide c. Turn the camshaft timing gear assembly approximately 180° counterclockwise.

Fig. 44: Turning Camshaft Timing Gear Approximately 180° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide d. Align the paint mark with the timing mark to install the chain.

Fig. 45: Aligning Paint Mark And Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Timing *b Mark e. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Fig. 46: Identifying No. 1 Camshaft Knock Pin & Camshaft Timing Gear Knock Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Knock *a Pin Hole f. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 47: Checking Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Clearance Camshaft *3 Flange *a INCORRECT *b CORRECT *c No Clearance g. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

h. If the lock pin has not been released, release it. 1. After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

Fig. 48: Identifying Seal Oil Hole With Adhesive Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Make a *a Hole Adhesive Tape *b Sealing Area NOTE:

Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A) 3. Apply approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the hole made in

procedure A to release the lock pin.

Fig. 49: Applying Air Pressure To Hole To Release Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

If air leaks out, reattach the adhesive tape. Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

4. Forcibly turn the camshaft timing gear in the advance direction (counterclockwise). HINT: Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand. 5. Remove the adhesive tape from the No. 1 camshaft bearing cap. i. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

Fig. 50: Installing No. 1 Camshaft Bolt Using A Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

j. Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark located as shown in the illustration.

Fig. 51: Aligning Paint Mark And Timing Mark With Camshaft Timing Gear And Camshaft Timing Exhaust Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Timing *b Mark HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Refer to INITIALIZATION . 10. ADD ENGINE OIL See step 17 11. INSTALL TIMING CHAIN GUIDE See step 23 12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

a. Turn the crankshaft approximately 10° clockwise.

Fig. 52: View Of Turning Crankshaft 10° Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install a new gasket and the chain tensioner with the 2 bolts.

Fig. 53: No. 1 Chain Tensioner Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Make sure not to drop the gasket inside the timing chain cover.

c. Remove the pin from the stopper plate. 13. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 54: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Timing Mark *2 Timing Notch Approximately *a 7° Approximately *b 32° b. Check that the timing marks of the camshaft timing gears are as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration. HINT: "A" is not a timing mark. 14. INSTALL TIMING CHAIN COVER PLATE a. Install a new gasket and the timing chain cover plate with the 4 bolts.

Fig. 55: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 15. 16. 17. 18.

INSTALL TIMING CHAIN COVER TIGHT PLUG See step 38 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 43 INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 CONNECT ENGINE WIRE

a. Install the engine wire to the engine with the bolts and nuts.

Fig. 56: Identifying Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Nut A Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Nut B Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Bolt Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

19. 20. 21. 22. 23. 24. 25.

b. Connect the connectors and clamps. INSTALL ENGINE MOVING CONTROL ROD See step 38 INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 40 INSTALL AIR CLEANER CASE SUB-ASSEMBLY See step 50 INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY See step 51 INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL INLET AIR CLEANER ASSEMBLY See step 53 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL a. Connect the negative (-) battery terminal. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) NOTE:

26. 27. 28. 29. 30. 31. 32.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

INSPECT FOR OIL LEAK INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY See step 68 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL FRONT WHEEL RH

CYLINDER HEAD GASKET COMPONENTS ILLUSTRATION

Fig. 57: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 58: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (2 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 59: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 60: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 61: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 62: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (6 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 63: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (7 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Refer to REMOVAL - Step 9 2. REMOVE MANIFOLD STAY . Refer to REMOVAL - Step 6 3. REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 7 4. REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) . Refer to REMOVAL - Step 9 5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to REMOVAL - Step 8 6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to REMOVAL - Step 11 7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to REMOVAL - Step 6

8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to REMOVAL - Step 7 9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 9 10. DISCONNECT NO. 2 VENTILATION HOSE . Refer to REMOVAL - Step 8 11. REMOVE INTAKE MANIFOLD . Refer to REMOVAL - Step 12 12. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 64: Identifying Crankshaft & Camshaft Timing Gear Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Approximately Approximately *a *b 7° 32° *c Timing Mark *d Key

HINT: "A" is not a timing mark. b. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration. HINT: If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks. c. Remove the crankshaft pulley bolt. 13. REMOVE TIMING CHAIN GUIDE a. Remove the bolt and timing chain guide.

Fig. 65: Locating Timing Chain Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY a. Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

Fig. 66: Identifying Stopper Plate And Plunger Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stopper *1 Plate *2 Plunger b. Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

Fig. 67: Insert Pin Into Stopper Plate Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin c. Remove the 2 bolts, chain tensioner and gasket.

Fig. 68: Locating Chain Tensioner Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE CHAIN TENSIONER SLIPPER a. Remove the bolt and chain tensioner slipper.

Fig. 69: Locating Bolt And Chain Tensioner Slipper

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE CHAIN SUB-ASSEMBLY a. Remove the chain sub-assembly. 17. REMOVE NO. 1 CHAIN VIBRATION DAMPER a. Remove the 2 bolts and chain vibration damper.

Fig. 70: Locating Chain Vibration Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear assembly.

Fig. 71: Removing Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:





Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench. Do not disassemble the camshaft timing gear assembly.

19. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly.

Fig. 72: Removing Camshaft Timing Exhaust Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:





Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench. Do not disassemble the camshaft timing exhaust gear assembly.

20. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY a. Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

Fig. 73: Identifying Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the camshaft housing by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

Fig. 74: Locating Contact Surfaces Of Cylinder Head And Camshaft Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly.

21. REMOVE CAMSHAFT BEARING CAP a. Remove the 11 bearing cap bolts in the sequence shown in the illustration.

Fig. 75: Identifying Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bearing caps. HINT: Arrange the removed parts in the correct order. 22. REMOVE OIL CONTROL VALVE FILTER See step 35 23. REMOVE NO. 1 CAMSHAFT BEARING See step 37 24. REMOVE CAMSHAFT a. Remove the camshaft and No. 2 camshaft. 25. REMOVE NO. 2 CAMSHAFT BEARING See step 38 26. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Remove the 16 valve rocker arms from the cylinder head sub-assembly. HINT: Arrange the removed parts in the correct order. 27. REMOVE VALVE LASH ADJUSTER ASSEMBLY

a. Remove the 16 valve lash adjusters from the cylinder head sub-assembly. HINT: Arrange the removed parts in the correct order. 28. REMOVE VALVE STEM CAP a. Remove the 16 valve stem caps from the cylinder head sub-assembly. HINT: Arrange the removed parts in the correct order. 29. REMOVE CYLINDER HEAD SUB-ASSEMBLY a. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

Fig. 76: Identifying Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Be sure to keep the removed parts separate for each installation position. NOTE:



Be careful not to drop washers into the cylinder head subassembly.



Head warpage or cracking could result from removing bolts in the incorrect order.

b. Remove the cylinder head sub-assembly. 30. REMOVE CYLINDER HEAD GASKET a. Remove the cylinder head gasket from the cylinder block. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION . 1. INSPECT CYLINDER HEAD BOLT See step 17 2. INSPECT CYLINDER HEAD SUB-ASSEMBLY See step 1 3. INSTALL CYLINDER HEAD GASKET a. Clean the cylinder block and cylinder head with solvent.

Fig. 77: Identifying Cylinder Block And Cylinder Head Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder

Head Gasket Cylinder *2 Block *a Lot No. 3.0 mm *b or more 20 mm *c or more Seal Packing Front *1

b. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal dimension 3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick HINT: Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block. NOTE:

 

Remove any oil from the contact surface. Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

c. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp facing upward. NOTE:

Pay attention to the installation direction.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 4 progressive steps. a. Place the cylinder head on the cylinder block.

NOTE:





Ensure that no oil is on the mounting surface of the cylinder head sub-assembly. Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

b. Install the plate washers to the cylinder head bolts. c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. d. Step 1: 1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

Fig. 78: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) NOTE:

Do not drop the plate washer for the cylinder head bolt into the cylinder head sub-assembly.

e. Step 2: 1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)

f. Step 3: 1. Mark each cylinder head bolt head with paint as shown in the illustration.

Fig. 79: Identifying Paint Mark On Cylinder Head Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Painted *a Mark 2. Tighten the cylinder head bolts 90° in the sequence shown in step 1. g. Step 4: 1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1. 2. Check that the paint marks are now facing rearward. NOTE:

 



HINT:

Do not apply oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. After installation, if the seal packing has seeped out, wipe it off.

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION . 5. INSTALL VALVE STEM CAP a. Apply a light coat of engine oil to the valve stem ends. b. Install the 16 valve stem caps to the cylinder head. NOTE:

Do not drop the valve stem caps into the cylinder head.

6. SET CAMSHAFT TIMING GEAR ASSEMBLY HINT: When installing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation. a. Check the camshaft timing gear position.

Fig. 80: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock Pin

*1 Hole Alignment *2 Mark Advanced *a Position: Retarded *b Position: NOTE:

If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation. If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

b. Align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

Fig. 81: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin

c. Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

Fig. 82: Identifying No Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear Assembly *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance

d. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand. NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

e. Release the lock pin.

Fig. 83: Identifying Rubber, Vinyl Tape, Knock Pin, Retard Side Path And Advance Side Path Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Rubber Vinyl *2 Tape Knock *3 Pin Retard *a Side Path Advance *b Side Path *c Open *d Close 1. Clean the camshaft journal with non-residue solvent. 2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber. 3. Open a hole at port A shown in the illustration. 4. While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig. 84: Turning Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT: The camshaft timing gear assembly may be turned in the advance direction without applying any force.  If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult. 5. Remove the vinyl tape and rubber pieces from the camshaft. f. Remove the bolt and camshaft timing gear. 

NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY a. Inspect the valve lash adjuster before installing it. See step 2. b. Install the 16 lash adjusters to the cylinder head. NOTE:

Install the lash adjuster to the same place it was removed from.

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Apply engine oil to the lash adjuster tips and valve stem caps.

Fig. 85: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap

9. 10. 11. 12.

b. Install the 16 valve rocker arms as shown in the illustration. INSTALL NO. 2 CAMSHAFT BEARING See step 18 INSTALL NO. 1 CAMSHAFT BEARING See step 17 INSTALL OIL CONTROL VALVE FILTER See step 19 INSTALL CAMSHAFT a. Clean the camshaft journals, camshaft housing and bearing caps. b. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps. c. Install the camshaft and No. 2 camshaft to the camshaft housing. HINT:

Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft. Refer to INITIALIZATION . 13. INSTALL CAMSHAFT BEARING CAP a. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

Fig. 86: Identifying Camshaft Bearing Caps Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 11 bolts in the order shown in the illustration.

Fig. 87: Identifying Camshaft Bearing Caps Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE:

Make sure that the camshaft rotates smoothly after installing the bearing caps.

14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY a. Check that the valve rocker arms are installed as shown in the illustration.

Fig. 88: Identifying Valve Rocker Arm Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve Rocker *1 Arm *2 Valve Stem

Cap Valve Lash *3 Adjuster *a INCORRECT *b CORRECT b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 89: Identifying Seal Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE:

 

Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

c. Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

Fig. 90: Identifying No. 1 & No. 2 Camshaft Knock Pin Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Knock Pin Approximately *a 17° Approximately *b 2° d. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

Fig. 91: Identifying Camshaft Housing Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) NOTE:

  

Do not apply oil for at least 2 hours after the installation. Do not start the engine for at least 2 hours after the installation. Thoroughly wipe clean any seal packing.

15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY a. Check the camshaft timing gear position.

Fig. 92: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock Pin *1 Hole Alignment *2 Mark If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "Set Camshaft Timing Gear Assembly" procedures" in step 6). b. Align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

Fig. 93: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin c. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 94: Identifying No Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance d. Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

Fig. 95: Installing Camshaft Bolt Using Hexagonal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:





Be careful not to damage the cylinder head or spark plug tube with the wrench. Do not disassemble the camshaft timing gear assembly.

HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Refer to INITIALIZATION . 16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY a. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

Fig. 96: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin b. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

Fig. 97: Identifying No Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Exhaust Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance c. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

Fig. 98: Installing No. 2 Camshaft Bolt Using Hexagonal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:





Be careful not to damage the cylinder head or spark plug tube with the wrench. Do not disassemble the camshaft timing exhaust gear assembly.

HINT: Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 17. ADD ENGINE OIL a. Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

Fig. 99: Adding Engine Oil Into Oil Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Oil must be added if the lash adjusters were removed. Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

18. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 100: Identifying Crankshaft Pulley Key Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration. c. Check that the timing marks of the camshaft timing gears are as shown in the illustration.

Fig. 101: Camshaft Timing Gear Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Timing Mark

Approximately 7° Approximately *b 32° *a

HINT: "A" is not a timing mark. 19. INSTALL NO. 1 CHAIN VIBRATION DAMPER a. Install the chain vibration damper with the 2 bolts.

Fig. 102: Locating Chain Vibration Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 20. INSTALL CHAIN SUB-ASSEMBLY a. Place the chain onto the camshaft timing gears and crankshaft timing sprocket. HINT: Make sure the mark plate of the chain faces away from the engine.  It is not necessary to install the chain to the teeth of the gears and sprocket. b. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear. 

Fig. 103: Identifying Mark Plate And Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark *1 Plate Timing *2 Mark c. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

Fig. 104: Installing Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark *1 Plate Timing *2 Mark d. Tie a string above the crankshaft timing sprocket so that the chain is secure.

Fig. 105: Tying String Above Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

Fig. 106: Rotating Intake Camshaft Counterclockwise With Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark

*1 Plate Timing *2 Mark HINT: Hold the intake camshaft in place with a wrench until the chain tensioner is installed. f. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

Fig. 107: Rotating Crankshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure the chain is secure.

21. INSTALL CHAIN TENSIONER SLIPPER a. Install the chain tensioner slipper with the bolt.

Fig. 108: Locating Bolt And Chain Tensioner Slipper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY a. Install a new gasket and the chain tensioner with the 2 bolts.

Fig. 109: Locating Chain Tensioner Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Remove the pin from the stopper plate. 23. INSTALL TIMING CHAIN GUIDE a. Install the timing chain guide with the bolt.

Fig. 110: Locating Timing Chain Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 24. CHECK NO. 1 CYLINDER AT TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 111: Identifying Crankshaft & Camshaft Timing Gear Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Approximately Approximately *a *b 7° 32° *c Timing Mark *d Key b. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration. HINT: "A" is not a timing mark. c. Remove the crankshaft pulley bolt. 25. INSTALL INTAKE MANIFOLD . Refer to INSTALLATION - Step 1

26. CONNECT NO. 2 VENTILATION HOSE . Refer to INSTALLATION - Step 5 27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 28. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to INSTALLATION Step 6 29. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to INSTALLATION - Step 7 30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to INSTALLATION Step 3 31. INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) . Refer to INSTALLATION Step 5 32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to INSTALLATION - Step 4 33. INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 6 34. INSTALL MANIFOLD STAY . Refer to INSTALLATION - Step 7 35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Refer to INSTALLATION - Step 1

FRONT CRANKSHAFT OIL SEAL COMPONENTS ILLUSTRATION

Fig. 112: Identifying Front Crankshaft Oil Seal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-RIBBED BELT See step 5

6. REMOVE CRANKSHAFT PULLEY a. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

Fig. 113: Removing Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Using SST and the pulley bolt, remove the crankshaft pulley. 

Fig. 114: Removing Crankshaft Pulley Using SST & Pulley Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pulley *1 Bolt *a Hold *b Turn 

SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05011

HINT: Apply a lubricant to the threads and end of SST. 7. REMOVE TIMING CHAIN COVER OIL SEAL a. Using a screwdriver, pry out the oil seal.

Fig. 115: Prying Out Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. NOTE:

Do not damage the surface of the oil seal press fit hole or the crankshaft.

INSTALLATION INSTALLATION

1. INSTALL TIMING CHAIN COVER OIL SEAL a. Apply MP grease to the lip of a new oil seal. NOTE:

 

Do not allow foreign matter to contact the lip of the oil seal. Do not allow MP grease to contact the dust seal.

b. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

Fig. 116: Installing Oil Seal Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09223-22010

NOTE:

 

Keep the lip of the oil seal free from foreign matter. Do not tap in the oil seal at an angle.

2. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST, hold the crankshaft pulley and install the pulley bolt.

Fig. 117: Installing Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn   

SST: 09213-54015 SST: 09330-00021 SST: 91551-80650

Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 3. 4. 5. 6. 7.

INSTALL V-RIBBED BELT See step 1 INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR CRANKSHAFT OIL SEAL COMPONENTS

ILLUSTRATION

Fig. 118: Identifying Rear Crankshaft Oil Seal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Refer to REMOVAL 2. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY a. Using SST, hold the crankshaft pulley.

Fig. 119: Identifying SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly, and rear drive plate spacer. 

Fig. 120: Locating Drive Plate And Ring Gear Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE REAR ENGINE OIL SEAL a. Using a knife, cut off the lip of the oil seal.

Fig. 121: Removing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cut *a Position b. Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. NOTE:

Do not damage the surface of the oil seal press fit hole or the crankshaft.

INSTALLATION INSTALLATION

1. INSTALL REAR ENGINE OIL SEAL a. Apply MP grease to the lip of a new oil seal. NOTE:

 

Do not allow foreign matter to contact the lip of the oil seal. Do not allow MP grease to contact the dust seal.

b. Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

Fig. 122: Installing Rear Engine Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09223-15030 SST: 09950-70010 09951-07150

NOTE:

 

Keep the lip of the oil seal free from foreign matter. Do not tap in the oil seal at an angle.

2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY a. Using SST, hold the crankshaft.

Fig. 123: Identifying SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 91551-80650  SST: 09330-00021 b. Clean the bolts and their installation holes. c. Install the front drive plate spacer. 

Fig. 124: Aligning Pin Of Front Drive Plate Spacer With Pin Hole Of Crankshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT:

Align the pin of the front drive plate spacer with the pin hole of the crankshaft. d. Install the drive plate and rear drive plate spacer onto the crankshaft.

Fig. 125: Identifying Drive Plate And Rear Drive Plate Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive *1 Plate Rear Drive *2 Plate Spacer Transaxle Side

e. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts.

Fig. 126: Apply Adhesive To End Threads Of Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent f. Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

Fig. 127: Identifying Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf) NOTE:

Do not start the engine for at least an hour after installing the drive plate.

3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to INSTALLATION

ENGINE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 128: Identifying Engine Assembly Replacement Components With Torque Specifications (1 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 129: Identifying Engine Assembly Replacement Components With Torque Specifications (2 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 130: Identifying Engine Assembly Replacement Components With Torque Specifications (3 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 131: Identifying Engine Assembly Replacement Components With Torque Specifications (4 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 132: Identifying Engine Assembly Replacement Components With Torque Specifications (5 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 133: Identifying Engine Assembly Replacement Components With Torque Specifications (6 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

WARNING: The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop. NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to REPLACEMENT Step 1 3. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 4. 5. 6. 7.

PLACE FRONT WHEELS FACING STRAIGHT AHEAD SECURE STEERING WHEEL REMOVE FRONT WHEELS DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL . Refer to REPLACEMENT - Step 1 DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 DRAIN AUTOMATIC TRANSAXLE FLUID . Refer to REPLACEMENT - Step 1 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY a. Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

Fig. 134: Identifying No. 1 Engine Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

19. REMOVE INLET AIR CLEANER ASSEMBLY a. Remove the 2 bolts and inlet air cleaner assembly.

Fig. 135: Identifying Inlet Air Cleaner Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY a. Remove the air cleaner filter element sub-assembly. 22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY a. Disconnect the wire harness clamp.

Fig. 136: Identifying Air Cleaner Case Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and air cleaner case sub-assembly. 23. REMOVE BATTERY a. Loosen the nut, and separate the positive (+) battery terminal.

Fig. 137: Identifying Battery Clamp, Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Loosen the nut, and remove the bolt and battery clamp. c. Remove the battery and battery tray. 24. DISCONNECT NO. 1 RADIATOR HOSE a. Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.

Fig. 138: Identifying Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the No. 1 radiator hose. 25. DISCONNECT NO. 2 RADIATOR HOSE a. Disconnect the No. 2 radiator hose.

Fig. 139: Identifying No. 2 Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. DISCONNECT INLET HEATER WATER HOSE a. Disconnect the inlet heater water hose.

Fig. 140: Identifying Inlet Heater Water Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. DISCONNECT OUTLET HEATER WATER HOSE a. Disconnect the 3 outlet heater water hoses.

Fig. 141: Identifying Outlet Heater Water Hoses

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE STARTER ASSEMBLY . Refer to REMOVAL - Step 10 29. DISCONNECT ENGINE WIRE a. Remove the No. 1 relay block cover. b. Remove the 2 nuts and disconnect the wire clamp.

Fig. 142: Disconnecting Wire Clamp And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. d. Disconnect the 4 connectors.

Fig. 143: Identifying Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. f. Pull up the lever to disconnect the ECM connector.

Fig. 144: Identifying ECM Connector And Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disconnect the 2 wire clamps. 30. DISCONNECT NO. 1 AIR CLEANER BRACKET a. Disconnect the 2 wire clamps.

Fig. 145: Identifying No. 1 Air Cleaner Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and No. 1 air cleaner bracket. 31. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY a. Remove the nut and disconnect the transmission control cable from the control shaft lever.

Fig. 146: Locating Transmission Control Cable Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.

Fig. 147: Remove The Clip From The Transmission Cable Bracket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE NO. 2 ENGINE MOUNTING STAY RH a. Remove the 2 bolts and No. 2 engine mounting stay RH.

Fig. 148: Identifying No. 2 Engine Mounting Stay Bolts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. SEPARATE EARTH WIRE a. Remove the bolt and separate the earth wire from the engine moving control rod bracket.

Fig. 149: Identifying Earth Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE ENGINE MOVING CONTROL ROD BRACKET a. Remove the 4 bolts and engine moving control rod bracket.

Fig. 150: Identifying Engine Moving Control Rod Bracket And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE ENGINE MOVING CONTROL ROD a. Remove the bolt and engine moving control rod from the engine moving control rod bracket.

Fig. 151: Identifying Engine Moving Control Rod Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary. 36. DISCONNECT UNION TO CONNECTOR TUBE HOSE a. Disconnect the union to connector tube hose.

Fig. 152: Identifying Union And Connector Tube Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to REMOVAL Step 5 38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) . Refer to REMOVAL Step 6 39. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) . Refer to REMOVAL - Step 7 40. DISCONNECT FUEL TUBE SUB-ASSEMBLY a. Release the claw and remove the No. 1 fuel pipe clamp.

Fig. 153: Removing No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pinch the fuel tube connector and then pull out the fuel main tube. NOTE:



  



Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector. Disconnect the connector by hand. Do not bend, fold or rotate the nylon tube. If the pipe and connector are stuck together, push and pull the connector until it becomes free. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

41. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to REMOVAL - Step 4 42. REMOVE FRONT AXLE SHAFT NUT LH . Refer to REMOVAL - Step 9 43. REMOVE FRONT AXLE SHAFT NUT RH HINT: Use the same procedure described for the LH side. 44. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to REMOVAL - Step 4 45. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedure described for the LH side. 46. SEPARATE FRONT SPEED SENSOR LH . Refer to REMOVAL - Step 3 47. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side. 48. SEPARATE TIE ROD ASSEMBLY LH . Refer to REMOVAL - Step 5 49. SEPARATE TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side. 50. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 8 51. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Use the same procedure described for the LH side. 52. SEPARATE FRONT AXLE ASSEMBLY LH . Refer to REMOVAL - Step 7 53. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedure described for the LH side. 54. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to REMOVAL - Step 4 55. REMOVE FLYWHEEL HOUSING UNDER COVER a. Remove the flywheel housing under cover.

Fig. 154: Locating Flywheel Housing Under Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 56. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT a. Turn the crankshaft to gain access to the removal locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

Fig. 155: Locating Torque Converter Clutch Setting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE a. Set the engine lifter.

Fig. 156: Identifying Engine Lifter Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Attachment Installation Position NOTE:







Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.





Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.

b. Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.

Fig. 157: Identifying Frame Side Rail Plate Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.

d. Operate the engine lifter and remove the engine assembly from the vehicle. NOTE:

 

58. 59. 60. 61. 62. 63. 64. 65.

Make sure that the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle.

e. Install engine hangers See step 20. REMOVE ENGINE WIRE a. Remove the engine wire from the engine with transaxle. REMOVE V-RIBBED BELT See step 5 REMOVE COMPRESSOR ASSEMBLY WITH PULLEY . Refer to REMOVAL - Step 8 REMOVE GENERATOR ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to REMOVAL - Step 15 REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REMOVAL - Step 17 REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to REMOVAL - Step 16 REMOVE FRONT FRAME ASSEMBLY a. Remove the nut and separate the engine mounting insulator LH.

Fig. 158: Identifying Engine Mounting Insulator Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and separate the front engine mounting insulator.

Fig. 159: Identifying Front Engine Mounting Insulator Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the nut and separate the engine mounting insulator RH.

Fig. 160: Identifying Engine Mounting Insulator Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the front frame assembly. e. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface. NOTE:







Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Using an engine sling device and engine lift, secure the engine assembly before service.

66. REMOVE FRONT ENGINE MOUNTING INSULATOR a. Remove the 3 nuts and front engine mounting insulator.

Fig. 161: Identifying Engine Mounting Insulator Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. 67. REMOVE ENGINE MOUNTING INSULATOR LH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 162: Front Frame Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. 68. REMOVE ENGINE MOUNTING INSULATOR RH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 163: Identifying Front Frame Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 69. REMOVE DRIVE SHAFT BEARING BRACKET a. Remove the 3 bolts and drive shaft bearing bracket.

Fig. 164: Locating Drive Shaft Bearing Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 70. REMOVE ENGINE MOUNTING BRACKET RH a. Remove the 3 bolts and engine mounting bracket RH.

Fig. 165: Locating Engine Mounting Bracket RH Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 71. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY . Refer to REMOVAL - Step 8 72. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 73. INSTALL ENGINE STAND a. Install the engine onto an engine stand with the bolts. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. REMOVE ENGINE STAND a. Using a chain block and engine sling device, secure the engine assembly. NOTE:





Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged. Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

b. Remove the engine stand from the engine. 2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY . Refer to INSTALLATION - Step 8 4. INSTALL ENGINE MOUNTING BRACKET RH a. Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 5. INSTALL DRIVE SHAFT BEARING BRACKET a. Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 6. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR a. Temporarily install the front engine mounting insulator with the 3 nuts. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary.

7. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH a. Temporarily install the engine mounting insulator LH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. 8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH a. Temporarily install the engine mounting insulator RH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 9. INSTALL FRONT FRAME ASSEMBLY a. Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) b. Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) c. Install the front engine mounting insulator with the bolt. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) d. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

Fig. 166: Identifying Engine Mounting Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Front Engine Engine Mounting *1 *2 Mounting Insulator Insulator RH Engine Mounting *3 - Insulator LH HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary. A Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) B Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 4 hole plugs.

Fig. 167: Identifying Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine Engine Mounting Mounting *1 *2 Insulator Insulator RH LH HINT:

Perform this procedure only when replacement of the engine mounting insulator is necessary. 10. 11. 12. 13. 14. 15. 16.

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REASSEMBLY - Step 13 INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL GENERATOR ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL COMPRESSOR ASSEMBLY WITH PULLEY . Refer to INSTALLATION - Step 2 INSTALL V-RIBBED BELT See step 1 INSTALL ENGINE WIRE a. Install the engine wire to the engine with transaxle. 17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE a. Set the engine assembly with transaxle on an engine lifter. NOTE:









Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Make sure to support the engine assembly with transaxle securely to prevent it from falling.

b. Remove the engine hangers See step 1. c. Install the engine assembly to the vehicle. NOTE:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

HINT: Make sure that the engine is clear of all wiring and hoses.  While raising the engine into the vehicle, do not allow it to contact the vehicle. d. Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts. 

Fig. 168: Identifying Frame Side Rail Plate Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf) B Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) e. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. C Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf)

D Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 18. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT a. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter setting bolts.

Fig. 169: Apply Adhesive To End Threads Of Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent b. Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

Fig. 170: Locating Torque Converter Clutch Setting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTE:

Install the black colored bolt first, and then the 5 silver colored bolts.

19. INSTALL FLYWHEEL HOUSING UNDER COVER a. Install the flywheel housing under cover. 20. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to INSTALLATION Step 10 21. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 8 22. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Use the same procedure described for the LH side. 23. INSTALL TIE ROD ASSEMBLY LH . Refer to INSTALLATION - Step 8 24. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side.

25. INSTALL FRONT SPEED SENSOR LH . Refer to INSTALLATION - Step 19 26. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side. 27. INSTALL FRONT STABILIZER LINK ASSEMBLY LH . Refer to INSTALLATION - Step 10 28. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure described for the LH side. 29. INSTALL FRONT AXLE SHAFT NUT LH . Refer to INSTALLATION - Step 7 30. INSTALL FRONT AXLE SHAFT NUT RH HINT: Use the same procedure described for the LH side. 31. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to INSTALLATION - Step 2 32. CONNECT FUEL TUBE SUB-ASSEMBLY a. Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.

Fig. 171: Pushing Fuel Tube Connector To Fuel Pipe

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Check for damage or contamination on the connected part of the pipe. Check if the pipe and the connector are securely connected by trying to pull them apart.

b. Install the No. 1 fuel pipe clamp.

Fig. 172: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to INSTALLATION Step 3 34. INSTALL SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) . Refer to INSTALLATION Step 4 35. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) . Refer to INSTALLATION - Step 5 36. CONNECT UNION TO CONNECTOR TUBE HOSE a. Connect the union to connector tube hose. 37. INSTALL ENGINE MOVING CONTROL ROD a. Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt. HINT:

Perform this procedure only when replacement of the engine moving control rod is necessary. 38. INSTALL ENGINE MOVING CONTROL ROD BRACKET a. When the engine moving control rod has been replaced. 1. Temporarily install the engine moving control rod bracket with the 4 bolts.

Fig. 173: Identifying Engine Moving Control Rod Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Fully tighten the engine moving control rod bracket with the bolts except bolt A.

Fig. 174: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 3. Fully tighten the bolt A.

Fig. 175: Identifying Engine Moving Control Rod Bracket Bolt A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09961-00950

Without SST Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) With SST Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf) NOTE:







The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.24 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench. Fully tighten the bolt A using SST.

b. When the engine moving control rod has been reused.

Fig. 176: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1. Temporarily install the engine moving control rod bracket with the 4 bolts. 2. Fully tighten the engine moving control rod bracket with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 39. INSTALL EARTH WIRE a. Install the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 40. INSTALL NO. 2 ENGINE MOUNTING STAY RH a. Install the No. 2 engine mounting stay RH with the 2 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY a. Connect the control cable to the bracket with a new clip.

Fig. 177: Remove The Clip From The Transmission Cable Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the control cable to the control shaft lever with the nut.

Fig. 178: Locating Transmission Control Cable Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 42. INSTALL NO. 1 AIR CLEANER BRACKET a. Install the No. 1 air cleaner bracket to the battery carrier with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 2 wire clamps. 43. CONNECT ENGINE WIRE a. Connect the 2 wire clamps.

Fig. 179: Identifying Engine Wire Clamps And Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Connect the connector to the ECM with the lock lever. Connect the engine wire to the engine room relay block. Connect the 4 connectors. Connect the engine wire to the engine room relay block.

Fig. 180: Identifying Wire Clamp And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Connect the wire clamp and install the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

44. 45. 46. 47. 48. 49.

g. Install the No. 1 relay block cover. INSTALL STARTER ASSEMBLY . Refer to INSTALLATION - Step 1 CONNECT INLET HEATER WATER HOSE a. Connect the inlet heater water hose. CONNECT OUTLET HEATER WATER HOSE a. Connect the 3 outlet heater water hoses. CONNECT NO. 1 RADIATOR HOSE a. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp. CONNECT NO. 2 RADIATOR HOSE a. Connect the No. 2 radiator hose. INSTALL BATTERY a. Install the battery and battery tray. b. Install the battery clamp with the bolt and nut. Bolt Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

Nut Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) c. Connect the positive (+) battery terminal Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 50. INSTALL AIR CLEANER CASE SUB-ASSEMBLY a. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

Fig. 181: Identifying Air Cleaner Case Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hole *b Projection

b. Tighten the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) c. Connect the wire harness clamp. 51. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY a. Install the air cleaner filter element sub-assembly. NOTE:

Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

52. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 53. INSTALL INLET AIR CLEANER ASSEMBLY a. Install the inlet air cleaner with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL a. Connect the negative (-) battery terminal. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

55. ADD ENGINE OIL 56. ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 57. ADD AUTOMATIC TRANSAXLE FLUID Refer to ADJUSTMENT 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68.

CHARGE WITH REFRIGERANT . Refer to REPLACEMENT - Step 2 WARM UP ENGINE INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSPECT FOR OIL LEAK INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSPECT FOR EXHAUST GAS LEAK INSPECT REFRIGERANT LEAK . Refer to REPLACEMENT - Step 4 INSPECT IGNITION TIMING See step 7 INSPECT ENGINE IDLE SPEED See step 8 INSPECT CO/HC See step 10 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

a. Fit the 3 retainers and install the No. 1 engine cover sub-assembly. 69. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 70. INSPECT SHIFT LEVER POSITION Refer to ADJUSTMENT - Step 1 71. ADJUST SHIFT LEVER POSITION Refer to ADJUSTMENT - Step 2 72. 73. 74. 75. 76. 77. 78.

INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

79. ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT 80. CHECK ABS SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

ENGINE UNIT COMPONENTS ILLUSTRATION

Fig. 182: Identifying Engine Unit Replacement Components With Torque Specifications (1 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 183: Identifying Engine Unit Replacement Components With Torque Specifications (2 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 184: Identifying Engine Unit Replacement Components With Torque Specifications (3 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 185: Identifying Engine Unit Replacement Components With Torque Specifications (4 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 186: Identifying Engine Unit Replacement Components With Torque Specifications (5 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 187: Identifying Engine Unit Replacement Components With Torque Specifications (6 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 188: Identifying Engine Unit Replacement Components With Torque Specifications (7 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 189: Identifying Engine Unit Replacement Components With Torque Specifications (8 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 190: Identifying Engine Unit Replacement Components With Torque Specifications (9 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 191: Identifying Engine Unit Replacement Components With Torque Specifications (10 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 192: Identifying Engine Unit Replacement Components With Torque Specifications (11 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE ENGINE HANGERS a. Remove the 2 bolts and 2 engine hangers.

Fig. 193: Identifying Engine Hangers Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Engine Hanger No. 2 *2 Engine Hanger 2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE a. Remove the engine oil level dipstick.

Fig. 194: Locating Dipstick Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6. 7. 8.

b. Remove the bolt and engine oil level dipstick guide. c. Remove the O-ring from the engine oil level dipstick guide. REMOVE MANIFOLD STAY . Refer to REMOVAL - Step 6 REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 7 REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) . Refer to REMOVAL - Step 9 REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to REMOVAL - Step 8 REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to REMOVAL - Step 11 REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET a. Remove the 4 bolts and bracket.

Fig. 195: Locating NO. 1 Compressor Mounting Bracket & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to REMOVAL - Step 8 10. REMOVE WATER BY-PASS HOSE a. Remove the No. 1 and No. 2 water by-pass hoses.

Fig. 196: Locating No. 1 And No. 2 Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to REMOVAL - Step 7 12. DISCONNECT NO. 2 VENTILATION HOSE . Refer to REMOVAL - Step 8 13. REMOVE UNION TO CONNECTOR TUBE HOSE . Refer to REMOVAL - Step 9 14. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 9 15. REMOVE INTAKE MANIFOLD . Refer to REMOVAL - Step 12 16. REMOVE SENSOR WIRE a. Disconnect the knock control sensor connector.

Fig. 197: Identifying Knock Control Sensor Connector, Wire And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

17. 18. 19. 20.

b. Remove the bolt and knock control sensor wire. REMOVE KNOCK CONTROL SENSOR . Refer to REMOVAL - Step 2 REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to REMOVAL - Step 1 REMOVE ENGINE COOLANT TEMPERATURE SENSOR . Refer to REMOVAL - Step 9 REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2

DISASSEMBLY DISASSEMBLY

1. REMOVE ENGINE COVER JOINT a. Remove the 3 joints.

Fig. 198: Locating Engine Cover Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SPARK PLUG . Refer to REMOVAL - Step 3 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to REMOVAL Step 3 4. REMOVE CAMSHAFT POSITION SENSOR . Refer to REMOVAL - Step 2 5. REMOVE OIL FILLER CAP SUB-ASSEMBLY a. Remove the oil filler cap from the cylinder head. b. Remove the gasket from the oil filler cap. 6. REMOVE CRANKSHAFT POSITION SENSOR . Refer to REMOVAL - Step 1 7. REMOVE VENTILATION VALVE SUB-ASSEMBLY . Refer to REMOVAL - Step 2 8. REMOVE VENTILATION CASE SUB-ASSEMBLY a. Remove the 8 bolts and 2 nuts.

Fig. 199: Locating Ventilation Case Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the ventilation case by prying between the ventilation case and cylinder block with a screwdriver.

Fig. 200: Locating Contact Surfaces Of Cylinder Block And Ventilation Case

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. NOTE:

Be careful not to damage the contact surfaces of the cylinder block and ventilation case.

9. REMOVE SEPARATOR CASE a. Remove the 2 bolts, separator case and gasket.

Fig. 201: Identifying Case And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 1 WATER BY-PASS PIPE a. Remove the bolt, 2 nuts, water by-pass pipe and gasket.

Fig. 202: Locating Water By-Pass Pipe And Gasket Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE WATER INLET . Refer to REMOVAL - Step 3 12. REMOVE THERMOSTAT . Refer to REMOVAL - Step 4 13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY a. Remove the bolt and V-ribbed belt tensioner.

Fig. 203: Locating Bolt And V-Ribbed Belt Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE ENGINE WATER PUMP ASSEMBLY . Refer to REMOVAL - Step 5 15. REMOVE WATER INLET HOUSING a. Remove the 4 bolts, nut, inlet water housing and gasket.

Fig. 204: Locating Inlet Water Housing And Gasket Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE CRANKSHAFT PULLEY a. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

Fig. 205: Removing Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Using SST and the pulley bolt, remove the crankshaft pulley. 

Fig. 206: Removing Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pulley *1 Bolt *a Hold *b Turn 

SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05011

HINT: Apply a lubricant to the threads and end of SST. 17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY a. Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.

Fig. 207: Locating Cylinder Head Cover And Gasket Bolts And Seal Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 gaskets from the camshaft bearing caps.

Fig. 208: Locating Camshaft Bearing Caps Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE SPARK PLUG TUBE GASKET a. Using a screwdriver, pry out the 4 plug tube gaskets.

Fig. 209: Prying Out Plug Tube Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the cylinder head cover.

HINT: Tape the screwdriver tip before use.

19. REMOVE ENGINE MOUNTING BRACKET RH . Refer to REMOVAL - Step 7 20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 9 21. REMOVE TIMING CHAIN COVER TIGHT PLUG a. Using a 14 mm hexagon wrench, remove the plug and gasket.

Fig. 210: Identifying Plug And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE TIMING CHAIN COVER PLATE a. Remove the 4 bolts, timing chain cover plate and gasket.

Fig. 211: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. 24. 25. 26. 27. 28.

REMOVE TIMING CHAIN COVER OIL SEAL . Refer to REMOVAL - Step 10 SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 12 REMOVE TIMING CHAIN GUIDE See step 13 REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 14 REMOVE CHAIN TENSIONER SLIPPER See step 15 REMOVE CHAIN SUB-ASSEMBLY a. Remove the chain sub-assembly. 29. REMOVE NO. 1 CHAIN VIBRATION DAMPER See step 17 30. REMOVE CRANKSHAFT TIMING SPROCKET a. Remove the crankshaft timing sprocket from the crankshaft.

Fig. 212: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. 32. 33. 34. 35.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY See step 18 REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY See step 19 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY See step 20 REMOVE CAMSHAFT BEARING CAP See step 21 REMOVE OIL CONTROL VALVE FILTER a. Remove the oil control valve filter from the No. 1 camshaft bearing cap.

Fig. 213: Identifying Oil Control Valve Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE CAMSHAFT See step 24 37. REMOVE NO. 1 CAMSHAFT BEARING a. Remove the No. 1 camshaft bearing.

Fig. 214: Identifying No. 1 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE NO. 2 CAMSHAFT BEARING a. Remove the No. 2 camshaft bearing.

Fig. 215: Identifying No. 2 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. REMOVE CAMSHAFT HOUSING STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

40. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

41. REMOVE CAMSHAFT HOUSING STRAIGHT PIN NOTE: 42. 43. 44. 45.

It is not necessary to remove the straight pin unless it is being replaced.

REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 26 REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 27 REMOVE VALVE STEM CAP See step 28 REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 29

46. REMOVE CYLINDER HEAD GASKET See step 30 47. REMOVE CYLINDER BLOCK WATER JACKET SPACER a. Remove the cylinder block water jacket spacer from the cylinder block.

Fig. 216: Identifying Cylinder Block Water Jacket Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block is inverted.

48. REMOVE OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 2 49. REMOVE OIL PAN SUB-ASSEMBLY a. Remove the 11 bolts and 2 nuts.

Fig. 217: Identifying Oil Pan Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut b. Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.

Fig. 218: Inserting Blade Of SST Between No. 1 & No. 2 Oil Pans Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to damage the stiffening crankcase contact surface of the oil pan. Be careful not to damage the stiffening crankcase flange.

50. REMOVE OIL STRAINER SUB-ASSEMBLY a. Remove the 3 bolts, oil strainer and gasket.

Fig. 219: Locating Oil Strainer And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 51. REMOVE NO. 1 OIL PAN BAFFLE PLATE a. Remove the 5 bolts and oil pan baffle plate.

Fig. 220: Locating Oil Pan Baffle Plate Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 52. INSPECT CRANKSHAFT BACKLASH a. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

Fig. 221: Measuring Backlash Of Crankshaft And Balance Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard backlash 0.005 to 0.020 mm (0.000197 to 0.000787 in.) Maximum backlash 0.020 mm (0.000787 in.) If the backlash is more than the maximum, replace the engine balancer assembly. 53. REMOVE ENGINE BALANCER ASSEMBLY a. Remove the 7 bolts and engine balancer.

Fig. 222: Locating Engine Balancer Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the engine balancer.

54. INSPECT BALANCE SHAFT THRUST CLEARANCE See step 14 55. REMOVE STIFFENING CRANKCASE ASSEMBLY a. Remove the 7 bolts.

Fig. 223: Locating Stiffening Crankcase Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

Fig. 224: Locating Stiffening Crankcase & Cylinder Block Prying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*a Side: RH *b Side: HINT: Tape the screwdriver tip before use. NOTE:

Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.

56. REMOVE STIFFENING CRANKCASE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

57. REMOVE STIFFENING CRANKCASE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

58. REMOVE REAR ENGINE OIL SEAL a. Remove the rear engine oil seal from the cylinder block.

Fig. 225: Identifying Rear Engine Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION

INSPECTION

1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Turn the roller by hand to check that it turns smoothly.

Fig. 226: Inspecting No. 1 Valve Rocker Arm Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the roller does not turn smoothly, replace the valve rocker arm sub-assembly. 2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE:

 

Keep the adjuster free from dirt and foreign matter. Use only clean engine oil.

Fig. 227: Inspecting Valve Lash Adjuster Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Plunger *2 Check Ball *a CORRECT *b INCORRECT *c Taper Part Low Pressure *d Chamber High Pressure *e Chamber a. Place the lash adjuster into a container full of new engine oil. b. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.  SST: 09276-75010 c. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times. d. Check the movement of the plunger and bleed the air. OK Plunger moves up and down. NOTE:

When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

e. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly. 3. INSPECT CAMSHAFT OIL CLEARANCE See step 8 4. INSPECT CAMSHAFT THRUST CLEARANCE See step 9 5. INSPECT CAMSHAFT a. Inspect the camshaft runout.

Fig. 228: Checking Camshaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Place the camshaft on V-blocks. 2. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the camshaft sub-assembly. HINT: Check the oil clearance after replacing the camshaft. b. Inspect the cam lobes.

Fig. 229: Checking Cam Lobes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Specified Condition 44.163 to 44.305 Intake mm (1.739 to 1.744 in.) 44.144 to 44.286 Exhaust mm (1.738 to 1.744 in.) Item

Minimum Cam Lobe Height Item

Specified Condition

Intake 44.013 mm

(1.733 in.) 43.996 Exhaust mm (1.732 in.) If the cam lobe height is less than the minimum, replace the camshaft sub-assembly. c. Inspect the camshaft journals.

Fig. 230: Checking Camshaft Journals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the journal diameter. Standard Journal Diameter Specified Condition 34.449 to 34.465 No. 1 mm journal (1.356 to 1.357 in.) Item

Other 22.959 to journals 22.975 mm

(0.904 to 0.905 in.) If the journal diameter is not as specified, check the oil clearance See step 8. 6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY a. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Fig. 231: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin b. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 232: Identifying No Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance c. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

d. Check the lock of the camshaft timing gear. 1. Make sure that the camshaft timing gear is locked. NOTE: e. Release the lock pin.

Be careful not to damage the camshaft.

Fig. 233: Identifying Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Rubber Vinyl *2 Tape Knock *3 Pin Retard *a Side Path Advance *b Side Path *c Open *d Close 1. Clean the camshaft journal with non-residue solvent. 2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber. 3. Open a hole at port A shown in the illustration. 4. While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig. 234: Turning Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT: The camshaft timing gear assembly may be turned in the advance direction without applying any force.  If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult. f. Check for smooth rotation. 1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. 

NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

g. Remove the vinyl tape and rubber pieces from the camshaft. h. Remove the bolt and camshaft timing gear. 7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY a. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

Fig. 235: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin b. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

Fig. 236: Identifying No Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Exhaust Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance c. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing

exhaust gear by hand. d. Check the lock of the camshaft timing exhaust gear. 1. Make sure that the camshaft timing exhaust gear is locked. NOTE: e. Release the lock pin.

Be careful not to damage the camshaft.

Fig. 237: Identifying Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Vinyl Tape *2 Rubber Knock *3 Pin Retard *a Side Path Advance *b Side Path *c Open *d Close *1

1. Clean the camshaft journal with non-residue solvent. 2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with rubber pieces. 3. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. 4. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the two open paths (the advance side path and retard side path).

Fig. 238: Applying Compressed Air To Camshaft Journal Oil Paths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Retard *1 Side Path Advance *2 Side Path NOTE:

Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

5. Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.

Fig. 239: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Retard Side *1 Path Advance *2 Side Path Hold *3 Pressure *4 Decompress HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction. 6. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTE:

Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.

f. Check for smooth rotation.

1. Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE:

When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

g. Check the lock at the most advanced position. 1. Make sure that the camshaft timing exhaust gear locks at the most advanced position. h. Remove the vinyl tape and rubber pieces from the camshaft. i. Remove the bolt and camshaft timing gear. 8. INSPECT CHAIN SUB-ASSEMBLY

Fig. 240: Inspecting Chain Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Area a. Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

b. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation 137.7 mm (5.42 in.) HINT: Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the chain sub-assembly. 9. INSPECT CRANKSHAFT TIMING SPROCKET a. Place the chain around the sprocket.

Fig. 241: Measuring Sprocket Diameter With Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 59.94 mm (2.36 in.) If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket. HINT:

The vernier caliper must contact the chain rollers for the measurement. 10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY a. Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.

Fig. 242: Inspecting No. 1 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If necessary, replace the No. 1 chain tensioner assembly. 11. INSPECT CHAIN TENSIONER SLIPPER a. Measure the worn depth of the chain tensioner slipper.

Fig. 243: Measuring Chain Tensioner Slipper Depth

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the chain tensioner slipper. 12. INSPECT NO. 1 CHAIN VIBRATION DAMPER a. Measure the worn depth of the chain vibration damper.

Fig. 244: Measuring Chain Vibration Damper Worn Depth Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper.

13. INSPECT TIMING CHAIN GUIDE a. Measure the worn depth of the timing chain guide.

Fig. 245: Measuring Timing Chain Guide Worn Depth Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the timing chain guide. 14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

Fig. 246: Inspecting No. 1 Balance Shaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly. 15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

Fig. 247: Inspecting No. 2 Balance Shaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly. 16. INSPECT BALANCE SHAFT BACKLASH a. Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

Fig. 248: Measuring No. 1 And No. 2 Balance Shafts Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Fix Standard backlash 0.04 to 0.17 mm (0.00157 to 0.00669 in.) Maximum backlash 0.17 m (0.00669 in.) NOTE:

Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.

If the backlash is more than the maximum, replace the engine balancer assembly. 17. INSPECT CYLINDER HEAD BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point.

Fig. 249: Inspecting Cylinder Head Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 10.85 to 11.00 mm (0.427 to 0.433 in.) Minimum diameter 10.6 mm (0.417 in.) Measurement point (distance from the seat) 106 mm (4.17 in.) HINT: If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the cylinder head bolt with a new one. 18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts 

the cylinder head.

Fig. 250: Measuring Warpage Of Exhaust Manifold Converter Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold. REASSEMBLY REASSEMBLY

1. INSTALL ENGINE BALANCER ASSEMBLY a. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

Fig. 251: Aligning Marks To Balance Shaft Damper And Balance Shaft Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment *a Mark If the alignment marks are not aligned, realign them. 1. Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

Fig. 252: Identifying Driven Gear And Damper Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Driven *1 Gear Damper *2 Cover Alignment *a Mark 2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover. b. Install the engine balancer to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

Fig. 253: Identifying Engine Balancer Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 2. INSTALL STIFFENING CRANKCASE STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

Fig. 254: Identifying Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for stud bolt A

Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for stud bolt B Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) TEXT IN ILLUSTRATION Front Lower *a *b Side Side 3. INSTALL STIFFENING CRANKCASE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

Fig. 255: Locating Stiffening Crankcase Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 4.3 to 5.3 mm (0.169 to 0.209 in.) TEXT IN ILLUSTRATION Protrusion *a Height 4. INSTALL STIFFENING CRANKCASE ASSEMBLY a. Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.

Fig. 256: Rotating Crankshaft Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Key b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 257: Identifying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Dimension Specified Condition 2.5 to 3.5 Continuous mm Line (0.0984 to 0.138 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.) Dashed wide and Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick Area

Application Length A 28 mm (1.10 in.) TEXT IN ILLUSTRATION Stiffening Crankcase Cylinder Block NOTE:

 



Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Do not apply oil for at least 2 hours after the installation.

c. Check that the rear cutout parts are as shown in the illustration.

Fig. 258: Identifying Stiffening Crankcase Rear Cutout Parts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout d. Clean the bolts and their installation holes. e. Apply adhesive to 3 or more threads of the ends of bolts A.

Fig. 259: Applying Adhesive To Bolt Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent TEXT IN ILLUSTRATION *1 Adhesive f. Temporarily install the stiffening crankcase with the 11 bolts.

Fig. 260: Identifying Stiffening Crankcase Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Length Item Length 65 mm Bolt (2.56 A in.) 35 mm Bolt (1.38 B in.) 125 Bolt mm C (4.92 in.) 165 Bolt mm D (6.50 in.) HINT: Apply adhesive to bolts A before installing them. g. Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

Fig. 261: Identifying Stiffening Crankcase Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for Bolt A Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) except Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 5. INSTALL NO. 1 OIL PAN BAFFLE PLATE a. Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

Fig. 262: Identifying No. 1 Oil Pan Baffle Plate Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 6. INSTALL OIL STRAINER SUB-ASSEMBLY a. Apply a light coat of engine oil to a new gasket. b. Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer.

Fig. 263: Identifying 3 Oil Strainer Bolts With Tightening Sequence & Aligning Gasket Protrusion To Oil Strainer Cutout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Protrusion c. Install the oil strainer with the 3 bolts in several steps, in the sequence shown in the illustration. Torque: 9 N*m (92 kgf*cm, 80 in.*lbf) 7. INSTALL OIL PAN SUB-ASSEMBLY a. Apply seal packing in a continuous line as shown in the illustration.

Fig. 264: Applying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTE:

 



Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing. Do not apply oil for at least 2 hours after the installation.

b. Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

Fig. 265: Identifying Oil Pan Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) TEXT IN ILLUSTRATION *1 Nut HINT: Bolt A and nut A are tightened twice. 8. INSTALL OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 3 9. INSTALL REAR ENGINE OIL SEAL See step 1 10. INSTALL CYLINDER BLOCK WATER JACKET SPACER a. Install the water jacket spacer to the cylinder block.

Fig. 266: Identifying Cylinder Block Water Jacket Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. 12. 13. 14.

INSTALL CYLINDER HEAD GASKET See step 3 INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 4 SET CAMSHAFT TIMING GEAR ASSEMBLY See step 6 INSTALL CAMSHAFT BEARING CAP SETTING RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

Fig. 267: Locating Camshaft Bearing Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) TEXT IN ILLUSTRATION Protrusion *a Height 15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN NOTE:

It is not necessary to remove the straight pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

Fig. 268: Locating Camshaft Housing Straight Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 5.0 to 7.0 mm (0.197 to 0.276 in.) TEXT IN ILLUSTRATION Protrusion *a Height 16. INSTALL CAMSHAFT HOUSING STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E8 "TORX" socket wrench, install the stud bolt.

Fig. 269: Identifying Camshaft Housing Stud Bolt Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) 17. INSTALL NO. 1 CAMSHAFT BEARING a. Clean the No. 1 camshaft bearing.

Fig. 270: Measuring No. 1 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier *1 Caliper b. Install the camshaft bearing to the No. 1 camshaft bearing cap. c. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) 18. INSTALL NO. 2 CAMSHAFT BEARING

a. Clean the No. 2 camshaft bearing. b. Install the camshaft bearing to the camshaft housing. c. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

Fig. 271: Measuring No. 2 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard distance 1.15 to 1.85 mm (0.0453 to 0.0728 in.) TEXT IN ILLUSTRATION Vernier *1 Caliper

19. INSTALL OIL CONTROL VALVE FILTER a. Install the oil control valve filter to the No. 1 camshaft bearing cap.

Fig. 272: Identifying Oil Control Valve Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. 21. 22. 23. 24. 25. 26. 27. 28.

INSTALL CAMSHAFT See step 12 INSTALL CAMSHAFT BEARING CAP See step 13 INSTALL VALVE STEM CAP See step 5 INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7 INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY See step 14 INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 15 INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY See step 16 INSTALL CRANKSHAFT TIMING SPROCKET a. Install the crankshaft timing sprocket to the crankshaft.

Fig. 273: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. 30. 31. 32. 33. 34. 35. 36. 37.

ADD ENGINE OIL See step 17 SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 18 INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 19 INSTALL CHAIN SUB-ASSEMBLY See step 20 INSTALL CHAIN TENSIONER SLIPPER See step 21 INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 22 INSTALL TIMING CHAIN GUIDE See step 23 CHECK NO. 1 CYLINDER TO TDC/COMPRESSION See step 24 INSTALL TIMING CHAIN COVER PLATE a. Install a new gasket and the timing chain cover plate with the 4 bolts.

Fig. 274: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 38. INSTALL TIMING CHAIN COVER TIGHT PLUG a. Using a 14 mm hexagon wrench, install a new gasket and the plug.

Fig. 275: Identifying Plug And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 39. 40. 41. 42.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL ENGINE MOUNTING BRACKET RH . Refer to INSTALLATION - Step 2 INSTALL TIMING CHAIN COVER OIL SEAL See step 1 INSTALL SPARK PLUG TUBE GASKET a. Install 4 new plug tube gaskets to the cylinder head cover.

Fig. 276: Identifying Plug Tube Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover.

43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY a. Apply a light coat of engine oil to 3 new gaskets.

Fig. 277: Locating Camshaft Bearing Caps Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 gaskets to the camshaft bearing caps. c. Install a new gasket to the cylinder head cover. NOTE:

Remove any oil from the contact surface.

d. Apply seal packing as shown in the illustration.

Fig. 278: Cylinder Head Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.0 to 6.0 mm (0.118 to 0.236 in.) Application width A 5.0 mm (0.197 in.) TEXT IN ILLUSTRATION

Seal packing Timing *2 Chain Cover Camshaft *3 Housing *1

NOTE:

 

Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

e. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

Fig. 279: Identifying Cylinder Head Cover Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE:

Do not apply oil for at least 2 hours after the installation.

44. INSTALL CRANKSHAFT PULLEY

a. Align the pulley set key with the key groove of the crankshaft pulley.

Fig. 280: Installing Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn b. Using SST, hold the crankshaft pulley and install the pulley bolt.  SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 45. INSTALL CRANKSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 46. INSTALL WATER INLET HOUSING a. Install a new gasket and the inlet water housing with the 4 bolts and nut.

Fig. 281: Locating Inlet Water Housing And Gasket Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 47. INSTALL ENGINE WATER PUMP ASSEMBLY . Refer to INSTALLATION - Step 1 48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY a. Install the V-ribbed belt tensioner with the bolt.

Fig. 282: Locating Bolt And V-Ribbed Belt Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 49. INSTALL THERMOSTAT . Refer to INSTALLATION - Step 1 50. INSTALL WATER INLET . Refer to INSTALLATION - Step 2 51. INSTALL NO. 1 WATER BY-PASS PIPE a. Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.

Fig. 283: Locating Water By-Pass Pipe And Gasket Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 52. INSTALL SEPARATOR CASE a. Apply a light coat of engine oil to a new gasket.

Fig. 284: Identifying Case And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the gasket to the separator case. c. Install the separator case with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 53. INSTALL VENTILATION CASE SUB-ASSEMBLY a. Apply seal packing in a continuous line as shown in the illustration.

Fig. 285: Identifying Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTE:

 

Remove any oil from the contact surface. Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

b. Install the ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.

Fig. 286: Identifying Ventilation Case Sub-Assembly Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Bolt A is tightened twice. 54. INSTALL VENTILATION VALVE SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 55. INSTALL CAMSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to INSTALLATION - Step 1 57. INSTALL OIL FILLER CAP SUB-ASSEMBLY a. Install a new gasket to the oil filler cap. b. Install the oil filler cap to the cylinder head. 58. INSTALL SPARK PLUG . Refer to INSTALLATION - Step 1 59. INSTALL ENGINE COVER JOINT a. Install the 3 joints.

Fig. 287: Locating Engine Cover Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. 2. 3. 4. 5.

INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to INSTALLATION - Step 1 INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL KNOCK CONTROL SENSOR . Refer to INSTALLATION - Step 1 INSTALL SENSOR WIRE a. Install the sensor wire with the bolt.

Fig. 288: Identifying Knock Control Sensor Connector, Wire And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

6. 7. 8. 9. 10. 11.

b. Connect the knock control sensor connector. INSTALL INTAKE MANIFOLD . Refer to INSTALLATION - Step 1 INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL UNION TO CONNECTOR TUBE HOSE . Refer to INSTALLATION - Step 4 CONNECT NO. 2 VENTILATION HOSE . Refer to INSTALLATION - Step 5 INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to INSTALLATION Step 6 INSTALL WATER BY-PASS HOSE a. Install the No. 1 and No. 2 water by-pass hoses.

Fig. 289: Locating No. 1 And No. 2 Water By-Pass Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to INSTALLATION - Step 1 13. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET a. Install the bracket with the 4 bolts.

Fig. 290: Locating NO. 1 Compressor Mounting Bracket & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to INSTALLATION Step 3 15. INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) . Refer to INSTALLATION Step 5 16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to INSTALLATION - Step 4 17. INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 6 18. INSTALL MANIFOLD STAY . Refer to INSTALLATION - Step 7 19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE a. Apply a light coat of engine oil to a new O-ring.

Fig. 291: Locating Dipstick Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the O-ring to the engine oil level dipstick guide. c. Install the engine oil level dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) d. Install the engine oil level dipstick.

20. INSTALL ENGINE HANGERS a. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Fig. 292: Identifying Engine Hangers With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PART NO. Part Item No. No. 1 12281engine 36020 hanger No. 2 12282engine 36021 hanger

9155281040 Bolt or 9155281025 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) b. Attach an engine sling device and hang the engine with the chain block.

CYLINDER HEAD COMPONENTS ILLUSTRATION

Fig. 293: Identifying Cylinder Head Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE INTAKE VALVE

a. Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks.

Fig. 294: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 b. Remove the retainer, compression spring and valve. 

HINT: Arrange the removed parts in the correct order. 2. REMOVE EXHAUST VALVE a. Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks.

Fig. 295: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 b. Remove the retainer, compression spring and valve. 

HINT: Arrange the removed parts in the correct order. 3. REMOVE VALVE STEM OIL SEAL a. Using needle-nose pliers, remove the oil seals.

Fig. 296: Removing Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE VALVE SPRING SEAT a. Using compressed air and a Magnet Hand, remove the valve spring seat by blowing air onto it.

Fig. 297: Removing Valve Spring Seat

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 STRAIGHT SCREW PLUG NOTE:

If water leaks from the No. 1 screw plug or the plug is corroded, replace it.

Fig. 298: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets. 6. REMOVE NO. 2 STRAIGHT SCREW PLUG NOTE:

If water leaks from the No. 2 screw plug or the plug is corroded, replace it.

Fig. 299: Locating No. 2 Straight Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a 14 mm hexagon wrench, remove the screw plug and gasket. 7. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

INSPECTION INSPECTION

1. INSPECT CYLINDER HEAD SUB-ASSEMBLY a. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.

Fig. 300: Measuring Warpage Of Contact Surfaces Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum Warpage

Item Cylinder head lower side Intake manifold side Exhaust manifold side

Specified Condition 0.05 mm (0.00197 in.) 0.10 mm (0.00394 in.) 0.10 mm (0.00394 in.)

TEXT IN ILLUSTRATION Cylinder Head *a Lower Side Intake *b Manifold Side Exhaust *c Manifold Side If the warpage is more than the maximum, replace the cylinder head. b. Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.

Fig. 301: Checking Cylinder Contact Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSPECT COMPRESSION SPRING a. Using a vernier caliper, measure the free length of the inner compression spring.

Fig. 302: Measuring Free Length Of Inner Compression Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard free length 47.2 to 49.2 mm (1.86 to 1.94 in.) If the free length is not as specified, replace the spring. b. Using a steel square, measure the deviation of the inner compression spring.

Fig. 303: Measuring Inner Compression Spring Deviation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum deviation 1.0 mm (0.0394 in.) Maximum angle 2° TEXT IN ILLUSTRATION *a Deviation If the deviation is more than the maximum, replace the spring. 3. INSPECT INTAKE VALVE

a. Using a micrometer, measure the diameter of the valve stem.

Fig. 304: Measuring Diameter Of Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard valve stem diameter 5.470 mm to 5.485 mm (0.21535 to 0.21594 in.) b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 305: Measuring Valve Head Margin Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION Margin *a Thickness If the margin thickness is less than the minimum, replace the valve. c. Using a vernier caliper, measure the overall length of the valve.

Fig. 306: Measuring Overall Length Of Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard overall length 103.92 mm (4.09 in.) Minimum overall length 103.42 mm (4.07 in.) TEXT IN ILLUSTRATION Overall *a Length If the overall length is less than the minimum, replace the intake valve. 4. INSPECT EXHAUST VALVE a. Using a micrometer, measure the diameter of the valve stem.

Fig. 307: Measuring Diameter Of Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard valve stem diameter 5.465 mm to 5.480 mm (0.21516 to 0.21575 in.) b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 308: Measuring Valve Head Margin Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION Margin *a Thickness If the margin thickness is less than the minimum, replace the exhaust valve. c. Using a vernier caliper, measure the overall length of the valve.

Fig. 309: Measuring Overall Length Of Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard overall length 112.91 mm (4.44 in.) Minimum overall length 112.41 mm (4.43 in.) TEXT IN ILLUSTRATION Overall *a Length If the overall length is less than the minimum, replace the exhaust valve. 5. INSPECT VALVE GUIDE BUSH OIL CLEARANCE a. Using a caliper gauge, measure the inside diameter of the guide bush.

Fig. 310: Measuring Inside Diameter Of Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) b. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard Oil Clearance Specified Condition 0.025 to 0.060 mm Intake (0.000984 to 0.00236 in.) 0.030 to 0.065 mm Exhaust (0.00118 to 0.00256 in.) Item

Maximum Oil Clearance Specified

Item Condition 0.08 mm Intake (0.00315 in.) 0.10 mm Exhaust (0.00394 in.) If the oil clearance is more than the maximum, replace the valve and guide bush. 6. INSPECT INTAKE VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat.

Fig. 311: Inspecting Intake Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width HINT: Do not rotate the valve while pressing the valve. c. Check the valve face and valve seat. 1. Check that the contact surfaces of the valve seat and valve face are in the middle area of their

respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). If not, correct the valve seat. 2. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat. 7. INSPECT EXHAUST VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat.

Fig. 312: Inspecting Exhaust Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width HINT: Do not rotate the valve while pressing the valve. c. Check the valve face and valve seat. 1. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).

If not, correct the valve seat. 2. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat. 8. INSPECT CAMSHAFT OIL CLEARANCE NOTE:

Do not turn the camshafts.

a. Clean the bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing. c. Lay a strip of Plastigage across each of the camshaft journals.

Fig. 313: Inspecting Camshaft Oil Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage d. e. f. g.

Install the camshaft bearing caps See step 13. Install the camshaft housing sub-assembly See step 14. Remove the camshaft bearing caps See step 21. Measure the Plastigage at its widest point.

Fig. 314: Measuring Plastigage At Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Oil Clearance

Specified Condition 0.035 to Intake 0.072 mm No. 1 (0.00137 journal to 0.00283 in.) 0.049 to Exhaust 0.086 mm No. 1 (0.00193 journal to 0.00339 in.) 0.025 to 0.062 mm Other (0.000984 journal to 0.00244 in.) Item

Maximum Oil Clearance Specified Condition Intake 0.085 mm No. 1 (0.00335 journal in.) Exhaust 0.095 mm No. 1 (0.00374 journal in.) 0.085 mm Other (0.00335 journal in.) Item

TEXT IN ILLUSTRATION *1 Plastigage No. 1 *2 Journal Other *3 Journal If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing. 9. INSPECT CAMSHAFT THRUST CLEARANCE a. Clean the bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing.

c. Install the camshaft bearing caps See step 13. d. Install the camshaft housing sub-assembly See step 14. e. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Fig. 315: Measuring Camshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Thrust Clearance Specified Condition 0.060 to 0.155 mm Intake (0.00236 to 0.00610 in.) 0.060 to 0.155 mm Exhaust (0.00236 to 0.00610 in.) Item

Maximum Thrust Clearance Specified Condition 0.170 mm Intake (0.00669 in.) 0.170 mm Exhaust (0.00669 in.) Item

If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust

surface is damaged, replace the camshaft. REPLACEMENT REPLACEMENT

1. REPLACE INTAKE VALVE GUIDE BUSH a. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the valve guide bush.  SST: 09201-01055  SST: 09950-70010 09951-07100

Fig. 316: Tapping Out Valve Guide Bush Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Fig. 317: Measuring Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard bush bore diameter 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush bore diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. e. Select a new guide bush (STD or O/S 0.05), and measure its diameter. f. Machine the bush bore of the cylinder head to the diameter of the selected guide bush. Bush Bore Diameter Bush Specified Size Condition 10.333 to 10.344 mm STD (0.4068 to 0.4072 in.) 10.383 to

10.394 mm O/S (0.4088 to 0.05 0.4092 in.) Standard bush length 41.3 to 41.7 mm (1.626 to 1.642 in.) g. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). h. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.  SST: 09201-10000 09201-01050  SST: 09950-70010 09951-07100

Fig. 318: Identifying Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 14.8 to 15.2 mm (0.582 to 0.598 in.) TEXT IN ILLUSTRATION

*a Height i. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

Fig. 319: Reaming Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.) 2. REPLACE EXHAUST VALVE GUIDE BUSH a. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the valve guide bush.  SST: 09201-01055  SST: 09950-70010 09951-07100

Fig. 320: Tapping Out Valve Guide Bush Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Fig. 321: Measuring Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard bush bore diameter 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. e. Select a new guide bush (STD or O/S 0.05), and measure its diameter. f. Machine the bush bore of the cylinder head to the diameter of the selected guide bush. Bush Bore Diameter Bush Specified Size Condition 10.333 to 10.344 mm STD (0.4068 in 0.4072 in.) 10.383 to 10.394 O/S mm 0.05 (0.4088 to 0.4092 in.) Standard bush length 46.8 to 47.2 mm (1.843 to 1.858 in.) g. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). h. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.  SST: 09201-10000 09201-01050  SST: 09950-70010 09951-07100

Fig. 322: Identifying Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 14.2 to 14.6 mm (0.559 to 0.575 in.) TEXT IN ILLUSTRATION *a Height i. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

Fig. 323: Reaming Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.) 3. REPLACE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the ring pins. b. Using a plastic-faced hammer, tap in new ring pins to the cylinder head.

Fig. 324: Identifying Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 6.5 to 7.5 mm (0.256 to 0.295 in.) REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION .

1. INSTALL SPARK PLUG TUBE HINT: When using a new cylinder head, the spark plug tubes must be replaced. a. Apply adhesive onto the shaded area of a new spark plug tube.

Fig. 325: Applying Adhesive Onto Shaded Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard application width 2.0 mm (0.0787 in.) NOTE:



 

Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to coolant for at least 1 hour after installing it.

b. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

Fig. 326: Tapping Spark Plug Tube To Specified Protrusion Height Using A Wooden Block & Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Cylinder Head *a Casting Surface Standard protrusion height 112 mm (4.41 in.) NOTE:

To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

2. INSTALL CYLINDER HEAD STUD BOLT a. Using an E7 "TORX" socket wrench, install the cylinder head stud bolts.

Fig. 327: Identifying Cylinder Head Stud Bolt Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) 3. INSTALL NO. 1 STRAIGHT SCREW PLUG a. Using a 10 mm hexagon wrench, install 3 new gaskets and the 3 straight screw plugs.

Fig. 328: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 4. INSTALL NO. 2 STRAIGHT SCREW PLUG a. Using a 14 mm hexagon wrench, install a new gasket and the straight screw plug.

Fig. 329: Locating No. 2 Straight Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 5. INSTALL VALVE SPRING SEAT a. Install the valve spring seats to the cylinder head. 6. INSTALL VALVE STEM OIL SEAL a. Apply a light coat of engine oil to new oil seals.

Fig. 330: Identifying Valve Stem Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Intake *b Exhaust Mark *c "NOK" *d Gray *e Black NOTE:

Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal onto the exhaust side or installing the exhaust oil seal onto the intake side can cause installation problems later.

HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. b. Using SST, push in the intake and exhaust valve oil seals.

Fig. 331: Installing Valve Oil Seals using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT 

SST: 09201-41020

NOTE:

Failure to use SST will cause the seal to be damaged or improperly seated.

7. INSTALL INTAKE VALVE a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

Fig. 332: Identifying Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the valve, compression spring and spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to their original locations.

c. Using SST and wooden blocks, compress the spring and install the retainer locks.

Fig. 333: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 d. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 334: Tapping Valve Stem Tip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

8. INSTALL EXHAUST VALVE a. Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.

Fig. 335: Identifying Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the valve, compression spring and spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to their original locations.

c. Using SST and wooden blocks, compress the spring and install the retainer locks.

Fig. 336: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 d. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 337: Tapping Valve Stem Tip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

REPAIR REPAIR

1. REPAIR INTAKE VALVE SEAT NOTE:

  

Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the intake valve seat smooth.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.

Fig. 338: Cutting Intake Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.

Fig. 339: Measuring Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) TEXT IN ILLUSTRATION *a Width c. Hand-lap the valve and valve seat with an abrasive compound. d. Check the valve seating position. 2. REPAIR EXHAUST VALVE SEAT NOTE:

  

Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the exhaust valve seat smooth.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.

Fig. 340: Cutting Exhaust Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.

Fig. 341: Measuring Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard width 1.2 to 1.6 mm (0.0472 to 0.0630 in.) TEXT IN ILLUSTRATION *a Width c. Hand-lap the valve and valve seat with an abrasive compound. d. Check the valve seating position.

CYLINDER BLOCK COMPONENTS ILLUSTRATION

Fig. 342: Identifying Cylinder Block Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. INSPECT CONNECTING ROD THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Fig. 343: Measuring Connecting Rod Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.160 to 0.512 mm (0.00630 to 0.0202 in.) Maximum thrust clearance 0.512 mm (0.0202 in.) If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft. 2. INSPECT CONNECTING ROD OIL CLEARANCE a. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

Fig. 344: Identifying Alignment Marks On Connecting Rod And Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment *1 Mark b. Remove the 2 bolts and connecting rod cap.

Fig. 345: Locating Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Keep the lower bearing and connecting rod cap together. c. Clean the crank pin and bearing. d. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. e. Lay a strip of Plastigage on the crank pin.

Fig. 346: Laying Plastigage On Crank Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage f. Check that the front mark of the connecting rod cap is facing in the correct direction.

Fig. 347: Identifying Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *1 Mark g. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

Fig. 348: Locating Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:

Do not turn the crankshaft during the measurement.

If any one of the connecting rod bolts does not meet the torque specification, replace the connecting rod bolts. i. Mark the front of each connecting rod bolt with paint.

Fig. 349: Identifying Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *1 Mark Engine Front j. Tighten the bolts 90° as shown in the illustration. NOTE:

Do not turn the crankshaft during the measurement.

k. Remove the 2 bolts and connecting rod cap. HINT: Keep the lower bearing and connecting rod cap together. l. Measure the Plastigage at its widest point.

Fig. 350: Measuring Plastigage Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage

*2

Number Mark

Standard oil clearance 0.030 to 0.063 mm (0.00118 to 0.00248 in.) Maximum oil clearance 0.07 mm (0.00276 in.) NOTE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Standard crank pin diameter 51.492 to 51.500 mm (2.0272 to 2.0276 in.) Standard Connecting Rod Big End Inside Diameter Specified Condition 54.500 to 54.508 Mark mm 1 (2.1457 to 2.1460 in.) 54.509 to 54.516 Mark mm 2 (2.1460 to 2.1463 in.) Item

54.517 to Mark 54.524 mm 3 (2.1463 to 2.1466

in.) Standard Size Bearing Center Wall Thickness Specified Condition 1.483 to 1.487 mm Mark (0.0584 to 1 0.0585 in.) 1.488 to 1.491 mm Mark (0.0586 to 2 0.0587 in.) 1.492 to 1.495 mm Mark (0.0587 to 3 0.0589 in.) Item

m. Perform the inspection above for each cylinder. 3. REMOVE PISTON WITH CONNECTING ROD a. Using a ridge reamer, remove all the carbon from the top of the cylinder.

Fig. 351: Removing Carbon From Top Of Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 8 bolts, 4 connecting rod caps and 4 lower bearings. c. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together.  Arrange the piston and connecting rod assemblies in the correct order.  Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before. 4. REMOVE CONNECTING ROD BEARING a. Remove the connecting rod bearings from the connecting rods and connecting rod caps. 

HINT: Arrange the removed parts in the correct order. 5. INSPECT CRANKSHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Fig. 352: Measuring Crankshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Standard thrust washer thickness 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 6. REMOVE CRANKSHAFT a. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 353: Identifying Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bearing caps from the cylinder block. HINT: Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.  Arrange the bearing caps in the correct order. c. Remove the crankshaft from the cylinder block. 

HINT: Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block. d. Check each crankshaft journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. 7. REMOVE CRANKSHAFT THRUST WASHER a. Remove the thrust washers from the cylinder block.

Fig. 354: Locating Crankshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE CRANKSHAFT BEARING a. Remove the crankshaft bearings from the cylinder block and bearing caps. HINT: Arrange the bearings in the correct order. 9. REMOVE CRANKSHAFT PULLEY KEY a. Using a screwdriver, remove the 2 pulley keys from the crankshaft. 10. REMOVE PISTON RING SET a. Using a piston ring expander, remove the 2 compression rings.

Fig. 355: Removing Piston Compression Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring Expander b. Remove the oil ring and expander by hand. HINT: Arrange the removed parts in the correct order. 11. REMOVE PISTON PIN HOLE SNAP RING a. Using a screwdriver, pry out the 2 snap rings.

Fig. 356: Identifying Snap Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. 12. REMOVE PISTON a. Gradually heat each piston up to 80 to 90°C (176 to 194°F).

Fig. 357: Heating Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

Fig. 358: Tapping Out Piston Pin

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The piston and pin are a matched set.  Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.  Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. 13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, remove the 2 bolts and 2 oil nozzles. 

Fig. 359: Locating NO. 1 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

Fig. 360: Locating NO. 2 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

INSPECTION INSPECTION

1. INSPECT CYLINDER BLOCK FOR WARPAGE a. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts with the cylinder head gasket.

Fig. 361: Inspecting Cylinder Block For Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage

0.05 mm (0.00197 in.) If the warpage is more than the maximum, replace the cylinder block. 2. INSPECT CYLINDER BORE a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

Fig. 362: Measuring Cylinder Bore Diameter Using Cylinder Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Thrust

*a Direction Axial *b Direction Front Standard diameter 90.000 to 90.013 mm (3.543 to 3.544 in.) Maximum diameter 90.13 mm (3.548 in.) If the average diameter of the 4 positions is more than the maximum, replace the cylinder block. 3. INSPECT PISTON a. Using a gasket scraper, remove the carbon from the piston top.

Fig. 363: Removing Carbon Using Gasket Scraper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

Fig. 364: Cleaning Piston Ring Grooves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brush and solvent, thoroughly clean the piston.

Fig. 365: View Of Cleaning Piston Using Brush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not use a wire brush.

d. Using a micrometer, measure the piston diameter at a position that is 10.5 mm (0.413 in.) from the bottom of the piston (refer to the illustration).

Fig. 366: Measuring Piston Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard piston diameter 89.985 to 89.995mm (3.5427 to 3.5413 in.) If the diameter is less than the minimum, replace the piston with pin. 4. INSPECT PISTON OIL CLEARANCE a. Measure the cylinder bore diameter in the thrust direction. b. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.010 to 0.033 mm (0.000394 to 0.00130 in.) Maximum oil clearance 0.10 mm (0.00394 in.)

If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block. 5. INSPECT RING GROOVE CLEARANCE a. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

Fig. 367: Measuring Clearance Between Piston Ring And Wall Of Ring Groove Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Ring Groove Clearance Item No. 1 ring

No. 2 ring

Oil

Specified Condition 0.020 to 0.070 mm (0.000787 to 0.00276 in.) 0.020 to 0.060 mm (0.000787 to 0.00236 in.) 0.020 to 0.070 mm (0.000787

ring to 0.00276 in.) If the groove clearance is not as specified, replace the piston with pin. 6. INSPECT PISTON RING END GAP a. Insert the piston ring into the cylinder bore.

Fig. 368: Identifying Piston Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring b. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block. c. Using a feeler gauge, measure the end gap.

Fig. 369: Measuring End Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard End Gap Item No. 1 ring

No. 2 ring

Oil ring

Specified Condition 0.22 to 0.27 mm (0.00866 to 0.0106 in.) 0.37 to 0.42 mm (0.0146 to 0.0165 in.) 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

Maximum End Gap Item No. 1 ring No. 2 ring

Specified Condition 0.87 mm (0.0342 in.) 1.02 mm (0.0402 in.)

Oil 0.80 mm

ring (0.0315 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum, even with a new piston ring, replace the cylinder block. 7. INSPECT PISTON PIN OIL CLEARANCE a. Check each mark on the piston, piston pin and connecting rod.

Fig. 370: Checking Piston, Pin & Connecting Rod Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston Pin Hole *1 Front Mark *2 Inside Diameter Mark Connecting Rod Small End Bush *3 - Inside Diameter Mark HINT: The front mark is "2L" printed in raised letters. b. Using a caliper gauge, measure the inside diameter of the piston pin hole.

Fig. 371: Measuring Inside Diameter Of Piston Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Piston Pin Hole Inside Diameter Specified Condition 22.001 to 22.004 Mark mm A (0.86618 to 0.86630 in.) 22.005 to 22.007 Mark mm B (0.86634 to 0.86642 in.) 22.008 to 22.010 Mark mm C (0.86645 to 0.86653 in.) Item

c. Using a micrometer, measure the piston pin diameter.

Fig. 372: Measuring Piston Pin Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Piston Pin Diameter

Specified Condition 21.997 to 22.000 Mark mm (0.86602 A to 0.86614 in.) 22.001 to 22.003 Mark mm B (0.86617 to 0.86626 in.) 22.004 to 22.006 Mark mm (0.86630 C to 0.86638 in.) Item

If the diameter is not as specified, replace the piston pin. d. Using a caliper gauge, measure the connecting rod small end bush inside diameter.

Fig. 373: Measuring Connecting Rod Small End Bush Inside Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Connecting Rod Small End Bush Inside Diameter Specified Condition 22.005 to 22.008 Mark mm (0.86634 A to 0.86645 in.) 22.009 to 22.011 Mark mm B (0.86649 to 0.86657 in.) 22.012 to 22.014 Mark mm C (0.86661 to 0.86669 in.) Item

If the diameter is not as specified, replace the connecting rod. e. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.013 mm (0.000512 in.) If the oil clearance is more than the maximum, replace the piston and piston pin as a set. f. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance

0.017 mm (0.000669 in.) If the oil clearance is more than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set. 8. INSPECT CONNECTING ROD SUB-ASSEMBLY a. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.

Fig. 374: Checking Connecting Rod Alignment (For Band) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check for bend. Maximum bend 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the bend is more than the maximum, replace the connecting rod. 2. Check for twist.

Fig. 375: Checking Connecting Rod Alignment (For Twist) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod. 9. INSPECT CRANKSHAFT a. Inspect for circle runout.

Fig. 376: Measuring Circle Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout 0.003 mm (0.000118 in.) If the circle runout is more than the maximum, replace the crankshaft. b. Inspect the main journals.

Fig. 377: Checking Crankshaft Main Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the diameter of each main journal. Standard main journal diameter 54.988 to 55.000 mm (2.1649 to 2.1654 in.) If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft. 2. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft. c. Inspect the crank pin.

Fig. 378: Measuring Diameter Of Crank Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter 51.492 to 51.500 mm (2.027 to 2.028 in.) If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft. 2. Inspect each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft. 10. INSPECT CRANKSHAFT OIL CLEARANCE a. Install the crankshaft bearings See step 7. b. Install the crankshaft thrust washers See step 8. c. Clean each main journal and bearing.

Fig. 379: Laying Strip Of Plastigage Across Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Place the crankshaft onto the cylinder block. e. Lay a strip of Plastigage across each journal. f. Install the crankshaft bearing caps See step 9. NOTE:

Do not turn the crankshaft.

g. Remove the crankshaft bearing caps See step 6. h. Measure the Plastigage at its widest point.

Fig. 380: Measuring Oil Clearance Using Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.016 to 0.039 mm (0.000630 to 0.00154 in.) Maximum oil clearance 0.05 mm (0.00197 in.)

NOTE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

Fig. 381: Identifying Cylinder Block/Crankshaft Number Marks & Diameter Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder Block Crankshaft *a Number *b Number Mark Mark (B) (A) Diameter *c - Mark EXAMPLE Cylinder block (A) "3" + Crankshaft (B) "4" = Total "7" Select the bearing marked "3".

Bearing Chart (A) Use + Bearing (B) 0 to 1 2 3 to 2 5 6 to 3 8 9 to 4 11 Standard Cylinder Block Journal Inside Diameter (A) Specified Condition 59.000 to 59.002 Mark mm 0 (2.32283 to 2.32291 in.) 59.003 to 59.004 Mark mm (2.32295 1 to 2.32299 in.) 59.005 to 59.006 Mark mm 2 (2.32303 to 2.32307 in.) 59.007 to 59.009 Mark mm 3 (2.32311 to 2.32318 in.) Item

59.010 to 59.011 Mark mm 4 (2.32322 to 2.32326 in.) 59.012 to 59.013 Mark mm 5 (2.32330 to 2.32334 in.) 59.014 to 59.016 Mark mm 6 (2.32338 to 2.32346 in.) Standard Crankshaft Main Journal Diameter (B) Specified Condition 54.999 to 55.000 Mark mm 0 (2.16531 to 2.16535 in.) 54.997 to 54.998 Mark mm 1 (2.16523 to 2.16527 in.) 54.995 to 54.996 Mark mm 2 (2.16515 to 2.16519 in.) Item

54.993 to Mark 54.994 mm 3 (2.16507 to 2.16511

in.) 54.991 to 54.992 Mark mm 4 (2.16500 to 2.16504 in.) 54.988 to 54.990 Mark mm 5 (2.16488 to 2.16496 in.) Standard Bearing Center Wall Thickness Specified Condition 1.991 to 1.994 mm Mark (0.07839 1 to 0.07850 in.) 1.995 to 1.997 mm Mark (0.07854 2 to 0.07862 in.) 1.998 to 2.000 mm Mark (0.07866 3 to 0.07874 in.) 2.001 to 2.003 mm Mark (0.07878 4 to 0.07886 in.) Item

i. Perform the inspection above for each journal. 11. INSPECT CRANKSHAFT BEARING CAP BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point shown in the illustration.

Fig. 382: Measuring Crankshaft Bearing Cap Bolt Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 9.77 to 9.96 mm (0.385 to 0.392 in.) Minimum diameter 9.1 mm (0.358 in.) HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the crankshaft bearing cap bolt with a new one. 12. INSPECT CONNECTING ROD BOLT a. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration. 

Fig. 383: Inspecting Connecting Rod Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Area Standard diameter 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter 8.3 mm (0.327 in.) HINT: Diameter measurements should be done at several points.  If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the connecting rod bolt with a new one. 13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Push the check valve with a pin to check if it is stuck. 

Fig. 384: Pushing Check Valve With Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If stuck, replace the No. 1 oil nozzle. b. Push the check valve with a pin to check if it moves smoothly. If it does not move smoothly, clean or replace the No. 1 oil nozzle. c. Apply air into A. Check that air does not leak through B.

Fig. 385: Checking Air Leak Through B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air leaks, clean or replace the No. 1 oil nozzle. d. Push the check valve while applying air into A. Check that air passes through B.

Fig. 386: Pushing Check Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air does not pass through B, clean or replace the No. 1 oil nozzle. 14. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Push the check valve with a pin to check if it is stuck.

Fig. 387: Pushing Check Valve With Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If stuck, replace the No. 2 oil nozzle. b. Push the check valve with a pin to check if it moves smoothly. If it does not move smoothly, clean or replace the No. 2 oil nozzle. c. While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A.

Fig. 388: Checking Air Leak Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air leaks, clean or replace the No. 2 oil nozzle. d. Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A.

Fig. 389: Locating Ring Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air does not pass through C, clean or replace the No. 2 oil nozzle. REPLACEMENT REPLACEMENT

1. REPLACE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the 12 ring pins. b. Using a plastic-faced hammer, install 12 new ring pins.

Fig. 390: Identifying Ring Pins & Standard Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Upper Lower *a *b Side: Side: Protrusion *c - Height Standard Protrusion Height Specified Condition 5.0 to 7.0 mm A (0.197 to 0.276 in.)

Item

B

4.0 to 7.0 mm (0.157 to 0.276 in.)

2. REPLACE STRAIGHT PIN NOTE:

It is not necessary to remove the straight pin unless it is being replaced.

a. Remove the 14 straight pins. b. Using a plastic-faced hammer, install 14 new straight pins.

Fig. 391: Identifying Straight Pins & Standard Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Front Rear *b Side: Side: LH Lower *c *d Side: Side: RH Protrusion *e *f Side: Height *a

Standard Protrusion Height Item

A

B

Specified Condition 11.0 to 13.0 mm (0.433 to 0.512 in.) 5.0 to 7.0 mm (0.197 to 0.276 in.)

REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the piston or piston ring. Refer to INITIALIZATION . 1. INSTALL STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E8 and E10 "TORX" socket wrench, install the stud bolts.

Fig. 392: Identifying Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION RH LH *a *b Side: Side: for stud bolt A Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) for stud bolt B Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

Fig. 393: Locating NO. 2 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, install the 2 oil nozzles with the 2 bolts.

Fig. 394: Locating NO. 1 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 4. INSTALL PISTON a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole. b. Gradually heat the piston up to 80 to 90°C (176 to 194°F). c. Coat the piston, piston pin and connecting rod with engine oil. d. Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the pin comes into contact with the snap ring.

Fig. 395: Identifying Front Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark HINT: The piston and pin are a matched set. e. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

Fig. 396: Installing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Service *1 Hole HINT: Be sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston. f. Check the fitting condition between the piston and piston pin.

Fig. 397: Checking Fitting Condition Between Piston And Piston Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. 2. Rotate the piston back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. HINT: Perform "Inspection After Repair" after replacing the piston. Refer to INITIALIZATION . 5. INSTALL PISTON RING SET a. Install the oil ring expander and oil ring by hand.

Fig. 398: Identifying Rings Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Oil Ring Oil Ring *2 Expander Coil *3 Joint Oil Ring *4 End HINT: Arrange the oil ring ends and coil joint as shown in the illustration.

b. Using a piston ring expander, install the 2 compression rings with the code mark positioned as shown in the illustration.

Fig. 399: Identifying Compression Rings Using Piston Ring Expander Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. *a 1 No. *b 2 Code *c Mark Paint *d Mark Paint Mark Piston Ring Mark Item

Code Paint Mark Mark

No. 1N 1 No. 2N 2 NOTE:

Blue Orange Install the compression ring with the code mark facing upward.

HINT: Perform "Inspection After Repair" after replacing the piston, piston ring. Refer to INITIALIZATION . 6. INSTALL CRANKSHAFT PULLEY KEY a. Install the 2 crankshaft pulley keys to the crankshaft. 7. INSTALL CRANKSHAFT BEARING a. Clean the main journal and both surfaces of the bearing.

Fig. 400: Installing Upper Bearing At Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT

*b INCORRECT b. Install the upper bearing to the cylinder block as shown in the illustration. NOTE:









Do not apply engine oil to the bearings or their contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

c. Install the lower bearing onto the bearing cap.

Fig. 401: Measuring Distance Between Crankshaft Bearing Cap Edge And Lower Bearing Edge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

Vernier Caliper

d. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower bearing edge. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) NOTE:







Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

8. INSTALL CRANKSHAFT THRUST WASHER a. Apply engine oil to the thrust washers.

Fig. 402: Identifying Oil Groove Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Oil

Groove b. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. 9. INSTALL CRANKSHAFT a. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.

Fig. 403: Identifying Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark b. Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration. HINT: The crankshaft bearing cap bolts are tightened in 3 progressive steps. c. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. d. Step 1: 1. Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 404: Identifying Bearing Cap Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) e. Step 2: 1. Tighten the 10 bearing cap bolts again in the sequence shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) If a crankshaft bearing cap bolt does not meet the specified torque, replace it. f. Step 3: 1. Mark the front of the bearing cap bolts with paint.

Fig. 405: Identifying Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Engine Front 2. Tighten the 10 bearing cap bolts 90° in the same sequence. 3. Check that the paint marks are now at a 90° angle to the front. g. Check that the crankshaft turns smoothly. 10. INSTALL CONNECTING ROD BEARING a. Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

Fig. 406: Cleaning Bearing Contact Surface Of Connector Rod And Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier

*1 Caliper b. Install the connecting rod bearings to the connecting rods and connecting rod caps. c. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) NOTE:







Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

11. INSTALL PISTON WITH CONNECTING ROD a. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

Fig. 407: Piston Ring Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Front Mark No. 2 *2 Compression Ring No. 1 *3 Compression Ring *4 Oil Ring Oil Ring *5 (Expander)

b. Position the piston rings so that the ring ends are as shown in the illustration. c. Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward.

Fig. 408: Pressing Connecting Rod Into Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark NOTE:

When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod.

HINT: The front mark is "2L" printed in raised letters. d. Check that the front mark of the connecting rod cap is facing in the correct direction.

Fig. 409: Identifying Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark NOTE:

Match the numbered connecting rod cap with the connecting rod.

e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

Fig. 410: Locating Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Temporarily install the connecting rod bolts. HINT: The connecting rod bolts are tightened in 2 progressive steps. g. Step 1: 1. Alternately tighten the connecting rod bolts in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) h. Step 2:

Fig. 411: Identifying Connecting Rod Cap Bolts Final Torque Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Engine Front 1. Mark the front of the connecting rod bolts with paint. 2. Tighten the bolts 90° as shown in the illustration. 3. Check that the paint marks are now at a 90° angle to the front. i. Check that the crankshaft turns smoothly.

2012-2017 ENGINE Engine Mechanical (Service Information) - Camry (2GR-FE)

ENGINE ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT Refer to ON-VEHICLE INSPECTION 2. INSPECT ENGINE OIL Refer to ON-VEHICLE INSPECTION 3. INSPECT BATTERY Refer to ON-VEHICLE INSPECTION 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY a. Remove the air cleaner filter element sub-assembly. b. Visually check that the air cleaner filter is not excessively damaged or oily. If necessary, replace the air cleaner filter. HINT: If there is any dirt or a blockage in the air cleaner filter element sub-assembly, clean it with compressed air.  If any dirt or a blockage remains even after cleaning the air cleaner filter element subassembly with compressed air, replace it. c. Install the air cleaner filter element sub-assembly. 5. INSPECT V-RIBBED BELT 

Refer to ON-VEHICLE INSPECTION 6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY a. Remove the V-ribbed belt. Refer to REMOVAL. b. Check that nothing is caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the tensioner. c. Install the V-ribbed belt. Refer to INSTALLATION. 7. INSPECT SPARK PLUG

Refer to ON-VEHICLE INSPECTION 8. INSPECT VALVE LASH ADJUSTER NOISE a. Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the preceding inspection. HINT: If any defects or problems are found during the preceding inspection, perform lash adjuster inspection See step 2. 9. INSPECT IGNITION TIMING a. Warm up and stop the engine. HINT: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized. b. When using the Techstream: Check the ignition timing. 1. 2. 3. 4.

Connect the Techstream to the DLC3. Start the engine and run it at idle. Turn the Techstream main switch on. Enter the following menus: Powertrain / Engine / Data List / IGN Advance. Standard ignition timing 9.5 to 24.5° BTDC at idle NOTE:

  

Check the ignition timing with the cooling fans off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in neutral or park.

HINT: Refer to the Techstream operator's manual for further details. 5. Check that the ignition timing advances immediately when the engine speed is increased.

6. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1. 7. Monitor IGN Advance. 8. Perform the Active Test. Standard ignition timing 8 to 12° BTDC at idle NOTE:

When checking the ignition timing, the transaxle should be in neutral or park.

HINT: Refer to the Techstream operator's manual for further details. c. When not using the Techstream: 1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

Fig. 1: Identifying DLC3 Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3 

SST: 09843-18040

NOTE:



  

Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components. Check the ignition timing with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the ignition timing, the transaxle should be in neutral or park.

2. Remove the V-bank cover sub-assembly See step 17. 3. Connect the timing light tester probe to the ignition coil wire for No. 1 cylinder. NOTE:

Use a timing light that detects primary signals.

4. Check the ignition timing at idle. Standard ignition timing 8 to 12° BTDC at idle NOTE:

When checking the ignition timing, the transaxle should be in neutral or park.

HINT: Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. 5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. 6. Check the ignition timing at idle. Standard ignition timing 9.5 to 24.5° BTDC at idle 7. Confirm that the ignition timing advances immediately when the engine rpm is increased. 8. Remove the timing light from the engine. 9. Install the V-bank cover sub-assembly See step 82. 10. INSPECT ENGINE IDLE SPEED a. Warm up and stop the engine. HINT: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

b. When using the Techstream: Check the idle speed. 1. 2. 3. 4. 5.

Connect the Techstream to the DLC3. Start the engine and run it at idle. Turn the Techstream main switch on. Enter the following menus: Powertrain / Engine / Data List / Engine Speed. Read the value displayed on the tester. Standard idle speed 600 to 700 rpm NOTE:

  

Check the idle speed with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the idle speed, the transaxle should be in neutral or park.

HINT: Refer to the Techstream operator's manual for further details.  If the speed is not as specified, check the air intake system. c. When not using the Techstream: 1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3. 

Fig. 2: Identifying DLC3 Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3 SST: 09843-18030 2. Check the idle speed. 

Standard idle speed 600 to 700 rpm NOTE:

  

Check the idle speed with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the idle speed, the transaxle should be in neutral or park.

HINT: If the speed is not as specified, check the air intake system. 11. INSPECT COMPRESSION a. Warm up and stop the engine. HINT:

A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized. b. Remove the 6 spark plugs. Refer to REMOVAL . c. Check the cylinder compression pressure.

Fig. 3: Checking Cylinder Compression Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Insert a compression gauge into the spark plug hole. 2. While cranking the engine, measure the compression pressure. Standard compression pressure 1300 kPa (13 kgf/cm2 , 189 psi) Minimum pressure 980 kPa (10 kgf/cm2 , 142 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2 , 15 psi) NOTE:



Always use a fully charged battery to obtain an engine speed of 250 rpm or more.





Check the compression pressure of the other cylinders in the same way. This measurement must be done as quickly as possible.

3. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT: If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.  If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. d. Install the 6 spark plugs. Refer to INSTALLATION . 12. INSPECT CO/HC 

HINT: This check determines whether or not the idle CO/HC complies with regulations. a. b. c. d.

Start the engine. Keep the engine speed at 2500 rpm for approximately 180 seconds. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idle. Immediately check CO/HC concentration during idle and when running at 2500 rpm. HINT: When performing the 2 mode (with the engine idling/running at 2500 rpm) test, follow the measurement order determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below. 1. Check the DTCs. Refer to DTC CHECK / CLEAR . 2. See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO

HC

Problem

Cause a. Faulty ignition:  Incorrect valve timing  Fouled,

Normal High Rough idle

Low

High

shorted or improperly gapped plugs b. Incorrect valve clearance (valve lash adjuster) c. Leaks in intake or exhaust valves d. Leaks in cylinders

Rough idle (Fluctuating High HC reading)

a. Vacuum leaks:  PCV hoses  Intake manifold  Throttle body assembly  Brake booster line b. Lean mixture causing misfire

Rough idle (Black High smoke from exhaust)

a. Restricted air cleaner filter element subassembly b. Plugged PCV valve c. Faulty SFI system:  Faulty fuel pressure regulator  Defective engine coolant temperature sensor  Defective mass air flow meter  Faulty ECM





Faulty injector assemblies Faulty throttle position sensor (built in throttle body assembly)

DRIVE BELT COMPONENTS ILLUSTRATION

Fig. 4: Identifying Drive Belt Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT V-RIBBED BELT a. Check the belt for wear, cracks or other signs of damage.

Fig. 5: Inspecting Condition Of Fan & Generator V Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT If any of the following defects is found, replace the V-ribbed belt. The belt is cracked.  The belt is worn out to the extent that the cords are exposed.  The belt has chunks missing from the ribs. b. Check that the belt fits properly in the ribbed grooves. 

Fig. 6: Checking V Belt For Proper Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT HINT: Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the V-ribbed. Install a new V-ribbed correctly. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-RIBBED BELT a. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner.

Fig. 7: Removing V-Ribbed Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. While turning the V-ribbed belt tensioner counterclockwise, align its holes, and then insert a 5 mm hexagon wrench into the holes to fix the V-ribbed belt tensioner.

INSTALLATION INSTALLATION

1. INSTALL V-RIBBED BELT a. Install the V-ribbed belt.

Fig. 8: Identifying V-Ribbed Belt Routing Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Water *1 Pump *2 Idler *3 Generator

*4 Crankshaft *5 Tensioner A/C *6 Compressor b. Turn the V-ribbed belt tensioner counterclockwise and remove the 5 mm hexagon wrench.

Fig. 9: Turning V-Ribbed Belt Tensioner Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3. 4. 5.

c. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand. INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

CAMSHAFT COMPONENTS ILLUSTRATION

Fig. 10: Identifying Camshaft Replacement Components With Torque Specifications (1 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 11: Identifying Camshaft Replacement Components With Torque Specifications (2 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 12: Identifying Camshaft Replacement Components With Torque Specifications (3 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 13: Identifying Camshaft Replacement Components With Torque Specifications (4 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 14: Identifying Camshaft Replacement Components With Torque Specifications (5 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 15: IIdentifying Camshaft Replacement Components With Torque Specifications (6 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 16: Identifying Camshaft Replacement Components With Torque Specifications (7 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 17: Identifying Camshaft Replacement Components With Torque Specifications (8 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 18: Identifying Camshaft Replacement Components With Torque Specifications (9 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 INSTALL ENGINE ON ENGINE STAND See step 78 REMOVE ENGINE HANGERS See step 1 REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE NO. 1 SURGE TANK STAY See step 3 REMOVE THROTTLE BODY BRACKET See step 4 REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE NO. 2 ENGINE MOUNTING STAY RH See step 6 REMOVE INTAKE MANIFOLD See step 7 REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 8 REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 9 REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 11 REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to REMOVAL - Step 10 REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 12 REMOVE V-RIBBED BELT TENSIONER ASSEMBLY See step 13 REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE See step 13 REMOVE NO. 2 TIMING GEAR COVER See step 14 REMOVE WATER PUMP PULLEY See step 15 REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 16 REMOVE NO. 1 VACUUM SWITCHING VALVE See step 17 REMOVE CRANK POSITION SENSOR . Refer to REMOVAL - Step 2 REMOVE NO. 1 OIL PIPE See step 8 REMOVE OIL PIPE See step 9 REMOVE CRANKSHAFT PULLEY See step 6 REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 14 REMOVE WATER INLET HOUSING . Refer to REMOVAL - Step 10 REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 17 REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 18 REMOVE NO. 2 OIL PAN SUB-ASSEMBLY See step 19 REMOVE OIL STRAINER SUB-ASSEMBLY See step 20 REMOVE OIL PAN SUB-ASSEMBLY See step 21 REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 31 REMOVE TIMING CHAIN CASE OIL SEAL . Refer to REMOVAL - Step 32

35. 36. 37. 38. 39. 40.

SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 28 REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 29 REMOVE CHAIN TENSIONER SLIPPER See step 30 REMOVE CHAIN SUB-ASSEMBLY See step 31 REMOVE IDLE SPROCKET ASSEMBLY See step 32 REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) a. While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly.

Fig. 19: Raising No. 2 Chain Tensioner & Inserting Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin

*2 Plunger *a Push b. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Fig. 20: Removing/Installing Camshaft Timing Gear & Exhaust Gear Assembly Flange Bolts Using SST RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 

SST: 09922-10010

NOTE:

 

Be careful not to damage the cylinder head with SST. Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

c. Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain. 41. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY a. Remove the bolt and No. 2 chain tensioner assembly.

Fig. 21: Identifying No. 2 Chain Tensioner Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. REMOVE CAMSHAFT BEARING CAP (for Bank 1) a. Check that the camshafts are positioned as shown in the illustration.

Fig. 22: Identifying Camshaft Position (For Bank 1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Front *a View b. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 23: Identifying Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 24: Identifying Bearing Cap Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Uniformly loosen the bolts while keeping the camshaft level.

d. Remove the 5 camshaft bearing caps. 43. REMOVE CAMSHAFT a. Remove the camshaft. 44. REMOVE NO. 2 CAMSHAFT a. Remove the No. 2 camshaft. 45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH a. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.

Fig. 25: Identifying Camshaft Housing Sub-Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly RH.

HINT: Tape the screwdriver tip before use. 46. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) a. While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly.

Fig. 26: Pushing Down No. 3 Chain Tensioner & Inserting Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Pin *2 Plunger *a Push b. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Fig. 27: Removing/Installing Camshaft Timing Gear & Exhaust Gear Assembly Flange Bolts Using SST LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 

SST: 09922-10010

NOTE:

 

Be careful not to damage the cylinder head with SST. Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

c. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain. 47. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

a. Remove the bolt and No. 3 chain tensioner assembly.

Fig. 28: Identifying No. 3 Chain Tensioner Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 48. REMOVE CAMSHAFT BEARING CAP (for Bank 2) a. Check that the camshafts are positioned as shown in the illustration.

Fig. 29: Identifying Camshaft Position (For Bank 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Front *a View b. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 30: Identifying Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 31: Locating Bearing Cap Bolts In Sequence

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Uniformly loosen the bolts while keeping the camshaft level.

d. Remove the 5 camshaft bearing caps. 49. REMOVE NO. 3 CAMSHAFT a. Remove the No. 3 camshaft. 50. REMOVE NO. 4 CAMSHAFT a. Remove the No. 4 camshaft. 51. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH a. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.

Fig. 32: Identifying Camshaft Housing Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH.

HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, No. 3 camshaft, No. 4 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 1. INSTALL NO. 3 CAMSHAFT a. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH. b. Install the No. 3 camshaft to the camshaft housing sub-assembly LH. HINT: Perform "Inspection After Repair" after replacing the No. 3 camshaft. Refer to INITIALIZATION . 2. INSTALL NO. 4 CAMSHAFT a. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH. b. Install the No. 4 camshaft to the camshaft housing sub-assembly LH. HINT: Perform "Inspection After Repair" after replacing the No. 4 camshaft. Refer to INITIALIZATION . 3. INSTALL CAMSHAFT BEARING CAP (for Bank 2) a. Apply engine oil to the camshaft bearing caps. b. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

Fig. 33: Identifying Marks And Numbers On Camshaft Bearing Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Temporarily tighten the 8 bolts in the order shown in the illustration.

Fig. 34: Tightening Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH a. Make sure that the valve rocker arm is installed as shown in the illustration.

Fig. 35: Identifying Valve Rocker Arm Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Lash *2 Adjuster Valve *3 Stem Valve *4 Stem Cap b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 36: Identifying Camshaft Housing Sub-Assembly Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal packing *a diameter (3.5 to 4.5 mm) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE:

 



Remove any oil from the contact surface. Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts. Do not start the engine for at least 2 hours after installing.

c. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

Fig. 37: Identifying 13 LH Camshaft Housing Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Front *a View Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE:



When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a





camshaft is rotated, valve contact with a piston at TDC will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

d. Tighten the 8 bolts in the order shown in the illustration.

Fig. 38: Locating Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 5. INSTALL CAMSHAFT a. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH. b. Install the camshaft to the camshaft housing sub-assembly RH. HINT: Perform "Inspection After Repair" after replacing the camshaft. Refer to INITIALIZATION . 6. INSTALL NO. 2 CAMSHAFT

a. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH. b. Install the No. 2 camshaft to the camshaft housing sub-assembly RH. HINT: Perform "Inspection After Repair" after replacing the No. 2 camshaft. Refer to INITIALIZATION . 7. INSTALL CAMSHAFT BEARING CAP (for Bank 1) a. Apply engine oil to the camshaft bearing caps. b. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

Fig. 39: Identifying Marks And Numbers On Camshaft Bearing Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

Fig. 40: Tightening Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH a. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Fig. 41: Identifying Valve Rocker Arm Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Lash *2 Adjuster Valve *3 Stem Valve *4 Stem Cap b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 42: Identifying Camshaft Housing Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal packing *a diameter (3.5 to 4.5 mm) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE:

 



Remove any oil from the contact surface. Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts. Do not start the engine for at least 2 hours after installing.

c. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

Fig. 43: Identifying Camshaft Housing Bolts With Tightening Sequence RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Front *a View Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE:



When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage

due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC will occur. 



If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

d. Tighten the 8 bolts in the order shown in the illustration.

Fig. 44: Tightening Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY a. Install the No. 3 chain tensioner assembly with the bolt.

Fig. 45: Identifying No. 3 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) b. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it. 10. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) a. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Fig. 46: Identifying Timing Marks Of Camshaft Timing Gears And No. 2 Chain (For Bank 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *1 Mark Mark *2 Plate b. Apply a light coat of engine oil to the bolt threads and bolt-seating surface. c. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

d. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Fig. 47: Removing/Installing Camshaft Timing Gear & Exhaust Gear Assembly Flange Bolts Using SST LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 

SST: 09922-10010

Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) e. Remove the pin from the No. 3 chain tensioner assembly. HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY a. Install the No. 2 chain tensioner assembly with the bolt.

Fig. 48: Identifying No. 2 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) b. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it. 12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) a. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Fig. 49: Identifying Camshaft Timing Gears And No 2 Chain (Bank 1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *1 Mark Mark *2 Plate b. Apply a light coat of engine oil to the bolt threads and bolt-seating surface. c. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed. d. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Fig. 50: Removing/Installing Camshaft Timing Gear & Exhaust Gear Assembly Flange Bolts Using SST RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 

SST: 09922-10010

Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) e. Remove the pin from the No. 2 chain tensioner assembly. HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to INITIALIZATION . 13. 14. 15. 16. 17. 18.

INSTALL IDLE SPROCKET ASSEMBLY See step 26 INSTALL CHAIN SUB-ASSEMBLY See step 27 INSTALL CHAIN TENSIONER SLIPPER See step 28 INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 29 INSPECT VALVE TIMING See step 30 INSTALL TIMING CHAIN CASE OIL SEAL . Refer to INSTALLATION - Step 1

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL OIL PAN SUB-ASSEMBLY See step 37 INSTALL OIL STRAINER SUB-ASSEMBLY See step 38 INSTALL NO. 2 OIL PAN SUB-ASSEMBLY See step 39 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 41 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 42 INSTALL WATER INLET HOUSING . Refer to INSTALLATION - Step 3 INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 35 INSTALL CRANKSHAFT PULLEY See step 2 INSTALL NO. 1 OIL PIPE See step 48 INSTALL OIL PIPE See step 49 INSTALL CRANK POSITION SENSOR . Refer to INSTALLATION - Step 1 INSTALL NO. 1 VACUUM SWITCHING VALVE See step 5 INSTALL WATER PUMP PULLEY See step 6 INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 7 INSTALL NO. 2 TIMING GEAR COVER See step 8 INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE See step 44 INSTALL V-RIBBED BELT TENSIONER ASSEMBLY See step 9 INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 10 INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 3 INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 2 INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 13 INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 14 INSTALL INTAKE MANIFOLD See step 15 INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 16 INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL THROTTLE BODY BRACKET See step 19 INSTALL NO. 1 SURGE TANK STAY See step 18 INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to INSTALLATION - Step 6 INSTALL ENGINE HANGERS See step 1 REMOVE ENGINE STAND INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to INSTALLATION

CYLINDER HEAD GASKET

COMPONENTS ILLUSTRATION

Fig. 51: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 52: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE CAMSHAFT Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8. 9. 10.

REMOVE NO. 2 CAMSHAFT See step 44 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 45 REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 46 REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 47 REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 48 REMOVE NO. 3 CAMSHAFT See step 49 REMOVE NO. 4 CAMSHAFT See step 50 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 51 REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Remove the 24 valve rocker arms. HINT: Arrange the removed parts in the correct order.

11. REMOVE VALVE LASH ADJUSTER ASSEMBLY a. Remove the 24 valve lash adjuster assemblies from the cylinder head. HINT: Arrange the removed parts in the correct order. 12. REMOVE VALVE STEM CAP a. Remove the 24 valve stem caps. 13. REMOVE WATER OUTLET See step 16 14. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH a. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

Fig. 53: Locating Cylinder Head Bolts And Plate Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to drop washers into the cylinder head subassembly. Cylinder head warpage or cracking could result from removing bolts in the incorrect order.

HINT: Arrange the removed parts in the correct order. b. Remove the cylinder head sub-assembly RH. 15. REMOVE CYLINDER HEAD GASKET RH a. Remove the cylinder head gasket RH. 16. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH a. Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration.

Fig. 54: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

Fig. 55: Locating Cylinder Head Bolts And Plate Washers

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to drop washers into the cylinder head subassembly. Cylinder head warpage or cracking could result from removing bolts in the incorrect order.

HINT: Be sure to keep separate the removed parts for each installation position. c. Remove the cylinder head sub-assembly LH. 17. REMOVE CYLINDER HEAD GASKET LH a. Remove the cylinder head gasket LH. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the cylinder head RH or cylinder head LH. Refer to INITIALIZATION . 1. INSTALL CYLINDER HEAD GASKET RH a. Place a new cylinder head gasket RH on the cylinder block surface with the Lot No. stamp facing upward.

Fig. 56: Identifying RH Cylinder Head Gasket, Lot No. & Engine Front Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lot *a No. Engine Front NOTE:

Be careful of the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH a. Place the cylinder head on the cylinder block. NOTE:





Be careful not to allow oil to adhere to the bottom part of the cylinder head. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.

HINT: The cylinder head bolts are tightened in 3 progressive steps. b. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. c. Step 1

1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

Fig. 57: Identifying Cylinder Head Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) d. Step 2

Fig. 58: Tightening Cylinder Head Bolts Another 90Degrees With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Turn *a 90° Painted *b Mark Engine Front 1. Mark each cylinder head bolt head with paint as shown in the illustration. 2. Tighten the cylinder head bolts 90° in the sequence shown in step 1. e. Step 3 1. Tighten the cylinder head bolts an additional 90° in the sequence shown in step 1. 2. Check that the painted mark is now facing rearward. HINT: Perform "Inspection After Repair" after replacing the cylinder head RH. Refer to INITIALIZATION . 3. INSTALL CYLINDER HEAD GASKET LH a. Place a new cylinder head gasket LH on the cylinder block surface with the Lot No. stamp facing upward.

Fig. 59: Identifying LH Cylinder Head Gasket, Lot No. & Engine Front Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lot *a No. Engine Front NOTE:

Be careful of the installation direction.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH a. Place the cylinder head on the cylinder block. NOTE:





Be careful not to allow oil to adhere to the bottom part of the cylinder head. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.

HINT: The cylinder head bolts are tightened in 3 progressive steps. b. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. c. Step 1

1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

Fig. 60: Locating Cylinder Head Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) d. Step 2

Fig. 61: Turning Head Bolt An Additional 90 Degrees Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Turn *a 90° Painted *b Mark Engine Front 1. Mark each cylinder head bolt head with paint as shown in the illustration. 2. Tighten the cylinder head bolts 90° in the sequence shown in step 1. e. Step 3 1. Tighten the cylinder head bolts an additional 90° in the sequence shown in step 1. 2. Check that the painted mark is now facing rearward. f. Tighten the 2 bolts in the order shown in the illustration.

Fig. 62: Identifying Bolt Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the cylinder head LH. Refer to INITIALIZATION . 5. INSTALL WATER OUTLET See step 43 6. INSTALL VALVE STEM CAP a. Install the 24 valve stem caps. 7. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTE:

 

Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil.

a. Place the lash adjuster into a container filled with engine oil. b. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

Fig. 63: Bleeding Valve Lash Adjuster Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Tapered Part *2 Plunger *3 Check Ball *a CORRECT *b INCORRECT Low Pressure *c Chamber High Pressure *d Chamber SST: 09276-75010 c. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times. d. Check the movement of the plunger and bleed the air. 

OK Plunger moves up and down. NOTE:

When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

e. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster. f. Install the valve lash adjusters. NOTE:

Install each valve lash adjuster to the same place it was removed from.

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Apply engine oil to the lash adjuster tip and valve stem cap end. b. Install the valve rocker arms as shown in the illustration.

Fig. 64: Identifying Valve Rocker Arm Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Lash *2 Adjuster Valve *3 Stem Valve *4 Stem Cap 9. 10. 11. 12. 13. 14. 15. 16.

INSTALL NO. 3 CAMSHAFT See step 1 INSTALL NO. 4 CAMSHAFT See step 2 INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4 INSTALL CAMSHAFT See step 5 INSTALL NO. 2 CAMSHAFT See step 6 INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8

FRONT CRANKSHAFT OIL SEAL COMPONENTS ILLUSTRATION

Fig. 65: Identifying Front Crankshaft Oil Seal Replacement Components With Toque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5. 6.

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-RIBBED BELT See step 5 REMOVE CRANKSHAFT PULLEY a. Using SST, loosen the crankshaft pulley bolt.

Fig. 66: Removing Crankshaft Pulley Bolt Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 



SST: 09213-70011 09213-70020 SST: 09330-00021

TEXT IN ILLUSTRATION *a Hold Turn b. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

Fig. 67: Removing Crankshaft Pulley With Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021

TEXT IN ILLUSTRATION *a Hold Turn c. Remove the pulley set key from the crankshaft.

Fig. 68: Identifying Crankshaft & Set Key Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE TIMING CHAIN CASE OIL SEAL a. Using a knife, cut off the timing chain case oil seal lip.

Fig. 69: Removing Timing Chain Case Oil Seal Using A Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Cut *a Position b. Using a screwdriver, pry out the timing chain case oil seal. NOTE:

After removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL TIMING CHAIN CASE OIL SEAL a. Apply MP grease to a new timing chain case oil seal lip.

Fig. 70: Installing Timing Chain Case Oil Seal Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a hammer, tap in the timing chain case oil seal until its surface is flush with the timing chain cover edge. TEXT IN ILLUSTRATION Oil seal tap in *a depth (0 to 1.0 mm)

 

SST: 09223-22010 SST: 09506-35010

Oil seal tap in depth 0 to 1.0 mm (0 to 0.0393 in.) NOTE:

 

Keep the lip free of foreign matter. Do not tap the timing chain case oil seal at an angle.

2. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the pulley, and slide on the pulley. b. Using SST, install the pulley bolt.

Fig. 71: Installing Crankshaft Pulley Bolt Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 



SST: 09213-70011 09213-70020 SST: 09330-00021

Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf) TEXT IN ILLUSTRATION *a Hold Turn 3. 4. 5. 6. 7.

INSTALL V-RIBBED BELT See step 1 INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR CRANKSHAFT OIL SEAL COMPONENTS ILLUSTRATION

Fig. 72: Identifying Rear Crankshaft Oil Seal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Refer to REMOVAL 2. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY a. Using SST, hold the crankshaft pulley.

Fig. 73: Identifying Crankshaft Pulley And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-70011 09213-70020  SST: 09330-00021 b. Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer. 

Fig. 74: Identifying Drive Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE ENGINE REAR OIL SEAL a. Using a knife, cut off the engine rear oil seal lip.

Fig. 75: Removing Engine Rear Oil Seal Using A Screwdriver

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Cut *a Position b. Using a screwdriver, pry out the engine rear oil seal. NOTE:

Be careful not to damage the crankshaft.

HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL ENGINE REAR OIL SEAL a. Apply MP grease to a new engine rear oil seal lip.

Fig. 76: Installing Engine Rear Oil Seal Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Oil seal tap in depth *a (-0.5 to 0.5 mm) b. Using SST and a hammer, tap in the engine rear oil seal.  SST: 09223-15030  SST: 09950-70010

09951-07150 Oil seal tap in depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.) 2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY a. Using SST, hold the crankshaft pulley.  SST: 09213-70011 09213-70020  SST: 09330-00021 b. Clean the 8 bolts and 8 bolt holes. c. Install the front drive plate spacer.

Fig. 77: Aligning Pin With Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Align the pin of the front drive plate spacer with the pin hole of the crankshaft. d. Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.

Fig. 78: Identifying Drive Plate/Ring Gear & Rear Drive Plate Spacer Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive

*1 Plate Rear *2 Spacer Transaxle Side e. Apply adhesive to 2 or 3 threads of each bolt.

Fig. 79: Applying Adhesive To Bolt Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent f. In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Fig. 80: Tightening Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf) NOTE:

Do not start the engine for at least an hour after installing the drive plate.

3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to INSTALLATION

ENGINE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 81: Identifying Engine Assembly Replacement Components (1 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 82: Identifying Engine Assembly Replacement Components (2 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 83: Identifying Engine Assembly Replacement Components (3 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 84: Identifying Engine Assembly Replacement Components (4 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 85: Identifying Engine Assembly Replacement Components (5 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 86: Identifying Engine Assembly Replacement Components (6 Of 6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION WARNING: The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop. NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . Refer to REPLACEMENT - Step 1 3. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT FENDER APRON SEAL LH DRAIN ENGINE OIL . Refer to REPLACEMENT - Step 1 DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 DRAIN AUTOMATIC TRANSAXLE FLUID . Refer to REPLACEMENT - Step 1 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE V-BANK COVER SUB-ASSEMBLY a. Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

Fig. 87: Identifying V-Bank Cover Sub-Assembly Retainers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

18. REMOVE INLET NO. 2 AIR CLEANER a. Disconnect the 2 wire harness clamps and vacuum hose clamp.

Fig. 88: Identifying Wire Harness Clamps, Vacuum Hose Clamp, Inlet No. 2 Air Cleaner And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and inlet No. 2 air cleaner. 19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY a. Disconnect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose.

Fig. 89: Identifying Wire Harness Clamp, Connector, Vacuum Hose And No. 1 Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and air cleaner case sub-assembly. 22. REMOVE BATTERY a. Disconnect the positive (+) cable from the positive (+) battery terminal.

Fig. 90: Identifying Battery And Battery Tray Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Loosen the nut and remove the bolt. c. Remove the battery and battery tray. 23. REMOVE INLET NO. 1 AIR CLEANER a. Disengage the pin and remove the inlet No. 1 air cleaner.

Fig. 91: Identifying Inlet No. 1 Air Cleaner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY a. Disengage the claw and disconnect the 2 vacuum hoses.

Fig. 92: Identifying Intake Air Resonator Sub-Assembly Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and intake air resonator sub-assembly. 25. REMOVE NO. 2 ENGINE MOUNTING STAY RH a. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

Fig. 93: Identifying No. 2 Engine Mounting Stay Bolts And Nuts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE ENGINE MOVING CONTROL ROD BRACKET a. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.

Fig. 94: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE ENGINE MOVING CONTROL ROD a. Remove the bolt and engine moving control rod from the engine moving control rod bracket.

Fig. 95: Identifying Engine Moving Control Rod Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary. 28. SEPARATE EARTH WIRE a. Remove the 2 bolts and separate the earth wire from the engine assembly.

Fig. 96: Identifying Earth Wire And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE a. Disconnect the No. 1 fuel vapor feed hose.

Fig. 97: Identifying No. 1 Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. DISCONNECT UNION TO CHECK VALVE HOSE a. Disconnect the union to check valve hose from the brake booster.

Fig. 98: Identifying Union And Check Valve Hose

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. DISCONNECT INLET RADIATOR HOSE a. Remove the hose clamp to separate the air fuel ratio sensor wire from the inlet radiator hose.

Fig. 99: Identifying Inlet Radiator Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the hose clamp to separate the No. 3 water by-pass hose from the inlet radiator hose. c. Disconnect the inlet radiator hose. 32. DISCONNECT OUTLET RADIATOR HOSE a. Disconnect the outlet radiator hose.

Fig. 100: Identifying Outlet Radiator Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. DISCONNECT NO. 3 WATER BY-PASS HOSE a. Disconnect the No. 3 water by-pass hose from the transmission oil cooler.

Fig. 101: Identifying No. 3 Water By-Pass Hose Clamp

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. DISCONNECT INLET HEATER WATER HOSE a. Disconnect the inlet heater water hose.

Fig. 102: Identifying Inlet Heater Water Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. DISCONNECT WATER HOSE SUB-ASSEMBLY a. Disconnect the water hose sub-assembly.

Fig. 103: Identifying Water Hose Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE STARTER ASSEMBLY . Refer to REMOVAL - Step 11 37. DISCONNECT ENGINE WIRE a. Remove the No. 1 relay block cover. b. Remove the 2 nuts and disconnect the wire clamp.

Fig. 104: Identifying Engine Wire Nuts And Wire Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. d. Disconnect the 4 connectors.

Fig. 105: Identifying Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. f. Pull up the lever to disconnect the ECM connector.

Fig. 106: Identifying ECM Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disconnect the 2 wire clamps. 38. REMOVE AIR CLEANER BRACKET a. Disconnect the 2 wire clamps.

Fig. 107: Identifying Air Cleaner Bracket Wire Clamps And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and No. 1 air cleaner bracket from the battery carrier. 39. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to REMOVAL - Step 6 40. DISCONNECT FUEL MAIN TUBE a. Remove the No. 1 fuel pipe clamp.

Fig. 108: Identifying Fuel Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

Fig. 109: Disconnecting Fuel Main Tube Connector & Pipe

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Push Pull NOTE:



  





Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector. Do not use any tools to separate the pipe and connector. Do not forcefully bend or twist the nylon tube. Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary. Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination. If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

41. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to REMOVAL Step 5 42. DISCONNECT SUCTION HOSE SUB-ASSEMBLY . Refer to REMOVAL - Step 6 43. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET . Refer to REMOVAL - Step 7 44. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to REMOVAL - Step 5 45. SECURE STEERING WHEEL . Refer to REMOVAL - Step 3 46. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to REMOVAL - Step 4 47. REMOVE FRONT AXLE SHAFT NUT LH . Refer to REMOVAL - Step 9 48. REMOVE FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side. 49. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to REMOVAL - Step 4 50. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 51. SEPARATE FRONT SPEED SENSOR LH . Refer to REMOVAL - Step 3 52. SEPARATE FRONT SPEED SENSOR RH

HINT: Perform the same procedure as for the LH side. 53. SEPARATE TIE ROD ASSEMBLY LH . Refer to REMOVAL - Step 5 54. SEPARATE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 55. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 8 56. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 57. 58. 59. 60. 61.

SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to REMOVAL - Step 15 REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REMOVAL - Step 17 REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to REMOVAL - Step 16 REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET a. Remove the bolt and No. 1 exhaust pipe support bracket.

Fig. 110: Identifying No. 1 Exhaust Pipe Support Bracket Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY a. Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.

Fig. 111: Locating Flywheel Housing Under Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 63. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT a. Turn the crankshaft to gain access to the removable locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

Fig. 112: Identifying Driver Plate And Torque Converter Setting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: There will be one black colored bolt. 64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE a. Set the engine lifter.

Fig. 113: Identifying Engine Lifter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Attachment Installation Position NOTE:







Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.



Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

b. Remove the 4 bolts, 2 nuts and frame side rail plates RH and LH.

Fig. 114: Identifying Frame Side Rail Plates Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 4 bolts, 2 nuts and front suspension member rear braces RH and LH. d. Operate the engine lifter, then remove the engine assembly from the vehicle. NOTE:



Make sure that the engine is clear of all wiring and hoses.



65. 66. 67. 68. 69.

While lowering the engine from the vehicle, do not allow it to contact the vehicle.

e. Install the engine hangers See step 21. REMOVE V-RIBBED BELT See step 5 REMOVE GENERATOR ASSEMBLY . Refer to REMOVAL - Step 6 REMOVE COMPRESSOR AND MAGNETIC CLUTCH . Refer to REMOVAL - Step 7 REMOVE TRANSMISSION OIL COOLER . Refer to REMOVAL - Step 4 REMOVE FRONT FRAME ASSEMBLY a. Disconnect the oil pressure switch connector and 2 clamps.

Fig. 115: Identifying Oil Pressure Switch Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 clamps and vacuum switching valve connector.

Fig. 116: Identifying Vacuum Switching Valve Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and disconnect the front engine mounting insulator. d. Remove the nut and disconnect the engine mounting insulator LH.

Fig. 117: Identifying Engine Mounting Insulator Nut LH

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the nut and disconnect the engine mounting insulator RH.

Fig. 118: Identifying Engine Mounting Insulator Nut RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the front frame assembly. 70. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY a. Remove the 3 nuts and front engine mounting insulator assembly.

Fig. 119: Identifying Front Engine Mounting Insulator Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary. 71. REMOVE ENGINE MOUNTING INSULATOR LH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 120: Identifying Engine Mounting Insulator LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. 72. REMOVE ENGINE MOUNTING INSULATOR RH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 121: Identifying Engine Mounting Insulator RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 73. REMOVE ENGINE WIRE a. Remove the engine wire from the engine with transaxle. 74. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY . Refer to REMOVAL - Step 6 75. REMOVE ENGINE MOUNTING BRACKET RH a. Remove the 3 bolts and engine mounting bracket RH.

Fig. 122: Identifying Engine Mounting Bracket RH With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 76. REMOVE DRIVE SHAFT BEARING BRACKET a. Remove the 3 bolts and drive shaft bearing bracket.

Fig. 123: Identifying Drive Shaft Bearing Bracket Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 78. INSTALL ENGINE ON ENGINE STAND a. Install the engine onto an engine stand with the bolts. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. REMOVE ENGINE STAND 2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2 3. INSTALL DRIVE SHAFT BEARING BRACKET a. Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 4. INSTALL ENGINE MOUNTING BRACKET RH a. Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY . Refer to INSTALLATION - Step 6 6. INSTALL ENGINE WIRE a. Install the engine wire to the engine with transaxle. 7. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY a. Temporarily install the front engine mounting insulator assembly with the 3 nuts. HINT: Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary. 8. INSTALL ENGINE MOUNTING INSULATOR LH a. Temporarily install the engine mounting insulator LH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

9. INSTALL ENGINE MOUNTING INSULATOR RH a. Temporarily install the engine mounting insulator RH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 10. INSTALL FRONT FRAME ASSEMBLY a. Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) b. Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) c. Install the front engine mounting insulator assembly with the bolt. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) d. Connect the 2 wire clamps and vacuum switching valve connector. e. Connect the 2 wire clamps and oil pressure switch connector. f. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque. HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

Fig. 124: Identifying Front Engine Mounting Insulator Assembly Bolts\ And Engine Mounting Insulator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Front Engine Engine Mounting *1 Mounting *2 Insulator Insulator RH Assembly Engine Mounting *3 - Insulator LH A Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) B Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) g. Install the 4 hole plugs. HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

Fig. 125: Identifying Engine Mounting Insulator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine Engine Mounting Mounting *1 *2 Insulator Insulator RH LH

11. 12. 13. 14. 15.

INSTALL TRANSMISSION OIL COOLER . Refer to INSTALLATION - Step 8 INSTALL COMPRESSOR AND MAGNETIC CLUTCH . Refer to INSTALLATION - Step 2 INSTALL GENERATOR ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL V-RIBBED BELT See step 1 INSTALL ENGINE ASSEMBLY WITH TRANSAXLE a. Set the engine assembly with transaxle on an engine lifter. NOTE:











Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Make sure to support the engine assembly with transaxle securely to prevent it from falling.

b. Remove the engine hangers See step 1. c. Install the engine assembly with transaxle to the vehicle. NOTE:



 

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. Make sure that the engine is clear of all wiring and hoses. While raising the engine into the vehicle, do not allow it to contact the vehicle.

d. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

Fig. 126: Identifying Frame Side Rail Plates Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf) B Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) e. Install the front suspension member rear braces RH and LH with the 4 bolts and 2 nuts. C Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf)

D Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 16. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT a. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 torque converter setting bolts.

Fig. 127: Applying Adhesive To Threads Of Torque Converter Setting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Adhesive *1 1324 Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. b. Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTE:

First install the black colored bolt, and then the remaining 5 silver colored bolts.

17. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY a. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 18. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET a. Install the No. 1 exhaust pipe support bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 19. 20. 21. 22.

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REASSEMBLY - Step 13 INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to INSTALLATION - Step 2 CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 8 23. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as for the LH side.

24. CONNECT TIE ROD ASSEMBLY LH . Refer to INSTALLATION - Step 8 25. CONNECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 26. INSTALL FRONT SPEED SENSOR LH . Refer to INSTALLATION - Step 19 27. INSTALL FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side. 28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH . Refer to INSTALLATION - Step 10 29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT:

Perform the same procedure as for the LH side. 30. INSTALL FRONT AXLE SHAFT NUT LH . Refer to INSTALLATION - Step 7 31. INSTALL FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side. 32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to INSTALLATION Step 10 33. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to INSTALLATION - Step 8 34. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET . Refer to INSTALLATION - Step 4 35. CONNECT SUCTION HOSE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 36. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to INSTALLATION Step 4 37. CONNECT FUEL MAIN TUBE a. Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

Fig. 128: Connecting Fuel Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Check that there is no damage or foreign objects on the fuel tube connector.



After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

b. Install the No. 1 fuel pipe clamp.

Fig. 129: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected. 38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to INSTALLATION - Step 2 39. INSTALL AIR CLEANER BRACKET a. Install the air cleaner bracket to the battery carrier with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 2 wire clamps. 40. CONNECT ENGINE WIRE a. Connect the 2 wire clamps.

Fig. 130: Identifying Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Connect the connector to the ECM with the lock lever. Connect the engine wire to the engine room relay block. Connect the 4 connectors. Connect the engine wire to the engine room relay block.

Fig. 131: Identifying Wire Clamp And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Connect the wire clamp and install the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

41. 42. 43. 44. 45. 46.

47.

g. Install the No. 1 relay block cover. INSTALL STARTER ASSEMBLY . Refer to INSTALLATION - Step 1 CONNECT WATER HOSE SUB-ASSEMBLY a. Connect the water hose sub-assembly with the hose clip. CONNECT INLET HEATER WATER HOSE a. Connect the inlet heater water hose with the hose clip. CONNECT NO. 3 WATER BY-PASS HOSE a. Connect the No. 3 water by-pass hose to the transmission oil cooler with the hose clip. CONNECT OUTLET RADIATOR HOSE a. Connect the outlet radiator hose with the hose clip. CONNECT INLET RADIATOR HOSE a. Connect the inlet radiator hose with the hose clip. b. Install the No. 3 water by-pass hose to the inlet radiator hose with the hose clamp. c. Install the air fuel ratio sensor wire to the inlet radiator hose with the hose clamp. CONNECT UNION TO CHECK VALVE HOSE a. Connect the union to check valve hose to the brake booster with the hose clip.

48. CONNECT NO. 1 FUEL VAPOR FEED HOSE a. Connect the No. 1 fuel vapor feed hose with the hose clip. 49. CONNECT EARTH WIRE a. Install the earth wire with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 50. INSTALL ENGINE MOVING CONTROL ROD a. Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary. 51. INSTALL ENGINE MOVING CONTROL ROD BRACKET a. When replacing the engine moving control rod.

Fig. 132: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)

NOTE:

Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B.

2. Tighten the bolt E. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) b. When not replacing the engine moving control rod.

Fig. 133: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) NOTE:

Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B.

52. INSTALL NO. 2 ENGINE MOUNTING STAY RH a. Install the No. 2 engine mounting stay RH with the bolt. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) b. Tighten the 2 nuts.

Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) 53. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY a. Install the intake air resonator sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 2 vacuum hoses and engage the claw. 54. INSTALL INLET NO. 1 AIR CLEANER a. Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.

Fig. 134: Identifying Inlet No. 1 Air Cleaner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the pin to the radiator support. 55. INSTALL BATTERY a. Install the battery and battery tray. b. Install the battery clamp with the bolt and nut. Bolt Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)

c. Connect the positive (+) cable to the positive (+) battery terminal. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY a. Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.

Fig. 135: Identifying Air Cleaner Case Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration. TEXT IN ILLUSTRATION Air

Cleaner *1 Case Subassembly Inlet No. *2 1 Air Cleaner *a Projection *b Hole c. Tighten the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) d. Connect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose. 57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 58. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 59. INSTALL INLET NO. 2 AIR CLEANER a. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 2 wire harness clamps and vacuum hose clamp. 60. INSPECT VACUUM HOSES a. Inspect the vacuum hoses.

Fig. 136: Identifying Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL a. Connect the negative (-) cable to the negative (-) battery terminal. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 62. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 63. ADD ENGINE OIL . Refer to REPLACEMENT - Step 4 64. ADD ENGINE COOLANT Refer to REPLACEMENT - Step 2 65. ADD AUTOMATIC TRANSAXLE FLUID

Refer to ADJUSTMENT 66. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . Refer to REPLACEMENT Step 2 67. WARM UP ENGINE . Refer to REPLACEMENT - Step 3 68. INSPECT FOR REFRIGERANT LEAK . Refer to REPLACEMENT - Step 4 69. INSPECT ENGINE OIL LEVEL . Refer to ON-VEHICLE INSPECTION - Step 1 70. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR . Refer to ON-VEHICLE INSPECTION - Step 2 71. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 72. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 73. INSPECT FOR OIL LEAK 74. INSPECT FOR EXHAUST GAS LEAK 75. INSPECT IGNITION TIMING See step 9 76. INSPECT ENGINE IDLE SPEED See step 10 77. INSPECT CO/HC See step 12 78. CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE 79. INSPECT SHIFT LEVER POSITION . Refer to ADJUSTMENT - Step 1 80. ADJUST SHIFT LEVER POSITION . Refer to ADJUSTMENT - Step 2 81. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT 82. INSTALL V-BANK COVER SUB-ASSEMBLY a. Fit the 3 retainers and install the V-bank cover sub-assembly. 83. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 84. INSTALL FRONT FENDER APRON SEAL LH 85. INSTALL ENGINE UNDER COVER LH 86. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 87. INSTALL FRONT FENDER APRON SEAL RH 88. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 89. INSTALL ENGINE UNDER COVER RH

ENGINE UNIT COMPONENTS ILLUSTRATION

Fig. 137: Identifying Engine Unit Replacement Components With Torque Specifications (1 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 138: Identifying Engine Unit Replacement Components With Torque Specifications (2 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 139: Identifying Engine Unit Replacement Components With Torque Specifications (3 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 140: Identifying Engine Unit Replacement Components With Torque Specifications (4 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 141: Identifying Engine Unit Replacement Components With Torque Specifications (5 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 142: Identifying Engine Unit Replacement Components With Torque Specifications (6 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 143: Identifying Engine Unit Replacement Components With Torque Specifications (7 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 144: Identifying Engine Unit Replacement Components With Torque Specifications (8 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 145: Identifying Engine Unit Replacement Components With Torque Specifications (9 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 146: Identifying Engine Unit Replacement Components With Torque Specifications (10 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 147: Identifying Engine Unit Replacement Components With Torque Specifications (11 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 148: Identifying Engine Unit Replacement Components With Torque Specifications (12 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE ENGINE HANGERS a. Remove the 4 bolts and 2 engine hangers.

Fig. 149: Locating Engine Hangers & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 engine hanger No. 2 *2 engine hanger Bank *a 1 Bank *b 2 2. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to REMOVAL - Step 9 3. REMOVE NO. 1 SURGE TANK STAY a. Remove the bolt and No. 1 surge tank stay.

Fig. 150: Locating No. 1 Surge Tank Stay & Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE THROTTLE BODY BRACKET a. Remove the bolt and throttle body bracket.

Fig. 151: Identifying Throttle Body Bracket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 3 6. REMOVE NO. 2 ENGINE MOUNTING STAY RH a. Remove the bolt and No. 2 engine mounting stay RH.

Fig. 152: Locating Bolt And No. 2 Engine Mounting Stay RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE INTAKE MANIFOLD a. Uniformly loosen and remove the 6 bolts and 4 nuts.

Fig. 153: Locating Intake Manifold Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the intake manifold and 2 gaskets. 8. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH a. Uniformly loosen and remove the 6 nuts.

Fig. 154: Identifying Exhaust Manifold Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the exhaust manifold sub-assembly RH and gasket. 9. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE a. Remove the oil level dipstick.

Fig. 155: Identifying No. 2 Engine Oil Level Dipstick Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and No. 2 engine oil level dipstick guide. c. Remove the O-ring from the No. 2 engine oil level dipstick guide.

Fig. 156: Identifying No. 2 Engine Oil Level Dipstick Guide O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 11 11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to REMOVAL - Step 10 12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH a. Uniformly loosen and remove the 6 nuts.

Fig. 157: Identifying Exhaust Manifold Sub-Assembly LH & Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the exhaust manifold assembly LH and gasket. 13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY a. Remove the 5 bolts and V-ribbed belt tensioner assembly.

Fig. 158: Identifying V-Ribbed Belt Tensioner Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 2 TIMING GEAR COVER a. Remove the 2 bolts and No. 2 timing gear cover.

Fig. 159: Identifying No 2 Timing Gear Cover And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE WATER PUMP PULLEY a. Using SST, hold the water pump pulley.

Fig. 160: Identifying Water Pump Pulley, Bolts & SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09960-10010 09962-01000 09963-00700 b. Remove the 4 bolts and water pump pulley. 16. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY a. Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate. 

Fig. 161: Identifying No 2 Idler Pulley Sub-Assembly And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE NO. 1 VACUUM SWITCHING VALVE a. Remove the bolt and No. 1 vacuum switching valve.

Fig. 162: Locating No. 1 Vacuum Switching Valve Assembly & Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Using a deep socket wrench, remove the engine oil pressure switch assembly.

Fig. 163: Removing/Installing Oil Pressure Switch With Deep Socket Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE KNOCK CONTROL SENSOR . Refer to REMOVAL - Step 2 20. REMOVE KNOCK SENSOR WIRE a. Disconnect the 3 clamps and remove the knock sensor wire from the engine assembly.

Fig. 164: Identifying Knock Sensor Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE ENGINE COOLANT TEMPERATURE SENSOR a. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.

Fig. 165: Removing/Installing Engine Coolant Temperature Sensor With Deep Socket

Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY a. Remove the oil filler cap sub-assembly and oil filler gasket. 2. REMOVE SPARK PLUG . Refer to REMOVAL - Step 4 3. REMOVE OIL PAN DRAIN PLUG a. Remove the oil pan drain plug and oil pan drain plug gasket.

Fig. 166: Locating Oil Pan Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE VENTILATION VALVE SUB-ASSEMBLY a. Remove the ventilation valve sub-assembly.

Fig. 167: Identifying Ventilation Valve Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE VVT SENSOR . Refer to REMOVAL - Step 2 6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to REMOVAL Step 3 7. REMOVE CRANK POSITION SENSOR . Refer to REMOVAL - Step 2 8. REMOVE NO. 1 OIL PIPE a. Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.

Fig. 168: Identifying Oil Pipe Union And No. 1 Oil Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Pipe Union b. Remove the oil control valve filter LH and gaskets. 9. REMOVE OIL PIPE a. Remove the bolt.

Fig. 169: Identifying Oil Pipe Union Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Pipe Union *2 Bolt b. Remove the 2 oil pipe unions and oil pipe. c. Remove the oil control valve filter RH and gaskets. 10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

Fig. 170: Locating Bank 1 & Bank 2 Cylinder Block Water Drain Cock Sub-Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for *a Bank 1 for *b Bank 2 a. Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block. b. Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies. 11. REMOVE OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 2 12. REMOVE CRANKSHAFT PULLEY See step 6

13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE a. Remove the bolt and engine oil level dipstick guide.

Fig. 171: Identifying Engine Oil Level Dipstick Guide And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring.

Fig. 172: Identifying Engine Oil Level Dipstick Guide And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH a. Remove the 6 bolts and No. 1 front engine mounting bracket LH.

Fig. 173: Locating Engine Mounting Bracket Front And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an E8 "TORX" socket wrench, remove the 2 stud bolts. 15. REMOVE WATER INLET HOUSING a. Remove the 2 nuts, water inlet and thermostat.

Fig. 174: Locating Water Inlet With Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Remove the gasket. Remove the 2 stud bolts. Separate the No. 1 water by-pass hose from the water inlet housing. Remove the drain cock plug.

Fig. 175: Locating Water Inlet Housing Drain Cock Plug & Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Bolt f. Remove the drain cock assembly. g. Remove the 2 bolts, nut, and water inlet housing. h. Remove the 2 O-rings.

Fig. 176: Locating O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE WATER OUTLET a. Remove the 2 bolts, 4 nuts and water outlet.

Fig. 177: Identifying Water Outlet With Bolts And Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Bolt b. Remove the 2 gaskets and O-ring.

Fig. 178: Locating Gaskets And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY a. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

Fig. 179: Locating Bolts, Head Cover And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 gaskets.

Fig. 180: Identifying Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH a. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.

Fig. 181: Identifying Cylinder Head Cover Sub-Assembly Bolts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Baffle *1 Plate NOTE:

The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

b. Remove the 3 gaskets.

Fig. 182: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY a. Remove the 16 bolts and 2 nuts.

Fig. 183: Identifying No. 2 Oil Pan Sub-Assembly, Bolts & Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut b. Insert the blade of the oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

Fig. 184: Inserting Blade Of Oil Pan Seal Cutter Between Oil Pans Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the contact surfaces of the oil pans.

c. Using an E6 "TORX" socket wrench, remove the 2 stud bolts. 20. REMOVE OIL STRAINER SUB-ASSEMBLY a. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

Fig. 185: Locating Oil Pan Sub-Assembly With Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Bolt *2 Nut b. Using an E6 "TORX" socket wrench, remove the 2 stud bolts. 21. REMOVE OIL PAN SUB-ASSEMBLY a. Remove the 16 bolts and 2 nuts.

Fig. 186: Locating Oil Control Valves Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. b. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.

Fig. 187: Identifying Oil Pan Sub-Assembly And Pry Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT: Tape the screwdriver tip before use. c. Remove the 2 O-rings.

Fig. 188: Locating O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using an E8 "TORX" socket wrench, remove the 2 stud bolts. 22. REMOVE NO. 1 OIL PAN BAFFLE PLATE a. Remove the 7 bolts and No. 1 oil pan baffle plate.

Fig. 189: Locating Oil Pan Baffle Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE ENGINE REAR OIL SEAL RETAINER a. Remove the 6 bolts.

Fig. 190: Identifying Engine Rear Oil Seal Retainer Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, pry out the engine rear oil seal retainer.

Fig. 191: Prying Out Engine Rear Oil Seal Retainer Using A Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Pry NOTE:

Be careful not to damage the engine rear oil seal retainer.

HINT: Tape the screwdriver tip before use. 24. REMOVE ENGINE REAR OIL SEAL a. Place the engine rear oil seal retainer on wooden blocks.

Fig. 192: Removing Engine Rear Oil Using A Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Wooden *2 Block b. Using a screwdriver and a hammer, tap out the oil seal. NOTE:

Be careful not to damage the engine rear oil seal retainer.

HINT: Tape the screwdriver tip before use. 25. REMOVE ENGINE WATER PUMP ASSEMBLY a. Remove the 16 bolts, engine water pump assembly and water pump gasket.

Fig. 193: Locating Bolts, Water Pump And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY a. Remove the 15 bolts and 2 nuts as shown in the illustration.

Fig. 194: Locating Timing Chain Cover Sub-Assembly Nuts & Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut b. Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

Fig. 195: Removing Timing Chain Cover Sub-Assembly With Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape NOTE:

Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use. c. Remove the 4 bolts, timing chain cover plate and timing chain cover plate gasket. d. Remove the gasket.

Fig. 196: Identifying Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE TIMING CHAIN CASE OIL SEAL . Refer to REMOVAL - Step 32 28. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily tighten the pulley set bolt. b. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

Fig. 197: Turning Crankshaft Clockwise & Aligning Crank Angle Sensor Plate With RH Block Bore Center Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sensor *1 Plate Center *a Line Timing *b Mark c. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

Fig. 198: Identifying Alignment Of Camshaft Timing Gear & Bearing Cap Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a

Timing Mark

If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above. 29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Fig. 199: Removing No. 1 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plunger Stopper *2 Plate *3 Pin b. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate hole. c. Remove the 2 bolts and No. 1 chain tensioner assembly.

Fig. 200: Locating Chain Tensioner With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE CHAIN TENSIONER SLIPPER a. Remove the chain tensioner slipper. 31. REMOVE CHAIN SUB-ASSEMBLY a. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

Fig. 201: Turning Crankshaft Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sensor *1 Plate Center *a Line Timing *b Mark b. Remove the pulley set bolt. c. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

Fig. 202: Identifying Chain Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

Fig. 203: Turning Camshaft Timing Gear Assembly Clockwise (Bank 1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION for *a Bank 1 e. Remove the chain sub-assembly. 32. REMOVE IDLE SPROCKET ASSEMBLY a. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

Fig. 204: Locating Idle Gear Shaft No. 2, Idle Sprocket And Idle Gear Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE NO. 1 CHAIN VIBRATION DAMPER a. Remove the 2 bolts and No. 1 chain vibration damper.

Fig. 205: Locating Chain Vibration Damper With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE NO. 2 CHAIN VIBRATION DAMPER a. Remove the 2 No. 2 chain vibration dampers. 35. REMOVE CRANKSHAFT TIMING SPROCKET a. Remove the crankshaft timing sprocket from the crankshaft.

Fig. 206: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54.

b. Remove the 2 keys from the crankshaft. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 40 REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 41 REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 42 REMOVE CAMSHAFT See step 43 REMOVE NO. 2 CAMSHAFT See step 44 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 45 REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 46 REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 47 REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 48 REMOVE NO. 3 CAMSHAFT See step 49 REMOVE NO. 4 CAMSHAFT See step 50 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 51 REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 10 REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 11 REMOVE VALVE STEM CAP See step 12 REMOVE CYLINDER HEAD SUB-ASSEMBLY RH See step 14 REMOVE CYLINDER HEAD GASKET RH See step 15 REMOVE CYLINDER HEAD SUB-ASSEMBLY LH See step 16 REMOVE CYLINDER HEAD GASKET LH See step 17

55. REMOVE WATER INLET PIPE a. Remove the 2 clamps and separate the No. 1 water by-pass hose. b. Remove the 2 bolts and water inlet pipe.

Fig. 207: Identifying Water Inlet Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Turn the roller by hand to check that it turns smoothly.

Fig. 208: Turning Roller By Hand For Checking Smoothly Turns

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly. 2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE:





Keep the valve lash adjuster assembly free of dirt and foreign objects. Only use clean engine oil.

a. Place the valve lash adjuster assembly into a container filled with engine oil. b. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.

Fig. 209: Bleeding Valve Lash Adjuster Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Tapered Part *2 Plunger *3 Check Ball *a CORRECT *b INCORRECT Low Pressure *c Chamber High Pressure *d Chamber SST: 09276-75010 c. Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times. d. Check the movement of the plunger and bleed the air. 

OK Plunger moves up and down. NOTE:

When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

e. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly. 3. INSPECT CAMSHAFT a. Inspect the camshaft for runout. 1. Place the camshaft on V-blocks. 2. Using a dial indicator, measure the circle runout at the center journal.

Fig. 210: Measuring Circle Runout At Center Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.04 mm (0.00157 in.) If the runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. b. Using a micrometer, measure the cam lobe height.

Fig. 211: Checking Cam Lobe Height

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Cam Lobe Height Item Specification 44.316 to Intake 44.416 mm camshaft (1.7448 to 1.7486 in.) 44.262 to Exhaust 44.362 mm camshaft (1.7426 to 1.7465 in.) Minimum Cam Lobe Height Item Specification Intake 44.166 mm camshaft (1.7388 in.) Exhaust 44.112 mm camshaft (1.7366 in.) If the cam lobe height is less than the minimum, replace the camshaft. c. Using a micrometer, measure the journal diameter.

Fig. 212: Measuring Journal Diameter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Journal Diameter Item Specification 35.946 to No. 1 35.960 mm journal (1.4152 to 1.4157 in.) 25.959 to Other 25.975 mm journals (1.0221 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance. 4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY a. Clamp the camshaft in a vise. NOTE:

Be careful not to damage the camshaft in the vise.

b. Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

Fig. 213: Identifying Camshaft Timing Gear Key Groove & Camshaft Straight Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Straight *1 Pin Key *a Groove c. Check that there is no clearance between the camshaft timing gear assembly flange and the camshaft. d. Tighten the flange bolt while holding the camshaft.

Fig. 214: Tightening Flange Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) e. Check the lock of the camshaft timing gear assembly. 1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked. NOTE: f. Release the lock pin.

Be careful not to damage the camshaft.

Fig. 215: Covering 4 Oil Paths Of The Cam Journal Using Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Advance

Side Path Retard *2 Side Path Vinyl *3 Tape *4 Rubber *a Close *b Open *1

1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. 2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration. 3. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the 2 opened paths.

Fig. 216: Applying Air Pressure To Advanced & Retard Side Paths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Advanced Side Path Retard *2 Side Path *1

WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. 4. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

Fig. 217: Checking Camshaft Timing Gear Rotation With Air Pressure Applied To Retard Side Path Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Advance *1 Side Path Retard Side *2 Path Hold *a Pressure *b Decompress HINT:

This operation releases the lock pin at the most retarded position. 5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path. NOTE:

Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

g. Check for smooth rotation. 1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE:

Do not use air pressure to perform the smooth operation check.

h. Check the lock in the most retarded position. 1. Confirm that the camshaft timing gear assembly locks at the most retarded position. i. Remove the flange bolt and camshaft timing gear assembly.

Fig. 218: Identifying Straight Pin And Flange Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Straight *1 Pin Flange

*2 Bolt Do Not *a Remove NOTE:

 

Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY a. Clamp the camshaft in a vise. NOTE:

Be careful not to damage the camshaft in the vise.

b. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin.

Fig. 219: Identifying Camshaft Timing Gear Key Groove & Camshaft Straight Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Straight *1 Pin Key *a Groove

c. Check that there is no clearance between the gear flange and the camshaft. d. Tighten the flange bolt while holding the camshaft.

Fig. 220: Checking Camshaft Timing Exhaust Gear Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) e. Check the camshaft timing exhaust gear lock. 1. Make sure that the camshaft timing exhaust gear assembly locks. f. Release the lock pin.

Fig. 221: Covering 4 Oil Paths Of The Cam Journal Using Vinyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Retard

Side Path Advance *2 Side Path *3 Rubber Vinyl *4 Tape *a Open *b Close *1

1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. 2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration. 3. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).

Fig. 222: Applying Air Pressure To Advanced & Retard Side Paths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Advanced *1 Side Path Retard *2 Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. 4. Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

Fig. 223: Checking Camshaft Timing Exhaust Gear Rotation With Air Pressure Applied To Advance Side Path Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Advance *1 Side Path Retard Side *2 Path *a Decompress Hold *b Pressure HINT:

The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. 5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path. NOTE:

Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

g. Check for smooth rotation. 1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly. NOTE:

When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

h. Check the lock at the most advanced position. 1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position. i. Remove the flange bolt and camshaft timing exhaust gear assembly.

Fig. 224: Identifying Straight Pin And Flange Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Straight *1 Pin Flange *2 Bolt Do Not *a Remove NOTE:

 

Be sure not to remove the other 4 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

6. INSPECT CYLINDER HEAD SET BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point.

Fig. 225: Measuring Diameter Of Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 10.85 to 11.00 mm (0.4272 to 0.4330 in.) Minimum diameter 10.70 mm (0.4212 in.) Measurement point (distance from the seat) 103 mm (4.06 in.) HINT: If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the cylinder head bolt with a new one. 7. INSPECT CHAIN SUB-ASSEMBLY a. Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. 

Fig. 226: Inspecting Chain Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vernier caliper, measure the length of 15 links. TEXT IN ILLUSTRATION Measuring *a Point Maximum chain elongation 136.9 mm (5.389 in.) NOTE:

Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the chain sub-assembly. 8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY a. Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration.

Fig. 227: Inspecting Chain Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vernier caliper, measure the length of 15 links. TEXT IN ILLUSTRATION Measuring *a Point Maximum chain elongation 137.6 mm (5.417 in.) NOTE:

Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the chain sub-assembly. 9. INSPECT CRANKSHAFT TIMING SPROCKET a. Place the chain around the sprocket. b. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.

Fig. 228: Measuring Sprocket Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. 10. INSPECT IDLE SPROCKET ASSEMBLY a. Place the chain around the sprocket. b. Using a vernier caliper, measure the sprocket diameter with the chain.

Fig. 229: Measuring Sprocket Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.)

HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. 11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE a. Using a micrometer, measure the idle gear shaft diameter.

Fig. 230: Measuring Idle Gear Shaft Diameter Using A Micrometer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) b. Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

Fig. 231: Measuring Idle Sprocket Inside Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard idle gear inside diameter 23.020 to 23.030 mm (0.9063 to 0.9067 in.) c. Subtract the idle gear shaft diameter measurement from the idle sprocket inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.) Maximum oil clearance 0.093 mm (0.00366 in.) If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly. 12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY a. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

Fig. 232: Identifying Plunger And Stopper Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plunger Stopper *2 Plate If necessary, replace the No. 1 chain tensioner assembly. 13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY a. Check that the plunger moves smoothly.

Fig. 233: Inspecting No. 2 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth b. Using a vernier caliper, measure the worn depth of the No. 2 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly. 14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY a. Check that the plunger moves smoothly.

Fig. 234: Inspecting No. 3 Chain Tensioner Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth b. Using a vernier caliper, measure the worn depth of the No. 3 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly. 15. INSPECT CHAIN TENSIONER SLIPPER a. Measure the worn depth of the chain tensioner slipper.

Fig. 235: Inspecting Worn Depth Of Chain Tensioner Slipper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the chain tensioner slipper. 16. INSPECT NO. 1 CHAIN VIBRATION DAMPER a. Using a vernier caliper, measure the worn depth of the No. 1 chain vibration damper.

Fig. 236: Inspecting Worn Depth Of No. 1 Chain Vibration Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 1 chain vibration damper. 17. INSPECT NO. 2 CHAIN VIBRATION DAMPER a. Using a vernier caliper, measure the worn depth of the No. 2 chain vibration damper.

Fig. 237: Inspecting Worn Depth Of No. 2 Chain Vibration Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 2 chain vibration damper. 18. INSPECT CAMSHAFT THRUST CLEARANCE a. Inspect the bank 1 camshaft thrust clearance. 1. Install the bank 1 camshaft See step 5. 2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Fig. 238: Checking Camshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. b. Inspect the bank 2 camshaft thrust clearance. 1. Install the bank 2 camshaft. Refer to INSTALLATION. 2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. 19. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 1) a. Clean the camshaft bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing. c. Lay a strip of Plastigage across each camshaft journal.

Fig. 239: Applying Plastigage Across Camshaft Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage d. Install the camshaft bearing caps See step 7. NOTE:

Do not turn the camshaft.

e. Remove the camshaft bearing caps See step 42. f. Measure the Plastigage at its widest point.

Fig. 240: Measuring Plastigage At Its Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage

No. 1 Journal Other *3 Journals *2

Standard Oil Clearance Oil Clearance 0.032 to 0.071 mm No. 1 (0.00126 journal to 0.00280 in.) 0.025 to 0.062 mm Other (0.000984 journals to 0.00244 in.) Item

Maximum Oil Clearance Oil Clearance 0.10 mm No. 1 (0.00394 journal in.) 0.09 mm Other (0.00354 journals in.) Item

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. 20. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 2) a. Clean the camshaft bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing. c. Lay a strip of Plastigage across each camshaft journal.

Fig. 241: Applying Plastigage Across Camshaft Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage d. Install the camshaft bearing caps. Refer to INSTALLATION. NOTE:

Do not turn the camshaft.

e. Remove the camshaft bearing caps See step 48. f. Measure the Plastigage at its widest point.

Fig. 242: Measuring Widest Point Of Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage

No. 1 Journal Other *3 Journals *2

Standard Oil Clearance Oil Clearance 0.032 to 0.071 mm No. 1 (0.00126 journal to 0.00280 in.) 0.025 to 0.062 mm Other (0.000984 journals to 0.00244 in.) Item

Maximum Oil Clearance Oil Clearance 0.10 mm No. 1 (0.00394 journal in.) 0.09 mm Other (0.00354 journals in.) Item

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly. 21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Fig. 243: Inspecting Exhaust Manifold Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold. 22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Fig. 244: Inspecting Exhaust Manifold Sub-Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold. 23. INSPECT INTAKE MANIFOLD

Fig. 245: Inspecting Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder

Head Side Surge *b Tank Side *a

a. Cylinder head side: 1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold. b. Surge tank side: 1. Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold. REASSEMBLY REASSEMBLY

1. INSTALL ENGINE REAR OIL SEAL a. Place the oil seal retainer on wooden blocks. b. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.

Fig. 246: Installing Engine Rear Oil Seal Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09223-15030 SST: 09950-70010 09951-07100

TEXT IN ILLUSTRATION *a Depth NOTE:

 

Keep the lip free of foreign matter. Do not tap the engine rear oil seal at an angle.

2. INSTALL ENGINE REAR OIL SEAL RETAINER a. Apply seal packing in a continuous line as shown in the illustration.

Fig. 247: Identifying Rear Oil Seal Retainer Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal Packing Diameter (2.0 to *a 3.0 mm (0.0787 to 0.118 in.)) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE:

 



Remove any oil from the contact surfaces. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation.

b. Install the engine rear oil seal retainer with the 6 bolts.

Fig. 248: Identifying Oil Seal Retainer Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 3. INSTALL WATER INLET PIPE

Fig. 249: Identifying Water Inlet Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

b. Install the No. 1 water by-pass hose. INSTALL CYLINDER HEAD GASKET RH See step 1 INSTALL CYLINDER HEAD SUB-ASSEMBLY RH See step 2 INSTALL CYLINDER HEAD GASKET LH See step 3 INSTALL CYLINDER HEAD SUB-ASSEMBLY LH See step 4 INSTALL VALVE STEM CAP See step 6 INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7 INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8 INSTALL NO. 3 CAMSHAFT See step 1 INSTALL NO. 4 CAMSHAFT See step 2 INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4 INSTALL CAMSHAFT See step 5 INSTALL NO. 2 CAMSHAFT See step 6 INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8

19. 20. 21. 22. 23.

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 9 INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 10 INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 11 INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 12 INSTALL NO. 1 CHAIN VIBRATION DAMPER a. Install the No. 1 chain vibration damper with the 2 bolts.

Fig. 250: Identifying No. 1 Chain Vibration Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 24. INSTALL NO. 2 CHAIN VIBRATION DAMPER a. Install the 2 No. 2 chain vibration dampers. 25. INSTALL CRANKSHAFT TIMING SPROCKET a. Install the 2 keys and crankshaft timing sprocket as shown in the illustration.

Fig. 251: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. INSTALL IDLE SPROCKET ASSEMBLY a. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

Fig. 252: Installing Idle Sprocket Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin b. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTE:

Be careful of the idle gear installation position.

HINT: Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

c. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly. 27. INSTALL CHAIN SUB-ASSEMBLY a. Align the mark plates and timing marks as shown in the illustration and install the chain.

Fig. 253: Identifying Chain Mark Plates & Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark

*1 Plate Timing *a Mark HINT: The camshaft mark plates are orange. b. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

Fig. 254: Identifying Chain Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.

Fig. 255: Turning Bank 1 Camshaft Timing Gear Counterclockwise & Aligning Mark Plate/Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Mark Plate *a Turn When the idle *b sprocket is reused *c Mark *d Align *1

NOTE:

When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

d. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.

Fig. 256: Identifying Chain Mark Plate & Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark *1 Plate Timing *a Mark

HINT: The crankshaft mark plate is yellow. e. Temporarily tighten the pulley set bolt. f. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

Fig. 257: Turning Crankshaft Clockwise To Set RH Block Bore Center Line (TDC/Compression) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center *1 Line Timing *2 Mark Sensor *3 Plate 28. INSTALL CHAIN TENSIONER SLIPPER a. Install the chain tensioner slipper. 29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Fig. 258: Turning Stopper Plate Upward & Pushing Plunger Into Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stopper *1 Plate *2 Plunger b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. c. Install the No. 1 chain tensioner assembly with the 2 bolts.

Fig. 259: Locating Chain Tensioner With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) d. Remove the hexagon wrench from the No. 1 chain tensioner assembly. 30. INSPECT VALVE TIMING a. Check the camshaft timing marks. NOTE:





Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

b. Check that each camshaft timing mark is positioned as shown in the illustration.

Fig. 260: Identifying Camshaft Timing Mark Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *a *b Viewpoint Mark HINT: For the intake camshaft: Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

Fig. 261: Identifying Camshaft Timing Mark Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. If the valve timing is misaligned, reinstall the timing chain. d. Remove the pulley set bolt. 31. INSTALL TIMING CHAIN CASE OIL SEAL . Refer to INSTALLATION - Step 1 32. INSTALL ENGINE WATER PUMP ASSEMBLY a. Install a new water pump gasket and the engine water pump assembly with the 8 bolts.

Fig. 262: Identifying Water Pump Assembly And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE:

Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY a. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Fig. 263: Applying Seal Packing To Timing Chain Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal Diameter: Seal *a 3.0 mm Packing or more Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 mm (0.118 in.) NOTE:





 

Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes. Do not start the engine for at least 2 hours after installing.

b. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Fig. 264: Identifying Timing Chain Cover Seal Packing Applying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Dashed Continuous line area line area (Seal (Seal packing: packing: Toyota Toyota Genuine Genuine *a Seal *b Seal Packing Packing Black, Black, Three Three Bond Bond 1207B or 1207B or equivalent) equivalent) Alternate

long and Diagonal short line area dashed (Seal line area packing: (Seal Toyota packing: Genuine Toyota *c Genuine *d Seal Packing Seal Black, Packing Three 1282B, Bond Three 1207B or Bond equivalent) 1282B or equivalent) Be sure to apply seal - packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent NOTE:







If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

SEAL PACKING APPLICATION CHART Application Seal Position Area Packing from Inside Diameter Seal Line 4.5 mm 1.0 to 2.0 Continuous or more mm (0.0394 Line Area (0.177 to 0.0787 in.) in.) Alternate 3.5 mm Long and 2.0 to 3.0 or more Short mm (0.0787 (0.138 Dashed to 0.118 in.) in.) Line Area

3.5 mm Dashed or more Line Area (0.138 in.) 6.0 mm Diagonal or more Line Area (0.236 in.)

3.0 to 4.0 mm (0.118 to 0.158 in.) 5.0 mm (0.197 in.)

c. Install a new gasket.

Fig. 265: Identifying Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Fig. 266: Aligning Oil Pump Drive Rotor Spline & Crankshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive *1 Rotor Spline *2 Crankshaft e. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Fig. 267: Locating Timing Chain Cover Nuts & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut BOLT LENGTH Item Length 40 mm Bolt (1.57 A in.) 55 mm Bolt (2.17 B in.) Bolt 25 mm

C

(0.984 in.)

NOTE:

Make sure that there is no oil on the threads of bolts B and C.

f. Fully tighten the bolts in this order: Area 1 and Area 2.

Fig. 268: Identifying Timing Chain Cover Nuts & Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Area *a 1 Area *b 2

Area 3 Area *d 4 *c

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) g. Fully tighten the bolts and nuts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts from top to bottom as shown in the illustration. h. Fully tighten the bolts in Area 4. Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts from bottom to top as shown in the illustration. i. Install a new timing chain cover plate gasket and the timing chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 34. INSTALL WATER INLET HOUSING a. Install 2 new O-rings.

Fig. 269: Locating O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation. b. Install the 2 stud bolts.

Fig. 270: Locating Water Inlet Housing Studs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) c. Install the water inlet housing with the 2 bolts and nut.

Fig. 271: Aligning Thermostat Jiggle Valve With Upper Stud Bolt Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Be careful that the O-ring does not get caught between the parts.

d. Connect the No. 1 water by-pass hose. e. Apply adhesive around the drain cock. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent f. Install the drain cock assembly to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) g. Install the drain cock plug to the drain cock assembly. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)

h. Install a new gasket to the thermostat. i. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

Fig. 272: Identifying Jiggle Valve Angles Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The jiggle valve may be set within 10° of either side of the prescribed position. j. Install the water inlet with the 2 nuts.

Fig. 273: Locating Water Inlet With Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH a. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Fig. 274: Locating No. 1 LH Front Engine Mounting Bracket Bolts & Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stud

*1 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Install the No. 1 front engine mounting bracket LH with the 6 bolts. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) NOTE:





Install the water inlet and mounting bracket within 15 minutes after installing the chain cover. Do not start the engine for at least 2 hours after installation.

36. INSTALL NO. 1 OIL PAN BAFFLE PLATE a. Install the No. 1 oil pan baffle plate with the 7 bolts.

Fig. 275: Locating Oil Pan Baffle Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily tighten the 7 bolts. Fully tighten the 2 bolts (A) shown in the illustration before tightening the other bolts. 37. INSTALL OIL PAN SUB-ASSEMBLY

a. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Fig. 276: Identifying Oil Pan Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing Lower *a Chain *b Cylinder Cover Block Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Install 2 new O-rings.

Fig. 277: Locating O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Apply seal packing in a continuous line as shown in the illustration.

Fig. 278: Identifying Oil Pan Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal *a Diameter Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE:

  

Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

d. Install the oil pan with the 16 bolts and 2 nuts.

Fig. 279: Identifying Oil Pan Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 38. INSTALL OIL STRAINER SUB-ASSEMBLY a. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Fig. 280: Locating Oil Strainer Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *a Chain Cover Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) b. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

Fig. 281: Locating Oil Strainer Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY a. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Fig. 282: Identifying Location Of Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 283: Identifying No. 2 Oil Pan Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal *a Diameter Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE:

 



Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

c. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

Fig. 284: Identifying No. 2 Oil Pan Sub-Assembly, Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 40. INSTALL OIL PAN DRAIN PLUG a. Install a new oil pan drain plug gasket and the oil pan drain plug.

Fig. 285: Locating Oil Pan Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY a. Apply seal packing as shown in the illustration.

Fig. 286: Locating Cylinder Head Cover Seal Packing Applying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE:

 



Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

b. Install 3 new gaskets as shown in the illustration.

Fig. 287: Identifying Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly. d. Install the head cover with the 12 bolts and a new seal washer.

Fig. 288: Identifying Head Cover With Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary. 42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH a. Apply seal packing as shown in the illustration.

Fig. 289: Locating LH Cylinder Head Cover Seal Packing Applying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:

 



Remove any oil from the contact surfaces. Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

b. Install 3 new gaskets as shown in the illustration.

Fig. 290: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH. d. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

Fig. 291: Locating Gaskets And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary. 43. INSTALL WATER OUTLET a. Install 2 new gaskets and a new O-ring.

Fig. 292: Locating Gaskets And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Apply soapy water to the O-ring. b. Install the water outlet with the 2 bolts and 4 nuts.

Fig. 293: Identifying Water Outlet With Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Be careful that the O-ring does not get caught between the parts.

44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE a. Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

Fig. 294: Identifying Engine Oil Level Dipstick Guide And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the engine oil level dipstick guide with the bolt.

Fig. 295: Identifying Engine Oil Level Dipstick Guide And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 45. INSTALL CRANKSHAFT PULLEY See step 2 46. INSTALL OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 3 47. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY a. Apply adhesive around the drain cock sub-assembly.

Fig. 296: Applying Adhesive To Drain Cock Sub-Assembly Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent b. Install the water drain cocks as shown in the illustration.

Fig. 297: Identifying Bank 1 & Bank 2 Drain Cock Angles Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for *a Bank 1 for *b Bank 2 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE:

Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

c. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 48. INSTALL NO. 1 OIL PIPE a. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE:

Do not touch the mesh when installing the oil control valve filter.

b. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

Fig. 298: Identifying Oil Pipe Union And No. 1 Oil Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Pipe Union c. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. d. Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) e. Tighten the oil pipe union (on the cylinder head side).

Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

49. INSTALL OIL PIPE a. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTE:

Do not touch the mesh when installing the oil control valve filter.

b. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

Fig. 299: Identifying Oil Pipe Union Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Pipe Union c. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. d. Install the bolt (A) to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

e. Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) f. Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

50. INSTALL CRANK POSITION SENSOR . Refer to INSTALLATION - Step 1 51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to INSTALLATION - Step 1 52. INSTALL VVT SENSOR . Refer to INSTALLATION - Step 1 53. INSTALL VENTILATION VALVE SUB-ASSEMBLY a. Apply adhesive around the ventilation valve sub-assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent b. Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly.

Fig. 300: Identifying Ventilation Valve Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 54. INSTALL SPARK PLUG . Refer to INSTALLATION - Step 1 55. INSTALL OIL FILLER CAP SUB-ASSEMBLY a. Install a new oil filler gasket. b. Install the oil filler cap sub-assembly. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR a. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.

Fig. 301: Removing/Installing Engine Coolant Temperature Sensor With Deep Socket Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 2. INSTALL KNOCK SENSOR WIRE a. Connect the 2 clamps, 2 knock sensor connectors and knock sensor wire connector.

3. INSTALL KNOCK CONTROL SENSOR . Refer to INSTALLATION - Step 1 4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch assembly.

Fig. 302: Applying Adhesive To Oil Pressure Switch Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent b. Using a deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Do not start the engine within 1 hour after installation to prevent oil leaks.

5. INSTALL NO. 1 VACUUM SWITCHING VALVE a. Install the No. 1 vacuum switching valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

6. INSTALL WATER PUMP PULLEY a. Temporarily install the water pump pulley with the 4 bolts. b. Using SST, hold the water pump pulley.  SST: 09960-10010 09962-01000 09963-00700 c. Tighten the 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY a. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) 8. INSTALL NO. 2 TIMING GEAR COVER a. Install the No. 2 timing gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY a. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

Fig. 303: Identifying V-Ribbed Belt Tensioner

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) b. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) c. Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH a. Install a new gasket as shown in the illustration.

Fig. 304: Identifying Exhaust Manifold Gasket Engine Front Position LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine

Front b. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

Fig. 305: Identifying Exhaust Manifold Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 3 12. INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 2 13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE a. Install a new O-ring to the No. 2 engine oil level dipstick guide. b. Apply a light coat of engine oil to the O-ring. c. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide. d. Install the No. 2 engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) e. Install the engine oil level dipstick. 14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH a. Install a new gasket as shown in the illustration.

Fig. 306: Identifying Exhaust Manifold Gasket Engine Front Position RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine Front b. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

Fig. 307: Identifying Exhaust Manifold Sub-Assembly Nuts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 15. INSTALL INTAKE MANIFOLD a. Set a new gasket on each cylinder head. NOTE:

 

Align the port holes of the gasket and cylinder head. Make sure that the gasket is installed in the correct direction.

b. Set the intake manifold on the cylinder heads. c. Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 16. INSTALL NO. 2 ENGINE MOUNTING STAY RH a. Install the No. 2 engine mounting stay RH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 17. INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 18. INSTALL NO. 1 SURGE TANK STAY NOTE:

Do not apply oil to the bolt as listed below:

Oil Application Prohibited Bolt Bolt for No. 1 surge tank stay and cylinder head cover a. Install the No. 1 surge tank stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 19. INSTALL THROTTLE BODY BRACKET NOTE:

Do not apply oil to the bolt as listed below: Oil Application Prohibited Bolt Bolt for throttle body bracket and cylinder head cover

a. Install the throttle body bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to INSTALLATION - Step 6 21. INSTALL ENGINE HANGERS a. Install the 2 engine hangers with the 4 bolts as shown in the illustration. PART NO. Part Item No. No. 1 1228131120 engine

hanger No. 2 12282engine 31100 hanger 90119Bolt A0117 Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) b. Attach an engine sling device and hang the engine with a chain block.

CYLINDER HEAD COMPONENTS ILLUSTRATION

Fig. 308: Identifying Cylinder Head Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE VALVE STEM CAP

a. Remove the valve stem caps from the cylinder heads. HINT: Arrange the removed parts in the correct order. 2. REMOVE INTAKE VALVE a. Using SST, compress the inner compression spring and remove the valve spring retainer locks.

Fig. 309: Compressing Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 09202-01010 09202-01020 b. Remove the valve spring retainer, inner compression spring and intake valve. 

HINT: Arrange the removed parts in the correct order. 3. REMOVE EXHAUST VALVE a. Using SST, compress the inner compression spring and remove the valve spring retainer locks.

Fig. 310: Compressing Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 09202-01010 09202-01020 b. Remove the valve spring retainer, inner compression spring and exhaust valve. 

HINT: Arrange the removed parts in the correct order. 4. REMOVE VALVE STEM OIL SEAL a. Using needle-nose pliers, remove the valve stem oil seals.

Fig. 311: Removing Valve Stem Oil Seal Using Needle-Nose Pliers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE VALVE SPRING SEAT a. Using compressed air and a Magnet Hand, remove the valve spring seats by blowing air onto them.

Fig. 312: Removing Valve Spring Seat

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE NO. 1 STRAIGHT SCREW PLUG a. Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets.

Fig. 313: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for *a Bank 1 for *b Bank 2 NOTE:

If water leaks from a straight screw plug or the plug is corroded, replace it.

7. REMOVE NO. 2 STRAIGHT SCREW PLUG a. Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets.

Fig. 314: Locating No. 2 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

Bank 1 for *b Bank 2 *a

NOTE:

If water leaks from a straight screw plug or the plug is corroded, replace it.

INSPECTION INSPECTION

1. INSPECT CYLINDER HEAD SUB-ASSEMBLY

Fig. 315: Inspecting Cylinder Head Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Cylinder Head *a Lower Side Intake *b Side Exhaust *c Side a. Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder block sub-assembly and manifolds. Standard Warpage Item Warpage Cylinder 0.05 mm head (0.00197 lower in.) 0.08 mm Intake (0.00315 in.) 0.08 mm Exhaust (0.00315 in.) Maximum Warpage Item Warpage Cylinder 0.10 mm head (0.00394 lower in.) 0.10 mm Intake (0.00394 in.) 0.10 mm Exhaust (0.00394 in.) If the warpage is greater than the maximum, replace the cylinder head sub-assembly. 2. INSPECT CYLINDER HEAD FOR CRACKS a. Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

Fig. 316: Checking Intake Ports, Exhaust Ports And Cylinder Surface For Cracks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracked, replace the cylinder head sub-assembly. 3. INSPECT INTAKE VALVE a. Using a micrometer, measure the diameter of the valve stem.

Fig. 317: Measuring Diameter Of Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.)

If the valve stem is not as specified, check the oil clearance. b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 318: Measuring Intake Valve Head Margin Thickness Using A Vernier Caliper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Margin *a thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. c. Using a vernier caliper, measure the valve overall length.

Fig. 319: Identifying Overall Length Of Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Overall *a Length Standard overall length 105.85 mm (4.1673 in.) Minimum overall length 105.35 mm (4.1476 in.) If the overall length is less than the minimum, replace the intake valve. 4. INSPECT EXHAUST VALVE a. Using a micrometer, measure the diameter of the valve stem.

Fig. 320: Checking Diameter Of Exhaust Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 321: Measuring Exhaust Valve Head Margin Thickness Using A Vernier Caliper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Margin *a thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. c. Using a vernier caliper, measure the valve overall length.

Fig. 322: Identifying Overall Length Of Exhaust Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Overall *a Length Standard overall length 110.40 mm (4.3464 in.) Minimum overall length 109.90 mm (4.3268 in.) If the overall length is less than the minimum, replace the exhaust valve. 5. INSPECT INTAKE VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat. c. Check the valve face and valve seat by using the following procedure:

Fig. 323: Inspecting Intake Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width 1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. 2. If Prussian blue appears around the entire valve seat, the valve seat and valve face are concentric. If not, resurface the valve seat. 3. Check that the valve seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). 6. INSPECT EXHAUST VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat. c. Check the valve face and valve seat by using the following procedure:

Fig. 324: Inspecting Intake Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width 1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. 2. If Prussian blue appears around the entire valve seat, the valve seat and valve face are concentric. If not, resurface the valve seat. 3. Check that the valve seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). 7. INSPECT INNER COMPRESSION SPRING a. Using a vernier caliper, measure the free length of the inner compression spring.

Fig. 325: Measuring Free Length Of Inner Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Free length 45.91 mm (1.8075 in.) If the free length is not as specified, replace the inner compression spring. b. Using a steel square, measure the deviation of the inner compression spring.

Fig. 326: Measuring Deviation Of Inner Compression Spring Using Steel Square Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Deviation Maximum deviation 1.0 mm (0.0394 in.) Maximum angle (reference) 2° If the deviation is greater than the maximum, replace the inner compression spring.

8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE a. Using a caliper gauge, measure the inside diameter of the valve guide bush.

Fig. 327: Measuring Inside Diameter Of Guide Bush Using Caliper Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) b. Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement. Standard Oil Clearance Item Clearance 0.025 to 0.060 mm Intake (0.000984 to 0.00236 in.) 0.030 to 0.065 mm Exhaust (0.00118 to 0.00256 in.) Maximum Oil Clearance Item Clearance 0.08 mm Intake (0.00315 in.) 0.10 mm

Exhaust

(0.00394 in.)

If the clearance is greater than the maximum, replace the valve and valve guide bush. REPLACEMENT REPLACEMENT

1. REPLACE INTAKE VALVE GUIDE BUSH a. Heat the cylinder head to 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the intake valve guide bushes.

Fig. 328: Tapping Out Intake Valve Guide Bush Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09201-10000 09201-01050  SST: 09950-70010 09951-07100 d. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head. 

Fig. 329: Checking Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Cylinder bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush Bore Diameter 10.333 to 10.344 mm STD (0.4068 to 0.4072 in.) 10.383 to 10.394 O/S mm 0.05 (0.4088 to 0.4092 in.) Bush Size

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05

valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. e. Heat the cylinder head to 80 to 100°C (176 to 212°F). f. Place the cylinder head on wooden blocks. g. Using SST, tap in new intake valve guide bushes to the specified protrusion height.

Fig. 330: Tapping In Intake Valve Guide Bush Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protrusion *a Height 



SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100

Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) h. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Fig. 331: Reaming Valve Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.) 2. REPLACE EXHAUST VALVE GUIDE BUSH a. Heat the cylinder head to 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the exhaust valve guide bushes.  SST: 09201-10000 09201-01050  SST: 09950-70010 09951-07100 d. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head.

Fig. 332: Checking Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Cylinder bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush Bore Diameter 10.333 to 10.344 mm STD (0.4068 to 0.4072 in.) 10.383 to 10.394 O/S mm 0.05 (0.4088 to 0.4092 in.) Bush Size

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05

valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. e. Heat the cylinder head to 80 to 100°C (176 to 212°F). f. Place the cylinder head on wooden blocks. g. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height.

Fig. 333: Tapping In Exhaust Valve Guide Bush Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protrusion *a Height 



SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100

Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) h. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Fig. 334: Reaming Valve Guide Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.) 3. REPLACE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Using a plastic hammer, tap in new ring pins to the specified protrusion height.

Fig. 335: Locating Cylinder Head Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

Bank 1 for *b Bank 2 *a

Specified protrusion height 2.5 to 3.5 mm (0.0984 to 0.138 in.) 4. REPLACE STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E6 and E8 "TORX" socket wrench, install the stud bolts.

Fig. 336: Identifying Cylinder Head Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bank 1 Bank 1 *a Rear *b Intake Side Side Bank 2 Bank 1 *c Intake *d Exhaust Side Side *e Bank 2 *f Bank 2 Exhaust Rear

Side

Side

Bolts A and B Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt C Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 5. REPLACE STRAIGHT PIN NOTE:

If a straight pin is deformed, replace it.

a. Using a plastic hammer, tap in new straight pins as shown in the illustration.

Fig. 337: Locating Cylinder Head Straight Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for for *a Bank *b Bank 1 2 Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.) REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the cylinder head. Refer to INITIALIZATION . 1. INSTALL SPARK PLUG TUBE

HINT: When using a new cylinder head, the spark plug tubes must be replaced. a. Apply adhesive onto the shaded area of a new spark plug tube.

Fig. 338: Applying Adhesive To Spark Plug Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard application width 1.0 to 3.0 mm (0.0394 to 0.118 in.) NOTE:



 

Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to engine oil for at least 1 hour after installing it.

b. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

Fig. 339: Tapping Spark Plug Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder

Head *a Top Surface Standard protrusion height 72.9 mm (2.87 in.) NOTE:

To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

2. INSTALL NO. 1 STRAIGHT SCREW PLUG a. Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.

Fig. 340: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bank

*a 1 Bank *b 2 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 3. INSTALL NO. 2 STRAIGHT SCREW PLUG a. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.

Fig. 341: Locating No. 2 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bank

*a 1 Bank *b 2 Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 4. INSTALL VALVE SPRING SEAT a. Install the valve spring seats to the cylinder head. 5. INSTALL VALVE STEM OIL SEAL a. Apply a light coat of engine oil to new valve stem oil seals.

Fig. 342: Identifying Valve Stem Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Gray *a (Intake Side) Black *b (Exhaust Side) NOTE:

Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. b. Using SST, push in the oil seals.

Fig. 343: Installing Valve Stem Oil Seals Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT 

SST: 09201-41020

NOTE:

Failure to use SST will cause the seal to be damaged or improperly seated.

6. INSTALL EXHAUST VALVE a. Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.

Fig. 344: Identifying Exhaust Valve Engine Oil Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to the original locations.

c. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

Fig. 345: Compressing Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 09202-01010 09202-01020 d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 346: Tapping Valve Stem Tip To Ensure Proper Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

7. INSTALL INTAKE VALVE a. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

Fig. 347: Identifying Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to their original locations.

c. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

Fig. 348: Compressing Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 09202-01010 09202-01020 d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 349: Tapping Valve Stem Tip To Ensure Proper Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

8. INSTALL VALVE STEM CAP a. Apply a light coat of engine oil to the valve stem caps. b. Install the valve stem caps on the valves. REPAIR REPAIR

1. REPAIR INTAKE VALVE SEAT NOTE:

 

Repair the intake valve seat while checking the seating position. Keep the lip free of foreign matter.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is greater than the specification.

Fig. 350: Resurfacing Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 60° cutters, correct the valve seat so that the intake valve contacts the entire circumference of the seat. The contact should be in the center of the intake valve seat, and the intake valve seat width should be maintained within the specified range around the entire circumference of the intake valve seat.

Fig. 351: Identifying Intake Valve Seat Contacts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Width

1.1 to 1.5 mm (0.0433 to 0.0591 in.) c. Handrub the intake valve and intake valve seat with an abrasive compound. d. Check the intake valve seating position. 2. REPAIR EXHAUST VALVE SEAT NOTE:

 

Repair the seat while checking the seating position. Keep the lip free of foreign matter.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is greater than the specification.

Fig. 352: Resurfacing Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 75° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the seat. The contact should be in the center of the exhaust valve seat, and the exhaust valve seat width should be maintained within the specified range around the entire circumference of the exhaust valve seat.

Fig. 353: Identifying Exhaust Valve Seat Contacts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Width 1.1 to 1.5 mm (0.0433 to 0.0591 in.) c. Handrub the exhaust valve and exhaust valve seat with an abrasive compound. d. Check the exhaust valve seating position.

CYLINDER BLOCK COMPONENTS ILLUSTRATION

Fig. 354: Identifying Cylinder Block Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

a. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned. HINT: The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for the correct reassembly. b. Remove the 2 connecting rod cap bolts.

Fig. 355: Removing Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine Front c. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

Fig. 356: Removing Connecting Rod Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Keep the lower bearing inserted to the connecting rod cap. d. Using a ridge reamer, remove all the carbon from the top of the cylinder.

Fig. 357: Removing Carbon From Top Of Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Ridge *1 Reamer

e. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together.  Arrange the piston and connecting rod assemblies in the correct order. 2. REMOVE CONNECTING ROD BEARING 

HINT: Arrange the removed parts in the correct order. 3. REMOVE PISTON RING SET a. Using a piston ring expander, remove the 2 compression rings.

Fig. 358: Removing Compression Rings Using Compression Ring Expander Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring Expander b. Remove the oil ring expander and 2 side rails by hand. HINT:

Arrange the removed parts in the correct order. 4. REMOVE PISTON a. Check the fitting condition between the piston and piston pin.

Fig. 359: Checking Fitting Condition Between Piston And Piston Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. b. Disconnect the connecting rod from the piston.

Fig. 360: Prying Off Snap Rings From Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a screwdriver, pry off the piston pin hole snap rings from the piston. 2. Gradually heat the piston to approximately 80°C (176°F).

Fig. 361: Heating Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Using a brass bar and a plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

Fig. 362: Removing Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The piston and piston pin are a matched set.  Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order. c. Using a gasket scraper, remove the carbon from the piston top. 

Fig. 363: Removing Carbon From Piston Top Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to scratch a piston.

d. Using a groove cleaning tool, clean the piston ring grooves. e. Using solvent and a brush, thoroughly clean the piston.

Fig. 364: Cleaning Piston Using Solvent And Brush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use a wire brush.

5. REMOVE CRANKSHAFT a. Uniformly loosen and remove the 8 crankshaft bearing cap bolts and the 8 seal washers in several steps and in the sequence shown in the illustration.

Fig. 365: Removing Main Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.

Fig. 366: Identifying Bearing Cap Bolts Loosening Sequence

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

Fig. 367: Prying Out Crankshaft Bearing Cap Using A Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Cylinder *2 Block Bearing *3 Cap Joint *a Surface NOTE:





Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed. Be careful not to damage the joint surface of the cylinder block and the crankshaft bearing cap.

d. Remove the crankshaft. 6. REMOVE CRANKSHAFT BEARING a. Remove the upper crankshaft bearings and lower crankshaft bearings. HINT: Arrange the removed parts in the correct order. 7. REMOVE CRANKSHAFT THRUST WASHER SET a. Remove the upper crankshaft thrust washers from the cylinder block sub-assembly.

Fig. 368: Identifying Upper Bearings And Upper Thrust Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

a. Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies.

Fig. 369: Identifying Bolt And Oil Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the 3 oil nozzles for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly. 9. CLEAN CYLINDER BLOCK INSPECTION INSPECTION

1. INSPECT CONNECTING ROD THRUST CLEARANCE a. Install the connecting rod cap See step 8. b. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Fig. 370: Measuring Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.15 to 0.40 mm (0.00591 to 0.0157 in.) Maximum thrust clearance 0.50 mm (0.0197 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. 2. INSPECT CONNECTING ROD OIL CLEARANCE a. Clean the crank pin and bearing. b. Check the crank pin and bearing for pitting and scratches. c. Lay a strip of Plastigage on the crank pin.

Fig. 371: Identifying Front Mark Of Connecting Rod Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage d. Ensure that the front mark of the connecting rod cap is facing forward.

Fig. 372: Identifying Front Mark Of Connecting Rod Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark Engine Front e. Install the connecting rod cap See step 8. NOTE:

Do not turn the crankshaft.

f. Remove the 2 bolts and connecting rod cap See step 1. g. Measure the Plastigage at its widest point.

Fig. 373: Measuring Widest Point Of Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage

*a

Mark 1, 2, 3, or 4

Standard oil clearance 0.045 to 0.067 mm (0.00177 to 0.00264 in.) Maximum oil clearance 0.070 mm (0.00276 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface. Connecting Rod Diameter Mark Diameter 56.000 to 56.006 mm (2.20472 1 to 2.20496 in.) 56.007 to 56.012 mm 2 (2.20500 to 2.20519 in.) 56.013 to 56.018 mm 3 (2.20523 to 2.20543 in.) 56.019 to 56.024 mm

4

(2.20547 to 2.20566 in.)

Connecting Rod Bearing Center Wall Thickness Mark Thickness 1.481 to 1.484 mm 1 (0.05831 to 0.05843 in.) 1.484 to 1.487 mm (0.05843 2 to 0.05854 in.) 1.487 to 1.490 mm (0.05854 3 to 0.05866 in.) 1.490 to 1.493 mm (0.05866 4 to 0.05878 in.) Standard crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) NOTE:

Completely remove the Plastigage after the measurement.

3. INSPECT CYLINDER BLOCK FOR WARPAGE a. Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

Fig. 374: Measuring Warpage Of Contact Surface Of Cylinder Head Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage

0.07 mm (0.00276 in.) If the warpage is greater than the maximum, replace the cylinder block sub-assembly. 4. INSPECT CYLINDER BORE a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

Fig. 375: Measuring Cylinder Bore Diameter Using A Cylinder Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard diameter

94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter 94.13 mm (3.7059 in.) TEXT IN ILLUSTRATION Axial *a Direction Thrust *b Direction 10 mm *c (0.394 in.) *d Center Front If the average diameter of 4 positions is greater than the maximum, replace the cylinder block subassembly. 5. INSPECT PISTON a. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified.

Fig. 376: Measuring Piston Diameter Using A Micrometer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Distance 8.9 mm (0.3504 in.) Standard diameter 93.960 to 93.980 mm (3.6992 to 3.7000 in.) Minimum diameter 93.830 mm (3.6941 in.) TEXT IN ILLUSTRATION *a Distance If the piston diameter is less than the minimum, replace the piston and piston pin as a set. 6. INSPECT PISTON OIL CLEARANCE a. Measure the cylinder bore diameter in the thrust directions. b. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.020 to 0.052 mm (0.000787 to 0.00205 in.) Maximum oil clearance 0.060 mm (0.00236 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly. 7. INSPECT RING GROOVE CLEARANCE a. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Fig. 377: Measuring Ring Groove Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Ring Groove Clearance Item Clearance 0.020 to 0.070 mm No. (0.000787 1 to 0.00276 in.) 0.020 to 0.060 mm No. (0.000787 2 to 0.00236 in.) 0.070 to 0.150 mm Oil (0.00276 to 0.00591 in.) If the clearance is not as specified, replace the piston. 8. INSPECT PISTON PIN OIL CLEARANCE a. Using a caliper gauge, measure the inside diameter of the piston pin hole.

Fig. 378: Measuring Inside Diameter Of Piston Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Piston Pin Hole Inside Diameter Mark Diameter 22.001 to 22.004 mm A (0.8662 to 0.8663 in.) 22.004 to 22.007 mm B (0.8663 to 0.8664 in.) 22.007 to 22.010 mm C (0.8664 to 0.8665 in.) b. Using a micrometer, measure the piston pin diameter.

Fig. 379: Measuring Inside Diameter Of Connecting Rod Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Piston Pin Diameter Mark Diameter 21.997 to 22.000 mm A (0.8660 to 0.8661 in.) B

22.000 to 22.003 mm (0.8661

C

to 0.8663 in.) 22.003 to 22.006 mm (0.8663 to 0.8664 in.)

c. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.015 mm (0.000591 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. d. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

Fig. 380: Checking Inside Diameter Of Connecting Rod Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bushing Inside Diameter Mark Diameter 22.005 to 22.008 mm A (0.86634 to 0.86645

B

C

in.) 22.009 to 22.011 mm (0.86649 to 0.86657 in.) 22.012 to 22.014 mm (0.86661 to 0.86669 in.)

e. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Fig. 381: Identifying Front Mark, Piston Pin Hole Inside Diameter Mark & Connecting Rod Bushing Inside Diameter Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a Front Mark Piston Pin Hole *b Inside Diameter Mark Connecting Rod Bushing *c Inside Diameter Mark Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.030 mm (0.00118 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set. 9. INSPECT PISTON RING END GAP a. Insert the piston ring into the cylinder bore. b. Using a piston, push the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

Fig. 382: Identifying Piston Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring c. Using a feeler gauge, measure the end gap.

Fig. 383: Checking End Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard End Gap End Gap 0.22 to 0.32 mm No. (0.00866 1 to 0.0126 in.) 0.35 to 0.45 mm No. (0.0138 2 to 0.0177 in.) 0.10 to 0.40 mm (0.00394 Oil to 0.0157 in.) Item

Maximum End Gap

End Gap 0.50 No. mm 1 (0.0197 in.) 0.85 No. mm (0.0335 2 in.) 0.60 mm Oil (0.0236 in.) Item

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block sub-assembly. 10. INSPECT CRANKSHAFT THRUST CLEARANCE a. Install the crankshaft bearing cap See step 8. b. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Fig. 384: Measuring Crankshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 11. INSPECT CONNECTING ROD SUB-ASSEMBLY a. Using a rod aligner and feeler gauge, check the connecting rod alignment.

Fig. 385: Checking Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check for out-of-alignment. Maximum out-of-alignment 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod subassembly. 2. Check for twist.

Fig. 386: Checking Connecting Rod For Twist Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod sub-assembly. 12. INSPECT CONNECTING ROD BOLT a. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

Fig. 387: Inspecting Connecting Rod Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Area Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. HINT: Diameter measurements should be done at several points.  If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the connecting rod bolt with a new one. 13. INSPECT CRANKSHAFT a. Inspect for runout. 1. Clean the crank journal. 

2. Place the crankshaft on V-blocks. 3. Using a dial indicator, measure the runout at the center journal.

Fig. 388: Checking Circle Runout At Center Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum runout 0.06 mm (0.00236 in.) If the runout is greater than the maximum, replace the crankshaft. b. Inspect the main journals. 1. Using a micrometer, measure the diameter of each main journal.

Fig. 389: Checking Main Journal For Taper And Out-Of Round Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. 2. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. c. Inspect the crank pin. 1. Using a micrometer, measure the diameter of each crank pin.

Fig. 390: Checking Crank Pin For Taper And Out-Of Round Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. 2. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round

0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. 14. INSPECT CRANKSHAFT OIL CLEARANCE a. Check the crank journal and crankshaft bearing for pitting and scratches. b. Install the crankshaft bearing See step 8. c. Place the crankshaft on the cylinder block. d. Lay a strip of Plastigage across each journal.

Fig. 391: Applying Plastigage Across Crankshaft Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage e. Examine the front marks and numbers to install the crankshaft bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. f. Install the main bearing cap See step 8. NOTE:

Do not turn the crankshaft.

g. Remove the main bearing caps See step 1. h. Measure the Plastigage at its widest point.

Fig. 392: Measuring Widest Point Of Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage Standard oil clearance 0.026 to 0.047 mm (0.00102 to 0.00185 in.) Maximum oil clearance 0.050 mm (0.00197 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTE:

Completely remove the Plastigage after the measurement.

i. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Fig. 393: Identifying Bearing Number Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Number Mark No. 2 and No. *b 3 Journal Bearing No. 1 and No. *c 4 Journal Bearing *a

JOURNAL BEARINGS Cylinder block + Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3") Crankshaft Main Journal Diameter Mark Diameter 60.999 to 61.000 mm "00" (2.40153 to 2.40157 in.) 60.998 to 60.999 mm "01" (2.40149 to 2.40153 in.) 60.997 to 60.998 mm "02" (2.40145 to 2.40149 in.) 60.996 to

"03"

"04"

"05"

"06"

"07"

"08"

60.997 mm (2.40141 to 2.40145 in.) 60.995 to 60.996 mm (2.40137 to 2.40141 in.) 60.994 to 60.995 mm (2.40133 to 2.40137 in.) 60.993 to 60.994 mm (2.40129 to 2.40133 in.) 60.992 to 60.993 mm (2.40126 to 2.40129 in.) 60.991 to 60.992 mm (2.40122 to 2.40126 in.)

60.990 to 60.991 "09" mm (2.40118 to 2.40122

in.) 60.989 to 60.990 mm "10" (2.40114 to 2.40118 in.) 60.988 to 60.989 mm "11" (2.40110 to 2.40114 in.) Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Thickness 2.500 to 2.503 mm "1" (0.09843 to 0.09854 in.) 2.503 to 2.506 mm "2" (0.09854 to 0.09866 in.) 2.506 to 2.509 mm "3" (0.09866 to 0.09878 in.) 2.509 to 2.512 mm "4" (0.09878 to 0.09890 in.) 2.512 to 2.515 mm "5" (0.09890 to 0.09902 in.) Standard Lower Bearing Center Wall Thickness (No. 1 and No. 4 journal)

Mark Thickness 2.478 to 2.481 mm "1" (0.09756 to 0.09768 in.) 2.481 to 2.484 mm "2" (0.09768 to 0.09780 in.) 2.484 to 2.487 mm "3" (0.09780 to 0.09791 in.) 2.487 to 2.490 mm "4" (0.09791 to 0.09803 in.) 2.490 to 2.493 mm "5" (0.09803 to 0.09815 in.) Standard Upper Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness 2.478 to 2.481 mm "1" (0.09756 to 0.09768 in.) 2.481 to 2.484 mm "2" (0.09768 to 0.09780 in.) 2.484 to 2.487 mm "3" (0.09780 to 0.09791 in.) 2.487 to

"4"

"5"

2.490 mm (0.09791 to 0.09803 in.) 2.490 to 2.493 mm (0.09803 to 0.09815 in.)

Standard Lower Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness 2.500 to 2.503 mm "1" (0.09843 to 0.09854 in.) 2.503 to 2.506 mm "2" (0.09854 to 0.09866 in.) 2.506 to 2.509 mm "3" (0.09866 to 0.09878 in.) 2.509 to 2.512 mm "4" (0.09878 to 0.09890 in.) 2.512 to 2.515 mm "5" (0.09890 to 0.09902 in.) 15. INSPECT CRANKSHAFT BEARING CAP SET BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point.

Fig. 394: Measuring Diameter Of Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter 10.7 mm (0.4213 in.) Measurement Point 40 mm (1.57 in.) HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one. 16. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Check the oil nozzles for damage or clogs. 

HINT: If there is damage or clogs, replace the oil nozzle. REPLACEMENT REPLACEMENT

1. REPLACE STRAIGHT PIN a. Using a plastic hammer, tap in new straight pins to the cylinder block.

Fig. 395: Identifying Cylinder Block Straight Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Front Rear *a Cylinder *b Cylinder Block Block Upper Lower *c Cylinder *d Cylinder Block Block Cylinder *e Block - RH Side Standard Protrusion Item Protrusion Pin 23 mm A (0.906 in.) Pin 6 mm B (0.236 in.) Pin 11 mm C (0.433 in.) Pin 9 mm D (0.354 in.) 2. REPLACE STUD BOLT a. Using an E8 and E10 "TORX" socket wrench, install the stud bolts.

Fig. 396: Identifying Cylinder Block Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Front Cylinder *a Cylinder *b Block Block LH Side Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the piston and piston ring. Refer to INITIALIZATION . 1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.

Fig. 397: Identifying Bolt And Oil Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 2. INSTALL PISTON a. Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.

Fig. 398: Installing New Piston Pin Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Service *1 Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. b. Gradually heat the piston to approximately 80°C (176°F).

Fig. 399: Heating Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Coat the piston pin with engine oil. d. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

Fig. 400: Identifying Piston & Connecting Rod Front Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Front *a Mark HINT: The piston and pin are a matched set. e. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Fig. 401: Checking Fitting Condition Between Piston And Piston Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

Fig. 402: Installing Piston Pin Hole Snap Ring Using A Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Service *1 Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.  Perform "Inspection After Repair" after replacing the piston. Refer to INITIALIZATION . 3. INSTALL PISTON RING SET a. Install the oil ring expander and 2 side rails by hand. b. Using a piston ring expander, install the compression ring as shown in the illustration. 

Fig. 403: Installing Piston Ring Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston

Ring Expander Upper *2 Side Rail Oil Ring *3 Expander Lower *4 Side Rail *5 Oil Ring No. 1 *6 Ring No. 2 *7 Ring *1

c. Position the piston rings so that the ring ends are as shown in the illustration.

Fig. 404: Identifying Piston Ring Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lower *1 Side Rail No. 2 *2 Ring Oil Ring *3 Expander No. 1 *4 Ring Upper *5 Side Rail *a Front

Mark NOTE:

Do not align the ring ends.

HINT: Perform "Inspection After Repair" after replacing the piston ring. Refer to INITIALIZATION . 4. INSTALL CRANKSHAFT BEARING a. Clean the main journal and both surfaces of the bearings.

Fig. 405: Identifying Main Bearing Widths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

No. 1 and No. *1 4 Journal Bearing No. 2 and No. *2 3 Journal Bearing NOTE:

Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

b. Install the upper crankshaft bearing.

Fig. 406: Installing Upper Crankshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Install the upper crankshaft bearings to the cylinder block as shown in the illustration. TEXT IN ILLUSTRATION

Upper Bearing *a CORRECT *b INCORRECT *1

NOTE:





Do not apply engine oil to the bearings and the contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

c. Install the lower crankshaft bearing.

Fig. 407: Installing Lower Crankshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Vernier *1 Caliper Mark *a 1, 2, 3, 4 or 5 1. Install the lower crankshaft bearings to the crankshaft bearing caps. 2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge. Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE:

Do not apply engine oil to the crankshaft bearings and the contact surfaces.

5. INSTALL CRANKSHAFT THRUST WASHER SET a. Apply engine oil to the crankshaft thrust washer. b. Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

Fig. 408: Identifying Oil Grooves Facing Outward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Oil *1 Grooves 6. INSTALL CRANKSHAFT a. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block. b. Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

Fig. 409: Identifying Main Bearing Cap Projections & Numbers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Projection Number

*a Mark HINT: A number is marked on each main bearing cap to indicate the installation position. c. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. d. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions. e. Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide.

Fig. 410: Identifying Crankshaft Bearing Cap & Cylinder Block Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Less

than 6 mm Bolt Length *b 100 to 102 mm *a

Bolt length 100 to 102 mm (3.94 to 4.02 in.) f. Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

Fig. 411: Tapping Bearing Cap To Ensure Proper Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts. h. Install the 8 crankshaft bearing cap bolts to the outside positions.

Fig. 412: Identifying Crankshaft Bearing Cap Bolt Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt

*a Length Bolt length 105.5 to 107.5 mm (4.15 to 4.23 in.) i. Install the crankshaft bearing cap bolts. HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps. j. Step 1 1. Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 413: Locating Main Bearing Cap Bolts Loosening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it. k. Step 2 TEXT IN ILLUSTRATION

Paint Mark Turn *b 90° Engine Front *a

1. Mark the front of the bearing cap bolts with paint.

Fig. 414: Identifying Connecting Rod Bolt Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Retighten the bearing cap bolts 90° in the sequence shown in the illustration. 3. Check that the painted mark is now at a 90° angle to the front of the engine. l. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig. 415: Locating Main Bearing Cap Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) Bolt Length Item Length 45 mm Bolt A (1.77 in.) 30 mm Except (1.18 bolt A in.) m. Check that the crankshaft turns smoothly. n. Check the crankshaft thrust clearance See step 10. 7. INSTALL CONNECTING ROD BEARING a. Install the connecting rod bearing to the connecting rod and connecting rod cap. b. Using a vernier caliper, measure the distance between the connecting rod and bearing cap edges and the connecting rod bearing edge.

Fig. 416: Installing Connecting Rod Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier *1 Caliper

Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE:

Do not apply engine oil to the bearings and the contact surfaces.

8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. b. Position the piston rings so that the ring ends are as shown in the illustration.

Fig. 417: Identifying Piston Ring Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Lower

Side Rail No. 2 *2 Ring Oil Ring *3 Expander No. 1 *4 Ring Upper *5 Side Rail Front *a Mark NOTE:

Do not align the ring ends.

c. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

Fig. 418: Pushing Piston & Connecting Rod Assembly Into Cylinder Using A Piston Ring Compressor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark Engine Front NOTE:

Match the numbered connecting rod cap with the connecting rod.

d. Check that the front mark of the connecting rod cap is facing forward.

Fig. 419: Installing Connecting Rod Cap Bolt With Front Mark Facing Forward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark Engine Front e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. f. Install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. g. Step 1 1. Install and alternately tighten the bolts of the connecting rod cap in several steps.

Fig. 420: Tightening Connecting Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) h. Step 2

Fig. 421: Identifying Connecting Rod Cap Bolt Paint Mark

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Turn *b 90° Engine Front 1. Mark the front side of each connecting rod cap bolt with paint. 2. Retighten the cap bolts 90° as shown in the illustration. 3. Check that the painted mark is now at a 90° angle to the front. i. Confirm that the crankshaft turns smoothly. j. Check the connecting rod thrust clearance See step 1.

2012-2017 ENGINE Engine Mechanical (Service Information) - Camry (Hybrid)

ENGINE ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT COOLANT (for Engine) Refer to ON-VEHICLE INSPECTION 2. INSPECT ENGINE OIL Refer to ON-VEHICLE INSPECTION 3. INSPECT AUXILIARY BATTERY Refer to ON-VEHICLE INSPECTION 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY a. Remove the air cleaner cap. b. Remove the air cleaner filter element. c. Visually check that the air cleaner filter element is not excessively damaged or oily. If necessary, replace the air cleaner filter element. d. Install the air cleaner filter element. e. Install the air cleaner cap. 5. INSPECT VALVE AND ADJUSTER NOISE a. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . b. Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then, perform the inspection above again. If any defects or problems are found during the inspection above, perform a lash adjuster inspection See step 2. 6. INSPECT IGNITION TIMING a. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . b. Warm up and stop the engine. c. When using the Techstream: Check the ignition timing.

1. Connect the Techstream to the DLC3. 2. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . 3. Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance. Standard ignition timing 5 to 20 degrees BTDC NOTE:

  

Check the ignition timing with the cooling fans off. Turn off all electrical systems and the A/C. When checking the ignition timing, the shift lever should be in P.

HINT: Refer to the Techstream operator's manual for further details. 4. Check that the ignition timing advances immediately when the engine speed is increased. 5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON. 6. Monitor IGN Advance of the Data List. Standard ignition timing 8 to 12 degrees BTDC NOTE:

When checking the ignition timing, the shift lever should be in P.

HINT: Refer to the Techstream operator's manual for further details. 7. Enter the following menus: Connect the TC and TE1 / OFF. 8. Turn the power switch off. 9. Turn the Techstream off. 10. Disconnect the Techstream from the DLC3. d. When not using the Techstream: 1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

Fig. 1: DLC3 Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3 

SST: 09843-18040

NOTE:



  

Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components. Check the ignition timing with the cooling fans off. Turn off all electrical systems and the A/C. When checking the ignition timing, the shift lever should be in P.

2. Remove the No. 1 engine cover sub-assembly. 3. Pull out the wire harness. NOTE:

After checking, wrap the wire harness with tape.

4. Connect the clip of the timing light to the wire harness.

Fig. 2: Connect Clip Of Timing Light To Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Use a timing light that detects the primary signal.

5. Inspect the ignition timing at idle. Standard ignition timing 8 to 12 degrees BTDC NOTE:

When checking the ignition timing, the shift lever should be in P.

HINT: After running the engine at 1000 to 1300 rpm for 5 seconds, check that it returns to idle speed. 6. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. 7. Inspect the ignition timing at idle. Standard ignition timing 5 to 20 degrees BTDC

8. Confirm that the ignition timing advances when the engine rpm is increased. 9. Remove the timing light. 10. Install the No. 1 engine cover sub-assembly. 7. INSPECT ENGINE IDLE SPEED a. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . b. Warm up and stop the engine. c. When using the Techstream: 1. Connect the Techstream to the DLC3. 2. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . 3. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed. HINT: Refer to the Techstream operator's manual for further details. 4. Inspect the engine idle speed. Standard idle speed 900 to 1050 rpm NOTE:

  

Turn all electrical systems and the A/C off. Inspect the idle speed with the cooling fans off. When checking the ignition timing, the shift lever should be in P.

5. Turn the power switch off. 6. Turn the Techstream off. 7. Disconnect the Techstream from the DLC3. d. When not using the Techstream: 1. Using SST, connect a tachometer tester probe to terminal 9 (TAC) of the DLC3.

Fig. 3: DLC3 Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 DLC3 SST: 09843-18030 2. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . 3. Inspect the engine idle speed. 

Standard idle speed 900 to 1050 rpm NOTE:

  

Turn all electrical systems and the A/C off. Inspect the idle speed with the cooling fans off. When checking the ignition timing, the shift lever should be in P.

4. Disconnect the tachometer probe from the DLC3. 8. INSPECT COMPRESSION a. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . b. Warm up and stop the engine. c. Remove the 4 spark plugs. Refer to REMOVAL .

NOTE:

If the ignition coil assembly connector is disconnected because a DTC is detected in inspection, always reconnect it.

d. Inspect the cylinder compression pressure.

Fig. 4: Inspecting Cylinder Compression Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. 2. 3. 4.

Insert a compression gauge into the spark plug hole. Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. NOTE:

Check the HV battery voltage in the data list to ensure that the battery is fully charged.

5. Enter the following menus: Powertrain / Hybrid Control / Active Test / Compression Test / ON. 6. Depress and hold the brake pedal, and turn the power switch on (READY). NOTE:

The measurement must be done as quickly as possible.

HINT: Noise may be emitted from the transmission. However, this is not a malfunction.

Standard compression pressure 1100 kPa (11.2 kgf/cm2 , 160 psi) Minimum pressure 750 kPa (7.6kgf/cm2 , 109 psi) Pressure difference between each cylinder 100 kPa (1.0 kgf/cm2 , 15 psi) NOTE:

 

Inspect the other cylinders in the same way. Measure the compression as quickly as possible.

7. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect it again. HINT: If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.  If the pressure stays low, a valve may be stuck or seated improperly, or there may be leaks from the gasket. e. Install the 4 spark plugs. Refer to INSTALLATION . 

NOTE:

After performing all the steps, be sure to clear any DTCs stored in memory.

9. INSPECT CO/HC HINT: This check determines whether or not the idle CO / HC complies with regulations. a. b. c. d. e.

Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . Warm up the engine. Run the engine at 2500 rpm for approximately 180 seconds. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe while idling. Check the CO/HC concentration while idling and when the engine is running at 2500 rpm. HINT: When doing a 2 mode (with the engine idling/ running at 2500 rpm) test, the measurement

procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. 1. Check the DTCs. Refer to DTC CHECK / CLEAR . 2. See the table below for possible causes, then inspect the applicable parts and repair them if necessary. CO

HC

Problem

Normal High Rough idle

Rough idle (Fluctuating Low High HC reading)

Possible Cause a. Faulty ignition:  Incorrect timing  Fouled, shorted or improperly gapped plugs b. Incorrect valve clearance c. Leaks from intake and exhaust valves d. Leaks from cylinders e. Faulty EGR a. Vacuum leaks:  PCV hoses  Intake manifold  Throttle body b. Lean mixture causing misfire c. Faulty EGR a. Restricted air cleaner filter element b. Plugged PCV valve c. Faulty EFI systems:

Faulty pressure regulator  Faulty engine coolant temperature sensor  Faulty mass air flow meter  Faulty ECM  Faulty injectors  Throttle body d. Faulty EGR 

Rough idle (Black High High smoke from exhaust)

CAMSHAFT COMPONENTS ILLUSTRATION

Fig. 5: Identifying Camshaft Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 6: Identifying Camshaft Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 7: Identifying Camshaft Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT WHEEL RH

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY See step 25 REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY See step 30 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE AIR CLEANER FILTER ELEMENT See step 32 REMOVE AIR CLEANER CASE SUB-ASSEMBLY See step 33 REMOVE NO. 2 ENGINE MOUNTING STAY RH See step 58 DISCONNECT EARTH WIRE See step 59 REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY See step 60 DISCONNECT INVERTER RESERVE TANK ASSEMBLY (for LHD) a. Remove the 2 bolts and disconnect the inverter reserve tank assembly.

Fig. 8: Identifying Inverter Reserve Tank Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. DISCONNECT NO. 2 ENGINE ROOM RELAY BLOCK (for LHD) a. Remove the screw and disconnect the front fender liner RH.

Fig. 9: Identifying Front Fender Liner Screw RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt, harness clamp and disconnect the No. 2 engine room relay block.

Fig. 10: Identifying No. 2 Engine Room Relay Block Harness Clamp And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. DISCONNECT ENGINE WIRE a. Disconnect the 8 connectors and 2 harness clamps.

Fig. 11: Identifying Connectors And Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bolts and 3 nuts and disconnect the engine wire from the engine. 17. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 15 19. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 12: Identifying Paint Mark, Timing Mark And Timing Notch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint

*a Mark Timing *b Mark Timing *c Notch b. Check that each timing mark of the camshaft timing gear assembly and camshaft timing sprocket are aligned with each timing mark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration. c. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket. 20. REMOVE TIMING CHAIN COVER PLATE a. Remove the 4 bolts, timing chain cover plate and gasket.

Fig. 13: Identifying Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY a. Turn the crankshaft approximately 10° clockwise.

Fig. 14: Turning Crankshaft Approximately 10° Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the crankshaft approximately 10° counterclockwise.

Fig. 15: Turning Crankshaft Approximately 10° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Align the holes of the stopper plate and tensioner, and insert a pin into the stopper plate hole to lock the tensioner.

Fig. 16: Insert Pin Into Stopper Plate Hole To Lock Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin d. Turn the crankshaft approximately 10° clockwise.

Fig. 17: Turning Crankshaft Approximately 10° Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the 2 bolts, chain tensioner and gasket.

Fig. 18: Identifying Timing Chain Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Make sure not to drop the gasket inside the timing chain cover.

f. Turn the crankshaft approximately 10° counterclockwise.

Fig. 19: Turning Crankshaft Approximately 10° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE TIMING CHAIN GUIDE See step 14 23. REMOVE OIL PUMP RELIEF VALVE PLUG See step 20 24. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt from the camshaft.

Fig. 20: Removing Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

b. Separate the camshaft timing gear assembly from the camshaft.

Fig. 21: Removing Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the timing chain from the camshaft timing gear assembly, and turn the camshaft timing gear assembly approximately 180°.

Fig. 22: Turning Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide d. Remove the camshaft timing gear assembly.

Fig. 23: Removing Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the camshaft timing gear.

25. REMOVE CAMSHAFT BEARING CAP a. Using several steps, remove the 11 bearing cap bolts in the sequence shown in the illustration.

Fig. 24: Removing Camshaft Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using several steps, remove the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 25: Removing Camshaft Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 5 bearing caps. HINT: Arrange the removed parts in the correct order. 26. REMOVE CAMSHAFT a. Remove the camshaft from the camshaft housing.

Fig. 26: Identifying Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE NO. 2 CAMSHAFT a. Hold up the chain and remove the No. 2 camshaft from the camshaft housing.

Fig. 27: Identifying No. 2 Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Suspend the chain with a string or equivalent as shown in the illustration.

Fig. 28: Suspending Chain With A String Or Equivalent Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be careful not to drop the chain inside the timing chain cover.

28. REMOVE CAMSHAFT TIMING SPROCKET a. Secure the camshaft in a vice by clamping the hexagonal part using aluminum plates. NOTE:

Do not damage the camshaft by tightening the vice excessively.

b. Remove the flange bolt and camshaft timing sprocket.

Fig. 29: Identifying Flange Bolt And Camshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the No. 2 camshaft or camshaft timing sprocket.

29. REMOVE OIL CONTROL VALVE FILTER See step 34 30. REMOVE NO. 1 CAMSHAFT BEARING See step 36 31. REMOVE NO. 2 CAMSHAFT BEARING See step 37 INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft or camshaft timing gear assembly. Refer to INITIALIZATION .

1. 2. 3. 4. 5.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY See step 6 INSTALL NO. 2 CAMSHAFT BEARING See step 18 INSTALL NO. 1 CAMSHAFT BEARING See step 17 INSTALL OIL CONTROL VALVE FILTER See step 19 INSTALL CAMSHAFT TIMING SPROCKET a. Secure the camshaft in a vice by clamping the hexagonal part using aluminum plates. NOTE:

Do not damage the camshaft by tightening the vice excessively.

b. Install the camshaft timing sprocket to the No. 2 camshaft with the bolt.

Fig. 30: Identifying Flange Bolt And Camshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:

Do not damage the No. 2 camshaft or camshaft timing sprocket.

6. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 31: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Timing *a Notch 7. INSTALL NO. 2 CAMSHAFT a. Make sure that the valve rocker arms are installed as shown in the illustration.

Fig. 32: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap b. Clean the camshaft journals. c. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. d. Hold up the chain and align the timing mark and the paint mark, and install the No. 2 camshaft.

Fig. 33: Identifying Paint Mark And Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint

*a Mark Timing *b mark HINT: Perform "Inspection After Repair" after replacing the No. 2 camshaft. Refer to INITIALIZATION . 8. INSTALL CAMSHAFT a. Make sure that the valve rocker arms are installed as shown in the illustration.

Fig. 34: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap

b. Clean the camshaft journals. c. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. d. Install the camshaft to the camshaft housing as shown in the illustration.

Fig. 35: Installing Camshaft To Camshaft Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Knock Pin Approximately *a 17° HINT: Perform "Inspection After Repair" after replacing the camshaft. Refer to INITIALIZATION .

9. INSTALL CAMSHAFT BEARING CAP a. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

Fig. 36: Identifying Camshaft Bearing Cap Marks And Numbers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.

Fig. 37: Tightening Camshaft Bearing Cap In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) c. Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

Fig. 38: Tightening Camshaft Bearing Cap In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) d. Check the torque of each bolt again. 10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY a. Check the camshaft timing gear position.

Fig. 39: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock Pin

*1 Hole Alignment *2 Mark Advanced *a Position Retarded *b Position NOTE:





If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation. If the camshaft timing gear has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear to the most advanced position before tightening the camshaft timing gear.

b. Install the camshaft timing gear as shown in the illustration.

Fig. 40: Installing Camshaft Timing Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide c. Turn the camshaft timing gear approximately 180° counterclockwise.

Fig. 41: Turning Camshaft Timing Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Narrow *b Wide d. Align the paint mark with the timing mark to install the chain.

Fig. 42: Aligning Paint Mark And Timing Mark To Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Timing *b mark e. Align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear.

Fig. 43: Identifying No. 1 Camshaft Knock Pin & Camshaft Timing Gear Knock Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock *1 Pin Knock *a Pin Hole f. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 44: Identifying No Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear Camshaft *a Flange No *b Clearance g. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

h. If the lock pin has not been released, release it. 1. After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

Fig. 45: Identifying Seal On Oil Hole With Adhesive Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Adhesive Tape *1 Sealing Area Make a *a Hole NOTE:

Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A) 3. Apply approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the hole made in

procedure A to release the lock pin.

Fig. 46: Making Hole In Adhesive Tape Covering Oil Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

If air leaks out, reattach the adhesive tape. Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

4. Forcibly turn the camshaft timing gear in the advance direction (counterclockwise). HINT: Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without assistance by hand. 5. Remove the adhesive tape from the No. 1 camshaft bearing cap. i. Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

Fig. 47: Removing/Installing Camshaft Bolt Using Hexagonal And Turning Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

j. Check that each timing mark of the camshaft timing gear and camshaft timing sprocket are aligned with each timing mark located as shown in the illustration.

Fig. 48: Aligning Paint Mark And Timing Mark With Camshaft Timing Gear And Camshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Timing *b Mark HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Refer to INITIALIZATION . 11. ADD ENGINE OIL See step 17 12. INSTALL TIMING CHAIN GUIDE See step 23 13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY a. Turn the crankshaft approximately 10° clockwise.

Fig. 49: Turning Crankshaft Approximately 10° Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Make sure not to drop the gasket inside the timing chain cover.

c. Remove the pin from the stopper plate. 14. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned.

Fig. 50: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Approximately 7° Approximately *b 32° *c Timing Mark *d Timing Notch *a

b. Check that the timing marks of the camshaft timing gears are as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration. HINT: "A" is not a timing mark. 15. INSTALL TIMING CHAIN COVER PLATE a. Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 16. 17. 18. 19.

INSTALL OIL PUMP RELIEF VALVE PLUG See step 38 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 44 INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 CONNECT ENGINE WIRE a. Install the engine wire to the engine with the 5 bolts and 3 nuts.

Fig. 51: Identifying Engine Wire, Engine, Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut - Bolt A Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Bolt B Torque: 10.0 N*m (102 kgf*cm, 7 ft.*lbf) Nut Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 8 connectors and 2 harness clamps. 20. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK (for LHD) a. Install the No. 2 engine room relay block with the bolt and harness clamp. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Install the front fender liner RH with the screw.

21. INSTALL INVERTER RESERVE TANK ASSEMBLY (for LHD) a. Temporarily install the inverter reserve tank assembly with the 2 bolts.

Fig. 52: Identifying Inverter Reserve Tank Assembly Bolts (For LHD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the 2 bolts to the inverter reserve tank assembly in the order the bolt A and bolt B. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY See step 32 CONNECT EARTH WIRE See step 33 INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 34 INSTALL AIR CLEANER CASE SUB-ASSEMBLY See step 60 INSTALL AIR CLEANER FILTER ELEMENT See step 61 INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL INLET AIR CLEANER ASSEMBLY See step 63 INSPECT FOR OIL LEAK INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY See step 86 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4

35. INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

CYLINDER HEAD GASKET COMPONENTS ILLUSTRATION

Fig. 53: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 54: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 55: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 56: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8.

REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to REMOVAL - Step 6 DISCONNECT NO. 1 WATER BY-PASS HOSE See step 4 REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE NO. 2 EGR PIPE . Refer to REMOVAL - Step 9 REMOVE MANIFOLD STAY . Refer to REMOVAL - Step 11 REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 10 REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 9. REMOVE EGR COOLER ASSEMBLY See step 10

10. 11. 12. 13.

REMOVE NO. 1 EGR PIPE See step 11 REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE INTAKE MANIFOLD . Refer to REMOVAL - Step 13 SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 57: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Approximately Approximately *a *b 7° 32° *c Timing Mark *d Key HINT:

"A" is not a timing mark. b. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration. HINT: If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks. c. Remove the crankshaft pulley bolt. 14. REMOVE TIMING CHAIN GUIDE a. Remove the bolt and timing chain guide.

Fig. 58: Identifying Timing Chain Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY a. Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the tensioner.

Fig. 59: Identifying Stopper Plate And Plunger Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stopper *1 Plate *2 Plunger b. Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

Fig. 60: Insert Pin Into Stopper Plate Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin c. Remove the 2 bolts, chain tensioner and gasket.

Fig. 61: Identifying Chain Tensioner Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE CHAIN TENSIONER SLIPPER a. Remove the bolt and chain tensioner slipper.

Fig. 62: Identifying Chain Tensioner Slipper Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE CHAIN SUB-ASSEMBLY See step 27 18. REMOVE NO. 1 CHAIN VIBRATION DAMPER a. Remove the 2 bolts and chain vibration damper.

Fig. 63: Identifying Chain Vibration Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear.

Fig. 64: Removing Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:





Be careful not to damage the cylinder head or spark plug tube with the wrench. Do not disassemble the camshaft timing gear.

20. REMOVE CAMSHAFT TIMING SPROCKET a. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing sprocket.

Fig. 65: Removing Camshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

21. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY a. Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

Fig. 66: Removing Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

Fig. 67: Identifying Camshaft Housing

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

22. REMOVE CAMSHAFT BEARING CAP a. Remove the 11 bearing cap bolts in the sequence shown in the illustration.

Fig. 68: Removing Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bearing caps. HINT: Arrange the removed parts in the correct order. 23. REMOVE OIL CONTROL VALVE FILTER See step 34 24. REMOVE NO. 1 CAMSHAFT BEARING See step 36 25. REMOVE CAMSHAFT a. Remove the camshaft and No. 2 camshaft. 26. REMOVE NO. 2 CAMSHAFT BEARING See step 37

27. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Remove the 16 valve rocker arms from the cylinder head. HINT: Arrange the removed parts in the correct order. 28. REMOVE VALVE LASH ADJUSTER ASSEMBLY a. Remove the 16 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order. 29. REMOVE VALVE STEM CAP a. Remove the 16 valve stem caps from the cylinder head. HINT: Arrange the removed parts in the correct order. 30. REMOVE CYLINDER HEAD SUB-ASSEMBLY a. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

Fig. 69: Identifying Bolts Loosening Sequence

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Be sure to keep the removed parts separate for each installation position. NOTE:

 

Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in the incorrect order.

b. Remove the cylinder head. 31. REMOVE CYLINDER HEAD GASKET a. Remove the cylinder head gasket from the cylinder block. INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION . 1. INSPECT CYLINDER HEAD BOLT See step 17 2. INSPECT CYLINDER HEAD SUB-ASSEMBLY See step 1 3. INSTALL CYLINDER HEAD GASKET a. Clean the cylinder block and cylinder head with solvent.

Fig. 70: Identifying Cylinder Block And Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder

Head Gasket Cylinder *2 Block *a Lot No. 3.0 mm *b or more 20 mm *c or more Seal Packing Front *1

b. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal dimension 3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick HINT: Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block. NOTE:

 

Remove any oil from the contact surface. Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

c. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp facing upward. NOTE:

Pay attention to the installation direction.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 4 progressive steps. a. Place the cylinder head on the cylinder block.

NOTE:





Ensure that no oil is on the mounting surface of the cylinder head. Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

b. Install the plate washers to the cylinder head bolts. c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. d. Step 1: 1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

Fig. 71: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) NOTE:

Do not drop the plate washer for the cylinder head bolt into the cylinder head.

e. Step 2: 1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)

f. Step 3: 1. Mark each cylinder head bolt head with paint as shown in the illustration.

Fig. 72: Identifying Paint Mark On Cylinder Head Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Painted *a Mark 2. Tighten the cylinder head bolts 90° in the sequence shown in step 1. g. Step 4: 1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1. 2. Check that the paint marks are now facing rearward. NOTE:

 



HINT:

Do not apply oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. After installation, if the seal packing has seeped out, wipe it off.

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION . 5. INSTALL VALVE STEM CAP a. Apply a light coat of engine oil to the valve stem ends. b. Install the 16 valve stem caps to the cylinder head. NOTE:

Do not drop the valve stem caps into the cylinder head.

6. SET CAMSHAFT TIMING GEAR ASSEMBLY HINT: When installing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation. a. Check the camshaft timing gear position.

Fig. 73: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock Pin

*1 Hole Alignment *2 Mark Advanced *a Position: Retarded *b Position: NOTE:

If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation. If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

b. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Fig. 74: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin

c. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 75: Identifying No Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance d. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing

gear by hand. NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

e. Release the lock pin.

Fig. 76: Identifying Rubber, Vinyl Tape, Knock Pin, Retard Side Path And Advance Side Path Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Rubber Vinyl *2 Tape Knock *3 Pin Retard *a Side Path Advance *b Side Path *c Open *d Close 1. Clean the camshaft journal with non-residue solvent. 2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber. 3. Open a hole at port A shown in the illustration. 4. While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig. 77: Turning Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT: The camshaft timing gear assembly may be turned in the advance direction without applying any force.  If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult. 5. Remove the vinyl tape and rubber pieces from the camshaft. f. Remove the bolt and camshaft timing gear. 

NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY a. Inspect the valve lash adjuster before installing it See step 2. b. Install the 16 lash adjusters to the cylinder head. NOTE:

Install the lash adjuster to the same place it was removed from.

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Apply engine oil to the lash adjuster tips and valve stem caps.

Fig. 78: Identifying Valve Rocker Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve *1 Rocker Arm Valve *2 Lash Adjuster Valve *3 Stem Cap

9. 10. 11. 12.

b. Install the 16 valve rocker arms as shown in the illustration. INSTALL NO. 2 CAMSHAFT BEARING See step 18 INSTALL NO. 1 CAMSHAFT BEARING See step 17 INSTALL OIL CONTROL VALVE FILTER See step 19 INSTALL CAMSHAFT a. Clean the camshaft journals, camshaft housing and bearing caps. b. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps. c. Install the camshaft and No. 2 camshafts to the camshaft housing. HINT:

Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft. Refer to INITIALIZATION . 13. INSTALL CAMSHAFT BEARING CAP a. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

Fig. 79: Identifying Marks And Numbers On Camshaft Bearing Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 11 bolts in the order shown in the illustration.

Fig. 80: Installing Camshaft Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE:

Make sure that the camshaft rotates smoothly after installing the bearing caps.

14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY a. Check that the valve rocker arms are installed as shown in the illustration.

Fig. 81: Identifying Valve Rocker Arm Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Valve Rocker *1 Arm Valve Stem *2 Cap Valve Lash *3 Adjuster *a INCORRECT *b CORRECT b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 82: Identifying Seal Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE:

 

Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

c. Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

Fig. 83: Position Knock Pin Of No. 1 And No. 2 Camshafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Knock Pin Approximately *a 17° Approximately *b 2° d. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

Fig. 84: Installing Camshaft Housing Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) NOTE:

  

Do not apply oil for at least 2 hours after the installation. Do not start the engine for at least 2 hours after the installation. Thoroughly wipe clean any seal packing.

15. INSTALL CAMSHAFT TIMING SPROCKET a. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, and install the camshaft timing sprocket with the bolt.

Fig. 85: Installing Camshaft Timing Sprocket Using Hexagonal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:

Be careful not to damage the cylinder head or spark plug tube with the wrench.

16. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY a. Check the camshaft timing gear position.

Fig. 86: Identifying Camshaft Timing Gear Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock Pin *1 Hole Alignment *2 Mark If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "Set Camshaft Timing Gear Assembly" procedure" in step 6). b. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Fig. 87: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin c. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 88: Identifying No Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance d. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

Fig. 89: Installing No. 1 Camshaft Bolt Using Hexagonal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTE:





Be careful not to damage the cylinder head or spark plug tube with the wrench. Do not disassemble the camshaft timing gear.

HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Refer to INITIALIZATION . 17. ADD ENGINE OIL a. Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

Fig. 90: Adding Engine Oil Into Oil Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Oil must be added if the lash adjusters were removed. Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

18. INSTALL NO. 1 CHAIN VIBRATION DAMPER a. Install the chain vibration damper with the 2 bolts.

Fig. 91: Identifying No. 1 Chain Vibration Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 19. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 92: Rotating Crankshaft 40° Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration. c. Check that the timing marks of the camshaft timing gears are as shown in the illustration.

Fig. 93: Identifying Timing Marks Of Camshaft Timing Gears Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Timing Mark

Approximately 7° Approximately *c 32°

*b

HINT: "A" is not a timing mark. 20. INSTALL CHAIN SUB-ASSEMBLY a. Place the chain onto the camshaft timing gears and crankshaft timing sprocket. HINT: Make sure the mark plate of the chain faces away from the engine.  It is not necessary to install the chain to the teeth of the gears and sprocket. b. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing sprocket and install the chain to the camshaft timing sprocket. 

Fig. 94: Aligning Mark Plate And Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark *a Plate Timing

*b Mark c. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

Fig. 95: Identifying Timing Chain Mark Plate & Crankshaft Sprocket Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark *1 Plate Timing *2 Mark d. Tie a string above the crankshaft timing sprocket so that the chain is secure.

Fig. 96: Tying String Above Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

Fig. 97: Rotating Intake Camshaft Counterclockwise With Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mark

*1 Plate Timing *2 Mark HINT: Hold the intake camshaft in place with a wrench until the chain tensioner is installed. f. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

Fig. 98: Installing Chain Tensioner Slipper By Loosening Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure the chain is secure.

21. INSTALL CHAIN TENSIONER SLIPPER a. Install the chain tensioner slipper with the bolt.

Fig. 99: Identifying Chain Tensioner Slipper Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY a. Install a new gasket and the chain tensioner with the 2 bolts.

Fig. 100: Identifying Chain Tensioner Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) b. Remove the pin from the stopper plate. 23. INSTALL TIMING CHAIN GUIDE a. Install the timing chain guide with the bolt.

Fig. 101: Identifying Timing Chain Guide Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 24. SET NO. 1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt.

Fig. 102: Setting No. 1 Cylinder To TDC/Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Approximately Approximately *a *b 7° 32° Crankshaft *c Timing Mark *d pulley set key b. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration. HINT: "A" is not a timing mark. c. Remove the crankshaft pulley bolt.

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

INSTALL INTAKE MANIFOLD . Refer to INSTALLATION - Step 4 INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL NO. 1 EGR PIPE See step 10 INSTALL NO. 1 WATER BY-PASS PIPE See step 17 INSTALL EGR COOLER ASSEMBLY See step 11 INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to INSTALLATION Step 2 INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 4 INSTALL MANIFOLD STAY . Refer to INSTALLATION - Step 3 INSTALL NO. 2 EGR PIPE . Refer to INSTALLATION - Step 5 INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 8 INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Refer to INSTALLATION

FRONT CRANKSHAFT OIL SEAL COMPONENTS ILLUSTRATION

Fig. 103: Identifying Front Crankshaft Oil Seal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH REMOVE CRANKSHAFT PULLEY

a. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

Fig. 104: Removing Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Using SST and the pulley bolt, remove the crankshaft pulley. 

Fig. 105: Removing Crankshaft Pulley Using SST & Pulley Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pulley *1 Bolt *a Hold *b Turn 

SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05011

HINT: Apply a lubricant to the threads and end of SST. 6. REMOVE TIMING CHAIN COVER OIL SEAL a. Using a screwdriver, pry out the oil seal.

Fig. 106: Prying Out Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. NOTE:

Do not damage the surface of the oil seal press fit hole or the crankshaft.

INSTALLATION INSTALLATION

1. INSTALL TIMING CHAIN COVER OIL SEAL a. Apply MP grease to the lip of a new oil seal. NOTE:

 

Do not allow foreign matter to contact the lip of the oil seal. Do not allow MP grease to contact the dust seal.

b. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

Fig. 107: Installing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09223-22010

NOTE:

 

Keep the lip of the oil seal free from foreign matter. Do not tap in the oil seal at an angle.

2. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST, hold the crankshaft pulley and install the pulley bolt.

Fig. 108: Installing Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn   

SST: 09213-54015 SST: 09330-00021 SST: 91551-80650

Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 3. 4. 5. 6. 7.

INSPECT FOR OIL LEAK INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR CRANKSHAFT OIL SEAL COMPONENTS

ILLUSTRATION

Fig. 109: Identifying Rear Crankshaft Oil Seal Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to REMOVAL 2. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY a. Using SST, hold the crankshaft pulley.

Fig. 110: Holding Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Remove the 6 bolts and transmission input damper assembly. 

Fig. 111: Identifying Transmission Input Damper Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FLYWHEEL SUB-ASSEMBLY a. Using SST, hold the crankshaft pulley.

Fig. 112: Holding Crankshaft Pulley Using SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Remove the 8 bolts and flywheel sub-assembly. 

Fig. 113: Identifying Flywheel Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE REAR ENGINE OIL SEAL a. Using a knife, cut off the lip of the oil seal.

Fig. 114: Removing Rear Engine Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cut *1 Position b. Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. NOTE:

After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

INSTALLATION INSTALLATION

1. INSTALL REAR ENGINE OIL SEAL a. Apply MP grease to the lip of a new oil seal. NOTE:

 

Do not allow foreign matter to contact the lip of the oil seal. Do not allow MP grease to contact the dust seal.

b. Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

Fig. 115: Installing Rear Engine Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09223-15030 SST: 09950-70010 09951-07150

NOTE:

 

Keep the lip of the oil seal free from foreign matter. Do not tap in the oil seal at an angle.

2. INSTALL FLYWHEEL SUB-ASSEMBLY a. Using SST, hold the crankshaft.

Fig. 116: Holding Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 91551-80650  SST: 09330-00021 b. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts. 

Fig. 117: Apply Adhesive To End Threads Of Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent c. Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

Fig. 118: Tightening Flywheel Sub-Assembly Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 130 N*m (1326 kgf*cm, 96 ft.*lbf) NOTE:

Do not start the engine for at least an hour after installing the flywheel sub-assembly.

d. Check that the crankshaft turns smoothly. 3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY a. Using SST, hold the crankshaft.

Fig. 119: Holding Crankshaft Pulley Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Install the transmission input damper assembly. c. Install and uniformly tighten the 6 bolts in the sequence shown in the illustration. 

Fig. 120: Tightening Transmission Input Damper Assembly Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTE:



Take care not to insert the transmission input damper assembly in the wrong direction.

4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to INSTALLATION - Step 10

ENGINE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 121: Identifying Engine Assembly Replacement Components With Torque Specifications (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 122: Identifying Engine Assembly Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 123: Identifying Engine Assembly Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 124: Identifying Engine Assembly Replacement Components With Torque Specifications (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 125: Identifying Engine Assembly Replacement Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 126: Identifying Engine Assembly Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 127: Identifying Engine Assembly Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 128: Identifying Engine Assembly Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

WARNING:





NOTE:

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop. The vehicle has a hybrid system that operates at voltages up to 650V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this service information to handle the system correctly. Failure to do so may result in serious injury or electrocution. Refer to PRECAUTION .

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . Refer to REPLACEMENT - Step 1 3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

5. 6. 7. 8. 9. 10. 11.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to REMOVAL - Step 1 REMOVE SPARE WHEEL COVER ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to REMOVAL - Step 6 REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL . Refer to REMOVAL - Step 8 REMOVE SERVICE PLUG GRIP . Refer to REMOVAL - Step 9 DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION

12. 13. 14. 15. 16. 17. 18.

ALIGN FRONT WHEELS FACING STRAIGHT AHEAD SECURE STEERING WHEEL . Refer to REMOVAL - Step 3 REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH

19. 20. 21. 22. 23. 24. 25.

REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL . Refer to REPLACEMENT - Step 1 DRAIN COOLANT (for Engine) . Refer to REPLACEMENT - Step 1 DRAIN COOLANT (for Inverter) . Refer to REPLACEMENT - Step 1 DRAIN HYBRID TRANSAXLE FLUID . Refer to ADJUSTMENT - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY a. Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the No. 1 engine cover sub-assembly.

Fig. 129: Identifying No. 1 Engine Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

26. 27. 28. 29. 30.

Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE CONNECTOR COVER ASSEMBLY . Refer to REMOVAL - Step 4 CHECK TERMINAL VOLTAGE . Refer to REMOVAL - Step 5 TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY . Refer to REMOVAL - Step 6 REMOVE INLET AIR CLEANER ASSEMBLY a. Remove the 2 bolts and inlet air cleaner assembly.

Fig. 130: Identifying Inlet Air Cleaner Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 32. REMOVE AIR CLEANER FILTER ELEMENT a. Remove the air cleaner filter element. 33. REMOVE AIR CLEANER CASE SUB-ASSEMBLY a. Remove the 2 bolts and air cleaner case sub-assembly.

Fig. 131: Identifying Air Cleaner Case Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Projection 34. 35. 36. 37. 38. 39. 40. 41.

REMOVE NO. 5 INVERTER BRACKET . Refer to REMOVAL - Step 12 REMOVE NO. 4 INVERTER BRACKET . Refer to REMOVAL - Step 13 REMOVE UPPER INVERTER COVER . Refer to REMOVAL - Step 14 DISCONNECT GENERATOR CABLE . Refer to REMOVAL - Step 15 REMOVE UPPER INVERTER COVER . Refer to REMOVAL - Step 16 DISCONNECT MOTOR CABLE . Refer to REMOVAL - Step 17 REMOVE NO. 3 MOTOR CABLE BRACKET . Refer to REMOVAL - Step 18 REMOVE CONNECTOR COVER ASSEMBLY . Refer to REMOVAL - Step 19

42. 43. 44. 45. 46. 47. 48. 49. 50.

DISCONNECT NO. 4 ENGINE WIRE . Refer to REMOVAL - Step 20 DISCONNECT NO. 4 FLOOR WIRE . Refer to REMOVAL - Step 21 TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY . Refer to REMOVAL - Step 22 DISCONNECT LOW VOLTAGE CONNECTOR . Refer to REMOVAL - Step 23 DISCONNECT NO. 3 ENGINE ROOM WIRE . Refer to REMOVAL - Step 24 REMOVE NO. 4 INVERTER COOLING HOSE . Refer to REMOVAL - Step 25 REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY . Refer to REMOVAL - Step 26 REMOVE INVERTER WITH CONVERTER ASSEMBLY . Refer to REMOVAL - Step 27 DISCONNECT NO. 4 ENGINE WIRE a. Remove the 3 wire harness clamps and disconnect the No. 4 engine wire from the fan shroud.

Fig. 132: Identifying No. 4 Engine Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 51. DISCONNECT ENGINE WIRE a. Disconnect the 4 connectors and disconnect the wire harness clamp.

Fig. 133: Identifying Engine Wire Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and disconnect the earth wire from the body.

Fig. 134: Identifying Earth Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Pull up the lever to disconnect the ECM connector.

Fig. 135: Disconnecting ECM Connector And Wire Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the wire clamp. 52. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY a. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

Fig. 136: Identifying Transmission Control Cable Assembly Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket. c. Remove the clip from the transmission control cable assembly. d. Disconnect the transmission control cable assembly from the 2 transmission control brackets.

Fig. 137: Identifying Transmission Control Cable Assembly Control Brackets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 53. DISCONNECT NO. 1 RADIATOR HOSE a. Remove the hose clamp to disconnect the air fuel ratio sensor wire from the No. 1 radiator hose.

Fig. 138: Identifying No. 1 Radiator Hose Clamp

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the No. 1 radiator hose. 54. DISCONNECT NO. 5 INVERTER COOLING HOSE a. Disconnect the No. 5 inverter cooling hose from the hybrid vehicle transaxle assembly.

Fig. 139: Identifying No. 5 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 55. DISCONNECT INLET HEATER WATER HOSE a. Disconnect the inlet heater water hose.

Fig. 140: Identifying Inlet Heater Water Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 56. DISCONNECT OUTLET HEATER WATER HOSE a. Disconnect the outlet heater water hose.

Fig. 141: Identifying Outlet Heater Water Hose

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 57. DISCONNECT FUEL MAIN TUBE a. Release the claw and remove the No. 1 EFI fuel pipe clamp.

Fig. 142: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pinch the fuel tube connector and then pull out the fuel main tube.

Fig. 143: Disconnecting Fuel Main Tube Connector & Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  



Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector. Disconnect the connector by hand. Do not bend, fold or rotate the nylon tube. If the pipe and connector are stuck together, push and pull the connector until it becomes free. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

58. REMOVE NO. 2 ENGINE MOUNTING STAY RH a. Remove the 2 bolts and No. 2 engine mounting stay RH.

Fig. 144: Identifying No. 2 Engine Mounting Stay Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 59. SEPARATE EARTH WIRE a. Remove the bolt and separate the earth wire from the engine moving control rod bracket.

Fig. 145: Identifying Earth Wire

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 60. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY a. Remove the 4 bolts and engine moving control rod sub-assembly.

Fig. 146: Identifying Engine Moving Control Rod Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 61. REMOVE ENGINE MOVING CONTROL ROD a. Remove the bolt and engine moving control rod from the engine moving control rod bracket.

Fig. 147: Identifying Engine Moving Control Rod Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary. 62. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to REMOVAL - Step 6 63. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to REMOVAL Step 5 64. DISCONNECT NO. 2 RADIATOR HOSE a. Disconnect the No. 2 radiator hose.

Fig. 148: Identifying No. 2 Radiator Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 65. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to REMOVAL - Step 5 66. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to REMOVAL - Step 10 67. REMOVE FRONT AXLE SHAFT NUT LH . Refer to REMOVAL - Step 9 68. REMOVE FRONT AXLE SHAFT NUT RH HINT: Use the same procedure described for the LH side. 69. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to REMOVAL - Step 4 70. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure described for the LH side. 71. SEPARATE FRONT SPEED SENSOR LH . Refer to REMOVAL - Step 5 72. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side.

73. SEPARATE TIE ROD ASSEMBLY LH . Refer to REMOVAL - Step 5 74. SEPARATE TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side. 75. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 10 76. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Use the same procedure described for the LH side. 77. SEPARATE FRONT AXLE ASSEMBLY LH . Refer to REMOVAL - Step 9 78. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedure described for the LH side. 79. REMOVE FLYWHEEL HOUSING UNDER COVER a. Remove the flywheel housing under cover.

Fig. 149: Identifying Flywheel Housing Under Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 80. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE a. Set an engine lifter.

Fig. 150: Identifying Engine Lifter Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Attachment Installation Position NOTE:



Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.









Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.

b. Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.

Fig. 151: Identifying Frame Side Rail Plate, Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut c. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH. d. Operate the engine lifter and remove the engine assembly from the vehicle. NOTE:

 

Make sure that the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle.

e. Install the engine hangers See step 20.

81. REMOVE ENGINE WIRE a. Remove the engine wire from the engine with transaxle. 82. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to REMOVAL - Step 15 83. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REMOVAL - Step 17 84. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to REMOVAL - Step 16 85. REMOVE FRONT FRAME ASSEMBLY a. Remove the bolt and disconnect the No. 4 engine wire from the front frame assembly.

Fig. 152: Identifying No. 4 Engine Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the nut and separate the engine mounting insulator LH.

Fig. 153: Identifying Engine Mounting Insulator Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and separate the front engine mounting insulator.

Fig. 154: Identifying Front Engine Mounting Insulator Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the nut and separate the engine mounting insulator RH.

Fig. 155: Identifying Engine Mounting Insulator Nut RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the front frame assembly. f. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface. NOTE:







Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Using an engine sling device and engine lift, secure the engine assembly before service.

86. REMOVE FRONT ENGINE MOUNTING INSULATOR a. Remove the 3 nuts and front engine mounting insulator.

Fig. 156: Identifying Engine Mounting Insulator Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. 87. REMOVE ENGINE MOUNTING INSULATOR LH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 157: Identifying Front Frame Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. 88. REMOVE ENGINE MOUNTING INSULATOR RH a. Remove the 2 hole plugs from the front frame assembly.

Fig. 158: Identifying Front Frame Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 89. REMOVE ENGINE MOUNTING BRACKET RH a. Remove the 3 bolts and engine mounting bracket RH.

Fig. 159: Identifying Engine Mounting Bracket RH Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 90. REMOVE DRIVE SHAFT BEARING BRACKET a. Remove the 3 bolts and drive shaft bearing bracket.

Fig. 160: Identifying Drive Shaft Bearing Bracket Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 91. 92. 93. 94.

REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY See step 2 REMOVE FLYWHEEL SUB-ASSEMBLY See step 3 INSTALL ENGINE STAND a. Install the engine onto an engine stand with the bolts.

INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. REMOVE ENGINE STAND a. Using a chain block and engine sling device, secure the engine assembly. NOTE:





2. 3. 4. 5. 6.

Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged. Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

b. Remove the engine stand from the engine. INSTALL ENGINE WIRE a. Install the engine wire to the engine with transaxle. INSTALL FLYWHEEL SUB-ASSEMBLY See step 2 INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY See step 3 INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY . Refer to INSTALLATION - Step 10 INSTALL ENGINE MOUNTING BRACKET RH a. Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

7. INSTALL DRIVE SHAFT BEARING BRACKET a. Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 8. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

a. Temporarily install the front engine mounting insulator with the 3 nuts. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. 9. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH a. Temporarily install the engine mounting insulator LH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. 10. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH a. Temporarily install the engine mounting insulator RH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. 11. INSTALL FRONT FRAME ASSEMBLY a. Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) b. Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) c. Install the front engine mounting insulator with the bolt. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) d. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

Fig. 161: Identifying Engine Mounting Insulators Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Engine Engine Mounting *a *b Mounting Insulator Insulator RH Engine Mounting *c - Insulator LH HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary. A Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) B Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 4 hole plugs.

Fig. 162: Identifying Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine Engine Mounting Mounting *a *b Insulator Insulator RH LH HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary. 12. 13. 14. 15.

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REASSEMBLY - Step 13 INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL ENGINE ASSEMBLY WITH TRANSAXLE a. Set the engine assembly with transaxle on an engine lifter. NOTE:









Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle. Make sure to support the engine assembly with transaxle securely to prevent it from falling.

b. Remove the engine hangers See step 1. c. Install the engine assembly to the vehicle.

NOTE:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

HINT: Make sure that the engine is clear of all wiring and hoses.  While raising the engine into the vehicle, do not allow it to contact the vehicle. d. Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts. 

Fig. 163: Identifying Frame Side Rail Plate Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf)

B Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) e. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. C Torque: 85 N*m (867 kgf*cm, 62 ft.*lbf) D Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 16. INSTALL FLYWHEEL HOUSING UNDER COVER a. Install the flywheel housing under cover. 17. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 8 18. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Use the same procedure described for the LH side. 19. INSTALL TIE ROD ASSEMBLY LH . Refer to INSTALLATION - Step 8 20. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side. 21. INSTALL FRONT SPEED SENSOR LH . Refer to INSTALLATION - Step 19 22. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side. 23. INSTALL FRONT STABILIZER LINK ASSEMBLY LH . Refer to INSTALLATION - Step 10 24. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedure described for the LH side. 25. INSTALL FRONT AXLE SHAFT NUT LH . Refer to INSTALLATION - Step 7 26. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to INSTALLATION Step 10 27. INSTALL FRONT AXLE SHAFT NUT RH HINT: Use the same procedure described for the LH side. 28. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to INSTALLATION - Step 1 29. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to INSTALLATION Step 4 30. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to INSTALLATION - Step 3 31. INSTALL ENGINE MOVING CONTROL ROD a. Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary. 32. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY a. When the engine moving control rod has been replaced. 1. Temporarily install the engine moving control rod sub-assembly with the 4 bolts.

Fig. 164: Identifying Engine Moving Control Rod Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Fully tighten the engine moving control rod sub-assembly with the bolts except bolt A.

Fig. 165: Identifying Engine Moving Control Rod Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 3. Using SST, fully tighten the bolt A.

Fig. 166: Identifying SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09961-00950

Without SST Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) With SST Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)

NOTE:







The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.24 in.). Refer to PRECAUTION . The "with SST" torque value is effective when SST is parallel to the torque wrench. Fully tighten bolt A using SST.

b. When the engine moving control rod has been reused.

Fig. 167: Identifying Engine Moving Control Rod Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Temporarily install the engine moving control rod sub-assembly with the 4 bolts. 2. Fully tighten the engine moving control rod sub-assembly with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 33. INSTALL EARTH WIRE a. Install the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 34. INSTALL NO. 2 ENGINE MOUNTING STAY RH a. Install the No. 2 engine mounting stay RH with the 2 bolts.

Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 35. CONNECT FUEL MAIN TUBE a. Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.

Fig. 168: Pushing Fuel Tube Connector To Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Check for damage or contamination on the connected part of the pipe. Check if the pipe and the connector are securely connected by trying to pull them apart.

b. Install the No. 1 fuel pipe clamp.

Fig. 169: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. CONNECT INLET HEATER WATER HOSE a. Connect the inlet heater water hose. 37. CONNECT OUTLET HEATER WATER HOSE a. Connect the outlet heater water hose. 38. CONNECT NO. 5 INVERTER COOLING HOSE a. Connect the No. 5 inverter cooling hose to the hybrid vehicle transaxle assembly. 39. CONNECT NO. 1 RADIATOR HOSE a. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp. 40. CONNECT NO. 2 RADIATOR HOSE a. Connect the No. 2 radiator hose. 41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY a. Connect the transmission control cable assembly to the 2 transmission control cable brackets. b. Install a new clip to the No. 1 transmission control cable bracket. c. Install the transmission control cable assembly to the No. 1 transmission control cable bracket

Fig. 170: Identifying Transmission Control Cable Assembly And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Transmission *1 Control Cable Assembly No. 1 Transmission *2 Control Cable Bracket *a Claw A *b Claw B

NOTE:





Make sure that the claws A on the clip are securely fit into the bracket holes. Make sure that the cable is securely installed inside of the claws B of the clip.

d. Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 42. INSTALL NO. 4 ENGINE WIRE a. Install the 3 wire harness clamps and connect the No. 4 engine wire to the fan shroud. 43. INSTALL INVERTER WITH CONVERTER ASSEMBLY . Refer to INSTALLATION - Step 11 44. CONNECT ENGINE WIRE a. Connect the wire harness clamp.

Fig. 171: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector to the ECM with the lock lever. c. Install the earth wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. Connect the 4 connectors and wire harness clamp. 45. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY . Refer to INSTALLATION - Step

46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60.

12 CONNECT NO. 4 INVERTER COOLING HOSE . Refer to INSTALLATION - Step 13 CONNECT NO. 3 ENGINE ROOM WIRE . Refer to INSTALLATION - Step 14 CONNECT LOW VOLTAGE CONNECTOR . Refer to INSTALLATION - Step 15 REMOVE CONNECTOR COVER ASSEMBLY . Refer to REMOVAL - Step 19 CONNECT NO. 4 FLOOR WIRE . Refer to INSTALLATION - Step 17 CONNECT NO. 4 ENGINE WIRE . Refer to INSTALLATION - Step 18 INSTALL CONNECTOR COVER ASSEMBLY . Refer to INSTALLATION - Step 19 INSTALL NO. 3 MOTOR CABLE BRACKET . Refer to INSTALLATION - Step 20 CONNECT MOTOR CABLE . Refer to INSTALLATION - Step 21 INSTALL UPPER INVERTER COVER . Refer to INSTALLATION - Step 22 CONNECT GENERATOR CABLE . Refer to INSTALLATION - Step 23 INSTALL UPPER INVERTER COVER . Refer to INSTALLATION - Step 22 INSTALL NO. 4 INVERTER BRACKET . Refer to INSTALLATION - Step 25 INSTALL NO. 5 INVERTER BRACKET . Refer to INSTALLATION - Step 26 INSTALL AIR CLEANER CASE SUB-ASSEMBLY a. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

Fig. 172: Identifying Air Cleaner Case Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Projection b. Tighten the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 61. INSTALL AIR CLEANER FILTER ELEMENT a. Install the air cleaner filter element. NOTE:

Install the air cleaner filter element with the printed side facing the vehicle front.

62. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 63. INSTALL INLET AIR CLEANER ASSEMBLY a. Install the inlet air cleaner assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 64. INSTALL SERVICE PLUG GRIP . Refer to INSTALLATION - Step 1 65. INSTALL NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL . Refer to INSTALLATION Step 2 66. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to INSTALLATION Step 9 67. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 11 68. INSTALL SPARE WHEEL COVER ASSEMBLY . Refer to INSTALLATION - Step 12 69. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to INSTALLATION - Step 13 70. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL . Refer to INSTALLATION - Step 2 71. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 72. ADD ENGINE OIL . Refer to REPLACEMENT - Step 4 73. ADD COOLANT (for Engine) . Refer to REPLACEMENT - Step 2 74. ADD COOLANT (for Inverter) . Refer to REPLACEMENT - Step 2 75. ADD HYBRID TRANSAXLE FLUID Refer to REPLACEMENT 76. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . Refer to REPLACEMENT Step 2 77. WARM UP ENGINE 78. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 79. INSPECT FOR OIL LEAK 80. INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 81. INSPECT FOR EXHAUST GAS LEAK 82. INSPECT REFRIGERANT LEAK . Refer to REPLACEMENT - Step 4 83. INSPECT IGNITION TIMING See step 6 84. INSPECT ENGINE IDLE SPEED See step 7 85. INSPECT CO/HC See step 9 86. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY a. Engage the 3 pins and install the No. 1 engine cover sub-assembly. 87. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 88. INSPECT AND ADJUST SHIFT LEVER POSITION

Refer to ADJUSTMENT 89. 90. 91. 92. 93. 94. 95.

INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

96. CHECK ABS SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE 97. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT

ENGINE UNIT COMPONENTS ILLUSTRATION

Fig. 173: Identifying Engine Unit Replacement Components With Torque Specifications (1 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 174: Identifying Engine Unit Replacement Components With Torque Specifications (2 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 175: Identifying Engine Unit Replacement Components With Torque Specifications (3 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 176: Identifying Engine Unit Replacement Components With Torque Specifications (4 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 177: Identifying Engine Unit Replacement Components With Torque Specifications (5 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 178: Identifying Engine Unit Replacement Components With Torque Specifications (6 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 179: Identifying Engine Unit Replacement Components With Torque Specifications (7 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 180: Identifying Engine Unit Replacement Components With Torque Specifications (8 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 181: Identifying Engine Unit Replacement Components With Torque Specifications (9 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 182: Identifying Engine Unit Replacement Components With Torque Specifications (10 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE ENGINE HANGERS a. Remove the 2 bolts and 2 engine hangers.

Fig. 183: Identifying Engine Hangers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Engine Hanger No. 2 *2 Engine Hanger 2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE a. Remove the engine oil level dipstick.

Fig. 184: Identifying Engine Oil Level Dipstick Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and engine oil level dipstick guide. c. Remove the O-ring from the engine oil level dipstick guide. 3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR a. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

Fig. 185: Identifying No. 1 Exhaust Manifold Heat Insulator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT NO. 1 WATER BY-PASS HOSE a. Disconnect the No. 1 water by-pass hose.

Fig. 186: Identifying No. 1 Water By-Pass Hose

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. 6. 7. 8. 9.

REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE NO. 2 EGR PIPE . Refer to REMOVAL - Step 9 REMOVE MANIFOLD STAY . Refer to REMOVAL - Step 11 REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 10 REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 10. REMOVE EGR COOLER ASSEMBLY a. Disconnect the water by-pass hose.

Fig. 187: Identifying Water By-Pass Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and nut.

Fig. 188: Identifying Water By-Pass Hose Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Separate the 2 clamps.

Fig. 189: Identifying Water By-Pass Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disconnect the No. 4 water by-pass hose and No. 6 water by-pass hose. e. Remove the bolt, nut and separate the EGR cooler assembly from the engine.

Fig. 190: Identifying EGR Cooler Assembly Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 1 EGR PIPE a. Remove the 2 bolts and No. 1 EGR pipe.

Fig. 191: Identifying No. 1 EGR Pipe Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY . Refer to REMOVAL - Step 7 13. REMOVE ENGINE WATER PUMP ASSEMBLY a. Disconnect the harness clamp.

Fig. 192: Identifying Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector from the engine water pump assembly.

Fig. 193: Identifying Engine Water Pump Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 5 bolts and engine water pump assembly.

Fig. 194: Identifying Engine Water Pump Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the gasket from the engine water pump assembly. 14. REMOVE WATER INLET SUB-ASSEMBLY a. Remove the 2 bolts and water inlet sub-assembly.

Fig. 195: Identifying Water Inlet Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the gasket from the water inlet sub-assembly.

Fig. 196: Identifying Water Inlet Sub-Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE WATER INLET HOUSING a. Remove the bolt and harness clamp bracket from the cylinder block.

Fig. 197: Identifying Cylinder Block Harness Clamp Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and harness clamp bracket from the water inlet housing.

Fig. 198: Identifying Water Inlet Housing Harness Clamp Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 3 bolts, nut, and water inlet housing.

Fig. 199: Identifying Water Inlet Housing Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Bolt *2 Nut d. Remove the gasket.

Fig. 200: Identifying Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using an E8 "TORX" socket wrench, remove the stud bolt from the cylinder block.

Fig. 201: Identifying Cylinder Block Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

f. Using an E5 "TORX" socket wrench, remove the stud bolt from the water inlet housing.

Fig. 202: Identifying Water Inlet Housing Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET a. Remove the 4 bolts and No. 1 compressor mounting bracket.

Fig. 203: Identifying No. 1 Compressor Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 7 18. REMOVE INTAKE MANIFOLD . Refer to REMOVAL - Step 13 19. REMOVE SENSOR WIRE a. Disconnect the knock control sensor connector.

Fig. 204: Identifying Knock Control Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and knock control sensor wire. 20. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2 DISASSEMBLY DISASSEMBLY

1. REMOVE ENGINE COVER JOINT a. Remove the 3 engine cover joints.

Fig. 205: Identifying Engine Cover Joints Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

REMOVE SPARK PLUG . Refer to REMOVAL - Step 3 REMOVE KNOCK CONTROL SENSOR . Refer to REMOVAL - Step 2 REMOVE ENGINE COOLANT TEMPERATURE SENSOR . Refer to REMOVAL - Step 5 REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to REMOVAL - Step 1 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to REMOVAL Step 2 REMOVE CAMSHAFT POSITION SENSOR . Refer to REMOVAL - Step 2 REMOVE OIL FILLER CAP SUB-ASSEMBLY a. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly. REMOVE OIL FILLER CAP GASKET a. Remove the oil filler cap gasket from the oil filler cap sub-assembly. REMOVE CRANKSHAFT POSITION SENSOR . Refer to REMOVAL - Step 1 REMOVE VENTILATION VALVE SUB-ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE VENTILATION CASE SUB-ASSEMBLY a. Remove the 8 bolts and 2 nuts.

Fig. 206: Identifying Ventilation Case Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the ventilation case by prying between the ventilation case and cylinder block with a screwdriver.

Fig. 207: Locating Contact Surfaces Of Cylinder Block And Ventilation Case

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the contact surfaces of the cylinder block and ventilation case.

HINT: Tape the screwdriver tip before use. 13. REMOVE SEPARATOR CASE a. Remove the 2 bolts, separator case and gasket.

Fig. 208: Identifying Case And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE CRANKSHAFT PULLEY a. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

Fig. 209: Loosening Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 b. Using SST and the pulley bolt, remove the crankshaft pulley. 

Fig. 210: Removing Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pulley *1 Bolt *a Hold *b Turn 

SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05011

HINT: Apply a lubricant to the threads and end of SST. 15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY a. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

Fig. 211: Identifying Cylinder Head Cover Sub-Assembly, Cylinder Head Cover Gasket Bolts And Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 gaskets from the camshaft bearing caps.

Fig. 212: Identifying Camshaft Bearing Caps Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

a. Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover subassembly.

Fig. 213: Identifying Cylinder Head Cover Sub-Assembly Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE SPARK PLUG TUBE GASKET a. Using a screwdriver, pry out the 4 spark plug tube gaskets.

Fig. 214: Identifying Spark Plug Tube Gaskets

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tape NOTE:

Be careful not to damage the cylinder head cover.

HINT: Tape the screwdriver tip before use. 18. REMOVE ENGINE MOUNTING BRACKET RH . Refer to REMOVAL - Step 7 19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 8 20. REMOVE OIL PUMP RELIEF VALVE PLUG a. Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.

Fig. 215: Identifying Plug And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE TIMING CHAIN COVER PLATE a. Remove the 4 bolts, timing chain cover plate and gasket.

Fig. 216: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. 23. 24. 25. 26. 27.

REMOVE TIMING CHAIN COVER OIL SEAL . Refer to REMOVAL - Step 9 SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 13 REMOVE TIMING CHAIN GUIDE See step 14 REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 15 REMOVE CHAIN TENSIONER SLIPPER See step 16 REMOVE CHAIN SUB-ASSEMBLY a. Remove the chain sub-assembly. 28. REMOVE NO. 1 CHAIN VIBRATION DAMPER See step 18 29. REMOVE CRANKSHAFT TIMING SPROCKET a. Remove the crankshaft timing sprocket from the crankshaft.

Fig. 217: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. 31. 32. 33. 34.

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY See step 19 REMOVE CAMSHAFT TIMING SPROCKET See step 20 REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY See step 21 REMOVE CAMSHAFT BEARING CAP See step 22 REMOVE OIL CONTROL VALVE FILTER a. Remove the oil control valve filter from the No. 1 camshaft bearing cap.

Fig. 218: Identifying Oil Control Valve Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE CAMSHAFT See step 25 36. REMOVE NO. 1 CAMSHAFT BEARING a. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

Fig. 219: Identifying No. 1 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE NO. 2 CAMSHAFT BEARING a. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

Fig. 220: Identifying No. 2 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

a. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing subassembly.

Fig. 221: Identifying Camshaft Housing Sub-Assembly Stud Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.

Fig. 222: Identifying Camshaft Housing Sub-Assembly Bearing Cap Setting Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE STRAIGHT PIN NOTE:

It is not necessary to remove the straight pin unless it is being replaced.

a. Remove the 2 straight pins from the camshaft housing sub-assembly.

Fig. 223: Identifying Camshaft Housing Sub-Assembly Straight Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 41. 42. 43. 44. 45. 46.

REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 27 REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 28 REMOVE VALVE STEM CAP See step 29 REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 30 REMOVE CYLINDER HEAD GASKET See step 31 REMOVE CYLINDER BLOCK WATER JACKET SPACER a. Remove the cylinder block water jacket spacer from the cylinder block.

Fig. 224: Identifying Cylinder Block Water Jacket Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block is inverted.

47. REMOVE OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 2 48. REMOVE OIL PAN DRAIN PLUG a. Remove the oil pan drain plug and gasket from the oil pan sub-assembly. 49. REMOVE OIL PAN SUB-ASSEMBLY a. Remove the 11 bolts and 2 nuts.

Fig. 225: Identifying Oil Pan Sub-Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut b. Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.

Fig. 226: Inserting Blade Of SST Between No. 1 & No. 2 Oil Pans Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to damage the stiffening crankcase contact surface of the oil pan. Be careful not to damage the stiffening crankcase flange.

50. REMOVE OIL STRAINER SUB-ASSEMBLY a. Remove the 3 bolts, oil strainer sub-assembly and gasket.

Fig. 227: Locating Oil Strainer And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 51. REMOVE NO. 1 OIL PAN BAFFLE PLATE a. Remove the 5 bolts and No. 1 oil pan baffle plate.

Fig. 228: Locating Oil Pan Baffle Plate Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 52. INSPECT CRANKSHAFT BACKLASH a. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

Fig. 229: Measuring Backlash Of Crankshaft And Balance Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard backlash 0.05 to 0.20 mm (0.00197 to 0.00787 in.) Maximum backlash 0.20 mm (0.00787 in.) If the backlash is more than the maximum, replace the engine balancer assembly. 53. REMOVE ENGINE BALANCER ASSEMBLY a. Remove the 7 bolts and engine balancer assembly.

Fig. 230: Locating Engine Balancer Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the engine balancer.

54. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE See step 14 55. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE See step 15 56. REMOVE STIFFENING CRANKCASE ASSEMBLY a. Remove the 7 bolts.

Fig. 231: Locating Stiffening Crankcase Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

Fig. 232: Locating Stiffening Crankcase & Cylinder Block Prying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*a Side: RH *b Side: NOTE:

Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.

HINT: Tape the screwdriver tip before use. 57. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

a. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.

Fig. 233: Identifying Stiffening Crankcase Assembly Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 58. REMOVE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the 2 ring pins from the stiffening crankcase assembly.

Fig. 234: Identifying Stiffening Crankcase Assembly Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 59. REMOVE REAR ENGINE OIL SEAL a. Remove the rear engine oil seal from the cylinder block.

Fig. 235: Identifying Rear Engine Oil Seal

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY a. Turn the roller by hand to check that it turns smoothly.

Fig. 236: Inspecting No. 1 Valve Rocker Arm Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly. 2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE:

 

Keep the adjuster free from dirt and foreign matter. Use only clean engine oil.

Fig. 237: Inspecting Valve Lash Adjuster Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Plunger *2 Check Ball *a CORRECT *b INCORRECT *c Taper Part Low Pressure *d Chamber High Pressure *e Chamber a. Place the lash adjuster into a container full of new engine oil. b. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.  SST: 09276-75010 c. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times. d. Check the movement of the plunger and bleed the air. OK Plunger moves up and down. NOTE:

When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

e. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly. 3. INSPECT CAMSHAFT OIL CLEARANCE See step 8 4. INSPECT CAMSHAFT THRUST CLEARANCE See step 9 5. INSPECT CAMSHAFT a. Inspect the camshaft runout.

Fig. 238: Checking Camshaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Place the camshaft on V-blocks. 2. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. b. Inspect the cam lobes.

Fig. 239: Checking Cam Lobes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Specified Condition 43.814 to 43.914 Intake mm (1.725 to 1.729 in.) 42.939 to 43.039 Exhaust mm (1.691 to 1.694 in.) Item

Minimum Cam Lobe Height Item

Specified Condition

Intake 43.704 mm

(1.721 in.) 42.829 Exhaust mm (1.686 in.) If the cam lobe height is less than the minimum, replace the camshaft sub-assembly. c. Inspect the camshaft journals.

Fig. 240: Checking Camshaft Journals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the journal diameter. Standard Journal Diameter Specified Condition 34.449 to 34.465 No. 1 mm journal (1.356 to 1.357 in.) Item

Other 22.959 to journals 22.975 mm

(0.904 to 0.905 in.) If the journal diameter is not as specified, check the oil clearance See step 8. 6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY a. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

Fig. 241: Identifying Pin Hole And Knock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hole Knock *2 Pin b. Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig. 242: Identifying No Clearance Between Camshaft Timing Gear And Camshaft Flange Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Camshaft *1 Timing Gear *2 Flange *a INCORRECT *b CORRECT *c Clearance *d No Clearance c. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

NOTE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

d. Check the lock of the camshaft timing gear. 1. Make sure that the camshaft timing gear is locked. NOTE: e. Release the lock pin.

Be careful not to damage the camshaft.

Fig. 243: Identifying Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Rubber Vinyl *2 Tape Knock *3 Pin Retard *a Side Path Advance *b Side Path *c Open *d Close 1. Clean the camshaft journal with non-residue solvent. 2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber. 3. Open a hole at port A shown in the illustration. 4. While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig. 244: Turning Camshaft Timing Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT: The camshaft timing gear assembly may be turned in the advance direction without applying any force.  If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult. f. Check for smooth rotation. 1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. 

NOTE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

g. Remove the vinyl tape and rubber pieces from the camshaft. h. Remove the bolt and camshaft timing gear. 7. INSPECT CHAIN SUB-ASSEMBLY a. Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Fig. 245: Inspecting Chain Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Area b. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation 137.7 mm (5.42 in.) HINT: Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the chain sub-assembly. 8. INSPECT CAMSHAFT TIMING SPROCKET a. Place the chain around the sprocket.

Fig. 246: Measuring Sprocket Diameter With Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 115.12 mm (4.53 in.) If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing sprocket. HINT: The vernier caliper must contact the chain rollers for the measurement. 9. INSPECT CRANKSHAFT TIMING SPROCKET a. Place the chain around the sprocket.

Fig. 247: Measuring Sprocket Diameter With Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 59.94 mm (2.36 in.) If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket. HINT: The vernier caliper must contact the chain rollers for the measurement. 10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY a. Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.

Fig. 248: Identifying Plunger And Stopper Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plunger Stopper *2 Plate If necessary, replace the No. 1 chain tensioner assembly. 11. INSPECT CHAIN TENSIONER SLIPPER a. Measure the wear depth of the chain tensioner slipper.

Fig. 249: Measuring Wear Depth Of Chain Tensioner Slipper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the chain tensioner slipper. 12. INSPECT NO. 1 CHAIN VIBRATION DAMPER a. Measure the wear depth of the No. 1 chain vibration damper.

Fig. 250: Measuring Wear Depth Of No. 1 Chain Vibration Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper. 13. INSPECT TIMING CHAIN GUIDE a. Measure the wear depth of the timing chain guide.

Fig. 251: Measuring Wear Depth Of Timing Chain Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the timing chain guide. 14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

Fig. 252: Inspecting No. 1 Balance Shaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly. 15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

Fig. 253: Inspecting No. 2 Balance Shaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly. 16. INSPECT BALANCE SHAFT BACKLASH a. Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

Fig. 254: Measuring No. 1 And No. 2 Balance Shafts Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Fix Standard backlash 0.04 to 0.17 mm (0.00157 to 0.00669 in.) Maximum backlash 0.17 m (0.00669 in.) NOTE:

Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.

If the backlash is more than the maximum, replace the engine balancer assembly. 17. INSPECT CYLINDER HEAD BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point.

Fig. 255: Inspecting Cylinder Head Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 10.85 to 11.00 mm (0.427 to 0.433 in.) Minimum diameter 10.6 mm (0.417 in.) Measurement point (distance from the seat) 106 mm (4.17 in.) HINT: If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the cylinder head bolt with a new one. 18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts 

the cylinder head.

Fig. 256: Checking Exhaust Manifold Converter Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold converter sub-assembly. REASSEMBLY REASSEMBLY

1. INSTALL RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 2 ring pins until they stop.

Fig. 257: Locating Stiffening Crankcase Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protrusion *a Height Standard protrusion height 4.3 to 5.3 mm (0.169 to 0.209 in.) 2. INSTALL ENGINE BALANCER ASSEMBLY a. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

Fig. 258: Aligning Marks Of Balance Shaft Damper Cover And Balance Shaft Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Driven *1 Gear Damper *2 Cover Alignment *a Mark If the alignment marks are not aligned, realign them. 1. Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

Fig. 259: Aligning Driven Gear And Damper Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Driven *1 Gear Damper *2 Cover Alignment *a Mark 2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover. b. Install the engine balancer assembly to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

Fig. 260: Identifying Engine Balancer Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 3. INSTALL STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E5 and E8 "TORX" socket wrench, install the 3 stud bolts.

Fig. 261: Identifying Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a

Front Lower *b Side Side

for Stud Bolt A Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) for Stud Bolt B Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 4. INSTALL STIFFENING CRANKCASE ASSEMBLY a. Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.

Fig. 262: Rotating Crankshaft Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Key b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 263: Applying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stiffening Crankcase Cylinder Block Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Dimension

Specified Condition 2.5 to 3.5 Continuous mm Line (0.0984 to 0.138 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.) Dashed wide and 2.5 to 3.5 Line mm (0.0984 to 0.138 in.) thick Area

Application Length A 28 mm (1.10 in.) NOTE:

  

Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not apply oil for at least 2 hours after the installation.

c. Check that the rear cutout parts are as shown in the illustration.

Fig. 264: Identifying Stiffening Crankcase Rear Cutout Parts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout d. Clean the bolts and their installation holes. e. Apply adhesive to 3 or more threads of the ends of bolts A.

Fig. 265: Applying Adhesive To Bolt Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent TEXT IN ILLUSTRATION *1 Adhesive f. Temporarily install the stiffening crankcase with the 11 bolts.

Fig. 266: Identifying Stiffening Crankcase Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Length Item Length 65 mm Bolt (2.56 A in.) 35 mm Bolt (1.38 B in.) 125 Bolt mm C (4.92 in.) 165 Bolt mm D (6.50 in.) HINT: Apply adhesive to bolts A before installation. g. Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

Fig. 267: Identifying Stiffening Crankcase Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for Bolt A Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) except Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 5. INSTALL NO. 1 OIL PAN BAFFLE PLATE a. Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

Fig. 268: Identifying No. 1 Oil Pan Baffle Plate Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 6. INSTALL OIL STRAINER SUB-ASSEMBLY a. Apply a light coat of engine oil to a new gasket. b. Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer sub-assembly.

Fig. 269: Identifying 3 Oil Strainer Bolts With Tightening Sequence & Aligning Gasket Protrusion To Oil Strainer Cutout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Protrusion c. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the sequence shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 7. INSTALL OIL PAN SUB-ASSEMBLY a. Apply seal packing in a continuous line as shown in the illustration.

Fig. 270: Applying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTE:

 



Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing. Do not apply oil for at least 2 hours after the installation.

b. Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

Fig. 271: Installing Oil Pan Bolts And Nuts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) TEXT IN ILLUSTRATION *1 Nut HINT: Bolt A and nut A are tightened twice. 8. INSTALL OIL PAN DRAIN PLUG a. Install a new gasket and oil pan drain plug to the oil pan sub-assembly. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 9. INSTALL OIL FILTER CAP ASSEMBLY . Refer to REPLACEMENT - Step 3 10. INSTALL REAR ENGINE OIL SEAL See step 1 11. INSTALL CYLINDER BLOCK WATER JACKET SPACER a. Install the cylinder block water jacket spacer to the cylinder block.

Fig. 272: Identifying Cylinder Block Water Jacket Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL CYLINDER HEAD GASKET See step 3 13. INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 4 14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 10 camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

Fig. 273: Locating Camshaft Bearing Ring Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protrusion *a Height Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) 15. INSTALL STRAIGHT PIN NOTE:

It is not necessary to remove the straight pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in 2 straight pins to the camshaft housing sub-assembly.

Fig. 274: Locating Camshaft Housing Straight Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protrusion *a Height Standard protrusion height 5.0 to 7.0 mm (0.197 to 0.276 in.) 16. INSTALL STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. When reusing the stud bolt. 1. Apply adhesive to threads of the stud bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent b. Using an E8 "TORX" socket wrench, install the camshaft housing stud bolt.

Fig. 275: Identifying Camshaft Housing Stud Bolt Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 17. INSTALL NO. 1 CAMSHAFT BEARING a. Clean the No. 1 camshaft bearing. b. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

Fig. 276: Measuring Distance Between No. 1 Camshaft Bearing Cap Edge And No. 1 Camshaft Bearing Edge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier *1 Caliper c. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) 18. INSTALL NO. 2 CAMSHAFT BEARING

a. Clean the No. 2 camshaft bearing. b. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

Fig. 277: Measuring No. 2 Camshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier *1 Caliper c. Using a vernier caliper, measure the distance between the camshaft housing edge and the No. 2 camshaft bearing edge. Standard distance

1.15 to 1.85 mm (0.0453 to 0.0728 in.) 19. INSTALL OIL CONTROL VALVE FILTER a. Install the oil control valve filter to the No. 1 camshaft bearing cap.

Fig. 278: Identifying Oil Control Valve Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. 21. 22. 23. 24. 25. 26. 27. 28.

INSTALL CAMSHAFT See step 12 INSTALL CAMSHAFT BEARING CAP See step 13 INSTALL VALVE STEM CAP See step 5 INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7 INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8 INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY See step 14 INSTALL CAMSHAFT TIMING SPROCKET See step 15 INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 16 INSTALL CRANKSHAFT TIMING SPROCKET a. Install the crankshaft timing sprocket to the crankshaft.

Fig. 279: Identifying Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. 30. 31. 32. 33. 34. 35. 36. 37.

ADD ENGINE OIL See step 17 INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 18 SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 19 INSTALL CHAIN SUB-ASSEMBLY See step 20 INSTALL CHAIN TENSIONER SLIPPER See step 21 INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 22 INSTALL TIMING CHAIN GUIDE See step 23 SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 24 INSTALL TIMING CHAIN COVER PLATE a. Install a new gasket and the timing chain cover plate with the 4 bolts.

Fig. 280: Locating Timing Chain Cover Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 38. INSTALL OIL PUMP RELIEF VALVE PLUG a. Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.

Fig. 281: Identifying Plug And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 39. 40. 41. 42.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL ENGINE MOUNTING BRACKET RH . Refer to INSTALLATION - Step 2 INSTALL TIMING CHAIN COVER OIL SEAL See step 1 INSTALL SPARK PLUG TUBE GASKET a. Tap in the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

Fig. 282: Identifying Spark Plug Tube Gasket And Cylinder Head Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Spark Plug *1 Tube Gasket Cylinder Head *2 Cover Subassembly NOTE:



Do not allow foreign matter to contact the lip of the spark plug



tube gasket. Do not tap in the spark plug tube gasket at an angle.

43. INSTALL STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E6 "TORX" socket wrench, install the 3 stud bolts.

Fig. 283: Identifying Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

a. Apply a light coat of engine oil to 2 new gaskets.

Fig. 284: Identifying Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 gaskets to the camshaft bearing caps. c. Install a new gasket to the cylinder head cover sub-assembly. NOTE:

Remove any oil from the contact surface.

d. Apply seal packing as shown in the illustration.

Fig. 285: Identifying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.0 to 6.0 mm (0.118 to 0.236 in.) Application width A 5.0 mm (0.197 in.) TEXT IN ILLUSTRATION

Seal Packing Timing *2 Chain Cover Camshaft *3 Housing *1

NOTE:

 

Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes after applying seal packing.

e. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover sub-assembly.

Fig. 286: Identifying Cylinder Head Cover Sub-Assembly Bolts And Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE:

Do not apply oil for at least 2 hours after the installation.

45. INSTALL CRANKSHAFT PULLEY

a. Align the pulley set key with the key groove of the crankshaft pulley.

Fig. 287: Identifying Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn b. Using SST, hold the crankshaft pulley and install the pulley bolt.  SST: 09213-54015  SST: 09330-00021  SST: 91551-80650 Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 46. INSTALL CRANKSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 47. INSTALL SEPARATOR CASE a. Apply a light coat of engine oil to a new gasket.

Fig. 288: Identifying Case And Gasket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the gasket to the separator case. c. Install the separator case with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 48. INSTALL VENTILATION CASE SUB-ASSEMBLY a. Apply seal packing in a continuous line as shown in the illustration.

Fig. 289: Identifying Seal Packing Applying Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTE:

 

Remove any oil from the contact surface. Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

b. Install the ventilation case sub-assembly, and install the 8 bolts and 2 nuts in the order shown in the illustration.

Fig. 290: Identifying Ventilation Case Sub-Assembly Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE:

Do not apply oil for at least 2 hours after the installation.

HINT: Bolt A is tightened twice. 49. INSTALL VENTILATION VALVE SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 50. INSTALL CAMSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to INSTALLATION - Step 1 52. INSTALL OIL FILLER CAP GASKET a. Install a new oil filler cap gasket to the oil filler cap sub-assembly. 53. INSTALL OIL FILLER CAP SUB-ASSEMBLY a. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly. 54. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to INSTALLATION - Step 1 55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to INSTALLATION - Step 1 56. INSTALL KNOCK CONTROL SENSOR . Refer to INSTALLATION - Step 1 57. INSTALL SPARK PLUG . Refer to INSTALLATION - Step 1 58. INSTALL ENGINE COVER JOINT

a. Install the 3 engine cover joints.

Fig. 291: Identifying Engine Cover Joints Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) INSTALLATION INSTALLATION

HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION . 1. INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 2. INSTALL SENSOR WIRE a. Install the sensor wire with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) b. Connect the knock control sensor connector. 3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 4. INSTALL INTAKE MANIFOLD . Refer to INSTALLATION - Step 4 5. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET a. Install the No. 1 compressor mounting bracket with the 4 bolts.

Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 6. INSTALL WATER INLET HOUSING a. Using an E5 "TORX" socket, install the stud bolt to the water inlet housing. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Using an E8 "TORX" socket, install the stud bolt to the cylinder block. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) c. Install a new gasket. d. Install the water inlet housing with the 3 bolts and nut.

Fig. 292: Identifying Water Inlet Housing Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Bolt *2 Nut Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) e. Install the harness clamp bracket to the water inlet housing with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

f. Install the harness clamp bracket to the cylinder block with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 7. INSTALL WATER INLET SUB-ASSEMBLY a. Install a new gasket and the water inlet sub-assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 8. INSTALL ENGINE WATER PUMP ASSEMBLY a. Install a new gasket and the engine water pump assembly with the 5 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) b. Connect the connector to the engine water pump assembly. c. Connect the clamp. 9. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY . Refer to INSTALLATION - Step 2 10. INSTALL NO. 1 EGR PIPE a. Install the No. 1 EGR pipe with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 11. INSTALL EGR COOLER ASSEMBLY a. Install the No. 4 water by-pass hose, No. 6 water by-pass hose and No. 1 water by-pass pipe with the 2 clamps. b. Temporarily install 2 new gaskets and the EGR cooler assembly with the bolt (A) and nut (A).

Fig. 293: Identifying EGR Cooler Assembly Gaskets, Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Temporarily install the bolt (B) and nut (B). d. Tighten the 3 bolts and nut. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE:

Make sure that all installation surfaces of the EGR cooler assembly are in even contact when tightening the bolts and nuts.

12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY . Refer to INSTALLATION Step 2 13. INSTALL MANIFOLD STAY . Refer to INSTALLATION - Step 3 14. INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 4

15. INSTALL NO. 2 EGR PIPE . Refer to INSTALLATION - Step 5 16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 6 17. INSTALL NO. 1 WATER BY-PASS HOSE a. Connect the No. 1 water by-pass hose with the clamp. 18. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to INSTALLATION - Step 1 19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE a. Apply a light coat of engine oil to a new O-ring. b. Install the O-ring to the engine oil level dipstick guide. c. Install the engine oil level dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) d. Install the engine oil level dipstick. 20. INSTALL ENGINE HANGERS a. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Fig. 294: Identifying Engine Hangers With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PART NO. Part Item No. No. 1 12281Engine 36020 Hanger No. 2 12282Engine 36021 Hanger 91552Bolt 81040 or 91552-

81025 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) b. Attach an engine sling device and hang the engine with a chain block.

CYLINDER HEAD COMPONENTS ILLUSTRATION

Fig. 295: Identifying Cylinder Head Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE INTAKE VALVE

a. Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks.

Fig. 296: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 b. Remove the valve spring retainer, compression spring and intake valve. 

HINT: Arrange the removed parts in the correct order. 2. REMOVE EXHAUST VALVE a. Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks.

Fig. 297: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 b. Remove the valve spring retainer, compression spring and exhaust valve. 

HINT: Arrange the removed parts in the correct order. 3. REMOVE VALVE STEM OIL SEAL a. Using needle-nose pliers, remove the valve stem oil seal.

Fig. 298: Removing Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE VALVE SPRING SEAT a. Using compressed air and a Magnet Hand, remove the valve spring seat by blowing air onto it.

Fig. 299: Removing Valve Spring Seat

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 1 STRAIGHT SCREW PLUG NOTE:

If water leaks from the No. 1 straight screw plug or the plug is corroded, replace it.

Fig. 300: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a 10 mm hexagon wrench, remove the 3 No. 1 straight screw plugs and 3 gaskets. 6. REMOVE NO. 2 STRAIGHT SCREW PLUG NOTE:

If water leaks from the No. 2 straight screw plug or the plug is corroded, replace it.

Fig. 301: Locating No. 2 Straight Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a 14 mm hexagon wrench, remove the No. 2 straight screw plug and gasket. 7. REMOVE CYLINDER HEAD STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

a. Using an E7 "TORX" socket wrench, remove the 5 cylinder head stud bolts.

Fig. 302: Identifying Cylinder Head Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT CYLINDER HEAD SUB-ASSEMBLY a. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.

Fig. 303: Measuring Warpage Of Contact Surfaces Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum Warpage

Item Cylinder head lower side Intake manifold side Exhaust manifold side

Specified Condition 0.05 mm (0.00197 in.) 0.10 mm (0.00394 in.) 0.10 mm (0.00394 in.)

TEXT IN ILLUSTRATION Cylinder Head *a Lower Side Intake *b Manifold Side Exhaust *c Manifold Side If the warpage is more than the maximum, replace the cylinder head. b. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks.

Fig. 304: Checking Cylinder Contact Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracked, replace the cylinder head. 2. INSPECT COMPRESSION SPRING a. Using a vernier caliper, measure the free length of the inner compression spring.

Fig. 305: Measuring Free Length Of Inner Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard free length 47.2 to 49.2 mm (1.86 to 1.94 in.) If the free length is not as specified, replace the compression spring. b. Using a steel square, measure the deviation of the inner compression spring.

Fig. 306: Measuring Inner Compression Spring Deviation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum deviation 1.0 mm (0.0394 in.) Maximum angle 2° TEXT IN ILLUSTRATION *a Deviation If the deviation is more than the maximum, replace the spring. 3. INSPECT INTAKE VALVE a. Using a micrometer, measure the diameter of the valve stem.

Fig. 307: Measuring Diameter Of Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard valve stem diameter 5.470 to 5.485 mm (0.21535 to 0.21594 in.) b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 308: Measuring Valve Head Margin Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION Margin *a Thickness If the margin thickness is less than the minimum, replace the intake valve. c. Using a vernier caliper, measure the overall length of the intake valve.

Fig. 309: Measuring Overall Length Of Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard overall length 103.92 mm (4.09 in.) Minimum overall length 103.42 mm (4.07 in.) TEXT IN ILLUSTRATION Overall *a Length If the overall length is less than the minimum, replace the intake valve. 4. INSPECT EXHAUST VALVE a. Using a micrometer, measure the diameter of the valve stem.

Fig. 310: Measuring Diameter Of Valve Stem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard valve stem diameter 5.465 mm to 5.480 mm (0.21516 to 0.21575 in.) b. Using a vernier caliper, measure the valve head margin thickness.

Fig. 311: Measuring Valve Head Margin Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION Margin *a Thickness If the margin thickness is less than the minimum, replace the exhaust valve. c. Using a vernier caliper, measure the overall length of the exhaust valve.

Fig. 312: Measuring Overall Length Of Exhaust Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard overall length 112.91 mm (4.44 in.) Minimum overall length 112.41 mm (4.43 in.) TEXT IN ILLUSTRATION Overall *a Length If the overall length is less than the minimum, replace the exhaust valve. 5. INSPECT VALVE GUIDE BUSH OIL CLEARANCE a. Using a caliper gauge, measure the inside diameter of the guide bush.

Fig. 313: Measuring Inside Diameter Of Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) b. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard Oil Clearance Specified Condition 0.025 to 0.060 mm Intake (0.000984 to 0.00236 in.) 0.030 to 0.065 mm Exhaust (0.00118 to 0.00256 in.) Item

Maximum Oil Clearance Specified

Item Condition 0.08 mm Intake (0.00315 in.) 0.10 mm Exhaust (0.00394 in.) If the oil clearance is more than the maximum, replace the valve and guide bush. 6. INSPECT INTAKE VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat.

Fig. 314: Identifying Intake Valve Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width HINT: Do not rotate the valve while pressing the valve. c. Check the valve face and valve seat. 1. Check that the contact surfaces of the valve seat and valve face are in the middle area of their

respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). If not, correct the valve seat. 2. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat. 7. INSPECT EXHAUST VALVE SEAT a. Apply a light coat of Prussian blue to the valve face. b. Lightly press the valve face against the valve seat.

Fig. 315: Identifying Exhaust Valve Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width HINT: Do not rotate the valve while pressing the valve. c. Check the valve face and valve seat. 1. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).

If not, correct the valve seat. 2. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat. 8. INSPECT CAMSHAFT OIL CLEARANCE NOTE:

Do not turn the camshafts.

a. Clean the bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing. c. Lay a strip of Plastigage across each of the camshaft journals.

Fig. 316: Identifying Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage d. e. f. g.

Install the camshaft bearing caps See step 13. Install the camshaft housing sub-assembly See step 14. Remove the camshaft bearing caps See step 22. Measure the Plastigage at its widest point.

Fig. 317: Measuring Plastigage At Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Oil Clearance

Specified Condition 0.035 to Intake 0.072 mm No. 1 (0.00137 journal to 0.00283 in.) 0.005 to Exhaust 0.054 mm No. 1 (0.000197 journal to 0.00213 in.) 0.025 to 0.062 mm Other (0.000984 journal to 0.00244 in.) Item

Maximum Oil Clearance Specified Condition Intake 0.085 mm No. 1 (0.00335 journal in.) Exhaust 0.085 mm No. 1 (0.00335 journal in.) 0.085 mm Other (0.00335 journal in.) Item

TEXT IN ILLUSTRATION *1 Plastigage No. 1 *2 Journal Other *3 Journal If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing. 9. INSPECT CAMSHAFT THRUST CLEARANCE a. Clean the bearing caps, camshaft housing and camshaft journals. b. Place the camshafts on the camshaft housing.

c. Install the camshaft bearing caps See step 13. d. Install the camshaft housing sub-assembly See step 14. e. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Fig. 318: Measuring Thrust Clearance Using Dial Indicator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Thrust Clearance Specified Condition 0.060 to 0.155 mm Intake (0.00236 to 0.00610 in.) 0.060 to 0.155 mm Exhaust (0.00236 to 0.00610 in.) Item

Maximum Thrust Clearance Item

Specified Condition

0.170 mm Intake (0.00669 in.) 0.170 mm Exhaust (0.00669 in.) If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft. REPLACEMENT REPLACEMENT

1. REPLACE INTAKE VALVE GUIDE BUSH a. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the intake valve guide bush.

Fig. 319: Tapping Out Intake Valve Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09201-01055 SST: 09950-70010 09951-07100

d. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Fig. 320: Measuring Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard bush bore diameter 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. e. Select a new guide bush (STD or O/S 0.05), and measure its diameter. f. Machine the bush bore of the cylinder head to the diameter of the selected guide bush. Bush Bore Diameter Bush Specified Size Condition 10.333 to 10.344 mm STD (0.4068 to 0.4072 in.) 10.383 to

10.394 mm O/S (0.4088 to 0.05 0.4092 in.) Standard bush length 41.3 to 41.7 mm (1.626 to 1.642 in.) g. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). h. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

Fig. 321: Tapping Selected Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 



SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100

Standard protrusion height 14.8 to 15.2 mm (0.582 to 0.598 in.) TEXT IN ILLUSTRATION

*a Height i. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

Fig. 322: Reaming Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.) 2. REPLACE EXHAUST VALVE GUIDE BUSH a. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). b. Place the cylinder head on wooden blocks. c. Using SST and a hammer, tap out the exhaust valve guide bush.

Fig. 323: Tapping Exhaust Valve Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09201-01055  SST: 09950-70010 09951-07100 d. Using a caliper gauge, measure the bush bore diameter of the cylinder head. 

Fig. 324: Measuring Bush Bore Diameter Of Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard bush bore diameter 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. e. Select a new guide bush (STD or O/S 0.05), and measure its diameter. f. Machine the bush bore of the cylinder head to the diameter of the selected guide bush. Bush Bore Diameter Bush Specified Size Condition 10.333 to 10.344 mm STD (0.4068 in 0.4072 in.) 10.383 to 10.394 O/S mm 0.05 (0.4088 to 0.4092 in.) Standard bush length 46.8 to 47.2 mm (1.843 to 1.858 in.) g. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). h. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

Fig. 325: Tapping Selected Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 



SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100

Standard protrusion height 14.2 to 14.6 mm (0.559 to 0.575 in.) TEXT IN ILLUSTRATION *a Height i. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

Fig. 326: Reaming Guide Bush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.) 3. REPLACE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the ring pins. b. Using a plastic-faced hammer, tap in 2 new ring pins to the cylinder head.

Fig. 327: Identifying Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard protrusion height 6.5 to 7.5 mm (0.256 to 0.295 in.) REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION .

1. INSTALL SPARK PLUG TUBE HINT: When using a new cylinder head, the spark plug tubes must be replaced. a. Apply adhesive onto the shaded area of a new spark plug tube.

Fig. 328: Applying Adhesive To Spark Plug Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard application width 1.0 to 3.0 mm (0.0394 to 0.118 in.) NOTE:



 

Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to coolant for at least 1 hour after installing it.

b. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

Fig. 329: Tapping Spark Plug Tube To Specified Protrusion Height Using A Wooden Block & Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Cylinder Head *a Casting Surface Standard protrusion height 112 mm (4.41 in.) NOTE:

To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

2. INSTALL CYLINDER HEAD STUD BOLT a. Using an E7 "TORX" socket wrench, install the 5 cylinder head stud bolts.

Fig. 330: Identifying Cylinder Head Stud Bolt Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 3. INSTALL NO. 1 STRAIGHT SCREW PLUG a. Using a 10 mm hexagon wrench, install 3 new gaskets and the 3 No. 1 straight screw plugs.

Fig. 331: Locating No. 1 Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 4. INSTALL NO. 2 STRAIGHT SCREW PLUG a. Using a 14 mm hexagon wrench, install a new gasket and the No. 2 straight screw plug.

Fig. 332: Locating No. 2 Straight Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 5. INSTALL VALVE SPRING SEAT a. Install the valve spring seats to the cylinder head. 6. INSTALL VALVE STEM OIL SEAL a. Apply a light coat of engine oil to new oil seals.

Fig. 333: Identifying Valve Stem Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Intake *b Exhaust Mark *c "NOK" *d Gray *e Black NOTE:

Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal onto the exhaust side or installing the exhaust oil seal onto the intake side can cause installation problems later.

HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. b. Using SST, push in the intake and exhaust valve oil seals.

Fig. 334: Installing Valve Oil Seals Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT 

SST: 09201-41020

NOTE:

Failure to use SST will cause the seal to be damaged or improperly seated.

7. INSTALL INTAKE VALVE a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

Fig. 335: Measuring Exhaust Or Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the intake valve, compression spring and valve spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to their original locations.

c. Using SST and wooden blocks, compress the spring and install the valve spring retainer locks.

Fig. 336: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 d. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 337: Tapping Valve Stem Tip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

8. INSTALL EXHAUST VALVE a. Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.

Fig. 338: Measuring Exhaust Or Intake Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 30 mm (1.18 *a in.) or more b. Install the exhaust valve, compression spring and valve spring retainer to the cylinder head. NOTE:

Install the same parts in the same combination to their original locations.

c. Using SST and wooden blocks, compress the spring and install the valve spring retainer locks.

Fig. 339: Compressing Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09202-70020 09202-00010 d. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. 

Fig. 340: Tapping Valve Stem Tip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the retainer.

REPAIR REPAIR

1. REPAIR INTAKE VALVE SEAT NOTE:

  

Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the intake valve seat smooth.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.

Fig. 341: Cutting Intake Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.

Fig. 342: Measuring Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) TEXT IN ILLUSTRATION *a Width c. Hand-lap the valve and valve seat with an abrasive compound. d. Check the valve seating position. 2. REPAIR EXHAUST VALVE SEAT NOTE:

  

Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the exhaust valve seat smooth.

a. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.

Fig. 343: Cutting Exhaust Valve Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.

Fig. 344: Measuring Seat Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard width 1.2 to 1.6 mm (0.0472 to 0.0630 in.) TEXT IN ILLUSTRATION *a Width c. Hand-lap the valve and valve seat with an abrasive compound. d. Check the valve seating position.

CYLINDER BLOCK COMPONENTS ILLUSTRATION

Fig. 345: Identifying Cylinder Block Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. INSPECT CONNECTING ROD THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Fig. 346: Measuring Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance 0.160 to 0.512 mm (0.00630 to 0.0202 in.) Maximum thrust clearance 0.512 mm (0.0202 in.) If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft. 2. INSPECT CONNECTING ROD OIL CLEARANCE a. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

Fig. 347: Identifying Alignment Marks On Connecting Rod And Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment *a Mark b. Remove the 2 bolts and connecting rod cap.

Fig. 348: Identifying Connector Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Keep the lower bearing and connecting rod cap together. c. Clean the crank pin and bearing. d. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. e. Lay a strip of Plastigage on the crank pin.

Fig. 349: Identifying Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage f. Check that the front mark of the connecting rod cap is facing in the correct direction.

Fig. 350: Identifying Connecting Rod Cap Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *1 Mark g. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

Fig. 351: Identifying Connector Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE:

Do not turn the crankshaft during the measurement.

i. Mark the front of each connecting rod bolt with paint.

Fig. 352: Identifying Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *1 Mark Engine Front j. Tighten the bolts 90° as shown in the illustration. NOTE:

Do not turn the crankshaft during the measurement.

k. Remove the 2 bolts and connecting rod cap. HINT: Keep the lower bearing and connecting rod cap together. l. Measure the Plastigage at its widest point.

Fig. 353: Measuring Plastigage At Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage

*2

Number Mark

Standard oil clearance 0.030 to 0.063 mm (0.00118 to 0.00248 in.) Maximum oil clearance 0.07 mm (0.00276 in.) NOTE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Standard crank pin diameter 51.492 to 51.500 mm (2.0272 to 2.0276 in.) Standard Connecting Rod Big End Inside Diameter Specified Condition 54.500 to 54.508 Mark mm 1 (2.1457 to 2.1460 in.) 54.509 to 54.516 Mark mm 2 (2.1460 to 2.1463 in.) Item

54.517 to Mark 54.524 mm 3 (2.1463 to 2.1466

in.) Standard Size Bearing Center Wall Thickness Specified Condition 1.483 to 1.487 mm Mark (0.0584 to 1 0.0585 in.) 1.488 to 1.491 mm Mark (0.0586 to 2 0.0587 in.) 1.492 to 1.495 mm Mark (0.0587 to 3 0.0589 in.) Item

m. Perform the inspection above for each cylinder. 3. REMOVE PISTON WITH CONNECTING ROD a. Using a ridge reamer, remove all the carbon from the top of the cylinder.

Fig. 354: Removing Carbon From Top Of Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 8 bolts, 4 connecting rod caps and 4 lower bearings. c. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together.  Arrange the piston and connecting rod assemblies in the correct order.  Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before. 4. REMOVE CONNECTING ROD BEARING a. Remove the connecting rod bearings from the connecting rods and connecting rod caps. 

HINT: Arrange the removed parts in the correct order. 5. INSPECT CRANKSHAFT THRUST CLEARANCE a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Fig. 355: Measuring Thrust Clearance Using Dial Indicator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Standard thrust washer thickness 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 6. REMOVE CRANKSHAFT a. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 356: Removing Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bearing caps from the cylinder block. HINT: 

Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

Arrange the bearing caps in the correct order. c. Remove the crankshaft from the cylinder block. 

HINT: Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block. d. Check each crankshaft journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. 7. REMOVE CRANKSHAFT THRUST WASHER a. Remove the thrust washers from the cylinder block.

Fig. 357: Locating Crankshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE CRANKSHAFT BEARING a. Remove the crankshaft bearings from the cylinder block and bearing caps. HINT: Arrange the bearings in the correct order. 9. REMOVE CRANKSHAFT PULLEY KEY a. Using a screwdriver, remove the 2 pulley keys from the crankshaft.

10. REMOVE PISTON RING SET a. Using a piston ring expander, remove the 2 compression rings.

Fig. 358: Removing Piston Compression Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring Expander b. Remove the oil ring and expander by hand. HINT: Arrange the removed parts in the correct order. 11. REMOVE PISTON PIN HOLE SNAP RING a. Using a screwdriver, pry out the snap ring (front side).

Fig. 359: Identifying Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Front *a Mark NOTE:

Do not remove the snap ring (rear side) unless necessary.

HINT: Tape the screwdriver tip before use. 12. REMOVE PISTON a. Gradually heat each piston up to 80 to 90°C (176 to 194°F).

Fig. 360: Heating Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

Fig. 361: Tapping Out Piston Pin

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The piston and pin are a matched set.  Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.  Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. 13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, remove the 2 bolts and 2 No. 1 oil nozzles sub-assembly. 

Fig. 362: Locating No. 1 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzles sub-assembly.

Fig. 363: Locating No. 2 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE STUD BOLT NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

a. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

Fig. 364: Identifying Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT CYLINDER BLOCK FOR WARPAGE a. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts with the cylinder head gasket.

Fig. 365: Inspecting Cylinder Block For Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum warpage

0.05 mm (0.00197 in.) If the warpage is more than the maximum, replace the cylinder block. 2. INSPECT CYLINDER BORE a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

Fig. 366: Measuring Cylinder Bore Diameter Using Cylinder Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Thrust

*a Direction Axial *b Direction Front Standard diameter 90.000 to 90.013 mm (3.543 to 3.544 in.) Maximum diameter 90.13 mm (3.548 in.) If the average diameter of the 4 positions is more than the maximum, replace the cylinder block. 3. INSPECT PISTON a. Using a gasket scraper, remove the carbon from the piston top.

Fig. 367: Removing Carbon Using Gasket Scraper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

Fig. 368: Cleaning Piston Ring Grooves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brush and solvent, thoroughly clean the piston.

Fig. 369: Cleaning Piston With Brush And Solvent Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Do not use a wire brush.

d. Using a micrometer, measure the piston diameter at a position that is 10.5 mm (0.413 in.) from the bottom of the piston (refer to the illustration).

Fig. 370: Measuring Piston Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard piston diameter 89.980 to 89.995mm (3.5425 to 3.5413 in.) If the diameter is less than the minimum, replace the piston with pin. 4. INSPECT PISTON OIL CLEARANCE a. Measure the cylinder bore diameter in the thrust direction. b. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.004 to 0.043 mm (0.000158 to 0.00169 in.) Maximum oil clearance 0.10 mm (0.00394 in.)

If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block. 5. INSPECT RING GROOVE CLEARANCE a. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

Fig. 371: Measuring Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Ring Groove Clearance Item No. 1 ring

No. 2 ring

Oil

Specified Condition 0.020 to 0.070 mm (0.000787 to 0.00276 in.) 0.020 to 0.060 mm (0.000787 to 0.00236 in.) 0.020 to 0.070 mm (0.000787

ring to 0.00276 in.) If the groove clearance is not as specified, replace the piston with pin. 6. INSPECT PISTON RING END GAP a. Insert the piston ring into the cylinder bore.

Fig. 372: Identifying Piston Ring End Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston *1 Ring b. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block. c. Using a feeler gauge, measure the end gap.

Fig. 373: Measuring End Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard End Gap Item No. 1 ring

No. 2 ring

Oil ring

Specified Condition 0.22 to 0.27 mm (0.00866 to 0.0106 in.) 0.37 to 0.42 mm (0.0146 to 0.0165 in.) 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

Maximum End Gap Item No. 1 ring No. 2 ring

Specified Condition 0.87 mm (0.0342 in.) 1.02 mm (0.0402 in.)

Oil 0.80 mm

ring (0.0315 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum, even with a new piston ring, replace the cylinder block. 7. INSPECT PISTON PIN OIL CLEARANCE a. Check each mark on the piston, piston pin and connecting rod.

Fig. 374: Identifying Front Mark, Piston Pin Hole Inside Diameter Mark And Connector Rod Small End Bush Inside Diameter Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Piston Pin Hole *a Front Mark *b Inside Diameter Mark Connecting Rod Small End Bush *c - Inside Diameter Mark HINT: The front mark is "2H" printed in raised letters. b. Using a caliper gauge, measure the inside diameter of the piston pin hole.

Fig. 375: Measuring Inside Diameter Of Piston Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Piston Pin Hole Inside Diameter Specified Condition 22.001 to 22.004 Mark mm A (0.86618 to 0.86630 in.) 22.005 to 22.007 Mark mm B (0.86634 to 0.86642 in.) 22.008 to 22.010 Mark mm C (0.86645 to 0.86653 in.) Item

c. Using a micrometer, measure the piston pin diameter.

Fig. 376: Measuring Piston Pin Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Piston Pin Diameter

Specified Condition 21.997 to 22.000 Mark mm (0.86602 A to 0.86614 in.) 22.001 to 22.003 Mark mm B (0.86617 to 0.86626 in.) 22.004 to 22.006 Mark mm (0.86630 C to 0.86638 in.) Item

If the diameter is not as specified, replace the piston pin. d. Using a caliper gauge, measure the connecting rod small end bush inside diameter.

Fig. 377: Measuring Connecting Rod Small End Bush Inside Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Connecting Rod Small End Bush Inside Diameter Specified Condition 22.005 to 22.008 Mark mm (0.86634 A to 0.86645 in.) 22.009 to 22.011 Mark mm B (0.86649 to 0.86657 in.) 22.012 to 22.014 Mark mm C (0.86661 to 0.86669 in.) Item

If the diameter is not as specified, replace the connecting rod. e. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.013 mm (0.000512 in.) If the oil clearance is more than the maximum, replace the piston and piston pin as a set. f. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance

0.017 mm (0.000669 in.) If the oil clearance is more than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set. 8. INSPECT CONNECTING ROD SUB-ASSEMBLY a. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.

Fig. 378: Checking Connecting Rod Alignment (For Band) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check for bend. Maximum bend 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the bend is more than the maximum, replace the connecting rod. 2. Check for twist.

Fig. 379: Checking Connecting Rod Alignment (For Twist) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod. 9. INSPECT CRANKSHAFT a. Inspect for circle runout.

Fig. 380: Inspecting Crankshaft Circle Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout 0.003 mm (0.000118 in.) If the circle runout is more than the maximum, replace the crankshaft. b. Inspect the main journals.

Fig. 381: Checking Crankshaft Main Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the diameter of each main journal. Standard main journal diameter 54.988 to 55.000 mm (2.1649 to 2.1654 in.) If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft. 2. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft. c. Inspect the crank pin.

Fig. 382: Measuring Diameter Of Crank Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter 51.492 to 51.500 mm (2.027 to 2.028 in.) If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft. 2. Inspect each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft. 10. INSPECT CRANKSHAFT OIL CLEARANCE a. Install the crankshaft bearings See step 7. b. Install the crankshaft thrust washers See step 8. c. Place the crankshaft onto the cylinder block. d. Lay a strip of Plastigage across each journal.

Fig. 383: Identifying Plastigage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage e. Install the crankshaft bearing caps See step 9. NOTE:

Do not turn the crankshaft.

f. Remove the crankshaft bearing caps See step 6. g. Measure the Plastigage at its widest point.

Fig. 384: Measuring Plastigage At Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Plastigage Standard oil clearance 0.016 to 0.039 mm (0.000630 to 0.00154 in.) Maximum oil clearance 0.05 mm (0.00197 in.) NOTE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

Fig. 385: Identifying Diameter Mark, Cylinder Block Number Mark And Crankshaft Number Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Cylinder Block Crankshaft *a Number *b Number Mark Mark (B) (A) Diameter *c - Mark EXAMPLE Cylinder block (A) "3" + Crankshaft (B) "4" = Total "7" Select the bearing marked "3". Bearing Chart (A) Use + Bearing (B) 0 to 1 2 3 to 2 5

6 to 3 8 9 to 4 11 Standard Cylinder Block Journal Inside Diameter (A) Specified Condition 59.000 to 59.002 Mark mm (2.32283 0 to 2.32291 in.) 59.003 to 59.004 Mark mm 1 (2.32295 to 2.32299 in.) 59.005 to 59.006 Mark mm (2.32303 2 to 2.32307 in.) 59.007 to 59.009 Mark mm 3 (2.32311 to 2.32318 in.) 59.010 to 59.011 Mark mm 4 (2.32322 to 2.32326 in.) Item

59.012 to Mark 59.013 mm 5 (2.32330 to 2.32334

in.) 59.014 to 59.016 Mark mm 6 (2.32338 to 2.32346 in.) Standard Crankshaft Main Journal Diameter (B) Specified Condition 54.999 to 55.000 Mark mm 0 (2.16531 to 2.16535 in.) 54.997 to 54.998 Mark mm (2.16523 1 to 2.16527 in.) 54.995 to 54.996 Mark mm 2 (2.16515 to 2.16519 in.) 54.993 to 54.994 Mark mm 3 (2.16507 to 2.16511 in.) 54.991 to 54.992 Mark mm 4 (2.16500 to 2.16504 in.) Item

54.988 to Mark 54.990 5 mm (2.16488

to 2.16496 in.) Standard Bearing Center Wall Thickness Specified Condition 1.991 to 1.994 mm Mark (0.07839 1 to 0.07850 in.) 1.995 to 1.997 mm Mark (0.07854 2 to 0.07862 in.) 1.998 to 2.000 mm Mark (0.07866 3 to 0.07874 in.) 2.001 to 2.003 mm Mark (0.07878 4 to 0.07886 in.) Item

h. Perform the inspection above for each journal. 11. INSPECT CRANKSHAFT BEARING CAP BOLT a. Using a vernier caliper, measure the diameter of the threads at the measurement point shown in the illustration.

Fig. 386: Measuring Crankshaft Bearing Cap Bolt Thread At Measurement Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Point Standard diameter 9.77 to 9.96 mm (0.385 to 0.392 in.) Minimum diameter 9.1 mm (0.358 in.) HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap bolt. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the crankshaft bearing cap bolt with a new one. 12. INSPECT CONNECTING ROD BOLT a. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration. 

Fig. 387: Inspecting Connecting Rod Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Measurement *a Area Standard diameter 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter 8.3 mm (0.327 in.) HINT: Diameter measurements should be done at several points.  If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.  If there is any thread deformation, replace the connecting rod bolt with a new one. 13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Push the check valve with a pin to check if it is stuck. 

Fig. 388: Pushing Check Valve With Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If stuck, replace the No. 1 oil nozzle. b. Push the check valve with a pin to check if it moves smoothly. If it does not move smoothly, clean or replace the No. 1 oil nozzle. c. Apply air into A. Check that air does not leak through B.

Fig. 389: Checking Air Leak Through B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air leaks, clean or replace the No. 1 oil nozzle. d. Push the check valve while applying air into A. Check that air passes through B.

Fig. 390: Pushing Check Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air does not pass through B, clean or replace the No. 1 oil nozzle. 14. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Push the check valve with a pin to check if it is stuck.

Fig. 391: Pushing Check Valve With Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If stuck, replace the No. 2 oil nozzle. b. Push the check valve with a pin to check if it moves smoothly. If it does not move smoothly, clean or replace the No. 2 oil nozzle. c. While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A.

Fig. 392: Checking Air Leak Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air leaks, clean or replace the No. 2 oil nozzle. d. Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A.

Fig. 393: Applying Air Into B While Covering A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If air does not pass through C, clean or replace the No. 2 oil nozzle. REPLACEMENT REPLACEMENT

1. REPLACE RING PIN NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

a. Remove the 12 ring pins. b. Using a plastic-faced hammer, install 12 new ring pins.

Fig. 394: Identifying Ring Pins & Standard Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Upper Lower *a *b Side: Side: Protrusion *c - Height Standard Protrusion Height Specified Condition 5.0 to 7.0 mm A (0.197 to 0.276 in.)

Item

B

4.0 to 7.0 mm (0.157 to 0.276 in.)

2. REPLACE STRAIGHT PIN NOTE:

It is not necessary to remove the straight pin unless it is being replaced.

a. Remove the 14 straight pins. b. Using a plastic-faced hammer, install 14 new straight pins.

Fig. 395: Identifying Straight Pins & Standard Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Front Rear *b Side: Side: LH Lower *c *d Side: Side: RH Protrusion *e *f Side: Height *a

Standard Protrusion Height Item

A

B

Specified Condition 11.0 to 13.0 mm (0.433 to 0.512 in.) 5.0 to 7.0 mm (0.197 to 0.276 in.)

REASSEMBLY REASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the piston or piston ring. Refer to INITIALIZATION . 1. INSTALL STUD BOLT NOTE:

If a stud bolt is deformed or the threads are damaged, replace it.

a. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Fig. 396: Identifying Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzles sub-assembly with the 4 bolts.

Fig. 397: Locating No. 2 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY a. Using a 5 mm hexagon wrench, install the 2 No. 1 oil nozzles sub-assembly with the 2 bolts.

Fig. 398: Locating No. 1 Oil Nozzles Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 4. INSTALL PISTON a. Using a small screwdriver, install a new snap ring (rear side) at one end of the piston pin hole. b. Gradually heat the piston up to 80 to 90°C (176 to 194°F). c. Coat the piston, piston pin and connecting rod with engine oil. d. Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the pin comes into contact with the snap ring.

Fig. 399: Identifying Piston Front Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark HINT: The piston and pin are a matched set. e. Using a small screwdriver, install a new snap ring (front side) on the other side of the piston pin hole.

Fig. 400: Identifying Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Snap *1 Ring Front Mark *a Cutout Portion HINT: Be sure that the end gap of the snap ring is not aligned with the front mark cutout portion of the piston. f. Check the fitting condition between the piston and piston pin.

Fig. 401: Checking Fitting Condition Between Piston And Piston Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. 2. Rotate the piston back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. HINT: Perform "Inspection After Repair" after replacing the piston. Refer to INITIALIZATION . 5. INSTALL PISTON RING SET a. Install the oil ring expander and oil ring by hand.

Fig. 402: Identifying Rings Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Oil Ring Oil Ring *2 Expander Coil *3 Joint Oil Ring *4 End HINT: Arrange the oil ring ends and coil joint as shown in the illustration.

b. Using a piston ring expander, install the 2 compression rings with the code mark positioned as shown in the illustration.

Fig. 403: Identifying Compression Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. 1 *1 Compression Ring No. 2 *2 Compression Ring *a Paint Mark *b Code Mark Upward Piston Ring Mark Item

Code Paint Mark Mark

No. 1 Compression 1N Ring No. 2 Compression 2N Ring NOTE:

Blue

Orange

Install the compression ring with the code mark facing upward.

HINT: Perform "Inspection After Repair" after replacing the piston, piston ring. Refer to INITIALIZATION . 6. INSTALL CRANKSHAFT PULLEY KEY a. Install the 2 crankshaft pulley keys to the crankshaft. 7. INSTALL CRANKSHAFT BEARING a. Clean the main journal and both surfaces of the bearing.

Fig. 404: Identifying Crankshaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1, No. 5 *a Journal Bearing No. 2, No. 4 *b Journal Bearing No. 3 *c Journal Bearing *d Silver *e Black b. Install the upper bearing to the cylinder block as shown in the illustration.

Fig. 405: Installing Upper Bearing At Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT

*b INCORRECT NOTE:











The color of the No. 3 journal bearing is different from that of the No. 1, No. 2, No. 4 and No. 5 journal bearings. Be sure to check the color before installation. Do not apply engine oil to the bearings or their contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

c. Install the lower bearing onto the bearing cap.

Fig. 406: Measuring Distance Between Crankshaft Cap Edge And Lower Bearing Edge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier

*1 Caliper d. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower bearing edge. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) NOTE:









The color of the No. 1 and No. 5 journal bearing is different from that of the No. 2, No. 3 and No. 4 journal bearings. Be sure to check the color before installation. Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

8. INSTALL CRANKSHAFT THRUST WASHER a. Apply engine oil to the thrust washers. b. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig. 407: Identifying Oil Groove

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Groove 9. INSTALL CRANKSHAFT a. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block. b. Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration.

Fig. 408: Identifying Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a

Front Mark

HINT: The crankshaft bearing cap bolts are tightened in 3 progressive steps. c. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. d. Step 1: 1. Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Fig. 409: Tightening Bearing Cap Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) e. Step 2: 1. Tighten the 10 bearing cap bolts again in the sequence shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) f. Step 3: 1. Mark the front of the bearing cap bolts with paint.

Fig. 410: Identifying Bearing Cap Bolts And Paint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Engine Front 2. Tighten the 10 bearing cap bolts 90° in the same sequence. 3. Check that the paint marks are now at a 90° angle to the front. g. Check that the crankshaft turns smoothly. 10. INSTALL CONNECTING ROD BEARING a. Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

Fig. 411: Cleaning Bearing Contact Surface Of Connector Rod And Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vernier

*1 Caliper b. Install the connecting rod bearings to the connecting rods and connecting rod caps. c. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing. Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) NOTE:







Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

11. INSTALL PISTON WITH CONNECTING ROD a. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings. b. Position the piston rings so that the ring ends are as shown in the illustration.

Fig. 412: Identifying Compression Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 *1 Compression Ring No. 2 *2 Compression Ring *3 Oil Ring Oil Ring *4 (Expander) *a Front Mark Engine Front

c. Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward.

Fig. 413: Pressing Connecting Rod Into Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark NOTE:

HINT:

When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod.

The front mark is "2H" printed in raised letters. d. Check that the front mark of the connecting rod cap is facing in the correct direction.

Fig. 414: Identifying Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front *a Mark NOTE:

Match the numbered connecting rod cap with the connecting rod.

e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

Fig. 415: Identifying Connector Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Temporarily install the connecting rod bolts. HINT: The connecting rod bolts are tightened in 2 progressive steps. g. Step 1: 1. Alternately tighten the connecting rod bolts in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) h. Step 2:

Fig. 416: Identifying Connecting Rod Cap Bolts Final Torque Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Paint *a Mark Engine Front 1. Mark the front of the connecting rod bolts with paint. 2. Tighten the bolts 90° as shown in the illustration. 3. Check that the paint marks are now at a 90° angle to the front. i. Check that the crankshaft turns smoothly.

2012-2017 ENGINE Exhaust System (Service Information) - Camry (2AR-FE)

INTAKE MANIFOLD COMPONENTS ILLUSTRATION

Fig. 1: Identifying Intake Manifold Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Intake Manifold Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Intake Manifold Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Intake Manifold Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 5. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 3 6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY Refer to REMOVAL 7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) a. Disconnect the union to connector tube hose and wire harness clamp.

Fig. 5: Identifying Vacuum Switch Valve Assembly (For ACIS) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 vacuum hoses and connector. c. Remove the bolt and vacuum switching valve assembly.

8. DISCONNECT NO. 2 VENTILATION HOSE a. Disconnect the No. 2 ventilation hose from the intake manifold.

Fig. 6: Locating No. 2 Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. DISCONNECT UNION TO CONNECTOR TUBE HOSE a. Disconnect the union to connector tube hose from the intake manifold.

Fig. 7: Locating Connector Tube Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. DISCONNECT FUEL TUBE SUB-ASSEMBLY . Refer to REMOVAL - Step 6 11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 9 12. REMOVE INTAKE MANIFOLD a. Remove the 2 bolts and 2 wire harness clamp brackets.

Fig. 8: Locating Wire Harness Brackets And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel vapor feed hose.

Fig. 9: Identifying Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the 3 wire harness clamps and connector. d. Remove the bolt and wire harness clamp bracket. e. Apply battery voltage to the terminals of the connector to close the tumble control valves.

Fig. 10: Applying Battery Voltage To Terminals Of Connector And Tumble Control Valves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Tester Specified Connection Condition Positive (+) battery voltage applied to terminal 8 (M-), and Open --> negative (-) Closed battery voltage applied to terminal 4 (M+) NOTE:



 



If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed. Apply battery voltage for 1 to 3 seconds. If battery voltage is applied for more than 3 seconds, the actuator may be damaged. Do not allow the lead wires to contact the other terminals.

f. Remove the bolt and separate the wire harness.

Fig. 11: Identifying Wire Harness And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disconnect the 2 wire harness clamps and intake air control valve actuator connector. h. Remove the 6 bolts and intake manifold.

Fig. 12: Identifying Intake Manifold Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

The tumble control valves may be damaged if they are not closed before removing the intake manifold.

HINT: Connect the battery to the terminals of the actuator to operate the motor and close the valves. Refer

to ON-VEHICLE INSPECTION - Step 3 . i. Remove the intake manifold gasket from the intake manifold.

Fig. 13: Locating Gasket And Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Disconnect the 2 vacuum hoses from the intake manifold and remove the No. 1 check valve.

Fig. 14: Locating Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. k. Remove the bolt and wire harness clamp bracket.

Fig. 15: Identifying Wiring Harness Clamp Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT INTAKE AIR CONTROL VALVE (for ACIS) a. Inspect the diaphragm. 1. Using a vacuum pump, apply a vacuum of 60 kPa (450 mmHg, 17.7 in.Hg) or higher to the diaphragm chamber. Wait for 1 minute and check that the needle of the vacuum pump does not lower.

Fig. 16: Inspecting Intake Air Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the intake manifold. b. After applying vacuum in the step above, check that the actuator rod operates. 2. INSPECT VACUUM TANK AND NO. 1 CHECK VALVE a. Disconnect the vacuum hose from the No. 1 check valve.

Fig. 17: Inspecting Vacuum Tank And Check Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vacuum pump, apply vacuum to the No. 1 check valve. Wait for 1 minute and check that the needle of the vacuum pump does not lower. If the result is not as specified, replace the No. 1 check valve. c. Connect the vacuum hose to the No. 1 check valve. d. Using a vacuum pump, apply a vacuum of 60 kPa (450 mmHg, 17.7 in.Hg) or higher to the vacuum tank. Wait for 1 minute and check that the needle of the vacuum pump does not lower.

Fig. 18: Applying Vacuum To Vacuum Tank Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the intake manifold. INSTALLATION INSTALLATION

1. INSTALL INTAKE MANIFOLD a. Install the wire harness clamp bracket with the bolt.

Fig. 19: Identifying Wiring Harness Clamp Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (2 kgf*cm, 71 in.*lbf) b. Connect the 2 vacuum hoses and check that the No. 1 check valve is installed as shown in the illustration.

Fig. 20: Identifying Vacuum Hoses And No. 1 Check Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Black c. Check the tumble control valves. NOTE:

The tumble control valves may be damaged if they are not closed before installing the intake manifold.

HINT: Connect the battery to the terminals of the actuator to operate the motor and close the valves. Refer to ON-VEHICLE INSPECTION - Step 3 . d. Install a new intake manifold gasket to the intake manifold. e. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration.

Fig. 21: Tightening Intake Manifold Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (14 kgf*cm, 15 ft.*lbf) f. Connect the intake air control actuator connector and 2 wire harness clamps.

Fig. 22: Locating Intake Air Control Valve Actuator Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Install the wire harness clamp with the bolt. Torque: 8.0 N*m (2 kgf*cm, 71 in.*lbf) h. Install the wire harness clamp bracket with the bolt.

Fig. 23: Identifying Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (2 kgf*cm, 71 in.*lbf) i. Connect the 3 wire harness clamps and connector.

j. Connect the fuel vapor feed hose. k. Install the 2 wire harness clamp brackets with the 2 bolts.

Fig. 24: Locating Wire Harness Brackets And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (2 kgf*cm, 71 in.*lbf) 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 3. CONNECT FUEL TUBE SUB-ASSEMBLY . Refer to INSTALLATION - Step 5 4. CONNECT UNION TO CONNECTOR TUBE HOSE a. Connect the union to connector tube hose to the intake manifold. 5. CONNECT NO. 2 VENTILATION HOSE a. Connect the No. 2 ventilation hose to the intake manifold. 6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) a. Install the vacuum switching valve assembly with the bolt. Torque: 9.0 N*m (2 kgf*cm, 80 in.*lbf) b. Connect the 2 vacuum hoses and connector. c. Connect the union to connector tube hose and wire harness clamp. 7. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Refer to INSTALLATION

8. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 14 9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

11. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

INTAKE AIR CONTROL VALVE ACTUATOR (FOR TCV) COMPONENTS ILLUSTRATION

Fig. 25: Identifying Intake Air Control Valve Actuator Replacement Components With Torque Specifications (For TCV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE INTAKE MANIFOLD Refer to REMOVAL 2. REMOVE INTAKE AIR CONTROL VALVE ACTUATOR (for TCV) a. Remove the 2 bolts, intake air control valve actuator and gasket from the intake manifold.

Fig. 26: Identifying Intake Air Control Valve Actuator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Make sure that foreign matter, such as water, oil, sand or iron particles, does not enter the gear chamber or actuator at the locations marked by the circles in the illustration.

Fig. 27: Identifying Intake Air Control Valve Actuator Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

Do not loosen or remove the bolt and 2 nuts shown in the illustration.

Fig. 28: Locating Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT INTAKE AIR CONTROL VALVE ACTUATOR (for TCV) a. Check the intake air control valve actuator operation. 1. Check that the motor operates when the battery is connected to the terminals of the intake air control valve actuator.

Fig. 29: Identifying Intake Air Control Valve Actuator Connector Terminal Identification (For TCV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Apply battery voltage for 1 to 3 seconds. If battery voltage is applied for more than 3 seconds, the actuator may be damaged. If the positive (+) and negative (-) battery leads contact the sensor terminals, the actuator may be damaged.

Standard Tester Connection

Specified Condition

Positive (+) battery voltage applied to terminal 4 (M-), and negative (-) battery voltage applied to terminal 5 (M+) Positive (+) battery voltage applied to terminal 5 (M+), and negative (-) battery voltage applied to terminal 4 (M-)

Motor rotates clockwise

Motor rotates counterclockwise

If the result is not as specified, replace the intake air control valve actuator. INSTALLATION INSTALLATION

1. INSTALL INTAKE AIR CONTROL VALVE ACTUATOR (for TCV) NOTE:



Make sure that foreign matter, such as water, oil, sand or iron particles, does not enter the gear chamber or actuator at the locations marked by the circles in the illustration.

Fig. 30: Identifying Intake Air Control Valve Actuator Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

Do not loosen or remove the bolt and 2 nuts shown in the illustration.

Fig. 31: Locating Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Check the tumble control valves.

Fig. 32: Identifying Tumble Control Valves Closed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Condition: *a Closed HINT: If the tumble control valves are not closed, close them by hand. b. Check that the gear of each tumble control valve is in the position shown in the illustration.

Fig. 33: Checking Tumble Control Valve Gear Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Condition: *a Closed HINT: Turn the gear clockwise until it contacts the stopper. c. Install a new gasket to the intake air control valve actuator. d. Install the intake air control valve actuator to the intake manifold with the 2 bolts. Torque: 6.0 N*m (1 kgf*cm, 53 in.*lbf)

NOTE:





If excessive force is applied to the gear in the direction of rotation when installing the actuator, the valves and actuator may be damaged. After installing the actuator, make sure that the ends of the valves are not protruding from the surface where the intake manifold is installed. If the valves are protruding, remove and reinstall the actuator.

2. INSTALL INTAKE MANIFOLD Refer to INSTALLATION

VACUUM SWITCHING VALVE (FOR ACIS) COMPONENTS ILLUSTRATION

Fig. 34: Identifying Vacuum Switching Valve Replacement Components With Torque Specifications (For ACIS) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) a. Disconnect the union to connector tube hose and wire harness clamp.

Fig. 35: Identifying Connector Tube Hose And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 vacuum hoses and connector. c. Remove the bolt and vacuum switching valve assembly. d. Remove the bolt and vacuum hose clamp.

Fig. 36: Identifying Vacuum Hose Clamp Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 37 to 44 1-2 F) ohms 1 - Valve body 10 kohms Always or higher 2 - Valve body If the result is not as specified, replace the vacuum switching valve. b. Using a vacuum pump, check that air flows through the vacuum switching valve as specified. OK Measurement Specified Condition Condition Battery voltage applied Air is between sucked terminals 1 into port and 2 and E. vacuum applied to port F. Battery voltage not applied Air is between sucked terminals 1 into filter. and 2 and vacuum applied to port

E.

Fig. 37: Identifying Vacuum Switching Valve Assembly Filter (For ACIS) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Filter If the result is not as specified, replace the vacuum switching valve. INSTALLATION INSTALLATION

1. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) a. Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (5 kgf*cm, 48 in.*lbf) b. Install the vacuum switching valve assembly with the bolt. Torque: 9.0 N*m (2 kgf*cm, 80 in.*lbf) c. Connect the 2 vacuum hoses and connector. d. Connect the union to connector tube hose and wire harness clamp.

EXHAUST MANIFOLD COMPONENTS ILLUSTRATION

Fig. 38: Identifying Exhaust Manifold Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 39: Identifying Exhaust Manifold Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 40: Identifying Exhaust Manifold Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT EXHAUST PIPE ASSEMBLY

a. Disconnect the heated oxygen sensor connector.

Fig. 41: Identifying Heated Oxygen Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts, 2 compression springs and 2 nuts.

Fig. 42: Identifying Bolts, Compression Springs And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the front exhaust pipe assembly from the exhaust pipe support. d. Remove the 2 gaskets from the exhaust manifold converter sub-assembly and front exhaust pipe assembly. 6. REMOVE MANIFOLD STAY a. Remove the bolt, nut and manifold stay.

Fig. 43: Locating Manifold Stay Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 2 MANIFOLD STAY a. Remove the bolt, nut and No. 2 manifold stay.

Fig. 44: Locating No. 2 Manifold Stay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) a. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

Fig. 45: Locating No. 1 Exhaust Manifold Heat Insulator And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) a. Remove the bolt and EGR inlet exhaust manifold plate.

Fig. 46: Identifying EGR Inlet Exhaust Manifold Plate Bolt (For PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE AIR FUEL RATIO SENSOR Refer to REMOVAL 11. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Remove the 5 nuts and exhaust manifold converter sub-assembly (except PZEV).

Fig. 47: Locating Exhaust Manifold Converter Sub-Assembly And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 nuts and exhaust manifold converter sub-assembly (for PZEV).

Fig. 48: Identifying Exhaust Manifold Converter Sub-Assembly Nuts (For PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the exhaust manifold to head gasket (except PZEV).

Fig. 49: Identifying Exhaust Manifold Head Gasket (Except PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the exhaust manifold to head gasket (for PZEV).

Fig. 50: Identifying Exhaust Manifold Head Gasket (For PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) a. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

Fig. 51: Locating No. 2 Exhaust Manifold Heat Insulator And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR a. Remove the 4 bolts and No. 1 manifold converter insulator (except PZEV).

Fig. 52: Locating No. 1 Manifold Converter Insulator And Bolts (Except PZEV)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts and No. 1 manifold converter insulator (for PZEV).

Fig. 53: Locating No. 1 Manifold Converter Insulator (For PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR a. Install the No. 1 manifold converter insulator with the 4 bolts. Torque: 14 N*m (38 kgf*cm, 10 ft.*lbf) 2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) a. Install the No. 2 exhaust manifold heat insulator with the 2 bolts. Torque: 14 N*m (38 kgf*cm, 10 ft.*lbf) 3. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Install a new exhaust manifold to head gasket onto the cylinder head. b. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts. c. Tighten the 5 nuts in the sequence shown in the illustration (except PZEV).

Fig. 54: Tightening Exhaust Manifold Converter Sub-Assembly Nuts In Sequence (Except PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 35 N*m (57 kgf*cm, 26 ft.*lbf) d. Tighten the 5 nuts in the sequence shown in the illustration (for PZEV).

Fig. 55: Tightening Exhaust Manifold Converter Sub-Assembly Nuts In Sequence (For PZEV) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 35 N*m (57 kgf*cm, 26 ft.*lbf) 4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) a. Install the No. 1 exhaust manifold heat insulator with the 4 bolts. Torque: 12 N*m (22 kgf*cm, 9 ft.*lbf) 5. INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV) a. Install the EGR inlet exhaust manifold plate with the bolt. Torque: 14 N*m (38 kgf*cm, 10 ft.*lbf) 6. INSTALL NO. 2 MANIFOLD STAY a. Install the No. 2 manifold stay with the bolt and nut. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf) 7. INSTALL MANIFOLD STAY a. Install the manifold stay with the bolt and nut. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf)

8. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression spring.

Fig. 56: Measuring Free Length Of Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40.5 mm Minimum (1.60 in.) HINT: If the length is less than the minimum, replace the compression spring. b. Fully insert a new gasket to the exhaust manifold converter sub-assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

Fig. 57: Identifying Exhaust Manifold Converter Sub-Assembly, Wooden Block And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly *2 Gasket Wooden *3 Block NOTE:

 

Be sure to install the gasket in the correct direction. Do not reuse the gasket.

 

Do not damage the gasket. Do not push in the gasket by using the exhaust pipe when connecting it.

d. Install a new gasket to the front exhaust pipe assembly. e. Connect the front exhaust pipe assembly to the exhaust pipe support. f. Install the front exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf)

9. 10. 11. 12. 13.

g. Connect the heated oxygen sensor connector. INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL AIR FUEL RATIO SENSOR Refer to INSTALLATION

14. INSPECT FOR EXHAUST GAS LEAK

EXHAUST PIPE COMPONENTS ILLUSTRATION

Fig. 58: Identifying Exhaust Pipe Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE HEATED OXYGEN SENSOR Refer to REMOVAL 2. REMOVE TAIL EXHAUST PIPE ASSEMBLY a. Remove the 2 bolts and 2 compression springs.

Fig. 59: Identifying Compression Springs Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail exhaust pipe assembly from the 3 exhaust pipe supports. c. Remove the gasket from the center exhaust pipe assembly. 3. REMOVE CENTER EXHAUST PIPE ASSEMBLY a. Remove the 2 nuts.

Fig. 60: Identifying Center Exhaust Pipe Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the center exhaust pipe assembly from the exhaust pipe support. c. Remove the gasket from the front exhaust pipe assembly. 4. REMOVE FRONT EXHAUST PIPE ASSEMBLY a. Remove the 2 bolts, 2 compression springs.

Fig. 61: Identifying Compression Springs Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front exhaust pipe assembly from the exhaust pipe support. c. Remove the gasket from the exhaust manifold converter sub-assembly. 5. REMOVE TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY (w/ Tail Exhaust Pipe Baffle) a. Remove the tail exhaust pipe baffle sub-assembly.

Fig. 62: Identifying Tail Exhaust Pipe Baffle Sub-Assembly (W/Tail Exhaust Pipe Baffle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY (w/ Tail Exhaust Pipe Baffle) a. Align the concave area of the baffle with the protruding part of the tail exhaust pipe assembly as shown in the illustration.

Fig. 63: Tapping Tail Exhaust Pipe Baffle Sub-Assembly To Tail Exhaust Pipe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a plastic hammer, uniformly tap a new tail exhaust pipe baffle sub-assembly onto the tail exhaust pipe assembly. TEXT IN ILLUSTRATION Protruding *a Part *b Concave c. Check that the concave area of the baffle is aligned with the protruding part on the bottom of the tail exhaust pipe assembly as shown in the illustration.

Fig. 64: Aligning Baffle Edge And Concave With Protruding Part Of Tail Exhaust Pipe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Baffle *a Edge *b Concave Protruding *c Part 2. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression springs.

Fig. 65: Measuring Free Length Of Compression Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40.5 mm Minimum (1.60 in.) HINT: If the free length is less than minimum, replace the compression spring. b. Fully insert a new gasket to the exhaust manifold converter sub-assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

Fig. 66: Identifying Center Exhaust Pipe Assembly, Wooden Block And Gasket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly *2 Gasket Wooden *3 Block NOTE:

   

Be careful with the installation direction of the gasket. Do not reuse the gasket. Do not damage the gasket. Do not push in the gasket by using the exhaust pipe when connecting it.

d. Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf) e. Connect the front exhaust pipe assembly to the exhaust pipe support. 3. INSTALL CENTER EXHAUST PIPE ASSEMBLY a. Install a new gasket to the front exhaust pipe assembly. b. Connect the center exhaust pipe assembly to the exhaust pipe support. c. Install the center exhaust pipe assembly with the 2 nuts. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf) 4. INSTALL TAIL EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression springs.

Fig. 67: Measuring Free Length Of Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38.5 mm Minimum (1.52 in.) HINT: If the free length is less than minimum, replace the compression spring. b. Fully insert a new gasket to the center exhaust pipe assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly.

Fig. 68: Identifying Center Exhaust Pipe Assembly, Wooden Block And Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center Exhaust *1 Pipe Assembly *2 Gasket Wooden *3 Block NOTE:

  

Be careful with the installation direction of the gasket. Do not reuse the gasket. Do not damage the gasket.



Do not push in the gasket by using the exhaust pipe when connecting it.

d. Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports. e. Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs. Torque: 43 N*m (38 kgf*cm, 32 ft.*lbf) 5. INSTALL HEATED OXYGEN SENSOR Refer to INSTALLATION 6. INSPECT FOR EXHAUST GAS LEAK

2012-2017 ENGINE Exhaust System (Service Information) - Camry (2GR-FE)

INTAKE MANIFOLD COMPONENTS ILLUSTRATION

Fig. 1: Identifying Intake Manifold Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Intake Manifold Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 1 5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 6. 7. 8. 9.

REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE INTAKE AIR SURGE TANK ASSEMBLY a. Disconnect the ventilation hose.

Fig. 3: Identifying Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type

*A A Type *B B b. Disconnect the hose clamp and union to check valve hose. c. Disconnect the connector and wire harness clamp.

Fig. 4: Identifying Intake Air Surge Tank Connector And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the 2 water by-pass hoses and fuel vapor feed hose. e. Disconnect the connector from the intake air control valve assembly.

Fig. 5: Locating Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the bolt and vacuum hose clamp.

Fig. 6: Identifying Vacuum Hose Clamp Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

g. Remove the bolt and separate the throttle body bracket from the intake air surge tank assembly.

Fig. 7: Identifying Throttle Body Bracket Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the bolt and separate the No. 1 surge tank stay from the intake air surge tank assembly.

Fig. 8: Identifying No. 1 Surge Tank Stay Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Remove the 2 nuts from the intake air surge tank assembly.

Fig. 9: Identifying Intake Air Surge Tank Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Using a 5 mm socket hexagon wrench, remove the 4 bolts. k. Remove the intake air surge tank assembly and 3 gaskets.

Fig. 10: Identifying Intake Air Surge Tank Assembly Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side) . Refer to REMOVAL - Step 25 11. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) . Refer to REMOVAL - Step 6 12. DISCONNECT FUEL TUBE SUB-ASSEMBLY . Refer to REMOVAL - Step 5 13. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 6 14. REMOVE INTAKE MANIFOLD a. Remove the 6 bolts, 4 nuts and intake manifold.

Fig. 11: Identifying Intake Manifold Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type

*A A Type *B B b. Remove the 2 gaskets.

Fig. 12: Identifying Intake Manifold Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL INTAKE MANIFOLD a. Set 2 new gaskets on each cylinder head sub-assembly. NOTE:





Align the port holes of the gaskets and cylinder head subassembly. Make sure that the gaskets are installed in the correct direction.

b. Set the intake manifold on the cylinder head sub-assembly. c. Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2

3. CONNECT FUEL TUBE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 4. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) . Refer to INSTALLATION - Step 16 5. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side) . Refer to INSTALLATION - Step 52 6. INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTE:

DO NOT apply oil to the bolts as listed below Oil Application Prohibited Bolt Intake Air Surge Tank Assembly and Intake Manifold No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly Throttle Body Bracket and Intake Air Surge Tank Assembly

a. Install 3 new gaskets to the intake air surge tank assembly. b. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts. c. Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

Fig. 13: Tightening Intake Surge Tank Bolts And Nuts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) Nut Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) d. Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) e. Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) f. Connect the connector to the intake air control valve assembly. g. Connect the 2 water by-pass hoses and fuel vapor feed hose. h. Connect the connector and wire harness clamp to the throttle body assembly. i. Connect the hose clamp and union to check valve hose. j. Connect the ventilation hose. 7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 8. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION -

Step 14 9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

11. 12. 13. 14.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2 INSPECT FOR COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 82

INTAKE AIR CONTROL VALVE (FOR ACIS) ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT INTAKE AIR CONTROL VALVE (for ACIS) a. Perform the following inspection procedure when using the Techstream: 1. Stop the engine. 2. Remove the V-bank cover assembly. Refer to REMOVAL - Step 17 . 3. Connect the Techstream to the DLC3. 4. Start the engine and turn the Techstream on. 5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Active the VSV for Intake Control. 6. Make sure that a clicking sound is heard from the intake air control valve when current flows. If the intake air control valve does not operate, check the ACIS control circuit. Refer to ACIS Control Circuit . 7. Install the V-bank cover assembly. Refer to INSTALLATION - Step 82 . b. Perform the following inspection procedure when applying voltage between the terminals: 1. Remove the V-bank cover assembly. Refer to REMOVAL - Step 17 . 2. Disconnect the connector from the intake air control valve.

Fig. 14: Locating Intake Air Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Apply battery voltage between terminals 2 (+) and 1 (-) of the intake air control valve. Check that a clicking sound is heard from the intake air control valve. If the operation is not as specified, replace the intake air surge tank assembly.

Fig. 15: Applying Battery Voltage Between Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install the V-bank cover assembly. Refer to INSTALLATION - Step 82 .

VACUUM TANK ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT VACUUM TANK a. Using a vacuum pump, apply 80 kPa (600 mmHg, 23.6 in.Hg) or higher of vacuum to the vacuum tank. Wait for 1 minute and check that the needle of the vacuum pump does not lower.

Fig. 16: Inspecting Vacuum Tank Using Vacuum Pump

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the air cleaner cap sub-assembly.

EXHAUST MANIFOLD COMPONENTS ILLUSTRATION

Fig. 17: Identifying Exhaust Manifold Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 18: Identifying Exhaust Manifold Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR RESERVE TANK ASSEMBLY . Refer to REMOVAL - Step 13 REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) See step 7 REMOVE FRONT EXHAUST PIPE ASSEMBLY a. Disconnect the 2 wire harnesses from the clamp.

Fig. 19: Identifying Wire Harnesses Clamp And Oxygen Sensor Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 heated oxygen sensor connectors.

c. Remove the 2 bolts and No. 1 exhaust pipe support bracket (for Rear Side).

Fig. 20: Identifying No. 1 Exhaust Pipe Support Bracket Bolts (For Rear Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 4 bolts, 4 nuts and front exhaust pipe assembly.

Fig. 21: Identifying Front Exhasut Pipe Bolts, Nuts And Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the 3 gaskets from the front exhaust pipe assembly. 6. REMOVE AIR FUEL RATIO SENSOR (for Bank 1) . Refer to REMOVAL - Step 5 7. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH a. Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly RH.

Fig. 22: Identifying Exhaust Manifold Sub-Assembly Nuts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the gasket from the cylinder head sub-assembly.

Fig. 23: Identifying Cylinder Head Sub-Assembly Gasket RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE AIR FUEL RATIO SENSOR (for Bank 2) . Refer to REMOVAL - Step 3 9. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to REMOVAL - Step 9 10. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR a. Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

Fig. 24: Locating No. 2 Exhaust Manifold Heat Insulator And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 2 MANIFOLD STAY a. Remove the bolt, nut and No. 2 manifold stay.

Fig. 25: Locating No. 2 Manifold Stay With Bolt And Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH a. Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly LH.

Fig. 26: Locating Exhaust Manifold Sub-Assembly Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the gasket from the cylinder head sub-assembly.

Fig. 27: Identifying Cylinder head Sub-Assembly Gasket LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH a. Set a new gasket to the cylinder head sub-assembly. b. Temporarily install the exhaust manifold sub-assembly LH with the 6 nuts. c. Temporarily install the No. 2 manifold stay with the bolt and nut. d. Using a 12 mm deep socket wrench, in several steps, uniformly tighten the 6 nuts in the order shown in the illustration.

Fig. 28: Tightening Exhaust Manifold Sub-Assembly Nuts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 2. INSTALL NO. 2 MANIFOLD STAY a. Tighten the bolt and nut in the order shown in the illustration.

Fig. 29: Tightening No. 2 Manifold Stay Bolt And Nut In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR a. Install the No. 2 exhaust manifold heat insulator with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 4. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to INSTALLATION - Step 13 5. INSTALL AIR FUEL RATIO SENSOR (for Bank 2) . Refer to INSTALLATION - Step 3 6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH a. Set a new gasket to the cylinder head sub-assembly. b. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH by tightening the 6 nuts in the order shown in the illustration.

Fig. 30: Tightening Exhaust Manifold Sub-Assembly In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 7. INSTALL AIR FUEL RATIO SENSOR (for Bank 1) . Refer to INSTALLATION - Step 1 8. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Install 3 new gaskets to the front exhaust pipe assembly. b. Install the front exhaust pipe assembly with the 4 bolts and 4 nuts.

Fig. 31: Identifying Exhaust Pipe Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Bolt *2 Nut Bolt *3 and Nut Bolt Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) Nut Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) Bolt and Nut Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) c. Install the No. 1 exhaust pipe support bracket with the 2 bolts (for Rear Side). Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) d. Connect the 2 heated oxygen sensor connectors.

9. 10. 11. 12. 13.

e. Install the 2 wire harnesses to the clamp. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) See step 4 INSTALL RADIATOR RESERVE TANK ASSEMBLY . Refer to INSTALLATION - Step 6 INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSPECT FOR EXHAUST GAS LEAK

EXHAUST PIPE COMPONENTS ILLUSTRATION

Fig. 32: Identifying Exhaust Pipe Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 33: Identifying Exhaust Pipe Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE TAIL EXHAUST PIPE ASSEMBLY LH

a. Remove the 2 nuts.

Fig. 34: Identifying Tail Exhaust Pipe Assembly Nuts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail exhaust pipe assembly LH from the 2 exhaust pipe supports. c. Remove the gasket from the center exhaust pipe assembly. 2. REMOVE TAIL EXHAUST PIPE ASSEMBLY a. Remove the 2 nuts.

Fig. 35: Identifying Tail Exhaust Pipe Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail exhaust pipe assembly from the 3 exhaust pipe supports. c. Remove the gasket from the center exhaust pipe assembly. 3. REMOVE EXHAUST PIPE DAMPER a. Remove the 2 bolts and exhaust pipe damper.

Fig. 36: Identifying Exhaust Pipe Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE CENTER EXHAUST PIPE ASSEMBLY a. Remove the 2 bolts and 2 nuts.

Fig. 37: Identifying Center Exhaust Pipe Assembly Bolts And Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the center exhaust pipe assembly from the 2 exhaust pipe supports. c. Remove the gasket from the front exhaust pipe assembly. 5. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) a. Remove the 2 nuts and No. 1 exhaust pipe support bracket (for Front Side).

Fig. 38: Identifying No. 1 Exhaust Pipe Support Bracket Nuts (For Front Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FRONT EXHAUST PIPE ASSEMBLY a. Disconnect the 2 wire harnesses from the clamp.

Fig. 39: Identifying Front Exhaust Pipe Assembly Wire Harness And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 heated oxygen sensor connectors. c. Remove the 2 bolts and 2 nuts.

Fig. 40: Identifying Front Exhaust Pipe Assembly Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the front exhaust pipe assembly from the No. 1 exhaust pipe support bracket (for Rear Side). e. Remove the 2 gaskets from the front exhaust pipe assembly. 9. REMOVE HEATED OXYGEN SENSOR (for Bank 1) . Refer to REMOVAL - Step 2 10. REMOVE HEATED OXYGEN SENSOR (for Bank 2) . Refer to REMOVAL - Step 3 INSTALLATION INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) . Refer to INSTALLATION - Step 1 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1) . Refer to INSTALLATION - Step 2 3. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Install 2 new gaskets to the front exhaust pipe assembly. b. Connect the front exhaust pipe assembly to the No. 1 exhaust pipe support bracket (for Rear Side). c. Install the front exhaust pipe assembly with the 2 bolts and 2 nuts. Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) d. Connect the 2 heated oxygen sensor connectors. e. Install the 2 wire harnesses to the clamp. 4. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side)

a. Install the No. 1 exhaust pipe support bracket with the 2 nuts (for Front Side). Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 5. INSTALL ENGINE UNDER COVER RH 6. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 7. INSTALL CENTER EXHAUST PIPE ASSEMBLY a. Install a new gasket to the front exhaust pipe assembly. b. Connect the center exhaust pipe assembly to the exhaust pipe supports. c. Install the center exhaust pipe assembly with the 2 bolts and 2 nuts. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 8. INSTALL EXHAUST PIPE DAMPER a. Install the exhaust pipe damper with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 9. INSTALL TAIL EXHAUST PIPE ASSEMBLY a. Install a new gasket to the center exhaust pipe assembly. b. Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports. c. Install the tail exhaust pipe assembly with the 2 nuts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 10. INSTALL TAIL EXHAUST PIPE ASSEMBLY LH a. Install a new gasket to the center exhaust pipe assembly. b. Connect the tail exhaust pipe assembly LH to the 2 exhaust pipe supports. c. Install the tail exhaust pipe assembly LH with the 2 nuts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 11. INSPECT FOR EXHAUST GAS LEAK

2012-2017 ENGINE Exhaust System (Service Information) (Hybrid)

INTAKE MANIFOLD COMPONENTS ILLUSTRATION

Fig. 1: Identifying Intake Manifold Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Intake Manifold Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Intake Manifold Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work.

Refer to PRECAUTION . 2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY Refer to REMOVAL 6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 7. 8. 9. 10.

REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE EGR VALVE ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR . Refer to REMOVAL - Step 2 SEPARATE INTAKE MANIFOLD a. Disconnect the No. 2 ventilation hose.

Fig. 4: Disconnecting No. 2 Ventilation Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the heated oxygen sensor connector.

Fig. 5: Identifying Heated Oxygen Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the 6 wire harness clamps.

Fig. 6: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 6 bolts to separate the intake manifold from the engine assembly.

Fig. 7: Identifying Intake Manifold Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. DISCONNECT FUEL TUBE SUB-ASSEMBLY . Refer to REMOVAL - Step 6 12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 7 13. REMOVE INTAKE MANIFOLD a. Remove the intake manifold from the vehicle. b. Remove the gasket from the intake manifold.

Fig. 8: Identifying Intake Manifold Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and wire harness clamp bracket.

Fig. 9: Identifying Wire Harness Clamp Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the vacuum hose from the intake manifold.

Fig. 10: Identifying Intake Manifold Vacuum Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the fuel vapor feed hose from the intake manifold.

Fig. 11: Identifying Intake Manifold Fuel Vapor Feed Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. SET INTAKE MANIFOLD a. Install the fuel vapor feed hose to the intake manifold. b. Install the vacuum hose to the intake manifold. c. Install the wire harness clamp bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) d. Install a new gasket to the intake manifold. e. Set the intake manifold on the engine assembly. 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 3. CONNECT FUEL TUBE SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 4. INSTALL INTAKE MANIFOLD a. Temporarily install the intake manifold with the 6 bolts. b. Tighten the 6 bolts in the order shown in the illustration.

Fig. 12: Intake Manifold Bolt Tightening Order Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

5. 6. 7. 8.

c. Connect the 6 wire harness clamps. d. Connect the heated oxygen sensor connector. e. Connect the No. 2 ventilation hose. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR . Refer to INSTALLATION - Step 1 INSTALL EGR VALVE ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 18 INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION

9. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Refer to INSTALLATION 10. CONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

11. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 12. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

EXHAUST MANIFOLD COMPONENTS ILLUSTRATION

Fig. 13: Identifying Exhaust Manifold Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Identifying Exhaust Manifold Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT EXHAUST PIPE ASSEMBLY a. Disconnect the heated oxygen sensor connector.

Fig. 15: Identifying Heated Oxygen Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts, 2 compression springs and 2 nuts.

Fig. 16: Identifying Front Exhaust Pipe Assembly Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the front exhaust pipe assembly from the exhaust pipe support. d. Remove the 2 gaskets from the exhaust manifold converter sub-assembly and front exhaust pipe assembly. 6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR a. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

Fig. 17: Locating No. 1 Exhaust Manifold Heat Insulator And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE AIR FUEL RATIO SENSOR . Refer to REMOVAL - Step 2 8. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR a. Remove the 3 bolts and No. 1 manifold converter insulator.

Fig. 18: Identifying No. 1 Manifold Converter Insulator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 2 EGR PIPE a. Remove the 2 bolts, 2 nuts and No. 2 EGR pipe.

Fig. 19: Identifying No. 2 EGR Pipe Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 gaskets. 10. REMOVE NO. 2 MANIFOLD STAY a. Remove the bolt, nut and No. 2 manifold stay.

Fig. 20: Identifying No. 2 Manifold Stay Nut And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE MANIFOLD STAY a. Remove the bolt, nut and manifold stay.

Fig. 21: Identifying Manifold Stay Nut And Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Remove the 5 nuts and exhaust manifold converter sub-assembly.

Fig. 22: Locating Exhaust Manifold Converter Sub-Assembly And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the gasket.

Fig. 23: Identifying Cylinder Head Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR a. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

Fig. 24: Locating No. 2 Exhaust Manifold Heat Insulator And Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR a. Install the No. 2 exhaust manifold heat insulator with the 2 bolts. Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY a. Set a new gasket to the cylinder head sub-assembly. b. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts. c. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts. d. Tighten the 5 nuts in the order shown in the illustration.

Fig. 25: Locating Manifold Converter Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 3. INSTALL MANIFOLD STAY a. Tighten the bolt and nut in the order shown in the illustration.

Fig. 26: Identifying Manifold Stay Nut And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 4. INSTALL NO. 2 MANIFOLD STAY a. Tighten the bolt and nut in the order shown in the illustration.

Fig. 27: Identifying No. 2 Manifold Stay Nut And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 5. INSTALL NO. 2 EGR PIPE a. Install 2 new gaskets to the No. 2 EGR pipe. b. Install the No. 2 EGR pipe with the 2 bolts and 2 nuts. Torque: 36 N*m (367 kgf*cm, 26 ft.*lbf) 6. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR a. Install the No. 1 manifold converter insulator with the 3 bolts. Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 7. INSTALL AIR FUEL RATIO SENSOR . Refer to INSTALLATION - Step 1 8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR a. Install the No. 1 exhaust manifold heat insulator with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 9. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression spring.

Fig. 28: Measuring Free Length Of Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42.0 mm Standard (1.65 in.) 40.5 mm Minimum (1.60 in.) HINT: If the length is less than the minimum, replace the compression spring. b. Fully insert a new gasket to the exhaust manifold converter sub-assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

Fig. 29: Identifying Exhaust Manifold Converter Sub-Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly Wooden *2 Block *3 Gasket NOTE:

   

Be sure to install the gasket in the correct direction. Do not reuse the gasket. Do not damage the gasket. Do not push in the gasket by using the exhaust pipe when connecting it.

d. Install a new gasket to the front exhaust pipe assembly. e. Connect the front exhaust pipe assembly to the exhaust pipe support. f. Install the front exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

HINT: After the installation, check that the gaps between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

Fig. 30: Gaps Between The Flanges Of The Exhaust Manifold And Front Exhaust Pipe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly Front Exhaust *2 Pipe Assembly *3 Gasket Space between flanges: *a 8.5 mm (0.335 in.)

10. 11. 12. 13. 14.

g. Connect the heated oxygen sensor connector. INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSPECT FOR EXHAUST GAS LEAK

EXHAUST PIPE COMPONENTS ILLUSTRATION

Fig. 31: Identifying Exhaust Pipe Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE HEATED OXYGEN SENSOR . Refer to REMOVAL - Step 1 2. REMOVE TAIL EXHAUST PIPE ASSEMBLY a. Remove the 2 bolts and 2 compression springs.

Fig. 32: Identifying Tail Exhaust Pipe Assembly Bolts And Compression Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail exhaust pipe assembly from the 3 exhaust pipe supports. c. Remove the gasket from the center exhaust pipe assembly. 3. REMOVE CENTER EXHAUST PIPE ASSEMBLY a. Remove the 2 nuts.

Fig. 33: Identifying Center Exhaust Pipe Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the center exhaust pipe assembly from the exhaust pipe support. c. Remove the gasket from the front exhaust pipe assembly. 4. REMOVE FRONT EXHAUST PIPE ASSEMBLY a. Remove the 2 bolts and 2 compression springs.

Fig. 34: Identifying Front Exhaust Pipe Assembly Bolts And Compression Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front exhaust pipe assembly from the exhaust pipe support. c. Remove the gasket from the exhaust manifold converter sub-assembly. INSTALLATION INSTALLATION

1. INSTALL FRONT EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression spring.

Fig. 35: Measuring Free Length Of Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42.0 mm Standard (1.65 in.) 40.5 mm Minimum (1.60 in.) HINT: If the length is less than the minimum, replace the compression spring. b. Fully insert a new gasket to the exhaust manifold converter sub-assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

Fig. 36: Identifying Exhaust Manifold Converter Sub-Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly Wooden *2 Block *3 Gasket NOTE:

   

Be sure to install the gasket in the correct direction. Do not reuse the gasket. Do not damage the gasket. Do not push in the gasket by using the exhaust pipe when connecting it.

d. Connect the front exhaust pipe assembly to the exhaust pipe support. e. Install the front exhaust pipe assembly with the 2 compression springs and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) HINT:

After the installation, check that the gaps between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

Fig. 37: Gaps Between The Flanges Of The Exhaust Manifold And Front Exhaust Pipe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Exhaust Manifold *1 Converter Subassembly Front Exhaust *2 Pipe Assembly *3 Gasket Space between flanges: *a 8.5 mm (0.335 in.) 2. INSTALL CENTER EXHAUST PIPE ASSEMBLY a. Install a new gasket to the front exhaust pipe assembly.

b. Connect the center exhaust pipe assembly to the exhaust pipe support. c. Install the center exhaust pipe assembly with the 2 nuts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 3. INSTALL TAIL EXHAUST PIPE ASSEMBLY a. Using a vernier caliper, measure the free length of the compression spring.

Fig. 38: Measuring Free Length Of Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40.0 mm Standard (1.57 in.) 38.5 mm Minimum (1.52 in.) HINT: If the length is less than the minimum, replace the compression spring. b. Fully insert a new gasket to the center exhaust pipe assembly. c. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the

center exhaust pipe assembly.

Fig. 39: Identifying Center Exhaust Pipe Assembly Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Center Exhaust *1 Pipe Assembly Wooden *2 Block *3 Gasket NOTE:

   

Be sure to install the gasket in the correct direction. Do not reuse the gasket. Do not damage the gasket. Do not push in the gasket by using the exhaust pipe when connecting it.

d. Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports. e. Install the tail exhaust pipe assembly with the 2 compression springs and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

HINT: After the installation, check that the gaps between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

Fig. 40: Checking The Gaps Between The Flanges Of The Exhaust Manifold Converter SubAssembly And Front Exhaust Pipe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tail Exhaust *1 Pipe Assembly Center Exhaust *2 Pipe Assembly *3 Gasket Space between flanges: *a 6.5 mm (0.256 in.) 4. INSTALL HEATED OXYGEN SENSOR . Refer to INSTALLATION - Step 1

5. INSPECT FOR EXHAUST GAS LEAK

2012-2017 ACCESSORIES & EQUIPMENT Exterior Panels / Trim (Service Information) (Hybrid)

FRONT BUMPER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Bumper Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Front Bumper Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Front Bumper Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Front Bumper Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE FRONT BUMPER ASSEMBLY a. Put protective tape around the front bumper assembly.

Fig. 5: Applying Protective Tape Around The Front Bumper Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Use the same procedure for the RH side and LH side. b. Using a screwdriver, turn the pins 90 degrees and remove the pin hold clip.

Fig. 6: Removing Pin Hold Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hold Clip HINT: Use the same procedure for the RH side and LH side. c. Remove the clip. HINT:

Use the same procedure for the RH side and LH side. d. Remove the 6 screws.

Fig. 7: Identifying Front Bumper Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the 3 claws.

Fig. 8: Identifying Front Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. f. Pull back the side of the front bumper assembly as shown in the illustration and disconnect each connector.

Fig. 9: Identifying Intuitive Parking Assist System And Fog Light Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Intuitive *A Parking Assist System w/ Fog *B Light NOTE:

HINT:

Do not apply excessive force when separating the front bumper assembly.

Use the same procedure for the RH side and LH side. g. Using a clip remover, remove the 3 clips.

Fig. 10: Identifying Front Bumper Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the front bumper assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 2 2. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 3 3. REMOVE FOG LIGHT ASSEMBLY LH (w/ Fog Light) . Refer to REMOVAL - Step 2 4. REMOVE FOG LIGHT ASSEMBLY RH (w/ Fog Light) HINT: Use the same procedure as for the LH side. 5. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET a. w/o Side Turn Signal Light:

1. Remove the 2 screws.

Fig. 11: Identifying Front Bumper Extension Mounting Bracket Screws And Hook (W/O Side Turn Signal Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Disengage the 2 hooks and remove the front bumper extension mounting bracket. b. w/ Side Turn Signal Light: 1. Remove the 2 screws.

Fig. 12: Identifying Front Bumper Extension Mounting Bracket Screws And Hook (W/ Side Turn Signal Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Disengage the 2 hooks and remove the front bumper extension mounting bracket. 6. REMOVE FRONT FENDER LINER RETAINER a. Disengage the claw and remove the front fender liner retainer.

Fig. 13: Identifying Front Fender Liner Retainer Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. 7. REMOVE FRONT BUMPER HOLE COVER LH a. Disengage the 5 claws and remove the front bumper hole cover LH.

Fig. 14: Identifying Front Bumper Hole Cover LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Fog Light: 1. Disengage the 2 claws and 2 guides, and remove the fog light mounting bracket LH.

Fig. 15: Identifying Fog Light Mounting Bracket LH Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FRONT BUMPER HOLE COVER RH HINT: Use the same procedure as for the LH side. 9. REMOVE NO. 1 LOWER RADIATOR GRILLE a. Disengage the 16 claws and 2 guides, and remove the No. 1 lower radiator grille.

Fig. 16: Identifying No. 1 Lower Radiator Grille Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE FRONT BUMPER ENERGY ABSORBER a. Disengage the 2 guides and remove the front bumper energy absorber.

Fig. 17: Identifying Front Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY a. Disengage the 5 clamps.

Fig. 18: Identifying Front Bumper Reinforcement Sub-Assembly Bolts And Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 6 bolts and front bumper reinforcement sub-assembly. 12. REMOVE FRONT BUMPER SIDE RETAINER LH a. Remove the bolt.

Fig. 19: Identifying Front Bumper Side Retainer LH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and remove the front bumper side retainer LH. 13. REMOVE FRONT BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. REASSEMBLY REASSEMBLY

1. INSTALL FRONT BUMPER SIDE RETAINER LH a. Engage the claw.

Fig. 20: Identifying Front Bumper Side Retainer LH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front bumper side retainer LH with the bolt. Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) 2. INSTALL FRONT BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 3. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY a. Install the front bumper reinforcement sub-assembly with the 6 bolts.

Fig. 21: Identifying Front Bumper Reinforcement Sub-Assembly Bolts And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) b. Engage the 5 clamps. 4. INSTALL FRONT BUMPER ENERGY ABSORBER a. Engage the 2 guides to install the front bumper energy absorber.

Fig. 22: Identifying Front Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL NO. 1 LOWER RADIATOR GRILLE a. Engage the 2 guides and 16 claws to install the No. 1 lower radiator grille.

Fig. 23: Identifying No. 1 Lower Radiator Grille Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL FRONT BUMPER HOLE COVER LH a. w/ Fog Light:

1. Engage the 2 claws and 2 guides to install the fog light mounting bracket LH.

Fig. 24: Identifying Fog Light Mounting Bracket LH Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 5 claws to install the front bumper hole cover LH.

Fig. 25: Identifying Front Bumper Hole Cover LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL FRONT BUMPER HOLE COVER RH HINT: Use the same procedure as for the LH side. 8. INSTALL FRONT FENDER LINER RETAINER a. Engage the claw to install the front fender liner retainer.

Fig. 26: Identifying Front Fender Liner Retainer Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. 9. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET a. w/o Side Turn Signal Light: 1. Engage the 2 hooks.

Fig. 27: Identifying Front Bumper Extension Mounting Bracket Screws And Hook (W/O Side Turn Signal Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Install the front bumper extension mounting bracket with the 2 screws. b. w/ Side Turn Signal Light: 1. Engage the 2 hooks.

Fig. 28: Identifying Front Bumper Extension Mounting Bracket Screws And Hook (W/ Side Turn Signal Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Install the front bumper extension mounting bracket with the 2 screws. 10. INSTALL FOG LIGHT ASSEMBLY LH (w/ Fog Light) . Refer to INSTALLATION - Step 1 11. INSTALL FOG LIGHT ASSEMBLY RH (w/ Fog Light) HINT: Use the same procedure as for the LH side. 12. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 1 13. INSTALL NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 INSTALLATION INSTALLATION

1. INSTALL FRONT BUMPER ASSEMBLY a. Move the front bumper assembly into position and install the 3 clips.

b. Pull back the side of the front bumper assembly and connect each connector. NOTE:

Do not apply excessive force when pulling back the side of the front bumper assembly.

HINT: Use the same procedure for the RH side and LH side. c. Engage the 3 claws to install the front bumper assembly.

Fig. 29: Identifying Front Bumper Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT:

Use the same procedure for the RH side and LH side. d. Install the 6 screws. e. Install the pin hold clip as shown in the illustration.

Fig. 30: Installing Pin Hold Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin Hold *1 Clip *a Correct *b Incorrect NOTE:

Insert the pin hold clip with the slot aligned vertically. Do not rotate

the clip after inserting it. After installation, confirm that the slot is aligned vertically. HINT: Use the same procedure for the RH side and LH side. f. Install the clip. HINT: Use the same procedure for the RH side and LH side. 2. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION 3. ADJUST FOG LIGHT ASSEMBLY (w/ Fog Light) Refer to ADJUSTMENT

REAR BUMPER COMPONENTS ILLUSTRATION

Fig. 31: Identifying Rear Bumper Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 32: Identifying Rear Bumper Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 33: Identifying Rear Bumper Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE REAR BUMPER PLATE LH a. Using a screwdriver with the tip wrapped with protective tape, disengage the 2 claws.

Fig. 34: Identifying Rear Bumper Plate LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *2 Hook HINT: Tape the screwdriver tip before use.

b. Disengage the hook and remove the rear bumper plate LH. 2. REMOVE REAR BUMPER PLATE RH HINT: Use the same procedure as for the LH side. 3. REMOVE REAR BUMPER ASSEMBLY a. Put protective tape around the rear bumper assembly.

Fig. 35: Rear Bumper Assembly Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a clip remover, remove the 4 clips.

Fig. 36: Identifying Rear Bumper Assembly Clips And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 6 screws. d. Remove the 2 screws.

Fig. 37: Identifying Rear Bumper Assembly Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. e. Disengage the 7 claws as shown in the illustration.

Fig. 38: Identifying Rear Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. f. Disengage the 6 claws as shown in the illustration.

Fig. 39: Identifying Rear Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. w/ Intuitive Parking Assist System: 1. Disconnect the connector. h. Remove the rear bumper assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 2 LUGGAGE ROOM WIRE (w/ Intuitive Parking Assist System) a. Disengage the 4 clamps.

Fig. 40: Identifying No. 2 Luggage Room Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3. 4. 5.

b. Disconnect the connector and remove the No. 2 luggage room wire. REMOVE ULTRASONIC SENSOR CLIP (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 2 REMOVE NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 3 REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 4 REMOVE REAR BUMPER SIDE RETAINER LH a. Remove the 3 screws.

Fig. 41: Identifying Rear Bumper Side Retainer LH Claws And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 6 claws and remove the rear bumper side retainer LH. 6. REMOVE REAR BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 7. REMOVE WHEEL HOUSE REINFORCEMENT LH a. Disengage the clip. b. Remove the screw.

Fig. 42: Identifying Wheel House Reinforcement LH Clip, Screw, And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the nut and wheel house reinforcement LH. 8. REMOVE WHEEL HOUSE REINFORCEMENT RH HINT: Use the same procedure as for the LH side. 9. REMOVE REAR BUMPER ENERGY ABSORBER a. Disengage the 2 guides and remove the rear bumper energy absorber.

Fig. 43: Identifying Rear Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE REAR BUMPER REINFORCEMENT SUB-ASSEMBLY a. Remove the 6 nuts and rear bumper reinforcement sub-assembly.

Fig. 44: Identifying Rear Bumper Reinforcement Sub-Assembly Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL REAR BUMPER REINFORCEMENT SUB-ASSEMBLY a. Install the rear bumper reinforcement sub-assembly with the 6 nuts.

Fig. 45: Identifying Rear Bumper Reinforcement Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 2. INSTALL REAR BUMPER ENERGY ABSORBER a. Engage the 2 guides to install the rear bumper energy absorber.

Fig. 46: Identifying Rear Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL WHEEL HOUSE REINFORCEMENT LH a. Install the wheel house reinforcement LH with the screw and nut.

Fig. 47: Identifying Wheel House Reinforcement LH Clip, Screw, And Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clip. 4. INSTALL WHEEL HOUSE REINFORCEMENT RH HINT: Use the same procedure as for the LH side. 5. INSTALL REAR BUMPER SIDE RETAINER LH a. Engage the 6 claws.

Fig. 48: Identifying Rear Bumper Side Retainer LH Claws And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear bumper side retainer LH with the 3 screws.

6. INSTALL REAR BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 7. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 1 8. INSTALL NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 9. INSTALL ULTRASONIC SENSOR CLIP (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 3 10. INSTALL NO. 2 LUGGAGE ROOM WIRE (w/ Intuitive Parking Assist System) a. Connect the 4 connectors.

Fig. 49: Identifying No. 2 Luggage Room Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 4 clamps to install the No. 2 luggage room wire. INSTALLATION INSTALLATION

1. INSTALL REAR BUMPER ASSEMBLY a. w/ Intuitive Parking Assist System:

1. Connect the connector. b. Engage the 6 claws.

Fig. 50: Identifying Rear Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 7 claws and install the rear bumper assembly as shown in the illustration.

Fig. 51: Identifying Rear Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. d. Install the 10 screws. e. Install the 4 clips. 2. INSTALL REAR BUMPER PLATE LH a. Engage the hook.

Fig. 52: Identifying Rear Bumper Plate LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook b. Engage the 2 claws to install the rear bumper plate LH. 3. INSTALL REAR BUMPER PLATE RH HINT: Use the same procedure as for the LH side.

REAR SPOILER

COMPONENTS ILLUSTRATION

Fig. 53: Identifying Rear Spoiler Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 54: Identifying Rear Spoiler Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE REAR SPOILER SUB-ASSEMBLY HINT: When removing the rear spoiler sub-assembly, heat the vehicle body and rear spoiler sub-assembly using a heat light. Heating Temperature Item Temperature 40 to 60°C Vehicle (104 to 140° Body F)

Rear 20 to 30°C Spoiler (68 to 86°F) NOTE:

Do not heat the vehicle body, rear spoiler sub-assembly excessively.

a. Put protective tape around the rear spoiler sub-assembly.

Fig. 55: Rear Spoiler Sub-Assembly Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 2 nuts.

Fig. 56: Identifying Rear Spoiler Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert a piano wire between the vehicle body and rear spoiler sub-assembly.

Fig. 57: Inserting Piano Wire Between Vehicle Body And Rear Spoiler Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden Piano *1 *2 Block Wire No. 1 No. 2 Rear Rear *3 *4 Spoiler Spoiler Protector Protector Stud *5 Clip *6 Bolt d. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.

e. Pull the piano wire and scrape off the No. 1 rear spoiler protector and 2 No. 2 rear spoiler protectors that holds the rear spoiler sub-assembly to the vehicle body. NOTE:

Be careful not to damage the vehicle body.

f. Disengage the 4 clips and remove the rear spoiler sub-assembly. g. Remove the No. 1 rear spoiler protector.

Fig. 58: Identifying No. 1 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the No. 2 rear spoiler protector.

Fig. 59: Identifying No. 2 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. i. Remove the 4 clips from the rear spoiler. j. Remove the 2 gaskets from the rear spoiler. k. When replacing the rear spoiler with a new one: 1. Remove the 2 stud bolts from the rear spoiler. 3. REMOVE NO. 3 REAR SPOILER PROTECTOR a. Remove the 2 No. 3 rear spoiler protectors.

Fig. 60: Identifying No. 3 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 4 REAR SPOILER PROTECTOR a. Remove the 2 No. 4 rear spoiler protectors.

Fig. 61: Identifying No. 4 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 5 REAR SPOILER PROTECTOR a. Remove the 2 No. 5 rear spoiler protectors.

Fig. 62: Identifying No. 5 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 3 REAR SPOILER PROTECTOR a. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler.

2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 3 rear spoiler protectors. 1. Remove the release paper from the 2 No. 3 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install 2 new No. 3 rear spoiler protectors. 2. INSTALL NO. 4 REAR SPOILER PROTECTOR a. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 4 rear spoiler protectors. 1. Remove the release paper from the 2 No. 4 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install 2 new No. 4 rear spoiler protectors as shown in the illustration.

Fig. 63: Identifying No. 4 Rear Spoiler Protector Spacing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 5.2 mm (0.205 5.2 mm (0.205 A B in.) in.) 3. INSTALL NO. 5 REAR SPOILER PROTECTOR a. Clean the rear spoiler.

1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 5 rear spoiler protectors. 1. Remove the release paper from the 2 No. 5 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install 2 new No. 5 rear spoiler protectors as shown in the illustration.

Fig. 64: Identifying No. 5 Rear Spoiler Protector Spacing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 38.0 mm (1.50 38.0 mm (1.50 A B in.) in.) 4. INSTALL REAR SPOILER SUB-ASSEMBLY a. When replacing the rear spoiler with a new one: 1. Install the 2 stud bolts to the rear spoiler. b. Install 2 new gaskets to the rear spoiler. c. Install 4 new clips to the rear spoiler. d. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. e. Install a new No. 2 rear spoiler protector. 1. Remove the release paper from the No. 2 rear spoiler protector. HINT:

After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install a new No. 2 rear spoiler protector. HINT: Use the same procedure for the RH side and LH side. f. Install the No. 1 rear spoiler protector. 1. Remove the release paper from the No. 1 rear spoiler protector. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install the No. 1 rear spoiler protector as shown in the illustration.

Fig. 65: Identifying No. 1 Rear Spoiler Protector Spacing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 5.0 mm (0.197 5.0 mm (0.197 A B in.) in.) g. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. h. Install the rear spoiler sub-assembly. 1. Using a heat light, heat the vehicle body and rear spoiler sub-assembly. 2. Remove the release paper from the rear spoiler sub-assembly.

HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Engage the 4 clips.

Fig. 66: Identifying Rear Spoiler Sub-Assembly Clips And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install the rear spoiler sub-assembly with the 2 nuts. 5. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 10

RADIATOR GRILLE COMPONENTS ILLUSTRATION

Fig. 67: Identifying Radiator Grille Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL

a. Remove the 7 clips and cool air intake duct seal.

Fig. 68: Identifying Cool Air Intake Duct Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RADIATOR GRILLE SUB-ASSEMBLY a. Put protective tape around the radiator grille sub-assembly.

Fig. 69: Radiator Grille Sub-Assembly Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 clips. c. Disengage the 8 claws and remove the radiator grille sub-assembly.

Fig. 70: Identifying Radiator Grille Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE HOOD TO RADIATOR GRILLE SEAL a. Disengage the 15 clips to remove the hood to radiator grille seal.

Fig. 71: Identifying Radiator Grille Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE RADIATOR GRILLE EMBLEM ASSEMBLY a. Remove the 2 screws.

Fig. 72: Identifying Radiator Grille Emblem Assembly Screws, Claws, And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws and 2 guides, and remove the radiator grille emblem assembly. INSTALLATION INSTALLATION

1. INSTALL RADIATOR GRILLE EMBLEM ASSEMBLY a. Engage the 2 guides and 4 claws, and install the radiator grille emblem assembly. b. Install the 2 screws. 2. INSTALL HOOD TO RADIATOR GRILLE SEAL a. Engage the 15 clips to install the hood to radiator grille seal. 3. INSTALL RADIATOR GRILLE SUB-ASSEMBLY

a. Engage the 8 claws to install the radiator grille sub-assembly.

Fig. 73: Identifying Radiator Grille Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 clips. 4. INSTALL COOL AIR INTAKE DUCT SEAL a. Install the cool air intake duct seal with the 7 clips.

NAME PLATE COMPONENTS ILLUSTRATION

Fig. 74: Identifying Name Plate Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 75: Identifying Name Plate Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: When removing the name plates or emblem, heat the vehicle body and name plates or emblem using a heat light. HEATING TEMPERATURE Item Vehicle Body Name Plate or Emblem NOTE:

Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F)

Do not heat the vehicle body, name plates or emblem excessively.

1. REMOVE LUGGAGE COMPARTMENT DOOR EMBLEM a. Put protective tape around the luggage compartment door emblem.

Fig. 76: Luggage Compartment Door Emblem Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a molding remover, separate the double-sided tape and disengage the 2 pins to remove the luggage compartment door emblem. NOTE:





If reusing the luggage compartment door emblem, take care not to damage the symbol emblem. Be careful not to damage the vehicle body.

2. REMOVE NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE

a. Put protective tape around the No. 2 luggage compartment door name plate.

Fig. 77: NO. 2 Luggage Compartment Door Name Plate Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape b. Insert a piano wire between the vehicle body and No. 2 luggage compartment door name plate. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire to separate the double-sided tape that holds the No. 2 luggage compartment door name plate to the vehicle body. NOTE:





If reusing the No. 2 luggage compartment door name plate, take care not to damage the No. 2 luggage compartment door name plate. Be careful not to damage the vehicle body.

e. Remove the No. 2 luggage compartment door name plate. 3. REMOVE NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE

a. Put protective tape around the No. 3 luggage compartment door name plate.

Fig. 78: NO. 3 Luggage Compartment Door Name Plate Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape b. Insert a piano wire between the vehicle body and No. 3 luggage compartment door name plate. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire to separate the double-sided tape that holds the No. 3 luggage compartment door name plate to the vehicle body. NOTE:





If reusing the No. 3 luggage compartment door name plate, take care not to damage the No. 3 luggage compartment door name plate. Be careful not to damage the vehicle body.

e. Remove the No. 3 luggage compartment door name plate. 4. REMOVE NO. 1 LUGGAGE COMPARTMENT DOOR NAME PLATE

a. Put protective tape around the No. 1 luggage compartment door name plate.

Fig. 79: NO. 1 Luggage Compartment Door Name Plate Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape b. Insert a piano wire between the vehicle body and No. 1 luggage compartment door name plate. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire and cut the double-sided tape that holds the No. 1 luggage compartment door name plate to the vehicle body. NOTE:





If reusing the No. 1 luggage compartment door name plate, take care not to damage the No. 1 luggage compartment door name plate. Be careful not to damage the vehicle body.

e. Remove the No. 1 luggage compartment door name plate. 5. REMOVE SIDE PANEL EMBLEM (for LH Side)

a. Put protective tape around the side panel emblem.

Fig. 80: Side Panel Emblem (For LH Side) Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape b. Insert a piano wire between the vehicle body and side panel emblem. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire and cut the double-sided tape that holds the side panel emblem to the vehicle body. NOTE:





If reusing the side panel emblem, take care not to damage the side panel emblem. Be careful not to damage the vehicle body.

e. Remove the side panel emblem. 6. REMOVE SIDE PANEL EMBLEM (for RH Side) a. Put protective tape around the side panel emblem.

Fig. 81: Side Panel Emblem (For RH Side) Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape b. Insert a piano wire between the vehicle body and side panel emblem. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire and cut the double-sided tape that holds the side panel emblem to the vehicle body. NOTE:





If reusing the side panel emblem, take care not to damage the side panel emblem. Be careful not to damage the vehicle body.

e. Remove the side panel emblem. INSTALLATION INSTALLATION

HINT: When installing the name plates or emblem, heat the vehicle body and name plates or emblem using a heat light. HEATING TEMPERATURE Item Vehicle Body Name Plate or Emblem NOTE:

Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F)

Do not heat the vehicle body, name plates or emblem excessively.

1. INSTALL LUGGAGE COMPARTMENT DOOR EMBLEM a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the luggage compartment door emblem. (If reusing the luggage compartment door emblem) 1. Using a heat light, heat the luggage compartment door emblem. 2. Remove the double-sided tape from the luggage compartment door emblem. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the luggage compartment door emblem. c. Install the luggage compartment door emblem. 1. Using a heat light, heat the vehicle body and luggage compartment door emblem. 2. Remove the release paper from the luggage compartment door emblem. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Engage the 2 pins and install the luggage compartment door emblem as shown in the illustration.

Fig. 82: Identifying Luggage Compartment Door Emblem Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the No. 2 luggage compartment door name plate. (If reusing the No. 2 luggage compartment door name plate) 1. Using a heat light, heat the No. 2 luggage compartment door name plate. 2. Remove the double-sided tape from the No. 2 luggage compartment door name plate. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the No. 2 luggage compartment door name plate.

c. Install the No. 2 luggage compartment door name plate. 1. Using a heat light, heat the vehicle body and No. 2 luggage compartment door name plate. 2. Remove the release paper from the No. 2 luggage compartment door name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the No. 2 luggage compartment door name plate.

Fig. 83: No. 2 Luggage Compartment Door Name Plate Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of Luggage *1 -Compartment Door Panel Reference Measurement Area Measurement 51.7 mm (2.04 A in.) 223.0 mm B (8.78 in.) 52.9 mm (2.08 C in.) 3. INSTALL NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface.

2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the No. 3 luggage compartment door name plate. (If reusing the No. 3 luggage compartment door name plate) 1. Using a heat light, heat the No. 3 luggage compartment door name plate. 2. Remove the double-sided tape from the No. 3 luggage compartment door name plate. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the No. 3 luggage compartment door name plate. c. Install the No. 3 luggage compartment door name plate. 1. Using a heat light, heat the vehicle body and No. 3 luggage compartment door name plate. 2. Remove the release paper from the No. 3 luggage compartment door name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the No. 3 luggage compartment door name plate.

Fig. 84: No. 3 Luggage Compartment Door Name Plate Measurements

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of Luggage *1 -Compartment Door Panel Reference Measurement Area Measurement 47.4 mm (1.87 A in.) 140.8 mm B (5.54 in.) 48.0 mm (1.89 C in.) 47.1 mm (1.85 D in.) 165.5 mm E (6.52 in.) 47.9 mm (1.89 F in.) 4. INSTALL NO. 1 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the No. 1 luggage compartment door name plate. (If reusing the No. 1 luggage compartment door name plate) 1. Using a heat light, heat the No. 1 luggage compartment door name plate. 2. Remove the double-sided tape from the No. 1 luggage compartment door name plate. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the No. 1 luggage compartment door name plate. c. Install the No. 1 luggage compartment door name plate. 1. Using a heat light, heat the vehicle body and No. 1 luggage compartment door name plate. 2. Remove the release paper from the No. 1 luggage compartment door name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter.

3. Install the No. 1 luggage compartment door name plate as shown in the illustration.

Fig. 85: No. 1 Luggage Compartment Door Name Plate Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of Luggage *1 -Compartment Door Panel Reference Measurement Area Measurement 155.9 mm A (6.14 in.) 203.6 mm B (8.02 in.) 155.9 mm C (6.14 in.) 5. INSTALL SIDE PANEL EMBLEM (for LH Side) a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the side panel emblem. (If reusing the side panel emblem) 1. Using a heat light, heat the side panel emblem. 2. Remove the double-sided tape from the side panel emblem. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the side panel emblem.

c. Install the side panel emblem. 1. Using a heat light, heat the vehicle body and side panel emblem. 2. Remove the release paper from the side panel emblem. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the side panel emblem as shown in the illustration.

Fig. 86: Side Panel Emblem Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of *1 -Fender Panel Reference Measurement Area Measurement 163.0 mm A (6.42 in.) 241.1 mm B (9.49 in.) 152.4 mm C (6.00 in.) 6. INSTALL SIDE PANEL EMBLEM (for RH Side) a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface.

2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the side panel emblem. (If reusing the side panel emblem) 1. Using a heat light, heat the side panel emblem. 2. Remove the double-sided tape from the side panel emblem. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the side panel emblem. c. Install the side panel emblem. 1. Using a heat light, heat the vehicle body and side panel emblem. 2. Remove the release paper from the side panel emblem. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the side panel emblem as shown in the illustration.

Fig. 87: Side Panel Emblem Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of *1 -Fender Panel Reference Measurement Area Measurement 152.4 mm A (6.00 in.)

B C

240.9 mm (9.48 in.) 163.0 mm (6.42 in.)

FRONT DOOR BELT MOLDING COMPONENTS ILLUSTRATION

Fig. 88: Identifying Front Door Belt Molding Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 89: Identifying Front Door Belt Molding Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Refer to REMOVAL 5. 6. 7. 8.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 11 REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 16 REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 17 REMOVE FRONT DOOR BELT MOLDING ASSEMBLY a. Put protective tape around the front door belt molding assembly.

Fig. 90: Front Door Belt Molding Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Protective *1 Tape b. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws and remove the front door belt molding assembly.

Fig. 91: Identifying Front Door Belt Molding Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. INSTALL FRONT DOOR BELT MOLDING ASSEMBLY a. Engage the 6 claws to install the front door belt molding assembly.

Fig. 92: Identifying Front Door Belt Molding Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. 4. 5. 6.

INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 32 INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 33 INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Refer to INSTALLATION

7. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 9. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side)

Refer to INITIALIZATION 10. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK 11. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR DOOR BELT MOLDING COMPONENTS ILLUSTRATION

Fig. 93: Identifying Rear Door Belt Molding Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 94: Identifying Rear Door Belt Molding Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 95: Identifying Rear Door Belt Molding Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 5 6. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 6 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 7 8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 9 9. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 10 10. REMOVE REAR DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 11 11. REMOVE REAR DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 12 12. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 13 13. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 14 14. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 15 15. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 15 16. REMOVE REAR DOOR BELT MOLDING ASSEMBLY a. Put protective tape around the rear door belt molding assembly.

Fig. 96: Rear Door Belt Molding Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws to remove the rear door belt molding assembly as shown in the illustration.

Fig. 97: Identifying Rear Door Belt Molding Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL REAR DOOR BELT MOLDING ASSEMBLY a. Engage the 6 claws to install the rear door belt molding assembly as shown in the illustration.

Fig. 98: Identifying Rear Door Belt Molding Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 3. INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 4. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 5. INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 6. INSTALL REAR DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 25 7. INSTALL REAR DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 26 8. INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 9. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 10. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 11. INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 12. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 13. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 14. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

15. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 16. INSPECT POWER WINDOW OPERATION

Refer to OPERATION CHECK

ROCKER PANEL MOLDING COMPONENTS ILLUSTRATION

Fig. 99: Identifying Rocker Panel Molding Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT ROCKER PANEL MOLDING END COVER See step 1 2. REMOVE ROCKER PANEL MOLDING a. Put protective tape around the rocker panel molding and door.

Fig. 100: Rocker Panel Molding And Door Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 -Tape b. Remove the 2 screws and grommet.

Fig. 101: Identifying Rocker Panel Molding Screws And Grommet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the screw.

Fig. 102: Identifying Rocker Panel Molding Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the 7 clips.

Fig. 103: Identifying Rocker Panel Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the screw.

Fig. 104: Identifying Rocker Panel Molding Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disengage the 10 clips and remove the rocker panel molding.

Fig. 105: Identifying Rocker Panel Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the 10 clips from the rocker panel molding. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 4 ROCKER PANEL MOLDING PROTECTOR a. Remove the No. 4 rocker panel molding protector.

Fig. 106: Identifying No. 4 Rocker Panel Molding Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL NO. 4 ROCKER PANEL MOLDING PROTECTOR a. Install the No. 4 rocker panel molding protector.

Fig. 107: Identifying No. 4 Rocker Panel Molding Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ROCKER PANEL MOLDING a. Install the new 10 clips to the rocker panel molding. b. Engage the 10 clips and install the rocker panel molding. c. Install the screw. d. Install the 7 clips. e. Install the screw. f. Install a new grommet and 2 screws. 2. INSTALL FRONT ROCKER PANEL MOLDING END COVER See step 1

FRONT DOOR WINDOW FRAME MOLDING COMPONENTS ILLUSTRATION

Fig. 108: Identifying Front Door Window Frame Molding Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY Refer to REMOVAL 2. REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 21

3. REMOVE FRONT DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 36 4. REMOVE FRONT DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 37 5. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING HINT: When removing the front door rear window frame molding, heat the vehicle body and front door rear window frame molding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Molding (68 to 86°F) NOTE:

Do not heat the vehicle body or molding excessively.

a. Using a heat light, heat the front door rear window frame molding. b. Using a molding remover, disengage the clip and remove the front door rear window frame molding.

Fig. 109: Identifying Front Door Rear Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge 6. REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING a. Insert a 4.0 mm (0.157 in.) drill bit into a drill. b. Tape a 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

Fig. 110: Removing Front Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Dimension A 5.0 mm

NOTE:

Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

c. Lightly press the drill against the rivets to drill off the rivet flanges, and remove the 7 rivets. NOTE:







Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. Prying the rivets with the drill may damage the rivet installation holes or drill bit. Be careful of the drilled rivets, as they may be hot.

d. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. e. Disengage the claw and guide, and remove the front door upper window frame molding from the door frame. INSTALLATION INSTALLATION

1. INSTALL FRONT DOOR UPPER WINDOW FRAME MOLDING a. Engage the claw and guide of the front door upper window frame molding to the door frame.

Fig. 111: Installing Front Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an air riveter or hand riveter with a nose piece, install the front door upper window frame molding with 7 new rivets.

HINT: If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again. NOTE:



Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

Fig. 112: Installing The Rear Door Upper Window Frame Molding With 7 New Rivets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *2 Mandrel *a Incorrect 

Confirm that the rivets are seated properly against the molding. Do not tilt the riveter when installing the rivet to the molding. Do not leave any space between the rivet head and molding.

Fig. 113: Installing The Rivet To The Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 

Do not leave any space between the molding and door frame. Firmly ho the 2 items together while installing the rivet.

Fig. 114: Firmly Hold The 2 Items Together While Installing The Rivet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 2. INSTALL FRONT DOOR REAR WINDOW FRAME MOLDING HINT: When installing a new front door rear window frame molding, heat the vehicle body and front door rear window frame molding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Molding (68 to 86°F) NOTE:

Do not heat the vehicle body or front door rear window frame molding excessively.

a. Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Install a new front door rear window frame molding.

Fig. 115: Identifying Front Door Rear Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge

1. Using a heat light, heat the vehicle body and front door rear window frame molding. 2. Remove the release paper from the face of the front door rear window frame molding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter.

3. 4. 5. 6.

3. Install the front door rear window frame molding with the clip. INSTALL FRONT DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 12 INSTALL FRONT DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 13 INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 28 INSTALL FRONT DOOR BELT MOLDING ASSEMBLY Refer to INSTALLATION

REAR DOOR WINDOW FRAME MOLDING COMPONENTS ILLUSTRATION

Fig. 116: Identifying Rear Door Window Frame Molding Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR DOOR BELT MOLDING ASSEMBLY Refer to REMOVAL 2. REMOVE REAR DOOR FRONT WINDOW FRAME MOLDING HINT: When removing the rear door front window frame molding, heat the vehicle body and rear door front window frame molding using a heat light. HEATING TEMPERATURE Item Temperature Vehicle 40 to 60°C

Body

(104 to 140° F) 20 to 30°C Molding (68 to 86°F) NOTE:

Do not heat the vehicle body or molding excessively.

a. Using a heat light, heat the rear door front window frame molding. b. Using a molding remover, disengage the clip and remove the rear door front window frame molding.

Fig. 117: Identifying Rear Door Front Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Double*1 sided Tape Caulking *2 Sponge 3. REMOVE REAR DOOR UPPER WINDOW FRAME MOLDING a. Insert a 4.0 mm (0.157 in.) drill bit into a drill. b. Tape a 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

Fig. 118: Removing Rear Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Dimension A 5.0 mm

NOTE:

Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

c. Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 6 rivets. NOTE:







Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. Prying the rivets with the drill may damage the rivet installation holes or drill bit. Be careful of the drilled rivets, as they may be hot.

d. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. e. Disengage the guide, remove the rear door upper window frame molding from the door frame. INSTALLATION INSTALLATION

1. INSTALL REAR DOOR UPPER WINDOW FRAME MOLDING a. Engage the guide of the rear door upper window frame molding to the door frame.

Fig. 119: Installing Rear Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame molding with 6 new rivets.

HINT: If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again. NOTE:



Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

Fig. 120: Installing The Rear Door Upper Window Frame Molding With 7 New Rivets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *2 Mandrel *a Incorrect 

Confirm that the rivets are seated properly against the molding. Do not tilt the riveter when installing the rivet to the molding. Do not leave any space between the rivet head and molding.

Fig. 121: Installing The Rivet To The Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 

Do not leave any space between the molding and door frame. Firmly ho the 2 items together while installing the rivet.

Fig. 122: Firmly Hold The 2 Items Together While Installing The Rivet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 2. INSTALL REAR DOOR FRONT WINDOW FRAME MOLDING HINT: When installing a new rear door front window frame molding, heat the vehicle body and rear door front window frame molding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Molding (68 to 86°F) NOTE:

Do not heat the vehicle body or rear door front window frame molding excessively.

a. Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Install a new rear door front window frame molding.

Fig. 123: Identifying New Rear Door Front Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge

1. Using a heat light, heat the vehicle body and rear door front window frame molding. 2. Remove the release paper from the rear door front window frame molding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the rear door front window frame molding with the clip. 3. INSTALL REAR DOOR BELT MOLDING ASSEMBLY Refer to REASSEMBLY

ROOF DRIP SIDE FINISH MOLDING COMPONENTS ILLUSTRATION

Fig. 124: Identifying Roof Drip Side Finish Molding Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE CENTER ROOF DRIP SIDE FINISH MOLDING a. Put protective tape around the center roof drip side finish molding.

Fig. 125: Center Roof Drip Side Finish Molding Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a molding remover, disengage the 2 clips and remove the center roof drip side finish molding.

Fig. 126: Identifying Center Roof Drip Side Finish Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the clips. If any clip is damaged or falls out, replace it with a new one.

INSTALLATION INSTALLATION

1. INSTALL NO. 1 ROOF DRIP SIDE FINISH MOLDING CLIP NOTE:

When installing new clips, remove the double-sided tape remaining where the clips will be installed on the body and clean the body with a nonresidue solvent.

a. Apply a 2 to 3 mm (0.0787 to 0.118 in.) bead of adhesive (3M DP-105 or equivalent) to new No. 1 roof drip side finish molding clips.

Fig. 127: Applying A 2 To 3 Mm (0.0787 To 0.118 In.) Bead Of Adhesive (3M Dp-105 Or Equivalent) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive 2 to 3 mm *a Bead of Adhesive HINT: Adhesive strength (tensile strength): 13.7 MPa (140.0 kgf/cm2 , 1987 psi) or more (when the temperature is 23°C (73°F)) b. Press and install the 2 No. 1 roof drip side finish molding clips. c. Install the clips to the positions on the roof panel shown in the illustration. Determine the locations and firmly press and install the 2 No. 1 roof drip side finish molding clips after lightly applying adhesive (3M DP-105 or equivalent).

Fig. 128: Installing No. 1 Roof Drip Side Finish Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for *A for Front *B Rear Protruding *1 - Part STANDARD DIMENSION Installation Dimension Measurement Area 4.0 mm (0.157 A in.) 4.0 mm (0.157 B in.) for Front 1.8 mm C (0.0709 in.) 1.8 mm D (0.0709 in.) 4.0 mm (0.157 E in.) for Rear 4.0 mm (0.157 F in.)

G H

1.8 mm (0.0709 in.) 1.8 mm (0.0709 in.)

d. Install the roof drip center side finish molding when 20 minutes or more have elapsed after pressing and installing 2 new No. 1 roof drip side finish molding clips. HINT: Initial hardening time: 20 minutes  Complete hardening time: 48 hours 2. INSTALL CENTER ROOF DRIP SIDE FINISH MOLDING a. Engage the 2 clips and install the center roof drip side finish molding. 

Fig. 129: Identifying Center Roof Drip Side Finish Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH COMPONENTS ILLUSTRATION

Fig. 130: Identifying Luggage Compartment Door Outside Garnish Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 131: Identifying Luggage Compartment Door Outside Garnish Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY a. Disconnect the connector. b. Remove the 6 nuts.

Fig. 132: Identifying Luggage Compartment Door Outside Garnish Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Put protective tape around the luggage compartment door outside garnish sub-assembly.

Fig. 133: Luggage Compartment Door Outside Garnish Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Back Door *2 Outside Garnish Clip d. Disengage the 3 clips and remove the luggage compartment door outside garnish sub-assembly. e. Remove the clip (back door outside garnish clip) and 2 clips from the luggage compartment door outside garnish sub-assembly.

f. Remove the 6 gaskets from the luggage compartment door outside garnish sub-assembly. 3. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY . Refer to REMOVAL - Step 2 4. REMOVE LUGGAGE COMPARTMENT DOOR EMBLEM See step 1 5. REMOVE BACK DOOR OUTSIDE GARNISH PROTECTOR a. Remove the back door outside garnish protector.

Fig. 134: Identifying Back Door Outside Garnish Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL BACK DOOR OUTSIDE GARNISH PROTECTOR a. Clean the luggage compartment door outside garnish sub-assembly.

1. Remove any double-sided tape from the luggage compartment door outside garnish subassembly. 2. Wipe off any tape adhesive residue with cleaner. b. Install a new back door outside garnish protector. 1. Remove the release paper from the back door outside garnish protector. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. c. Install a new back door outside garnish protector shown in the illustration.

Fig. 135: Back Door Outside Garnish Protector Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

STANDARD MEASUREMENT Dimension Measurement 5.9 mm (0.232 a in.) 2. INSTALL LUGGAGE COMPARTMENT DOOR EMBLEM See step 1 3. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY . Refer to INSTALLATION Step 1 4. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY a. Install 6 new gaskets to the luggage compartment door outside garnish sub-assembly. b. Install a new clip (back door outside garnish clip) and 2 new clips to the luggage compartment door outside garnish sub-assembly. c. Engage the 3 clips to install the luggage compartment door outside garnish sub-assembly.

Fig. 136: Identifying Luggage Compartment Door Outside Garnish Sub-Assembly Clips

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the 6 nuts. e. Connect the connector. 5. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 10

REAR WHEEL HOUSE PLATE COMPONENTS ILLUSTRATION

Fig. 137: Identifying Rear Wheel House Plate Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT ROCKER PANEL MOLDING END COVER a. Remove the 2 screws and front rocker panel molding end cover.

Fig. 138: Identifying Front Rocker Panel Molding End Cover Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL FRONT ROCKER PANEL MOLDING END COVER a. Install the front rocker panel molding end cover with the 2 screws.

BLACK OUT TAPE (FOR FRONT DOOR) COMPONENTS ILLUSTRATION

Fig. 139: Identifying Black Out Tape (For Front Door) Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 140: Identifying Black Out Tape (For Front Door) Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 141: Identifying Black Out Tape (For Front Door) Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Refer to REMOVAL 5. 6. 7. 8. 9. 10. 11. 12.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 11 REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 16 REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 17 REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 17 REMOVE FRONT DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 36 REMOVE FRONT DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 37 REMOVE DOOR FRAME GARNISH . Refer to DISASSEMBLY - Step 38 REMOVE FRONT DOOR STRIPE a. Using a heat light, heat the front door stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Front (104 to 140° Door F) Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the front door stripe to remove it.

Fig. 142: Identifying Front Door Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. 13. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE a. Using a heat light, heat the front door lower outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Front (104 to 140° Door F) Rear Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the front door lower outside stripe to remove it.

Fig. 143: Identifying Front Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REPAIR INSTRUCTION a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. HEATING TEMPERATURE Item Temperature Vehicle 40 to 60°C

Body

(104 to 140° F)

NOTE:

Do not heat the vehicle body excessively.

2. Wipe off any tape adhesive residue with cleaner. b. Installation temperature 1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation. HINT: The most appropriate temperature for installing the tape is 25°C (77°F).  When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases. c. Before installation 1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance. 

HINT: Spray water on the shop floor to settle any dust. d. Key points for handling the tape 1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat. NOTE:

Do not bend the tape or leave it in high temperature places.

e. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces) NOTE:





Position the tape accurately to achieve a neat finish and to avoid peeling. The tape cannot be reused because it deforms and will not fit any more after being removed.

1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at

40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 30 to 70 mm (1.18 to 2.76 in.) per second.

Fig. 144: Slightly Raise The Part Of The Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressing *A *B Pulling Forward NonPadded *1 padded *2 Side Side Black *3 Squeegee *4 Out Tape Release *5 - Paper Side *a - View REFERENCE MEASUREMENT Area Measurement 10 to 20 mm A (0.393 to 0.787 in.) B

30 to 70 mm/sec. (1.18 to 2.76

C D

in./sec.) 40 to 50° (for pressing forward) 30 to 45° (for pulling)

NOTE:

Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

HINT: Either angle of the squeegee (pressing forward or pulling) is acceptable.  Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee. f. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces) 1. If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem. 

Fig. 145: Difficult To Apply The Tape, Install It In Several Steps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Squeegee *2 Hem *a First *b Second *c Third HINT: When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee. g. Key points for installation of the tape (how to use a squeegee and installation procedure for corners) 1. Remove the release paper and apply the tape carefully with your fingers. 2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish. h. Check after installation 1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape. NOTE:

Do not reuse the tape.

3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE a. Refer to the illustration to position the front door lower outside stripe.

Fig. 146: Installing Front Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION LH RH *A *B Side Side Edge of *a *b Square Curved Surface *c Round - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.) b. Remove the release paper and apply the stripe. 4. INSTALL FRONT DOOR STRIPE a. Refer to the illustration to position a new front door stripe.

Fig. 147: Installing Front Door Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH RH *A *B Side Side *a Edge of

*b Square

Curved Surface *c Round - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.)

5. 6. 7. 8. 9. 10. 11. 12.

b. Remove the release paper and apply the stripe. INSTALL DOOR FRAME GARNISH . Refer to REASSEMBLY - Step 11 INSTALL FRONT DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 12 INSTALL FRONT DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 13 INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 28 INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 32 INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 33 INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Refer to INSTALLATION

13. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

14. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 15. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION 16. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK 17. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

BLACK OUT TAPE (FOR REAR DOOR) COMPONENTS ILLUSTRATION

Fig. 148: Identifying Black Out Tape (For Rear Door) Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 149: Identifying Black Out Tape (For Rear Door) Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 150: Identifying Black Out Tape (For Rear Door) Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 151: Identifying Black Out Tape (For Rear Door) Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 5 6. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 6 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 7 8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 9 9. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 10 10. REMOVE REAR DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 11 11. REMOVE REAR DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 12 12. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 13 13. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 14 14. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 15 15. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 16. REMOVE REAR DOOR FRAME GARNISH . Refer to DISASSEMBLY - Step 17 17. REMOVE REAR DOOR OUTSIDE STRIPE a. Using a heat light, heat the rear door outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Rear (104 to 140° Door F) Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the rear door outside stripe to remove it.

Fig. 152: Identifying Rear Door Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. 18. REMOVE REAR DOOR LOWER OUTSIDE STRIPE a. Using a heat light, heat the rear door lower outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Rear (104 to 140° Door F) Lower Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the rear door lower outside stripe to remove it.

Fig. 153: Identifying Rear Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. INSTALLATION INSTALLATION

1. REPAIR INSTRUCTION See step 2 2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE a. Refer to the illustration to position a new rear door lower outside stripe.

Fig. 154: Installing Rear Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION RH *A LH Side *B Side Edge of *a Curved *b Straight Surface *c Triangle - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.) b. Remove the release paper and apply the stripe. 3. INSTALL REAR DOOR OUTSIDE STRIPE a. Refer to the illustration to position a new rear door outside stripe.

Fig. 155: Installing Rear Door Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION RH *A LH Side *B Side Edge of *a Curved *b Straight Surface *c Triangle - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.)

4. 5. 6. 7. 8. 9. 10. 11.

b. Remove the release paper and apply the stripe. INSTALL REAR DOOR FRAME GARNISH . Refer to REASSEMBLY - Step 20 INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 INSTALL REAR DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 25 INSTALL REAR DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 26 INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27

12. 13. 14. 15.

INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 16. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 17. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

18. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 19. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK

2012-2017 ACCESSORIES & EQUIPMENT Exterior Panels / Trim (Service Information) (Except Hybrid) - Camry

FRONT BUMPER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Bumper Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 2: Identifying Front Bumper Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Front Bumper Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Front Bumper Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 5: Identifying Front Bumper Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY

Refer to REMOVAL. 2. REMOVE FRONT BUMPER ASSEMBLY a. Put protective tape around the front bumper assembly.

Fig. 6: Identifying Protective Tape On Front Bumper Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Use the same procedure for the RH side and LH side. b. Using a screwdriver, turn the pins 90 degrees and remove the pin hold clip.

Fig. 7: Removing Front Bumper Assembly Pin Holding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin *1 Hold Clip HINT: Use the same procedure for the RH side and LH side. c. Remove the clip. HINT:

Use the same procedure for the RH side and LH side. d. Remove the 6 screws.

Fig. 8: Identifying Front Bumper Assembly Lower Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the 3 claws.

Fig. 9: Disengaging Front Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. f. Pull back the side of the front bumper assembly as shown in the illustration and disconnect each connector.

Fig. 10: Pulling Back Side Of Front Bumper Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Intuitive *A Parking Assist System w/ Fog *B Light NOTE:

HINT:

Do not apply excessive force when separating the front bumper assembly.

Use the same procedure for the RH side and LH side. g. Using a clip remover, remove the 3 clips.

Fig. 11: Identifying Front Bumper Assembly Upper Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the front bumper assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 2 . 2. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 3 . 3. REMOVE FOG LIGHT ASSEMBLY LH (w/ Fog Light) . Refer to REMOVAL - Step 2 . 4. REMOVE FOG LIGHT ASSEMBLY RH (w/ Fog Light) HINT: Use the same procedure as for the LH side. 5. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET (for Standard) a. w/o Side Turn Signal Light:

1. Remove the 2 screws.

Fig. 12: Identifying Front Bumper Extension Mounting Bracket (For Standard) w/o Side Turn Signal Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Disengage the 2 hooks and remove the front bumper extension mounting bracket. b. w/ Side Turn Signal Light: 1. Remove the 2 screws.

Fig. 13: Identifying Front Bumper Extension Mounting Bracket (For Standard) w/ Side Turn Signal Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Disengage the 2 hooks and remove the front bumper extension mounting bracket. 6. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET (for Sport Package) a. Remove the 2 screws.

Fig. 14: Identifying Front Bumper Extension Mounting Bracket (For Sport Package) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook b. Disengage the 2 hooks and remove the front bumper extension mounting bracket. 7. REMOVE FRONT FENDER LINER RETAINER a. Disengage the claw and remove the front fender liner retainer.

Fig. 15: Identifying Front Fender Liner Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. 8. REMOVE FRONT BUMPER HOLE COVER LH (for Standard) a. Disengage the 5 claws and remove the front bumper hole cover LH.

Fig. 16: Identifying Front Bumper Hole Cover LH (For Standard) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Fog Light: 1. Disengage the 2 claws and 2 guides, and remove the fog light mounting bracket LH.

Fig. 17: Identifying Front Bumper Hole Cover LH (For Standard) Claws w/ Fog Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE FRONT BUMPER HOLE COVER RH (for Standard) HINT: Use the same procedure as for the LH side. 10. REMOVE FRONT BUMPER HOLE COVER LH (for Sport Package) a. Remove the 2 screws.

Fig. 18: Identifying Front Bumper Hole Cover LH (For Sport Package) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 7 claws and remove the front bumper hole cover LH. c. Remove the 2 screws.

Fig. 19: Identifying Front Bumper Hole Cover LH (For Sport Package) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 claws and remove the front bumper side moulding LH. e. Disengage the 3 claws and guide to remove the fog light mounting bracket LH.

Fig. 20: Identifying Fog Light Mounting Bracket LH (For Sport Package) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT BUMPER HOLE COVER RH (for Sport Package) HINT: Use the same procedure as for the LH side. 12. REMOVE NO. 1 LOWER RADIATOR GRILLE a. for Standard: 1. Disengage the 16 claws and 2 guides, and remove the No. 1 lower radiator grille.

Fig. 21: Identifying No. 1 Lower Radiator Grille Claws And Guides (For Standard) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for Sport Package: 1. Disengage the 6 claws and 2 guides, and remove the No. 1 lower radiator grille.

Fig. 22: Identifying No. 1 Lower Radiator Grille Claws And Guides (For Sport Package) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE FRONT BUMPER ENERGY ABSORBER a. Disengage the 2 guides and remove the front bumper energy absorber.

Fig. 23: Identifying Front Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY a. Disengage the 5 clamps.

Fig. 24: Identifying Front Bumper Reinforcement Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 6 bolts and front bumper reinforcement sub-assembly. 15. REMOVE FRONT BUMPER SIDE RETAINER LH a. Remove the bolt.

Fig. 25: Identifying Front Bumper Side Retainer LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and remove the front bumper side retainer LH. 16. REMOVE FRONT BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. REASSEMBLY REASSEMBLY

1. INSTALL FRONT BUMPER SIDE RETAINER LH a. Engage the claw.

Fig. 26: Identifying Front Bumper Side Retainer LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front bumper side retainer LH with the bolt. Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) 2. INSTALL FRONT BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 3. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY a. Install the front bumper reinforcement sub-assembly with the 6 bolts.

Fig. 27: Identifying Front Bumper Reinforcement Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) b. Engage the 5 clamps. 4. INSTALL FRONT BUMPER ENERGY ABSORBER a. Engage the 2 guides to install the front bumper energy absorber.

Fig. 28: Identifying Front Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL NO. 1 LOWER RADIATOR GRILLE a. for Standard: 1. Engage the 2 guides and 16 claws to install the No. 1 lower radiator grille.

Fig. 29: Identifying No. 1 Lower Radiator Grille Claws And Guides (For Standard) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for Sport Package: 1. Engage the 2 guides and 6 claws to install the No. 1 lower radiator grille.

Fig. 30: Identifying No. 1 Lower Radiator Grille Claws And Guides (For Sport Package) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL FRONT BUMPER HOLE COVER LH (for Standard) a. w/ Fog Light: 1. Engage the 2 claws and 2 guides to install the fog light mounting bracket LH.

Fig. 31: Identifying Front Bumper Hole Cover LH (For Standard) Claws w/ Fog Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 5 claws to install the front bumper hole cover LH.

Fig. 32: Identifying Front Bumper Hole Cover LH (For Standard) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL FRONT BUMPER HOLE COVER RH (for Standard) HINT: Use the same procedure as for the LH side. 8. INSTALL FRONT BUMPER HOLE COVER LH (for Sport Package) a. Engage the 3 claws and guide to install the fog light mounting bracket LH.

Fig. 33: Identifying Fog Light Mounting Bracket LH (For Sport Package) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 claws to install the front bumper side moulding LH.

Fig. 34: Identifying Front Bumper Hole Cover LH (For Sport Package) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the 2 screws. d. Engage the 7 claws to install the front bumper hole cover LH.

Fig. 35: Identifying Front Bumper Hole Cover LH (For Sport Package) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the 2 screws. 9. INSTALL FRONT BUMPER HOLE COVER RH (for Sport Package) HINT: Use the same procedure as for the LH side. 10. INSTALL FRONT FENDER LINER RETAINER a. Engage the claw to install the front fender liner retainer.

Fig. 36: Identifying Front Fender Liner Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. 11. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET (for Standard) a. w/o Side Turn Signal Light: 1. Engage the 2 hooks.

Fig. 37: Identifying Front Bumper Extension Mounting Bracket (For Standard) w/o Side Turn Signal Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Install the front bumper extension mounting bracket with the 2 screws. b. w/ Side Turn Signal Light: 1. Engage the 2 hooks.

Fig. 38: Identifying Front Bumper Extension Mounting Bracket (For Standard) w/ Side Turn Signal Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook 2. Install the front bumper extension mounting bracket with the 2 screws. 12. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET (for Sport Package) a. Engage the 2 hooks.

Fig. 39: Identifying Front Bumper Extension Mounting Bracket (For Sport Package) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook b. Install the front bumper extension mounting bracket with the 2 screws. 13. INSTALL FOG LIGHT ASSEMBLY LH (w/ Fog Light) . Refer to INSTALLATION - Step 1 . 14. INSTALL FOG LIGHT ASSEMBLY RH (w/ Fog Light) HINT: Use the same procedure as for the LH side. 15. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 1 . 16. INSTALL NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 . INSTALLATION INSTALLATION

1. INSTALL FRONT BUMPER ASSEMBLY a. Move the front bumper assembly into position and install the 3 clips. b. Pull back the side of the front bumper assembly and connect each connector.

NOTE:

Do not apply excessive force when pulling back the side of the front bumper assembly.

HINT: Use the same procedure for the RH side and LH side. c. Engage the 3 claws to install the front bumper assembly.

Fig. 40: Engaging Front Bumper Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side.

d. Install the 6 screws. e. Install the pin hold clip as shown in the illustration.

Fig. 41: Installing Front Bumper Assembly Pin Holding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pin Hold *1 Clip *a Correct *b Incorrect NOTE:

Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is aligned vertically.

HINT: Use the same procedure for the RH side and LH side. f. Install the clip. HINT: Use the same procedure for the RH side and LH side. 2. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION. 3. ADJUST FOG LIGHT ASSEMBLY (w/ Fog Light) Refer to ADJUSTMENT .

REAR BUMPER COMPONENTS ILLUSTRATION

Fig. 42: Identifying Rear Bumper Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 43: Identifying Rear Bumper Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 44: Identifying Rear Bumper Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE REAR BUMPER PLATE LH a. Using a screwdriver with the tip wrapped with protective tape, disengage the 2 claws.

Fig. 45: Removing Rear Bumper Plate LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *2 Hook HINT: Tape the screwdriver tip before use.

b. Disengage the hook and remove the rear bumper plate LH. 2. REMOVE REAR BUMPER PLATE RH HINT: Use the same procedure as for the LH side. 3. REMOVE REAR BUMPER ASSEMBLY a. Put protective tape around the rear bumper assembly.

Fig. 46: Identifying Protective Tape On Rear Bumper Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a clip remover, remove the 2 clips.

Fig. 47: Identifying Rear Bumper Assembly Rear Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 6 screws. d. Remove the 2 screws.

Fig. 48: Identifying Rear Bumper Assembly Side Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. e. Disengage the 7 claws as shown in the illustration.

Fig. 49: Disengaging Rear Bumper Assembly Side Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. f. Disengage the 6 claws as shown in the illustration.

Fig. 50: Disengaging Rear Bumper Assembly Rear Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. w/ Intuitive Parking Assist System: 1. Disconnect the connector. h. Remove the rear bumper assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 2 LUGGAGE ROOM WIRE (w/ Intuitive Parking Assist System) a. Disengage the 4 clamps.

Fig. 51: Identifying No. 2 Luggage Room Wire Clamps (w/ Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3. 4. 5.

b. Disconnect the connector and remove the No. 2 luggage room wire. REMOVE ULTRASONIC SENSOR CLIP (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 2 . REMOVE NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 3 . REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to REMOVAL - Step 4 . REMOVE REAR BUMPER SIDE RETAINER LH a. Remove the 3 screws.

Fig. 52: Identifying Rear Bumper Side Retainer LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 6 claws and remove the rear bumper side retainer LH. 6. REMOVE REAR BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 7. REMOVE WHEEL HOUSE REINFORCEMENT LH a. Disengage the clip. b. Remove the screw.

Fig. 53: Identifying Wheel House Reinforcement LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the nut and wheel house reinforcement LH. 8. REMOVE WHEEL HOUSE REINFORCEMENT RH HINT: Use the same procedure as for the LH side. 9. REMOVE REAR BUMPER ENERGY ABSORBER a. Disengage the 2 guides and remove the rear bumper energy absorber.

Fig. 54: Locating Rear Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE REAR BUMPER REINFORCEMENT SUB-ASSEMBLY a. Remove the 6 nuts and rear bumper reinforcement sub-assembly.

Fig. 55: Identifying Rear Bumper Reinforcement Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL REAR BUMPER REINFORCEMENT SUB-ASSEMBLY a. Install the rear bumper reinforcement sub-assembly with the 6 nuts.

Fig. 56: Identifying Rear Bumper Reinforcement Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 2. INSTALL REAR BUMPER ENERGY ABSORBER a. Engage the 2 guides to install the rear bumper energy absorber.

Fig. 57: Locating Rear Bumper Energy Absorber Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL WHEEL HOUSE REINFORCEMENT LH a. Install the wheel house reinforcement LH with the screw and nut.

Fig. 58: Identifying Wheel House Reinforcement LH Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clip. 4. INSTALL WHEEL HOUSE REINFORCEMENT RH HINT: Use the same procedure as for the LH side. 5. INSTALL REAR BUMPER SIDE RETAINER LH a. Engage the 6 claws.

Fig. 59: Identifying Rear Bumper Side Retainer LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear bumper side retainer LH with the 3 screws.

6. INSTALL REAR BUMPER SIDE RETAINER RH HINT: Use the same procedure as for the LH side. 7. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 1 . 8. INSTALL NO. 1 ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 2 . 9. INSTALL ULTRASONIC SENSOR CLIP (w/ Intuitive Parking Assist System) . Refer to INSTALLATION - Step 3 . 10. INSTALL NO. 2 LUGGAGE ROOM WIRE (w/ Intuitive Parking Assist System) a. Connect the 4 connectors.

Fig. 60: Identifying No. 2 Luggage Room Wire Clamps (w/ Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 4 clamps to install the No. 2 luggage room wire. INSTALLATION INSTALLATION

1. INSTALL REAR BUMPER ASSEMBLY a. w/ Intuitive Parking Assist System:

1. Connect the connector. b. Engage the 6 claws.

Fig. 61: Identifying Rear Bumper Assembly Rear Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 7 claws and install the rear bumper assembly as shown in the illustration.

Fig. 62: Engaging Rear Bumper Assembly Side Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. d. Install the 10 screws. e. Install the 2 clips. 2. INSTALL REAR BUMPER PLATE LH a. Engage the hook.

Fig. 63: Identifying Rear Bumper Plate LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Hook b. Engage the 2 claws to install the rear bumper plate LH. 3. INSTALL REAR BUMPER PLATE RH HINT: Use the same procedure as for the LH side.

REAR SPOILER

COMPONENTS ILLUSTRATION

Fig. 64: Identifying Rear Spoiler Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 65: Identifying Rear Spoiler Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 . 2. REMOVE REAR SPOILER SUB-ASSEMBLY HINT: When removing the rear spoiler sub-assembly, heat the vehicle body and rear spoiler sub-assembly using a heat light. Heating Temperature Item Temperature 40 to 60°C Vehicle (104 to 140° Body F)

Rear 20 to 30°C Spoiler (68 to 86°F) NOTE:

Do not heat the vehicle body, rear spoiler sub-assembly excessively.

a. Put protective tape around the rear spoiler sub-assembly.

Fig. 66: Identifying Protective Tape On Rear Spoiler Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 2 nuts.

Fig. 67: Identifying Rear Spoiler Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert a piano wire between the vehicle body and rear spoiler sub-assembly.

Fig. 68: Removing Rear Spoiler Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden Piano *1 *2 Block Wire No. 1 No. 2 Rear Rear *3 *4 Spoiler Spoiler Protector Protector Stud *5 Clip *6 Bolt d. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.

e. Pull the piano wire and scrape off the No. 1 rear spoiler protector and 2 No. 2 rear spoiler protectors that holds the rear spoiler sub-assembly to the vehicle body. NOTE:

Be careful not to damage the vehicle body.

f. Disengage the 4 clips and remove the rear spoiler sub-assembly. g. Remove the No. 1 rear spoiler protector.

Fig. 69: Identifying No. 1 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the No. 2 rear spoiler protector.

Fig. 70: Identifying No. 2 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side and LH side. i. Remove the 4 clips from the rear spoiler. j. Remove the 2 gaskets from the rear spoiler. k. When replacing the rear spoiler with a new one: 1. Remove the 2 stud bolts from the rear spoiler. 3. REMOVE NO. 3 REAR SPOILER PROTECTOR a. Remove the 2 No. 3 rear spoiler protectors.

Fig. 71: Identifying No. 3 Rear Spoiler Protectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 4 REAR SPOILER PROTECTOR a. Remove the 2 No. 4 rear spoiler protectors.

Fig. 72: Identifying No. 4 Rear Spoiler Protectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NO. 5 REAR SPOILER PROTECTOR a. Remove the 2 No. 5 rear spoiler protectors.

Fig. 73: Identifying No. 5 Rear Spoiler Protectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 3 REAR SPOILER PROTECTOR a. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler.

2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 3 rear spoiler protectors. 1. Remove the release paper from the 2 No. 3 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install a 2 new No. 3 rear spoiler protectors. 2. INSTALL NO. 4 REAR SPOILER PROTECTOR a. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 4 rear spoiler protectors. 1. Remove the release paper from the 2 No. 4 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install 2 new No. 4 rear spoiler protectors as shown in the illustration.

Fig. 74: Identifying No. 4 Rear Spoiler Protectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 5.2 mm (0.205 5.2 mm (0.205 A B in.) in.) 3. INSTALL NO. 5 REAR SPOILER PROTECTOR a. Clean the rear spoiler.

1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. b. Install 2 new No. 5 rear spoiler protectors. 1. Remove the release paper from the 2 No. 5 rear spoiler protectors. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install a 2 new No. 5 rear spoiler protectors as shown in the illustration.

Fig. 75: Identifying No. 5 Rear Spoiler Protectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 38.0 mm (1.5 38.0 mm (1.5 A B in.) in.) 4. INSTALL REAR SPOILER SUB-ASSEMBLY a. When replacing the rear spoiler with a new one: 1. Install the 2 stud bolts to the rear spoiler. b. Install 2 new gaskets to the rear spoiler. c. Install 4 new clips to the rear spoiler. d. Clean the rear spoiler. 1. Remove any double-sided tape from the rear spoiler. 2. Wipe off any tape adhesive residue with cleaner. e. Install a new No. 2 rear spoiler protector. 1. Remove the release paper from the No. 2 rear spoiler protector. HINT:

After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install a new No. 2 rear spoiler protector. HINT: Use the same procedure for the RH side and LH side. f. Install the No. 1 rear spoiler protector. 1. Remove the release paper from the No. 1 rear spoiler protector. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 2. Install the No. 1 rear spoiler protector as shown in the illustration.

Fig. 76: Identifying No. 1 Rear Spoiler Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement Dimension Measurement 5.0 mm (0.197 5.0 mm (0.197 A B in.) in.) g. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. h. Install the rear spoiler sub-assembly. 1. Using a heat light, heat the vehicle body and rear spoiler sub-assembly. 2. Remove the release paper from the rear spoiler sub-assembly.

HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Engage the 4 clips.

Fig. 77: Identifying Rear Spoiler Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install the rear spoiler sub-assembly with the 2 nuts. 5. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 12 .

RADIATOR GRILLE COMPONENTS ILLUSTRATION

Fig. 78: Identifying Radiator Grille Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL

a. Remove the 7 clips and cool air intake duct seal.

Fig. 79: Identifying Cool Air Intake Duct Seal Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RADIATOR GRILLE SUB-ASSEMBLY a. Put protective tape around the radiator grille sub-assembly.

Fig. 80: Identifying Protective Tape On Radiator Grille Sub-Assembly And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 3 clips. c. Disengage the 8 claws, and remove the radiator grille sub-assembly.

Fig. 81: Removing Radiator Grille Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for for *A *B Sport Standard Package 3. REMOVE HOOD TO RADIATOR GRILLE SEAL a. Disengage the 15 clips to remove the hood to radiator grille seal.

Fig. 82: Identifying Hood To Radiator Grille Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE RADIATOR GRILLE EMBLEM ASSEMBLY a. w/o Screw: 1. Disengage the 3 claws and guide, and remove the radiator grille emblem assembly.

Fig. 83: Identifying Radiator Grille Emblem Assembly w/o Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Screw: 1. Remove the 2 screws.

Fig. 84: Identifying Radiator Grille Emblem Assembly w/ Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disengage the 4 claws and 2 guides, and remove the radiator grille emblem assembly. INSTALLATION INSTALLATION

1. INSTALL RADIATOR GRILLE EMBLEM ASSEMBLY a. w/o Screw: 1. Engage the guide and 3 claws to install the radiator grille emblem assembly. b. w/ Screw: 1. Engage the 2 guides and 4 claws, and remove the radiator grille emblem assembly. 2. Install the 2 screws.

2. INSTALL HOOD TO RADIATOR GRILLE SEAL a. Engage the 15 clips to install the hood to radiator grille seal. 3. INSTALL RADIATOR GRILLE SUB-ASSEMBLY a. Engage the 8 claws to install the radiator grille sub-assembly.

Fig. 85: Installing Radiator Grille Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for for *A *B Sport Standard Package b. Install the 3 clips. 4. INSTALL COOL AIR INTAKE DUCT SEAL a. Install the cool air intake duct seal with the 7 clips.

NAME PLATE COMPONENTS ILLUSTRATION

Fig. 86: Identifying Name Plate Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

When removing the name plates or emblem, heat the vehicle body and name plates or emblem using a heat light. HEATING TEMPERATURE Item Vehicle Body Name Plate or Emblem NOTE:

Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F)

Do not heat the vehicle body, name plates or emblem excessively.

1. REMOVE LUGGAGE COMPARTMENT DOOR EMBLEM a. Put protective tape around the luggage compartment door emblem.

Fig. 87: Identifying Protective Tape On Luggage Compartment Door Emblem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Protective *1 Tape b. Using a moulding remover, separate the double-sided tape and disengage the 2 pins to remove the luggage compartment door emblem. NOTE:





If reusing the luggage compartment door emblem, take care not to damage the symbol emblem. Be careful not to damage the vehicle body.

2. REMOVE NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Put protective tape around the No. 2 luggage compartment door name plate.

Fig. 88: Removing No. 2 Luggage Compartment Door Name Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape

b. Insert a piano wire between the vehicle body and No. 2 luggage compartment door name plate. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire to separate the double-sided tape that holds the No. 2 luggage compartment door name plate to the vehicle body. NOTE:





If reusing the No. 2 luggage compartment door name plate, take care not to damage the No. 2 luggage compartment door name plate. Be careful not to damage the vehicle body.

e. Remove the No. 2 luggage compartment door name plate. 3. REMOVE NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Put protective tape around the No. 3 luggage compartment door name plate.

Fig. 89: Removing No. 3 Luggage Compartment Door Name Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block Piano *2 Wire Protective *3 Tape

b. Insert a piano wire between the vehicle body and No. 3 luggage compartment door name plate. c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. d. Pull the piano wire to separate the double-sided tape that holds the No. 3 luggage compartment door name plate to the vehicle body. NOTE:





If reusing the No. 3 luggage compartment door name plate, take care not to damage the No. 3 luggage compartment door name plate. Be careful not to damage the vehicle body.

e. Remove the No. 3 luggage compartment door name plate. INSTALLATION INSTALLATION

HINT: When installing the name plates or emblem, heat the vehicle body and name plates or emblem using a heat light. HEATING TEMPERATURE Item Vehicle Body Name Plate or Emblem NOTE:

Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F)

Do not heat the vehicle body, name plates or emblem excessively.

1. INSTALL LUGGAGE COMPARTMENT DOOR EMBLEM a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the luggage compartment door emblem. (If reusing the luggage compartment door emblem) 1. Using a heat light, heat the luggage compartment door emblem. 2. Remove the double-sided tape from the luggage compartment door emblem. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the luggage compartment door emblem. c. Install the luggage compartment door emblem. 1. Using a heat light, heat the vehicle body and luggage compartment door emblem. 2. Remove the release paper from the luggage compartment door emblem.

HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Engage the 2 pins and install the luggage compartment door emblem as shown in the illustration.

Fig. 90: Identifying Luggage Compartment Door Emblem Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner.

b. Clean the No. 2 luggage compartment door name plate. (If reusing the No. 2 luggage compartment door name plate) 1. Using a heat light, heat the No. 2 luggage compartment door name plate. 2. Remove the double-sided tape from the No. 2 luggage compartment door name plate. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the No. 2 luggage compartment door name plate. c. Install the No. 2 luggage compartment door name plate. 1. Using a heat light, heat the vehicle body and No. 2 luggage compartment door name plate. 2. Remove the release paper from the No. 2 luggage compartment door name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the No. 2 luggage compartment door name plate.

Fig. 91: Identifying No. 2 Luggage Compartment Door Name Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of Luggage *1 -Compartment Door Panel Reference Measurement Area Measurement 51.7 mm (2.04 A in.) 223.0 mm B (8.78 in.)

C

52.9 mm (2.08 in.)

3. INSTALL NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Clean the No. 3 luggage compartment door name plate. (If reusing the No. 3 luggage compartment door name plate) 1. Using a heat light, heat the No. 3 luggage compartment door name plate. 2. Remove the double-sided tape from the No. 3 luggage compartment door name plate. 3. Wipe off any tape adhesive residue with cleaner. 4. Apply new double-sided tape to the No. 3 luggage compartment door name plate. c. Install the No. 3 luggage compartment door name plate. 1. Using a heat light, heat the vehicle body and No. 3 luggage compartment door name plate. 2. Remove the release paper from the No. 3 luggage compartment door name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. 3. Install the No. 3 luggage compartment door name plate.

Fig. 92: Identifying No. 3 Luggage Compartment Door Name Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Profile of Luggage *1 -Compartment Door Panel Reference Measurement Area Measurement

A B C D E F G H I

47.4 mm (1.87 in.) 140.8 mm (5.54 in.) 48.0 mm (1.89 in.) 47.1 mm (1.85 in.) 165.5 mm (6.52 in.) 47.9 mm (1.89 in.) 47.6 mm (1.87 in.) 142.8 mm (5.62 in.) 48.2 mm (1.90 in.)

FRONT DOOR BELT MOULDING COMPONENTS ILLUSTRATION

Fig. 93: Identifying Front Door Belt Moulding Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Refer to REMOVAL . 4. 5. 6. 7.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 10 . REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 15 . REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 . REMOVE FRONT DOOR BELT MOULDING ASSEMBLY a. Put protective tape around the front door belt moulding assembly.

Fig. 94: Identifying Protective Tape On Front Door Belt Moulding Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape

b. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws and remove the front door belt moulding assembly.

Fig. 95: Identifying Front Door Belt Moulding Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

a. Engage the 6 claws to install the front door belt moulding assembly.

Fig. 96: Identifying Front Door Belt Moulding Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. 4. 5. 6.

INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 33 . INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 34 . INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 . INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Refer to INSTALLATION .

7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION . 9. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK . 10. INSPECT SRS WARNING LIGHT

For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR DOOR BELT MOULDING COMPONENTS ILLUSTRATION

Fig. 97: Identifying Rear Door Belt Moulding Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 98: Identifying Rear Door Belt Moulding Replacement Components With Torque Specifications (2 Of 2)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 . 4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 4 . 5. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 5 . 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 6 . 7. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 8 . 8. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 9 . 9. REMOVE REAR DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 10 . 10. REMOVE REAR DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 . 11. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 12 . 12. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 13 . 13. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 14 . 14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 15 . 15. REMOVE REAR DOOR BELT MOULDING ASSEMBLY a. Put protective tape around the rear door belt moulding assembly.

Fig. 99: Identifying Protective Tape On Rear Door Belt Moulding Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws to remove the rear door belt moulding assembly as shown in the illustration.

Fig. 100: Identifying Rear Door Belt Moulding Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL REAR DOOR BELT MOULDING ASSEMBLY a. Engage the 6 claws to install the rear door belt moulding assembly as shown in the illustration.

Fig. 101: Identifying Rear Door Belt Moulding Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 . 3. INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 . 4. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 . 5. INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 . 6. INSTALL REAR DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 25 . 7. INSTALL REAR DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 26 . 8. INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 . 9. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 . 10. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 . 11. INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 . 12. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 . 13. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 . 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

15. INSPECT POWER WINDOW OPERATION

Refer to OPERATION CHECK .

ROCKER PANEL MOULDING COMPONENTS ILLUSTRATION

Fig. 102: Identifying Rocker Panel Moulding Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT ROCKER PANEL MOULDING END COVER . See step 1. 2. REMOVE ROCKER PANEL MOULDING a. Put protective tape around the rocker panel moulding and door.

Fig. 103: Identifying Protective Tape On Rocker Panel Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 -Tape b. Remove the 2 screws and grommet.

Fig. 104: Identifying Rocker Panel Moulding Front Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the screw.

Fig. 105: Identifying Rocker Panel Moulding Rear Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the 7 clips.

Fig. 106: Identifying Rocker Panel Moulding Lower Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the screw.

Fig. 107: Identifying Rocker Panel Moulding Front Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disengage the 10 clips and remove the rocker panel moulding.

Fig. 108: Identifying Rocker Panel Moulding Front Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the 10 clips from the rocker panel moulding. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 4 ROCKER PANEL MOULDING PROTECTOR a. Remove the No. 4 rocker panel moulding protector.

Fig. 109: Identifying No. 4 Rocker Panel Moulding Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL NO. 4 ROCKER PANEL MOULDING PROTECTOR a. Install the No. 4 rocker panel moulding protector.

Fig. 110: Identifying No. 4 Rocker Panel Moulding Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL ROCKER PANEL MOULDING a. Install new 10 clips to the rocker panel moulding. b. Engage the 10 clips and install the rocker panel moulding. c. Install the screw. d. Install the 7 clips. e. Install the screw. f. Install a new grommet and 2 screws. 2. INSTALL FRONT ROCKER PANEL MOULDING END COVER . See step 1.

FRONT DOOR WINDOW FRAME MOULDING COMPONENTS ILLUSTRATION

Fig. 111: Identifying Front Door Window Frame Moulding Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 112: Identifying Front Door Window Frame Moulding Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery

terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Refer to REMOVAL . 4. 5. 6. 7. 8. 9. 10. 11.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 10 . REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 15 . REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 . REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 20 . REMOVE FRONT DOOR BELT MOULDING ASSEMBLY . See step 7. REMOVE FRONT DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 36 . REMOVE FRONT DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 37 . REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING HINT: When removing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Moulding (68 to 86°F) NOTE:

Do not heat the vehicle body or moulding excessively.

a. Using a heat light, heat the front door rear window frame moulding. b. Using a moulding remover, disengage the clip and remove the front door rear window frame moulding.

Fig. 113: Identifying Front Door Rear Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge 12. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING a. Insert a 4.0 mm (0.157 in.) drill bit into a drill. b. Tape a 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

Fig. 114: Removing Front Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Dimension A 5.0 mm

NOTE:

Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

c. Lightly press the drill against the rivets to drill off the rivet flanges, and remove the 7 rivets. NOTE:







Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. Prying the rivets with the drill may damage the rivet installation holes or drill bit. Be careful of the drilled rivets, as they may be hot.

d. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. e. Disengage the claw and guide, and remove the front door upper window frame moulding from the door frame. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING a. Engage the claw and guide of the front door upper window frame moulding to the door frame.

Fig. 115: Installing Front Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 7 new rivets.

HINT: If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again. NOTE:



Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

Fig. 116: Do Not Pry The Rivet With The Riveter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *2 Mandrel *a Incorrect 

Confirm that the rivets are seated properly against the moulding. Do no tilt the riveter when installing the rivet to the moulding. Do not leave an space between the rivet head and moulding.

Fig. 117: Confirming That The Rivets Are Seated Properly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 

Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

Fig. 118: Firmly Hold The 2 Items Together While Installing The Rivet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 3. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING HINT: When installing a new front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Moulding (68 to 86°F) NOTE:

Do not heat the vehicle body or front door rear window frame moulding excessively.

a. Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Install a new front door rear window frame moulding.

Fig. 119: Identifying Front Door Rear Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge

1. Using a heat light, heat the vehicle body and front door rear window frame moulding. 2. Remove the release paper from the face of the front door rear window frame moulding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter.

4. 5. 6. 7. 8. 9. 10. 11.

3. Install the front door rear window frame moulding with the clip. INSTALL FRONT DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 12 . INSTALL FRONT DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 13 . INSTALL FRONT DOOR BELT MOULDING ASSEMBLY . See step 2. INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 29 . INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 33 . INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 34 . INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 . INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Refer to INSTALLATION .

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION . 14. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK . 15. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR DOOR WINDOW FRAME MOULDING COMPONENTS ILLUSTRATION

Fig. 120: Identifying Rear Door Window Frame Moulding Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 121: Identifying Rear Door Window Frame Moulding Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 122: Identifying Rear Door Window Frame Moulding Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 . 4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 4 . 5. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 5 . 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 6 . 7. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 8 . 8. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 9 . 9. REMOVE REAR DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 10 . 10. REMOVE REAR DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 . 11. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 12 . 12. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 13 . 13. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 14 . 14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 15 . 15. REMOVE REAR DOOR BELT MOULDING ASSEMBLY . See step 15. 16. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING HINT: When removing the rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Moulding (68 to 86°F) NOTE:

Do not heat the vehicle body or moulding excessively.

a. Using a heat light, heat the rear door front window frame moulding. b. Using a moulding remover, disengage the clip and remove the rear door front window frame moulding.

Fig. 123: Identifying Rear Door Front Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge 17. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING a. Insert a 4.0 mm (0.157 in.) drill bit into a drill. b. Tape a 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

Fig. 124: Removing Rear Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Area Dimension A 5.0 mm

NOTE:

Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

c. Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 6 rivets. NOTE:







Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. Prying the rivets with the drill may damage the rivet installation holes or drill bit. Be careful of the drilled rivets, as they may be hot.

d. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. e. Disengage the guide, remove the rear door upper window frame moulding from the door frame. INSTALLATION INSTALLATION

1. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING a. Engage the guide of the rear door upper window frame moulding to the door frame.

Fig. 125: Installing Rear Door Upper Window Frame Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 6 new rivets.

HINT: If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again. NOTE:



Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

Fig. 126: Do Not Pry The Rivet With The Riveter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *2 Mandrel *a Incorrect 

Confirm that the rivets are seated properly against the moulding. Do no tilt the riveter when installing the rivet to the moulding. Do not leave an space between the rivet head and moulding.

Fig. 127: Confirming That The Rivets Are Seated Properly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 

Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

Fig. 128: Firmly Hold The 2 Items Together While Installing The Rivet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Riveter *a Incorrect 2. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING HINT: When installing a new rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light. HEATING TEMPERATURE Item Temperature 40 to 60°C Vehicle (104 to 140° Body F) 20 to 30°C Moulding (68 to 86°F) NOTE:

Do not heat the vehicle body or rear door front window frame moulding excessively.

a. Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface. 2. Remove the double-sided tape from the vehicle body. 3. Wipe off any tape adhesive residue with cleaner. b. Install a new rear door front window frame moulding.

Fig. 129: Identifying New Rear Door Front Window Frame Molding Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Double*1 sided Tape Caulking *2 Sponge

1. Using a heat light, heat the vehicle body and rear door front window frame moulding. 2. Remove the release paper from the rear door front window frame moulding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

3. Install the rear door front window frame moulding with the clip. INSTALL REAR DOOR BELT MOULDING ASSEMBLY . See step 1. INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 . INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 . INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 . INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 . INSTALL REAR DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 25 . INSTALL REAR DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 26 . INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 . INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 . INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 . INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 . INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 . INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

17. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK .

ROOF DRIP SIDE FINISH MOULDING COMPONENTS ILLUSTRATION

Fig. 130: Identifying Roof Drip Side Finish Moulding Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CENTER ROOF DRIP SIDE FINISH MOULDING a. Put protective tape around the center roof drip side finish moulding.

Fig. 131: Identifying Protective Tape On Center Roof Drip Side Finish Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a moulding remover, disengage the 2 clips and remove the center roof drip side finish moulding.

Fig. 132: Identifying Center Roof Drip Side Finish Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the clips. If any clip is damaged or falls out, replace it with a new one.

INSTALLATION INSTALLATION

1. INSTALL NO. 1 ROOF DRIP SIDE FINISH MOULDING CLIP NOTE:

When installing new clips, remove the double-sided tape remaining where the clips will be installed on the body and clean the body with a nonresidue solvent.

a. Apply a 2 to 3 mm (0.0787 to 0.118 in.) bead of adhesive (3M DP-105 or equivalent) to new No. 1 roof drip side finish moulding clips.

Fig. 133: Applying 2 To 3 mm (0.0787 To 0.118 In.) Bead Of Adhesive (3M DP-105 Or Equivalent) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive 2 to 3 mm *a Bead of Adhesive HINT: Adhesive strength (tensile strength): 13.7 MPa (140.0 kgf/cm2 , 1987 psi) or more (when the temperature is 23°C (73°F)) b. Press and install the 2 No. 1 roof drip side finish moulding clips. c. Install the clips to the positions on the roof panel shown in the illustration. Determine the locations and firmly press and install the 2 No. 1 roof drip side finish moulding clips after lightly applying adhesive (3M DP-105 or equivalent).

Fig. 134: Installing No. 1 Roof Drip Side Finish Molding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for *A for Front *B Rear Protruding *1 - Part STANDARD DIMENSION Installation Dimension Measurement Area 4.0 mm (0.157 A in.) 4.0 mm (0.157 B in.) for Front 1.8 mm C (0.0709 in.) 1.8 mm D (0.0709 in.) 4.0 mm (0.157 E in.) for Rear 4.0 mm (0.157 F in.)

G H

1.8 mm (0.0709 in.) 1.8 mm (0.0709 in.)

d. Install the roof drip center side finish moulding when 20 minutes or more have elapsed after pressing and installing 2 new No. 1 roof drip side finish moulding clips. HINT: Initial hardening time: 20 minutes  Complete hardening time: 48 hours 2. INSTALL CENTER ROOF DRIP SIDE FINISH MOULDING a. Engage the 2 clips and install the center roof drip side finish moulding. 

Fig. 135: Identifying Center Roof Drip Side Finish Molding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH COMPONENTS ILLUSTRATION

Fig. 136: Identifying Luggage Compartment Door Outside Garnish Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 137: Identifying Luggage Compartment Door Outside Garnish Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 138: Identifying Luggage Compartment Door Outside Garnish Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 . 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to DISASSEMBLY - Step 5 . 3. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY a. w/ Smart Key System: 1. Disconnect the connector. b. w/ Wireless Door Lock Control System: 1. Remove the 6 nuts.

Fig. 139: Identifying Luggage Compartment Door Outside Garnish Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ Smart *A Key System w/ Wireless Door *B Lock Control System

c. w/o Wireless Door Lock Control System: 1. Remove the 4 nuts. d. Put protective tape around the luggage compartment door outside garnish sub-assembly.

Fig. 140: Identifying Protective Tape On Luggage Compartment Door Outside Garnish SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Back *2 Door Outside Garnish

Clip e. Disengage the 3 clips and remove the luggage compartment door outside garnish sub-assembly. f. Remove the clip (back door outside garnish clip) and 2 clips from the luggage compartment door outside garnish sub-assembly. g. Remove the 6 gaskets from the luggage compartment door outside garnish sub-assembly. 4. REMOVE LUGGAGE ELECTRICAL KEY SWITCH COVER (w/o Smart Key System) a. Remove the luggage electrical key switch cover.

Fig. 141: Identifying Luggage Electrical Key Switch Cover (w/o Smart Key System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) . Refer to REMOVAL - Step 2 . 6. REMOVE LUGGAGE COMPARTMENT DOOR EMBLEM . See step 1. 7. REMOVE BACK DOOR OUTSIDE GARNISH PROTECTOR a. Remove the back door outside garnish protector.

Fig. 142: Identifying Back Door Outside Garnish Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL BACK DOOR OUTSIDE GARNISH PROTECTOR a. Clean the luggage compartment door outside garnish sub-assembly. 1. Remove any double-sided tape from the luggage compartment door outside garnish subassembly. 2. Wipe off any tape adhesive residue with cleaner. b. Install a new back door outside garnish protector. 1. Remove the release paper from the back door outside garnish protector.

HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. c. Install a new back door outside garnish protector shown in the illustration.

Fig. 143: Identifying Back Door Outside Garnish Protector Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT Dimension Measurement 5.9 mm (0.232 a in.) 2. INSTALL LUGGAGE COMPARTMENT DOOR EMBLEM . See step 1.

3. INSTALL LUGGAGE ELECTRICAL KEY SWITCH COVER (w/o Smart Key System) a. Install the luggage electrical key switch cover. 4. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) . Refer to INSTALLATION - Step 1 . 5. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY a. Install 6 new gaskets to the luggage compartment door outside garnish sub-assembly. b. Install new clip (back door outside garnish clip) and 2 new clips to the luggage compartment door outside garnish sub-assembly. c. Engage the 3 clips to install the luggage compartment door outside garnish sub-assembly.

Fig. 144: Identifying Luggage Compartment Door Outside Garnish Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. w/ Wireless Door Lock Control System:

1. Install the 6 nuts. e. w/o Wireless Door Lock Control System: 1. Install the 4 nuts. f. w/ Smart Key System: 1. Connect the connector. 6. INSTALL LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to REASSEMBLY - Step 8 . 7. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 12 .

REAR WHEEL HOUSE PLATE COMPONENTS ILLUSTRATION

Fig. 145: Identifying Rear Wheel House Plate Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT ROCKER PANEL MOULDING END COVER a. Remove the 2 screws and front rocker panel moulding end cover.

Fig. 146: Identifying Front Rocker Panel Molding End Cover Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL FRONT ROCKER PANEL MOULDING END COVER a. Install the front rocker panel moulding end cover with the 2 screws.

BLACK OUT TAPE (FOR FRONT DOOR) COMPONENTS ILLUSTRATION

Fig. 147: Identifying Black Out Tape (For Front Door) Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 148: Identifying Black Out Tape (For Front Door) Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery

terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Refer to REMOVAL . 4. 5. 6. 7. 8. 9. 10. 11.

REMOVE DOOR SIDE AIRBAG SENSOR . Refer to REMOVAL - Step 10 . REMOVE FRONT DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 15 . REMOVE FRONT DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 16 . REMOVE FRONT DOOR GLASS RUN . Refer to DISASSEMBLY - Step 20 . REMOVE FRONT DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 36 . REMOVE FRONT DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 37 . REMOVE DOOR FRAME GARNISH . Refer to DISASSEMBLY - Step 38 . REMOVE FRONT DOOR STRIPE a. Using a heat light, heat the front door stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Front (104 to 140° Door F) Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the front door stripe to remove it.

Fig. 149: Identifying Front Door Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. 12. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE a. Using a heat light, heat the front door lower outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Front (104 to 140° Door F) Rear Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the front door lower outside stripe to remove it.

Fig. 150: Identifying Front Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REPAIR INSTRUCTION a. Clean the vehicle body surface. 1. Using a heat light, heat the vehicle body surface. HEATING TEMPERATURE Item Temperature Vehicle 40 to 60°C Body (104 to 140°

F) NOTE:

Do not heat the vehicle body excessively.

2. Wipe off any tape adhesive residue with cleaner. b. Installation temperature 1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation. HINT: The most appropriate temperature for installing the tape is 25°C (77°F).  When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases. c. Before installation 1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance. 

HINT: Spray water on the shop floor to settle any dust. d. Key points for handling the tape 1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat. NOTE:

Do not bend the tape or leave it in high temperature places.

e. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces) NOTE:





Position the tape accurately to achieve a neat finish and to avoid peeling. The tape cannot be reused because it deforms and will not fit any more after being removed.

1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the

tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 30 to 70 mm (1.18 to 2.76 in.) per second.

Fig. 151: Identifying Proper Tape Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Pressing *A *B Pulling Forward NonPadded *1 padded *2 Side Side Black *3 Squeegee *4 Out Tape Release *5 - Paper Side *a - View REFERENCE MEASUREMENT Area Measurement 10 to 20 mm A (0.393 to 0.787 in.) 30 to 70 mm/sec. (1.18 B to 2.76 in./sec.)

C D

40 to 50° (for pressing forward) 30 to 45° (for pulling)

NOTE:

Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

HINT: Either angle of the squeegee (pressing forward or pulling) is acceptable.  Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee. f. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces) 1. If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem. 

Fig. 152: Example Of Applying Tape In Several Steps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Squeegee

*2 Hem *a First *b Second *c Third HINT: When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee. g. Key points for installation of the tape (how to use a squeegee and installation procedure for corners) 1. Remove the release paper and apply the tape carefully with your fingers. 2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish. h. Check after installation 1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape. NOTE:

Do not reuse the tape.

3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE a. Refer to the illustration to position the front door lower outside stripe.

Fig. 153: Installing Front Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

LH RH *B Side Side Edge of *a *b Square Curved Surface *c Round - -

*A

STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.) b. Remove the release paper and apply the stripe. 4. INSTALL FRONT DOOR STRIPE a. Refer to the illustration to position a new front door stripe.

Fig. 154: Installing Front Door Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH RH *A *B Side Side Edge *a of *b Square Curved

Surface *c Round - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.)

5. 6. 7. 8. 9. 10. 11. 12.

b. Remove the release paper and apply the stripe. INSTALL DOOR FRAME GARNISH . Refer to REASSEMBLY - Step 11 . INSTALL FRONT DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 12 . INSTALL FRONT DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 13 . INSTALL FRONT DOOR GLASS RUN . Refer to REASSEMBLY - Step 29 . INSTALL FRONT DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 33 . INSTALL FRONT DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 34 . INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION - Step 1 . INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Refer to INSTALLATION .

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

14. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Refer to INITIALIZATION . 15. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK . 16. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

BLACK OUT TAPE (FOR REAR DOOR)

COMPONENTS ILLUSTRATION

Fig. 155: Identifying Black Out Tape (For Rear Door) Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 156: Identifying Black Out Tape (For Rear Door) Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 157: Identifying Black Out Tape (For Rear Door) Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 . 4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 4 . 5. REMOVE REAR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 5 . 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 6 . 7. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 8 . 8. REMOVE REAR DOOR SERVICE HOLE COVER . Refer to DISASSEMBLY - Step 9 . 9. REMOVE REAR DOOR CHECK ASSEMBLY . Refer to DISASSEMBLY - Step 10 . 10. REMOVE REAR DOOR WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 . 11. REMOVE REAR DOOR GLASS RUN . Refer to DISASSEMBLY - Step 12 . 12. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 13 . 13. REMOVE REAR DOOR QUARTER WINDOW GLASS . Refer to DISASSEMBLY - Step 14 . 14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 15 . 15. REMOVE REAR DOOR FRAME GARNISH . Refer to DISASSEMBLY - Step 16 . 16. REMOVE REAR DOOR OUTSIDE STRIPE a. Using a heat light, heat the rear door outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Rear (104 to 140° Door F) Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the rear door outside stripe to remove it.

Fig. 158: Identifying Rear Door Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. 17. REMOVE REAR DOOR LOWER OUTSIDE STRIPE a. Using a heat light, heat the rear door lower outside stripe and vehicle body. HEATING TEMPERATURE Item Temperature Vehicle Body and 40 to 60°C Rear (104 to 140° Door F) Lower Outside Stripe NOTE:

Do not heat the vehicle body excessively.

b. Pull back on one of the ends of the rear door lower outside stripe to remove it.

Fig. 159: Identifying Rear Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When pulling on the stripe, pull it parallel to the body. INSTALLATION INSTALLATION

1. REPAIR INSTRUCTION . See step 2. 2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE a. Refer to the illustration to position a new rear door lower outside stripe.

Fig. 160: Installing Rear Door Lower Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION RH *A LH Side *B Side Edge of *a Curved *b Straight Surface *c Triangle - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.) b. Remove the release paper and apply the stripe. 3. INSTALL REAR DOOR OUTSIDE STRIPE a. Refer to the illustration to position a new rear door outside stripe.

Fig. 161: Installing Rear Door Outside Stripe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION RH *A LH Side *B Side Edge of *a Curved *b Straight Surface *c Triangle - STANDARD MEASUREMENT Dimension Measurement 1.5 mm A (0.0591 in.) 1.0 mm B (0.0394 in.)

4. 5. 6. 7. 8. 9. 10. 11.

b. Remove the release paper and apply the stripe. INSTALL REAR DOOR FRAME GARNISH . Refer to REASSEMBLY - Step 20 . INSTALL REAR DOOR GLASS SUB-ASSEMBLY . Refer to REASSEMBLY - Step 21 . INSTALL REAR DOOR QUARTER WINDOW GLASS . Refer to REASSEMBLY - Step 22 . INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY . Refer to REASSEMBLY - Step 23 . INSTALL REAR DOOR GLASS RUN . Refer to REASSEMBLY - Step 24 . INSTALL REAR DOOR WEATHERSTRIP . Refer to REASSEMBLY - Step 25 . INSTALL REAR DOOR CHECK ASSEMBLY . Refer to REASSEMBLY - Step 26 . INSTALL REAR DOOR SERVICE HOLE COVER . Refer to REASSEMBLY - Step 27 .

12. 13. 14. 15.

INSTALL REAR DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 28 . INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 30 . INSTALL REAR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 31 . INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 32 . 16. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 33 . 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

18. INSPECT POWER WINDOW OPERATION Refer to OPERATION CHECK .

2012-2017 SUSPENSION Front Suspension (Service Information) (Hybrid)

FRONT SHOCK ABSORBER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Shock Absorber Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Front Shock Absorber Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT WHEEL 2. LOOSEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Loosen the front support to front shock absorber nut.

Fig. 3: Identifying Front Shock Absorber Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the front support to front shock absorber nut. Loosen the front support to front shock absorber nut only when the front shock absorber with coil spring needs to be disassembled.

3. SEPARATE FRONT SPEED SENSOR a. Remove the bolt and clamp, and separate the front speed sensor and front flexible hose from the front shock absorber assembly.

Fig. 4: Locating Front Speed Sensor Clamp And Front Flexible Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to separate the front speed sensor from the front shock absorber assembly completely.

4. SEPARATE FRONT STABILIZER LINK ASSEMBLY a. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

Fig. 5: Identifying Front Stabilizer Link Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 5. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING a. Support the front axle using a jack and wooden block.

Fig. 6: Identifying Jack Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Jack Wooden *2 Block Front of the Vehicle b. Remove the 2 bolts and 2 nuts, and separate the front shock absorber with coil spring (lower side) from the steering knuckle.

Fig. 7: Locating Front Axle Assembly Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

c. Remove the 3 nuts and front shock absorber with coil spring.

Fig. 8: Identifying Front Shock Absorber Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the front speed sensor is completely separated from the front shock absorber with coil spring.

6. SECURE FRONT SHOCK ABSORBER WITH COIL SPRING a. Install SST to the front coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 9: Identifying SST To The Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

b. Install the bolt and nut to the front shock absorber assembly as shown in the illustration and secure the front shock absorber assembly in a vise using aluminum plates.

Fig. 10: Installing Bolt And Nut To Front Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 7. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Using SST, compress the front coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 11: Compressing Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use an impact wrench. It will damage SST.

If the front coil spring is compressed at an angle, using 2 SST will make the work easier. b. Check that the front coil spring is sufficiently compressed. c. Remove the front support to front shock absorber nut.

Fig. 12: Identifying Front Support To Front Shock Absorber Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE FRONT SUSPENSION SUPPORT SUB-ASSEMBLY REMOVE FRONT SUSPENSION SUPPORT BEARING REMOVE FRONT UPPER COIL SPRING SEAT REMOVE FRONT UPPER COIL SPRING INSULATOR REMOVE FRONT COIL SPRING REMOVE FRONT SPRING BUMPER REMOVE FRONT LOWER COIL SPRING INSULATOR REMOVE FRONT SHOCK ABSORBER ASSEMBLY

INSPECTION INSPECTION

1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY a. Compress and extend the shock absorber rod 4 or more times. Standard There is no abnormal resistance or sound and operation resistance is normal. If there is any abnormality, replace the front shock absorber assembly with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. SECURE FRONT SHOCK ABSORBER ASSEMBLY a. Install the bolt and nut to the front shock absorber assembly as shown in the illustration and secure the front shock absorber assembly in a vise using aluminum plates.

Fig. 13: Installing Bolt And Nut To Front Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 2. INSTALL FRONT LOWER COIL SPRING INSULATOR a. Install the front lower coil spring insulator to the front shock absorber assembly.

Fig. 14: Identifying Front Lower Coil Spring Insulator Positioning Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Positioning

Pin NOTE:

Make sure that the positioning pins on the front lower coil spring insulator are inserted into the holes in the front shock absorber assembly.

3. INSTALL FRONT SPRING BUMPER a. Install the front spring bumper to the front shock absorber assembly.

Fig. 15: Identifying Front Spring Bumper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Face the smaller diameter end of the front spring bumper downward.

4. INSTALL FRONT COIL SPRING a. Install SST to the front coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 16: Compressing Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

If the front coil spring is compressed at an angle, using 2 SST will make the work easier. b. Using SST, compress the front coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031 NOTE:

Do not use an impact wrench. It will damage SST.

c. Install the front coil spring to the front shock absorber assembly.

Fig. 17: Identifying Front Coil Spring & Front Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the end of the front coil spring is positioned in the depression of the front lower coil spring insulator.

5. INSTALL FRONT UPPER COIL SPRING INSULATOR a. Install the front upper coil spring insulator as shown in the illustration.

Fig. 18: Installing Front Upper Coil Spring Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Outside of the Vehicle NOTE:

Any misalignment between the front shock absorber lower bracket and the alignment mark must be +/- 5°.

6. INSTALL FRONT UPPER COIL SPRING SEAT a. Install the front upper coil spring seat with the mark facing the outside of the vehicle.

Fig. 19: Installing Front Upper Coil Spring Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Outside of the Vehicle NOTE:

Any misalignment between the front shock absorber lower bracket and the alignment mark must be +/- 5°.

7. INSTALL FRONT SUSPENSION SUPPORT BEARING a. Install the front suspension support bearing as shown in the illustration.

Fig. 20: Identifying Front Suspension Support Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Upper *a Side NOTE:

Do not install the bearing upside down.

8. INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY a. Install the front suspension support sub-assembly as shown in the illustration.

Fig. 21: Installing Front Suspension Support Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Foam Outside of the Vehicle HINT: Check that the slot on the piston rod and the slot on the front suspension support sub-assembly are aligned. b. Temporarily tighten a new front support to front shock absorber nut.

c. While aligning the stud bolt of the front suspension support sub-assembly and the front shock absorber lower bracket, remove SST from the front coil spring.

Fig. 22: Aligning The Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Foam Outside of the Vehicle NOTE:





When reassembling the front suspension support subassembly, ensure that any misalignment between the absorber lower bracket and the stud bolt is within +/- 5°. Use the stud bolt that is closest to the outside of the vehicle. Do not use an impact wrench. It will damage SST.

9. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING a. Install the front shock absorber with coil spring (upper side) with the 3 nuts. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) b. Install the front shock absorber with coil spring (lower side) to the steering knuckle and insert the 2 bolts and 2 nuts.

Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

While keeping the bolts from rotating, tighten the nuts.

10. INSTALL FRONT STABILIZER LINK ASSEMBLY a. Install the front stabilizer link assembly to the front shock absorber assembly with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 11. INSTALL FRONT SPEED SENSOR a. Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt and clamp. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

HINT: Install the speed sensor harness bracket first and then the front flexible hose. 12. FULLY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Fully tighten the front support to front shock absorber nut. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) NOTE:

Perform this step only when the front shock absorber with coil spring has been disassembled.

13. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 14. STABILIZE SUSPENSION a. Lower the vehicle and bounce it up and down several times to stabilize the front suspension. 15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT DISPOSAL DISPOSAL

1. DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY a. Position the front shock absorber assembly level with the piston rod fully extended. Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside.

Fig. 23: Drilling Hole In Cylinder Between A And B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Always use proper safety equipment and be careful when drilling because shards of metal may fly about. HINT: The gas is colorless, odorless and non-poisonous.

FRONT LOWER SUSPENSION ARM COMPONENTS ILLUSTRATION

Fig. 24: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 25: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications

(2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 26: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications

(3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 27: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 28: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to REMOVAL 3. REMOVE FRONT WHEELS 4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 4 SEPARATE EARTH WIRE . Refer to REMOVAL - Step 59 REMOVE NO. 2 ENGINE MOUNTING STAY RH . Refer to REMOVAL - Step 58 REMOVE ENGINE MOVING CONTROL ROD BRACKET . Refer to REMOVAL - Step 60 REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH (for LH Side) REMOVE FRONT FENDER APRON SEAL RH (for RH Side) SEPARATE NO. 4 ENGINE WIRE a. Remove the bolt and separate the No. 4 engine wire from the front frame assembly.

Fig. 29: Identifying No. 4 Engine Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. DISCONNECT OXYGEN SENSOR a. Disconnect the oxygen sensor connector.

Fig. 30: Identifying Oxygen Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. SEPARATE FRONT ENGINE MOUNTING INSULATOR a. Remove the 3 nuts to separate the front engine mounting insulator from the front frame assembly.

Fig. 31: Identifying Front Engine Mounting Insulator Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE ENGINE MOUNTING INSULATOR LH (for LH Side) a. Remove the 2 hole plugs.

Fig. 32: Identifying Engine Mounting Insulator LH (For LH Side) Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 nuts from the engine mounting insulator LH.

Fig. 33: Identifying Engine Mounting Insulator LH Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a jack and a wooden block, support the engine assembly with transaxle at the position shown in the illustration. While ensuring that there is no interference from the components surrounding the engine, tilt the engine assembly with transaxle to a position that allows the engine mounting insulator LH to be removed.

Fig. 34: Identifying Jack Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block Front of the Vehicle

NOTE:

 

  

Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Tilt the engine assembly with transaxle as little as possible. Ensure that the jack and wooden block are stable. Keep the engine assembly with transaxle supported until installation of the engine mounting insulator LH is complete.

d. Remove the engine mounting insulator LH from the front frame assembly.

Fig. 35: Identifying Engine Mounting Insulator LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for LH Side) a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly LH from the front lower ball joint assembly.

Fig. 36: Identifying Front Lower No. 1 Suspension Arm Sub-Assembly LH (For LH Side) Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly LH from the front frame assembly.

Fig. 37: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

c. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly LH. 20. REMOVE ENGINE MOUNTING INSULATOR RH (for RH Side) a. Remove the 2 hole plugs.

Fig. 38: Identifying Engine Mounting Insulator RH (For RH Side) Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 nuts from the engine mounting insulator RH.

Fig. 39: Identifying Engine Mounting Insulator RH Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a jack and a wooden block, support the engine assembly with transaxle at the position shown in the illustration. While ensuring that there is no interference from the components surrounding the engine, tilt the engine assembly with transaxle to a position that allows the engine mounting insulator RH to be removed.

Fig. 40: Identifying Jack Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block Front of the Vehicle

NOTE:

 

  

Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Tilt the engine assembly with transaxle as little as possible. Ensure that the jack and wooden block are stable. Keep the engine assembly with transaxle supported until installation of the engine mounting insulator RH is complete.

d. Remove the engine mounting insulator RH from the front frame assembly.

Fig. 41: Identifying Engine Mounting Insulator RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH (for RH Side) a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly RH from the front lower ball joint assembly.

Fig. 42: Identifying Front Lower No. 1 Suspension Arm Sub-Assembly RH (For RH Side) Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly RH from the front frame assembly.

Fig. 43: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

c. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for LH Side) a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly LH. b. Install the front lower No. 1 suspension arm sub-assembly LH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 44: Identifying Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3

Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

c. Install the front lower No. 1 suspension arm sub-assembly LH to the front lower ball joint assembly with the bolt and 2 nuts. Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 2. INSTALL ENGINE MOUNTING INSULATOR LH (for LH Side) a. Set the engine mounting insulator LH on the front frame assembly.

Fig. 45: Identifying Engine Mounting Insulator LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Pin b. Slowly lower the engine assembly with transaxle using a jack and a wooden block. NOTE:

  



Match the position of the pin (stopper). Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Ensure that the jack and wooden block are stable.

c. Using SST, install the nut to the engine mounting insulator LH.  SST: 09961-00950

Fig. 46: Installing Engine Mounting Insulator LH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length without SST Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) with SST

Torque: 68 N*m (695 kgf*cm, 50 ft.*lbf) NOTE:

 

Use a torque wrench with a fulcrum length of 380 mm (1.25 ft.). This torque value is effective when SST is parallel to the torque wrench.

d. Install the engine mounting insulator LH with the 3 nuts.

Fig. 47: Identifying Engine Mounting Insulator LH Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 2 hole plugs. 3. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH (for RH Side) a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly RH. b. Install the front lower No. 1 suspension arm sub-assembly RH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 48: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3 Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

c. Install the front lower No. 1 suspension arm sub-assembly RH to the front lower ball joint assembly with the bolt and 2 nuts. Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 4. INSTALL ENGINE MOUNTING INSULATOR RH (for RH Side) a. Set the engine mounting insulator RH on the front frame assembly.

Fig. 49: Installing Engine Mounting Insulator RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout b. Slowly lower the engine assembly with transaxle using a jack and a wooden block. NOTE:

  



Match the position of the cutout (stopper). Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Ensure that the jack and wooden block are stable.

c. Using SST, install the nut to the engine mounting insulator RH.  SST: 09961-00950

Fig. 50: Installing Engine Mounting Insulator RH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length without SST Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) with SST Torque: 68 N*m (695 kgf*cm, 50 ft.*lbf) NOTE:

 

Use a torque wrench with a fulcrum length of 380 mm (1.25 ft.). This torque value is effective when SST is parallel to the torque wrench.

d. Install the engine mounting insulator RH with the 3 nuts.

Fig. 51: Identifying Engine Mounting Insulator RH Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 2 hole plugs. 5. INSTALL FRONT ENGINE MOUNTING INSULATOR a. Install the front engine mounting insulator to the front frame assembly with the 3 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 6. CONNECT OXYGEN SENSOR a. Connect the oxygen sensor connector. 7. CONNECT NO. 4 ENGINE WIRE a. Connect the No. 4 engine wire to the front frame assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 8. INSTALL FRONT FENDER APRON SEAL LH (for LH Side)

9. 10. 11. 12. 13. 14.

INSTALL FRONT FENDER APRON SEAL RH (for RH Side) INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL ENGINE MOVING CONTROL ROD BRACKET a. Temporarily install the engine moving control rod bracket with the 4 bolts.

Fig. 52: Identifying Engine Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Fully tighten the engine moving control rod bracket with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 15. INSTALL NO. 2 ENGINE MOUNTING STAY RH . Refer to INSTALLATION - Step 34 16. INSTALL EARTH WIRE . Refer to INSTALLATION - Step 33 17. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 18 18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION - Step 2 19. INSTALL FRONT WHEELS

Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 20. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to INSTALLATION - Step 11 21. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT

FRONT LOWER BALL JOINT COMPONENTS ILLUSTRATION

Fig. 53: Identifying Front Lower Ball Joint Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT AXLE ASSEMBLY Refer to REMOVAL 2. REMOVE FRONT LOWER BALL JOINT ASSEMBLY a. Secure the front axle assembly in a vise using aluminum plates. NOTE:

When using a vise, do not overtighten it.

b. Remove the cotter pin and nut.

Fig. 54: Locating Front Lower Ball Joint Assembly Fasteners. Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install SST to the front lower ball joint assembly as shown in the illustration.  SST: 09960-20010 09961-02050 09961-02050

Fig. 55: Identifying Clearance Between SST And Front Axle Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Check that the clearance measurement between SST and the front axle assembly is 1 mm (0.0394 in.).

d. Using SST, remove the front lower ball joint assembly from the front axle assembly as shown in the illustration.  SST: 09960-20010 09961-02010 09961-02050 09961-02050

Fig. 56: Removing Front Lower Ball Joint Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Apply

*a grease Place *b wrench here WARNING: Apply grease to the threads and end of the SST bolt.

NOTE:

 



Install SST so that A and B are parallel. Be sure to place a wrench on the part indicated in the illustration. Do not damage the front lower ball joint dust cover.

INSPECTION INSPECTION

1. INSPECT FRONT LOWER BALL JOINT ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 57: Inspecting Lower Ball Joint Assembly Front LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the front lower ball joint assembly in a vise using aluminum plates. 2. Install the nut to the front lower ball joint assembly stud.

3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.98 to 3.43 N*m (10 to 34 kgf*cm, 9 to 30 in.*lbf) If the turning torque is not within the specified range, replace the front lower ball joint assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If the dust cover is cracked or there is grease on it, replace the front lower ball joint assembly with a new one. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT LOWER BALL JOINT ASSEMBLY a. Secure the front axle assembly in a vise using aluminum plates. NOTE:

When using a vise, do not overtighten it.

b. Install the front lower ball joint assembly to the front axle assembly with a new nut. Torque: 123 N*m (1254 kgf*cm, 91 ft.*lbf) NOTE:

Prevent oil from adhering to the threaded and tapered parts.

c. Install a new cotter pin. NOTE:

Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

2. INSTALL FRONT AXLE ASSEMBLY Refer to INSTALLATION - Step 6

FRONT STABILIZER BAR COMPONENTS ILLUSTRATION

Fig. 58: Identifying Front Stabilizer Bar Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Refer to REMOVAL 2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH a. Remove the nut and front stabilizer link assembly LH from the front stabilizer bar.

Fig. 59: Identifying Front Stabilizer Link Assembly LH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 3. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 4. REMOVE FRONT NO. 1 STABILIZER BRACKET LH a. Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.

Fig. 60: Identifying No. 1 Stabilizer Bracket LH Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side. 6. REMOVE FRONT STABILIZER BAR a. Remove the front stabilizer bar from the front frame assembly. 7. REMOVE FRONT NO. 1 STABILIZER BAR BUSHING a. Remove the 2 front No. 1 stabilizer bar bushings from the front stabilizer bar. INSPECTION INSPECTION

1. INSPECT FRONT STABILIZER LINK ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 61: Inspecting Front Stabilizer Link Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the front stabilizer link assembly in a vise using aluminum plates. 2. Install the nut to the front stabilizer link assembly stud. 3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.05 to 1.96 N*m (0.6 to 19 kgf*cm, 0.5 to 17 in.*lbf) If the turning torque is not within the specified range, replace the front stabilizer link assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If the dust cover is cracked or there is grease on it, replace the front stabilizer link assembly with a new one. INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 1 STABILIZER BAR BUSHING a. Install the 2 front No. 1 stabilizer bar bushings to the front stabilizer bar as shown in the

illustration.

Fig. 62: Installing Front No. 1 Stabilizer Bar Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout Front of the Vehicle Inside of the Vehicle NOTE:

When installing the front No. 1 stabilizer bar bushings, make sure that the cutout faces the rear of the vehicle.

2. INSTALL FRONT STABILIZER BAR a. Install the front stabilizer bar to the front frame assembly. 3. INSTALL FRONT NO. 1 STABILIZER BRACKET LH a. Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 4. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

HINT: Perform the same procedure as the LH side. 5. INSTALL FRONT STABILIZER LINK ASSEMBLY LH a. Install the front stabilizer link assembly LH to the front stabilizer bar with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 6. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 7. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Refer to INSTALLATION - Step 15

FRONT SUSPENSION MEMBER COMPONENTS ILLUSTRATION

Fig. 63: Identifying Front Suspension Member Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 64: Identifying Front Suspension Member Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 65: Identifying Front Suspension Member Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE FRONT FRAME ASSEMBLY Refer to REMOVAL 2. 3. 4. 5. 6.

REMOVE FRONT ENGINE MOUNTING INSULATOR . Refer to REMOVAL - Step 86 REMOVE ENGINE MOUNTING INSULATOR LH . Refer to REMOVAL - Step 87 REMOVE ENGINE MOUNTING INSULATOR RH . Refer to REMOVAL - Step 88 REMOVE FRONT NO. 1 STABILIZER BRACKET LH See step 4 REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side.

7. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY a. Remove the front stabilizer bar with 2 front stabilizer link assemblies from the front frame assembly. 8. REMOVE STEERING LINK ASSEMBLY . Refer to REMOVAL - Step 11 9. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH a. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly from the front frame assembly.

Fig. 66: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

b. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly. 10. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as the LH side. 11. REMOVE FRONT SUSPENSION MEMBER DYNAMIC DAMPER a. Remove the 2 bolts and front suspension member dynamic damper from the front frame assembly.

Fig. 67: Locating Front Suspension Member Dynamic Damper & Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER a. Remove the 2 front suspension member body mounting front stoppers from the front frame assembly. 13. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER a. Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly.

14. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION a. Install SST as shown in the illustration.  SST: 09830-10010 09830-01010 09830-01040 09830-01050  SST: 09950-40011 09951-04020 09952-04010 09954-04010 09955-04011 09958-04011

Fig. 68: Identifying Front Suspension Member Body Mounting Front Cushion & SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Suspension Member *1 Body Mounting Front Cushion b. Using SST, remove the front suspension member body mounting front cushion from the front frame assembly.

Fig. 69: Removing Front Suspension Member Body Mounting Front Cushion

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold NOTE:



  

Make sure that the claws of SST are securely hung onto the mounting cushion. Tighten SST slowly and evenly. Be careful as the mounting cushion may fly out. The mounting cushion cannot be reused.

15. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH a. Install SST as shown in the illustration.  SST: 09830-10010 09830-01010 09830-01040 09830-01050  SST: 09950-40011 09951-04020 09952-04010 09954-04010 09955-04011 09958-04011

Fig. 70: Identifying Front Suspension Member Body Mounting Front Cushion & SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Suspension Member Body *1 Mounting Rear Cushion LH b. Using SST, remove the front suspension member body mounting rear cushion LH from the front frame assembly.

Fig. 71: Removing Front Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold NOTE:



  

Make sure that the claws of SST are securely hung onto the mounting cushion. Tighten SST slowly and evenly. Be careful as the mounting cushion may fly out. The mounting cushion cannot be reused.

16. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH

HINT: Perform the same procedure as the LH side. 17. REMOVE HOLE PLUG a. Remove each hole plug from the front frame assembly. INSTALLATION INSTALLATION

1. INSTALL HOLE PLUG a. Install each hole plug to the front frame assembly. 2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH a. Temporarily install a new front suspension member body mounting rear cushion LH while confirming the installation direction.

Fig. 72: Confirming Front Suspension Member Body Mounting Rear Cushion LH Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION View from *a Underneath Front of the Vehicle

NOTE:

Position the front suspension member body mounting rear cushion LH in the correct direction.

b. Install SST as shown in the illustration.

Fig. 73: Identifying SST On Mounting Cushion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Suspension Member *1 Body Mounting Rear Cushion

LH SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration. 

Fig. 74: Installing Front Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a Hold *b Turn NOTE:

Check that there is no clearance between the front suspension member and the front suspension member body mounting rear cushion LH.

3. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH a. Temporarily install a new front suspension member body mounting rear cushion RH while confirming the installation direction.

Fig. 75: Confirming Front Suspension Member Body Mounting Rear Cushion RH Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION View from *a Underneath Front of the Vehicle NOTE:

Position the front suspension member body mounting rear cushion RH in the correct direction.

b. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.

SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting rear cushion RH.  SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 

HINT: Perform the same procedure as the LH side. 4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION a. Temporarily install a new front suspension member body mounting front cushion while confirming the installation direction.

Fig. 76: Confirming Front Suspension Member Body Mounting Front Cushion Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a

View from Underneath Front of the Vehicle

NOTE:

Position the front suspension member body mounting front cushion in the correct direction.

b. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.  SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting front cushion as shown in the illustration.

Fig. 77: Installing Front Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn 

SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060

NOTE:

Check that there is no clearance between the front suspension

member and the front suspension member body mounting front cushion. 5. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER a. Install the 2 front suspension member body mounting rear stoppers to the front frame assembly. 6. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER a. Install the 2 front suspension member body mounting front stoppers to the front frame assembly. 7. INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER a. Install the front suspension member dynamic damper to the front frame assembly with the 2 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 8. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly. b. Install the front lower No. 1 suspension arm sub-assembly to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 78: Identifying Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3

Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

9. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as the LH side. 10. INSTALL STEERING LINK ASSEMBLY . Refer to INSTALLATION - Step 3 11. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY a. Install the front stabilizer bar with 2 front stabilizer link assemblies to the front frame assembly. 12. INSTALL FRONT NO. 1 STABILIZER BRACKET LH See step 3 13. INSTALL FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side. 14. 15. 16. 17.

INSTALL ENGINE MOUNTING INSULATOR LH . Refer to INSTALLATION - Step 9 INSTALL ENGINE MOUNTING INSULATOR RH . Refer to INSTALLATION - Step 10 INSTALL FRONT ENGINE MOUNTING INSULATOR . Refer to INSTALLATION - Step 8 INSTALL FRONT FRAME ASSEMBLY Refer to INSTALLATION - Step 11

2012-2017 SUSPENSION Front Suspension (Service Information) - Camry (Except Hybrid)

FRONT SHOCK ABSORBER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Shock Absorber Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Front Shock Absorber Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT WHEEL 2. LOOSEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Loosen the front support to front shock absorber nut.

Fig. 3: Identifying Front Shock Absorber Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the front support to front shock absorber nut. Loosen the front support to front shock absorber nut only when the front shock absorber with coil spring needs to be disassembled.

3. SEPARATE FRONT SPEED SENSOR a. Remove the bolt and clamp, and separate the front speed sensor and front flexible hose from the front shock absorber assembly.

Fig. 4: Locating Front Speed Sensor Clamp And Front Flexible Hose Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to separate the front speed sensor from the front shock absorber assembly completely.

4. SEPARATE FRONT STABILIZER LINK ASSEMBLY a. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

Fig. 5: Identifying Front Stabilizer Link Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 5. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING a. Support the front axle using a jack and wooden block.

Fig. 6: Identifying Jack Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 Jack Wooden *2 Block Front of the Vehicle b. Remove the 2 bolts and 2 nuts, and separate the front shock absorber with coil spring (lower side) from the steering knuckle.

Fig. 7: Locating Front Axle Assembly Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

c. Remove the 3 nuts and front shock absorber with coil spring.

Fig. 8: Identifying Front Shock Absorber Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the front speed sensor is completely separated from the front shock absorber with coil spring.

6. SECURE FRONT SHOCK ABSORBER WITH COIL SPRING a. Install SST to the front coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 9: Identifying SST To Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

b. Install the bolt and nut to the front shock absorber assembly as shown in the illustration and secure the front shock absorber assembly in a vise using aluminum plates.

Fig. 10: Identifying Standard Length A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 7. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Using SST, compress the front coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 11: Compressing Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use an impact wrench. It will damage SST.

If the front coil spring is compressed at an angle, using 2 SST will make the work easier. b. Check that the front coil spring is sufficiently compressed. c. Remove the front support to front shock absorber nut.

Fig. 12: Identifying Front Support To Front Shock Absorber Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE FRONT SUSPENSION SUPPORT SUB-ASSEMBLY REMOVE FRONT SUSPENSION SUPPORT BEARING REMOVE FRONT UPPER COIL SPRING SEAT REMOVE FRONT UPPER COIL SPRING INSULATOR REMOVE FRONT COIL SPRING REMOVE FRONT SPRING BUMPER REMOVE FRONT LOWER COIL SPRING INSULATOR REMOVE FRONT SHOCK ABSORBER ASSEMBLY

INSPECTION INSPECTION

1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY a. Compress and extend the shock absorber rod 4 or more times. Standard There is no abnormal resistance or sound and operation resistance is normal. If there is any abnormality, replace the front shock absorber assembly with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. SECURE FRONT SHOCK ABSORBER ASSEMBLY a. Install the bolt and nut to the front shock absorber assembly as shown in the illustration and secure the front shock absorber assembly in a vise using aluminum plates.

Fig. 13: Identifying Standard Length A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 2. INSTALL FRONT LOWER COIL SPRING INSULATOR a. Install the front lower coil spring insulator to the front shock absorber assembly.

Fig. 14: Identifying Front Lower Coil Spring Insulator Positioning Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Positioning

Pin NOTE:

Make sure that the positioning pins on the front lower coil spring insulator are inserted into the holes in the front shock absorber assembly.

3. INSTALL FRONT SPRING BUMPER a. Install the front spring bumper to the front shock absorber assembly.

Fig. 15: Identifying Front Spring Bumper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Face the smaller diameter end of the front spring bumper downward.

4. INSTALL FRONT COIL SPRING a. Install SST to the front coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 16: Compressing Front Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

If the front coil spring is compressed at an angle, using 2 SST will make the work easier. b. Using SST, compress the front coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031 NOTE:

Do not use an impact wrench. It will damage SST.

c. Install the front coil spring to the front shock absorber assembly.

Fig. 17: Identifying Front Coil Spring & Front Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the end of the front coil spring is positioned in the depression of the front lower coil spring insulator.

5. INSTALL FRONT UPPER COIL SPRING INSULATOR a. Install the front upper coil spring insulator as shown in the illustration.

Fig. 18: Installing Front Upper Coil Spring Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Outside of the Vehicle NOTE:

Any misalignment between the front shock absorber lower bracket and the alignment mark must be +/- 5°.

6. INSTALL FRONT UPPER COIL SPRING SEAT a. Install the front upper coil spring seat with the mark facing the outside of the vehicle.

Fig. 19: Installing Front Upper Coil Spring Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Outside of the Vehicle NOTE:

Any misalignment between the front shock absorber lower bracket and the alignment mark must be +/- 5°.

7. INSTALL FRONT SUSPENSION SUPPORT BEARING a. Install the front suspension support bearing as shown in the illustration.

Fig. 20: Identifying Front Suspension Support Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Upper *a Side NOTE:

Do not install the bearing upside down.

8. INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY a. Install the front suspension support sub-assembly as shown in the illustration.

Fig. 21: Installing Front Suspension Support Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Foam Outside of the Vehicle HINT: Check that the slot on the piston rod and the slot on the front suspension support sub-assembly are aligned. b. Temporarily tighten a new front support to front shock absorber nut.

c. While aligning the stud bolt of the front suspension support sub-assembly and the front shock absorber lower bracket, remove SST from the front coil spring.

Fig. 22: Aligning The Stud Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Foam Outside of the Vehicle NOTE:





When reassembling the front suspension support subassembly, ensure that any misalignment between the absorber lower bracket and the stud bolt is within +/- 5°. Use the stud bolt that is closest to the outside of the vehicle. Do not use an impact wrench. It will damage SST.

9. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING a. Install the front shock absorber with coil spring (upper side) with the 3 nuts. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) b. Install the front shock absorber with coil spring (lower side) to the steering knuckle and insert the 2 bolts and 2 nuts.

Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

While keeping the bolts from rotating, tighten the nuts.

10. INSTALL FRONT STABILIZER LINK ASSEMBLY a. Install the front stabilizer link assembly to the front shock absorber assembly with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 11. INSTALL FRONT SPEED SENSOR a. Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt and clamp. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTE:

Do not twist the front speed sensor when installing it.

HINT: Install the speed sensor harness bracket first and then the front flexible hose. 12. FULLY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT a. Fully tighten the front support to front shock absorber nut. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) NOTE:

Perform this step only when the front shock absorber with coil spring has been disassembled.

13. INSTALL FRONT WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 14. STABILIZE SUSPENSION a. Lower the vehicle and bounce it up and down several times to stabilize the front suspension. 15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT DISPOSAL DISPOSAL

1. DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY a. Position the front shock absorber assembly level with the piston rod fully extended. Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside.

Fig. 23: Drilling Hole In Cylinder Between A And B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Always use proper safety equipment and be careful when drilling because shards of metal may fly about. HINT: The gas is colorless, odorless and non-poisonous.

FRONT LOWER SUSPENSION ARM (FOR 2AR-FE) COMPONENTS ILLUSTRATION

Fig. 24: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2AR-FE) (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 25: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2AR-FE) (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 26: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2AR-FE) (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 27: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2AR-FE) (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 28: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2AR-FE) (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery

terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT WHEELS 4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to REMOVAL 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL - Step 22 REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH (for LH Side) REMOVE FRONT FENDER APRON SEAL RH (for RH Side) SEPARATE FRONT ENGINE MOUNTING INSULATOR a. Remove the 3 nuts to separate the front engine mounting insulator from the front frame assembly.

Fig. 29: Identifying Front Engine Mounting Insulator Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE ENGINE MOUNTING INSULATOR LH (for LH Side) a. Remove the 2 hole plugs.

Fig. 30: Identifying Engine Mounting Insulator Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 nuts from the engine mounting insulator LH. c. Using a jack and a wooden block, support the engine assembly with transaxle at the position shown in the illustration. While ensuring that there is no interference from the components surrounding the engine, tilt the engine assembly with transaxle to a position that allows the engine mounting insulator LH to be removed.

Fig. 31: Identifying Jack And Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack Wooden *2 Block NOTE:

 

  

Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Tilt the engine assembly with transaxle as little as possible. Ensure that the jack and wooden block are stable. Keep the engine assembly with transaxle supported until installation of the engine mounting insulator LH is complete.

d. Remove the engine mounting insulator LH from the front frame assembly.

Fig. 32: Identifying Engine Mounting Insulator Component LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for LH Side) a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly LH from the front lower ball joint assembly.

Fig. 33: Identifying Front Lower No. 1 Suspension Arm Sub-Assembly Bolt And Nuts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly LH from the front frame assembly.

Fig. 34: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

18. 19. 20. 21.

When removing the bolt, keep the nut from rotating.

c. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly LH. SEPARATE EARTH WIRE (for RH Side) . Refer to REMOVAL - Step 33 REMOVE NO. 2 ENGINE MOUNTING STAY RH (for RH Side) . Refer to REMOVAL - Step 32 REMOVE ENGINE MOVING CONTROL ROD BRACKET (for RH Side) . Refer to REMOVAL Step 34 REMOVE ENGINE MOUNTING INSULATOR RH (for RH Side) a. Remove the 2 hole plugs.

Fig. 35: Identifying engine Mounting Insulator Nuts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 nuts from the engine mounting insulator RH. c. Using a jack and a wooden block, support the engine assembly with transaxle at the position shown in the illustration. While ensuring that there is no interference from the components surrounding the engine, tilt the engine assembly with transaxle to a position that allows the engine mounting insulator RH to be removed.

Fig. 36: Identifying Jack And Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack Wooden *2 Block NOTE:

 

  

Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Tilt the engine assembly with transaxle as little as possible. Ensure that the jack and wooden block are stable. Keep the engine assembly with transaxle supported until installation of the engine mounting insulator RH is complete.

d. Remove the engine mounting insulator RH from the front frame assembly.

Fig. 37: Identifying The Engine Mounting Insulator Component RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH (for RH Side) a. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly RH from the front lower ball joint assembly.

Fig. 38: Identifying Front Lower No. 1 Suspension Arm Sub-Assembly Nuts And Bolt RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly RH from the front frame assembly.

Fig. 39: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

c. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for LH Side) a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly LH. b. Install the front lower No. 1 suspension arm sub-assembly LH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 40: Identifying Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3 Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

c. Install the front lower No. 1 suspension arm sub-assembly LH to the front lower ball joint assembly with the bolt and 2 nuts.

Fig. 41: Identifying Front Lower Ball Joint Assembly Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type

*A A Nut Type *B B Nut 20 mm *a (0.787 in.) 22 mm *b (0.866 in.) Bolt Nut Type A Nut and Bolt Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) Type B Nut and Bolt Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf) NOTE:





The tightening torque for the bolt differs depending on the type of nut. Make sure to tighten the bolt to the same torque as the nuts.

2. INSTALL ENGINE MOUNTING INSULATOR LH (for LH Side) a. Set the engine mounting insulator LH on the front frame assembly.

Fig. 42: Identifying Engine Mounting Insulator LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Pin b. Slowly lower the engine assembly with transaxle using a jack and a wooden block. NOTE:

  



Match the position of the pin (stopper). Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Ensure that the jack and wooden block are stable.

c. Using SST, install the nut to the engine mounting insulator LH.  SST: 09961-00950

Fig. 43: Identifying Engine Mounting Insulator Nut With Fulcrum Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length without SST Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) with SST Torque: 68 N*m (695 kgf*cm, 50 ft.*lbf) NOTE:

 

Use a torque wrench with a fulcrum length of 380 mm (1.25 ft.). This torque value is effective when SST is parallel to the torque wrench.

d. Install the engine mounting insulator LH with the 3 nuts.

Fig. 44: Identifying Engine Mounting Insulator Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 2 hole plugs. 3. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH (for RH Side) a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly RH. b. Install the front lower No. 1 suspension arm sub-assembly RH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 45: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3 Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

c. Install the front lower No. 1 suspension arm sub-assembly RH to the front lower ball joint assembly with the bolt and 2 nuts.

Fig. 46: Identifying Front Lower Ball Joint Assembly Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type

*A A Nut Type *B B Nut 20 mm *a (0.787 in.) 22 mm *b (0.866 in.) Bolt Nut Type A Nut and Bolt Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) Type B Nut and Bolt Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf) NOTE:





The tightening torque for the bolt differs depending on the type of nut. Make sure to tighten the bolt to the same torque as the nuts.

4. INSTALL ENGINE MOUNTING INSULATOR RH (for RH Side) a. Set the engine mounting insulator RH on the front frame assembly.

Fig. 47: Identifying Engine Mounting Insulator RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout b. Slowly lower the engine assembly with transaxle using a jack and a wooden block. NOTE:

  



Match the position of the cutout (stopper). Do not position the wooden block on the oil pan. Do not damage the components surrounding the engine assembly with transaxle. Ensure that the jack and wooden block are stable.

c. Using SST, install the nut to the engine mounting insulator RH.  SST: 09961-00950

Fig. 48: Installing Engine Mounting Insulator Nut RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length without SST Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) with SST Torque: 68 N*m (695 kgf*cm, 50 ft.*lbf) NOTE:

 

Use a torque wrench with a fulcrum length of 380 mm (1.25 ft.). This torque value is effective when SST is parallel to the torque wrench.

d. Install the engine mounting insulator RH with the 3 nuts.

Fig. 49: Identifying Engine Mounting Insulator Nuts RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) e. Install the 2 hole plugs. 5. INSTALL ENGINE MOVING CONTROL ROD BRACKET (for RH Side) a. Temporarily install the engine moving control rod bracket with the 4 bolts.

Fig. 50: Identifying Moving Control Rod Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Fully tighten the engine moving control rod bracket with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 6. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for RH Side) . Refer to INSTALLATION Step 40 7. INSTALL EARTH WIRE (for RH Side) . Refer to INSTALLATION - Step 39 8. INSTALL FRONT ENGINE MOUNTING INSULATOR a. Install the front engine mounting insulator to the front frame assembly with the 3 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 9. 10. 11. 12. 13. 14. 15. 16. 17.

INSTALL FRONT FENDER APRON SEAL LH (for LH Side) INSTALL FRONT FENDER APRON SEAL RH (for RH Side) INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 50 INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2

18. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to INSTALLATION Step 14 19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to INSTALLATION - Step 2 20. INSTALL FRONT WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT

FRONT LOWER SUSPENSION ARM (FOR 2GR-FE) COMPONENTS ILLUSTRATION

Fig. 51: Identifying Front Lower Suspension Arm Replacement Components With Torque Specifications (2GR-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed is for the LH side.

1. REMOVE FRONT FRAME ASSEMBLY Refer to REMOVAL 2. REMOVE ENGINE MOUNTING INSULATOR . Refer to REMOVAL - Step 71 3. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly from the front frame assembly.

Fig. 52: Locating Front Lower Suspension Arm Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

b. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm subassembly. INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY a. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly. b. Install the front lower No. 1 suspension arm sub-assembly to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.

Fig. 53: Identifying Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt 1, 2 Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) Bolt 3 Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) NOTE:

While keeping the nut from rotating, tighten the bolt.

2. INSTALL ENGINE MOUNTING INSULATOR . Refer to INSTALLATION - Step 8 3. INSTALL FRONT FRAME ASSEMBLY Refer to INSTALLATION - Step 10

FRONT LOWER BALL JOINT COMPONENTS ILLUSTRATION

Fig. 54: Identifying Front Lower Ball Joint Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE FRONT AXLE ASSEMBLY Refer to REMOVAL

2. REMOVE FRONT LOWER BALL JOINT ASSEMBLY a. Secure the front axle assembly in a vise using aluminum plates. NOTE:

When using a vise, do not overtighten it.

b. Remove the cotter pin and nut.

Fig. 55: Locating Front Lower Ball Joint Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install SST to the front lower ball joint assembly as shown in the illustration.  SST: 09960-20010 09961-02050 09961-02050

Fig. 56: Identifying Clearance Between SST And Front Axle Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Check that the clearance measurement between SST and the front axle assembly is 1 mm (0.0394 in.).

d. Using SST, remove the front lower ball joint assembly from the front axle assembly as shown in the illustration.  SST: 09960-20010 09961-02010 09961-02050 09961-02050

Fig. 57: Removing Front Lower Ball Joint Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Apply

*a grease Place *b wrench here WARNING: Apply grease to the threads and end of the SST bolt.

NOTE:

 



Install SST so that A and B are parallel. Be sure to place a wrench on the part indicated in the illustration. Do not damage the front lower ball joint dust cover.

INSPECTION INSPECTION

1. INSPECT FRONT LOWER BALL JOINT ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 58: Inspecting Lower Ball Joint Assembly Front LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the front lower ball joint assembly in a vise using aluminum plates. 2. Install the nut to the front lower ball joint assembly stud.

3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.98 to 3.43 N*m (10 to 34 kgf*cm, 9 to 30 in.*lbf) If the turning torque is not within the specified range, replace the front lower ball joint assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If the dust cover is cracked or there is grease on it, replace the front lower ball joint assembly with a new one. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT LOWER BALL JOINT ASSEMBLY a. Secure the front axle assembly in a vise using aluminum plates. NOTE:

When using a vise, do not overtighten it.

b. Install the front lower ball joint assembly to the front axle assembly with a new nut. Torque: 123 N*m (1254 kgf*cm, 91 ft.*lbf) NOTE:

Prevent oil from adhering to the threaded and tapered parts.

c. Install a new cotter pin. NOTE:

Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

2. INSTALL FRONT AXLE ASSEMBLY Refer to INSTALLATION - Step 6

FRONT STABILIZER BAR COMPONENTS ILLUSTRATION

Fig. 59: Identifying Front Stabilizer Bar Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE for 2GR-FE: Refer to REMOVAL for 2AR-FE: Refer to REMOVAL 2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH a. Remove the nut and front stabilizer link assembly LH from the front stabilizer bar.

Fig. 60: Identifying Front Stabilizer Link Assembly Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 3. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 4. REMOVE FRONT NO. 1 STABILIZER BRACKET LH a. Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.

Fig. 61: Identifying No. 1 Stabilizer Bracket Bolts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side. 6. REMOVE FRONT STABILIZER BAR a. Remove the front stabilizer bar from the front frame assembly. 7. REMOVE FRONT NO. 1 STABILIZER BAR BUSHING a. Remove the 2 front No. 1 stabilizer bar bushings from the front stabilizer bar. INSPECTION INSPECTION

1. INSPECT FRONT STABILIZER LINK ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 62: Inspecting Front Stabilizer Link Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the front stabilizer link assembly in a vise using aluminum plates. 2. Install the nut to the front stabilizer link assembly stud. 3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.05 to 1.96 N*m (0.6 to 19 kgf*cm, 0.5 to 17 in.*lbf) If the turning torque is not within the specified range, replace the front stabilizer link assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If the dust cover is cracked or there is grease on it, replace the front stabilizer link assembly with a new one. INSTALLATION INSTALLATION

1. INSTALL FRONT NO. 1 STABILIZER BAR BUSHING a. Install the 2 front No. 1 stabilizer bar bushings to the front stabilizer bar as shown in the

illustration.

Fig. 63: Installing Front No. 1 Stabilizer Bar Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout Front of the Vehicle Inside of the Vehicle NOTE:

When installing the front No. 1 stabilizer bar bushings, make sure that the cutout faces the rear of the vehicle.

2. INSTALL FRONT STABILIZER BAR a. Install the front stabilizer bar to the front frame assembly. 3. INSTALL FRONT NO. 1 STABILIZER BRACKET LH a. Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 4. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

HINT: Perform the same procedure as the LH side. 5. INSTALL FRONT STABILIZER LINK ASSEMBLY LH a. Install the front stabilizer link assembly LH to the front stabilizer bar with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt. 6. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 7. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE for 2GR-FE: Refer to INSTALLATION - Step 15 for 2AR-FE: Refer to INSTALLATION - Step 17

FRONT SUSPENSION MEMBER COMPONENTS ILLUSTRATION

Fig. 64: Identifying Front Suspension Member Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 65: Identifying Front Suspension Member Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 66: Identifying Front Suspension Member Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 67: Identifying Front Suspension Member Replacement Components With Torque Specifications (4 Of 4)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT FRAME ASSEMBLY for 2GR-FE: Refer to REMOVAL for 2AR-FE: Refer to REMOVAL 2. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY (for 2GR-FE) Refer to REMOVAL - Step 70 3. REMOVE FRONT ENGINE MOUNTING INSULATOR (for 2AR-FE) Refer to REMOVAL - Step 66 4. REMOVE ENGINE MOUNTING INSULATOR LH for 2GR-FE: Refer to REMOVAL - Step 71 for 2AR-FE: Refer to REMOVAL - Step 67 5. REMOVE ENGINE MOUNTING INSULATOR RH for 2GR-FE: Refer to REMOVAL - Step 72 for 2AR-FE: Refer to REMOVAL - Step 68 6. REMOVE FRONT NO. 1 STABILIZER BRACKET LH See step 4 7. REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side. 8. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY a. Remove the front stabilizer bar with 2 front stabilizer link assemblies from the front frame assembly. 9. REMOVE STEERING LINK ASSEMBLY . Refer to REMOVAL - Step 11 10. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH See step 3 11. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT: Perform the same procedure as the LH side. 12. REMOVE FRONT SUSPENSION MEMBER DYNAMIC DAMPER a. Remove the 2 bolts and front suspension member dynamic damper from the front frame assembly.

Fig. 68: Locating Front Suspension Member Dynamic Damper & Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER a. Remove the 2 front suspension member body mounting front stoppers from the front frame assembly. 14. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER a. Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly. 15. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION a. Install SST as shown in the illustration.  SST: 09830-10010 09830-01010 09830-01040 09830-01050  SST: 09950-40011 09951-04020

09952-04010 09954-04010 09955-04011 09958-04011

Fig. 69: Identifying Front Suspension Member Body Mounting Front Cushion & SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Suspension *1 Member Body Mounting Front

Cushion b. Using SST, remove the front suspension member body mounting front cushion from the front frame assembly.

Fig. 70: Removing Front Suspension Member Body Mounting Front Cushion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold NOTE:

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Make sure that the claws of SST are securely hung onto the mounting cushion. Tighten SST slowly and evenly.

 

Be careful as the mounting cushion may fly out. The mounting cushion cannot be reused.

16. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH a. Install SST as shown in the illustration.  SST: 09830-10010 09830-01010 09830-01040 09830-01050  SST: 09950-40011 09951-04020 09952-04010 09954-04010 09955-04011 09958-04011

Fig. 71: Identifying Front Suspension Member Body Mounting Front Cushion & SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Suspension Member Body *1 Mounting Rear Cushion LH b. Using SST, remove the front suspension member body mounting rear cushion LH from the front frame assembly.

Fig. 72: Removing Front Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold NOTE:

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Make sure that the claws of SST are securely hung onto the mounting cushion. Tighten SST slowly and evenly. Be careful as the mounting cushion may fly out. The mounting cushion cannot be reused.

17. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH

HINT: Perform the same procedure as the LH side. 18. REMOVE HOLE PLUG a. Remove each hole plug from the front frame assembly. INSTALLATION INSTALLATION

1. INSTALL HOLE PLUG a. Install each hole plug to the front frame assembly. 2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH a. Temporarily install a new front suspension member body mounting rear cushion LH while confirming the installation direction.

Fig. 73: Identifying Front Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A Type A

*B Type B View from *a Underneath Front of the Vehicle NOTE:

Position the front suspension member body mounting rear cushion LH in the correct direction.

b. Install SST as shown in the illustration.

Fig. 74: Identifying SST On Mounting Cushion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Front Suspension Member Body *1 Mounting Rear Cushion LH SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration. 

Fig. 75: Installing Front Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn NOTE:

Check that there is no clearance between the front suspension member and the front suspension member body mounting rear cushion LH.

3. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH a. Temporarily install a new front suspension member body mounting rear cushion RH while confirming the installation direction.

Fig. 76: Identifying Front Suspension Member Body Mounting Rear Cushion RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A Type A

*B Type B View from *a Underneath Front of the Vehicle NOTE:

Position the front suspension member body mounting rear cushion RH in the correct direction.

b. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.  SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting rear cushion RH.  SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 HINT: Perform the same procedure as the LH side. 4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION a. Temporarily install a new front suspension member body mounting front cushion while confirming the installation direction.

Fig. 77: Confirming Front Suspension Member Body Mounting Front Cushion Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION View from *a Underneath Front of the Vehicle NOTE:

Position the front suspension member body mounting front cushion in the correct direction.

b. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.  SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 c. Using SST, install the front suspension member body mounting front cushion as shown in the illustration.

Fig. 78: Installing Front Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold *b Turn 

SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060

NOTE:

Check that there is no clearance between the front suspension

member and the front suspension member body mounting front cushion. 5. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER a. Install the 2 front suspension member body mounting rear stoppers to the front frame assembly. 6. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER a. Install the 2 front suspension member body mounting front stoppers to the front frame assembly. 7. INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER a. Install the front suspension member dynamic damper to the front frame assembly with the 2 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 8. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH See step 1 9. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as the LH side. 10. INSTALL STEERING LINK ASSEMBLY . Refer to INSTALLATION - Step 3 11. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY a. Install the front stabilizer bar with 2 front stabilizer link assemblies to the front frame assembly. 12. INSTALL FRONT NO. 1 STABILIZER BRACKET LH See step 3 13. INSTALL FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as the LH side. 14. INSTALL ENGINE MOUNTING INSULATOR LH for 2GR-FE: Refer to INSTALLATION - Step 8 for 2AR-FE: Refer to INSTALLATION - Step 7 15. INSTALL ENGINE MOUNTING INSULATOR RH for 2GR-FE: Refer to INSTALLATION - Step 9 for 2AR-FE: Refer to INSTALLATION - Step 8 16. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY (for 2GR-FE) Refer to INSTALLATION - Step 7

17. INSTALL FRONT ENGINE MOUNTING INSULATOR (for 2AR-FE) Refer to INSTALLATION - Step 6 18. INSTALL FRONT FRAME ASSEMBLY for 2GR-FE: Refer to INSTALLATION - Step 10 for 2AR-FE: Refer to INSTALLATION - Step 9

2012-2017 ENGINE Fuel System (Service Information) - Camry (2AR-FE)

FUEL INJECTOR COMPONENTS ILLUSTRATION

Fig. 1: Identifying Fuel Injector Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Fuel Injector Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . 1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 6. DISCONNECT FUEL TUBE SUB-ASSEMBLY a. Remove the No. 1 fuel pipe clamp.

Fig. 3: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

Fig. 4: Identifying Fuel Tube Connector And Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fuel Pipe

Fuel Tube Connector Nylon *3 Tube *4 O-ring *5 Retainer Pinch Pull *2

NOTE:

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

 





Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe. Do not use any tools to separate the fuel tube connector and fuel pipe. Do not forcefully bend, kink or twist the nylon tube. Keep the fuel tube connector and fuel pipe free from foreign matter. If the fuel tube connector and fuel pipe are stuck, push and pull to release them. Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

c. Remove the fuel tube sub-assembly from the fuel hose clamp. 7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to REMOVAL - Step 7 8. DISCONNECT WIRE HARNESS

Fig. 5: Identifying Fuel Injectors Connectors, Connectors, Bolts, Clamp And Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Disconnect the 4 fuel injector connectors. b. Disconnect the 2 connectors. c. Remove the 2 bolts and separate the 2 wire harness brackets. d. Disengage the clamp to disconnect the wire harness. 9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY a. Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

Fig. 6: Identifying Fuel Deliver Pipe Fuel Injectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

b. Remove the 2 fuel delivery spacers from the cylinder head.

Fig. 7: Locating Fuel Delivery Spacers And Injector Vibration Insulators Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 4 injector vibration insulators from the cylinder head. 10. REMOVE FUEL INJECTOR ASSEMBLY a. Pull the 4 fuel injectors out of the fuel delivery pipe.

Fig. 8: Identifying Fuel Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from each fuel injector. c. For reinstallation, attach a tag or label to each injector shaft. NOTE:

Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

INSPECTION INSPECTION

1. INSPECT FUEL INJECTOR ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 9: Measuring Resistance Between Fuel Injector Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 11.6 to 1-2 F) 12.4 ohms If the result is not as specified, replace the fuel injector assembly. b. Inspect the injector injection. WARNING: Keep the injector away from sparks during the test.

1. Connect SST (fuel tube connector) to SST (hose) with SST (hose band), and then connect them to the fuel pipe (vehicle side).

Fig. 10: Identifying Fuel Tube Connector To SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09268-31014 09268-41500 09268-41700 95336-08070

TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Fuel Tube Connector) Fuel Pipe *4 (Vehicle Side) 2. Install a new O-ring to the fuel injector.

Fig. 11: Identifying Hose, Fuel Pipe, SST And Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09268-31014 09268-41110 09268-41300 09268-41700 95336-08070

TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Adapter) *4 O-ring SST *5 (Clamp) Vinyl *6 Tube 3. Connect SST (adapter and hose) to the injector, and hold the injector and union with SST (clamp).

4. Tie the clamp and adapter together with a tie band as shown in the illustration.

Fig. 12: Tying SST (Clamp And Adapter) Together With SST (Tie Band) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09268-31014 09268-41110 09268-41300 09268-41800

TEXT IN ILLUSTRATION SST *1 (Tie Band) SST *2 (Adapter) SST *3 (Clamp) 5. Install a vinyl tube onto the injector. WARNING: Install a suitable vinyl tube onto the injector to contain any gasoline spray. 6. Put the injector into the graduated cylinder.

7. Operate the fuel pump. 8. Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times.

Fig. 13: Connecting SST (Wire), Injector Assembly & Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Wire) *a Connect 

SST: 09842-30080

NOTE:

Always switch the voltage on and off at the battery side, not the injector side.

Standard Injection Volume Tester Specified Condition Connection Condition Positive 87 to 105 terminal Per 15 cc (5.3 to Ground seconds 6.4 cu.in.) terminal

Difference between each injector 18 cc (1.1 cu.in.) or less If the result is not as specified, replace the fuel injector assembly. c. Check for fuel drop. 1. In the condition above, disconnect the tester probes of SST (wire) from the battery and check for fuel drop from the injector. Standard fuel drop 1 drop or less per 20 minutes If fuel drop is not as specified, replace the fuel injector assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY a. Apply a light coat of gasoline or spindle oil to new O-rings, and then install one onto each fuel injector.

Fig. 14: Identifying Fuel Injector O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION O*1 ring b. Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly. c. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe subassembly.

Fig. 15: Turning Fuel Injector Assembly To Install Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the O-ring is not cracked or jammed when installing the injector. Refer to PRECAUTION .

HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . d. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring. 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY a. Install 4 new injector vibration insulators to the cylinder head.

Fig. 16: Identifying Fuel Delivery Space, Fuel Delivery Pipe Side And Cylinder Head Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Delivery Spacer Fuel Delivery *a Pipe Side Cylinder *b Head Side b. Install the 2 fuel delivery spacers onto the cylinder head.

HINT: Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side. c. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE:

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

Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

3. CONNECT WIRE HARNESS a. Install the 2 wire harness brackets with the 2 bolts.

Fig. 17: Identifying Wire Harness, Connectors, Fuel Injector Connectors, Bolts, Clamp And Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 2 connectors. c. Connect the 4 fuel injector connectors. d. Engage the clamp to connect the wire harness. 4. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) . Refer to INSTALLATION Step 6 5. CONNECT FUEL TUBE SUB-ASSEMBLY a. Push the fuel tube connector to the fuel pipe until the fuel tube connector makes a "click" sound.

Fig. 18: Identifying Fuel Pipe, Fuel Tube Connector, Nylon Tube And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fuel Pipe

Fuel Tube Connector Nylon *3 Tube *4 O-ring *5 Retainer *2

NOTE:





Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe. After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

b. Install the No. 1 fuel pipe clamp.

Fig. 19: Identifying No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the fuel tube sub-assembly to the fuel hose clamp. 6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 9. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68

FUEL PRESSURE REGULATOR COMPONENTS ILLUSTRATION

Fig. 20: Identifying Fuel Pressure Regulator Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 21: Identifying Fuel Pressure Regulator Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 3. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 22: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 23: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 24: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 25: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 26: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

  

Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 27: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the O-ring and spacer from the fuel pump.

Fig. 28: Identifying Fuel Pump, O-Ring & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring

*2 Spacer 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration. 4. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, remove the fuel pressure regulator assembly.

Fig. 29: Locating Fuel Pressure Regulator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Slowly pull out the fuel pressure regulator assembly because the Oring is firmly installed between the fuel pressure regulator assembly and the fuel filter.

b. Remove the 2 O-rings from the pressure regulator assembly.

Fig. 30: Identifying Pressure Regulator Assembly & O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSTALLATION INSTALLATION

1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY a. Apply gasoline to 2 new O-rings and then install them to the fuel pressure regulator assembly. 2. INSTALL FUEL PUMP See step 1 3. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 4. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

FUEL PRESSURE PULSATION DAMPER COMPONENTS ILLUSTRATION

Fig. 31: Identification Fuel Pressure Pulsation Damper Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 32: Identification Fuel Pressure Pulsation Damper Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 6. REMOVE FUEL TUBE SUB-ASSEMBLY

Fig. 33: Removing Fuel Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2

Fuel Pipe Clamp *2 Retainer Fuel Hose *3 Clamp Fuel Tube *4 Connector *a Turn *1

NOTE: a. b. c. d. e. f. g. h.

Do not forcibly bend, kink or twist the fuel tube.

Remove the fuel tube from the fuel hose clamp. Remove the No. 2 fuel pipe clamp. Wipe off any dirt on the fuel tube connector. Hold the fuel tube connector, and then install SST.  SST: 09268-21011 Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST. Mount the retainer of the fuel tube connector onto the chamfered part of SST. Slide SST and the fuel tube connector together toward the fuel tube until they make a "click" sound, and then disconnect the fuel tube.

Fig. 34: Identifying Fuel Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 O-ring *2 Retainer *3 Fuel Tube Fuel Tube *4 Connector *5 Fuel Pipe NOTE:

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



Check for foreign matter in the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-rings to seal the fuel tube connector and fuel pipe. Do not use any tools to separate the fuel tube connector and fuel pipe. Do not forcefully bend, kink or twist the fuel tube. Keep the fuel tube connector and fuel pipe free from foreign matter. If the fuel tube connector and fuel pipe are stuck together, pinch the fuel tube connector and turn it carefully to disconnect it. Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

7. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY a. Remove the 2 bolts and fuel pressure pulsation damper.

Fig. 35: Locating Fuel Pressure Pulsation Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from the fuel pressure pulsation damper. INSTALLATION INSTALLATION

1. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY a. Apply a light coat of gasoline or spindle oil to a new O-ring.

Fig. 36: Identifying Fuel Pressure Pulsation Damper O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring b. Install the O-ring to the fuel pressure pulsation damper. c. Install the fuel pressure pulsation damper with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Make sure that the O-ring is not cracked or jammed when installing the damper.

2. INSTALL FUEL TUBE SUB-ASSEMBLY

Fig. 37: Identifying No. 2 Fuel Pipe Clamp And Fuel Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2 Fuel *1 Pipe Clamp Fuel *2 Hose Clamp a. Connect the fuel tube. b. Push the fuel tube connector until it makes a "click" sound. c. Install a new No. 2 fuel pipe clamp.

3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68

FUEL PUMP COMPONENTS ILLUSTRATION

Fig. 38: Identifying Fuel Pump Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 39: Identifying Fuel Pump Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 40: Identifying Fuel Pump Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to INITIALIZATION . 1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. 4. 5. 6.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 REMOVE REAR FLOOR SERVICE HOLE COVER a. Remove the rear floor service hole cover.

Fig. 41: Identifying Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump connector. 7. DISCONNECT FUEL TANK VENT HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank vent hose.

Fig. 42: Identifying Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:





  

Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work. Do not allow any scratches or foreign matter on the parts when disconnecting them as the fuel tank vent hose connector has an O-ring that seals the pipe. Only disconnect the joint by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with a plastic bag



after disconnecting the fuel tank vent hose. If the vent hose connector and pipe are stuck, push and pull to release them.

8. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank breather elbow tube subassembly.

Fig. 43: Identifying Tube Joint Clip, Fuel Tube Joint, Fuel Tank Breather Elbow Tube And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube *1 Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Breather Elbow Tube *4 O-ring Fuel *5 Suction Plate NOTE:





 





Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank breather elbow tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

9. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank main tube sub-assembly.

Fig. 44: Identifying Tube Joint Clip And Fuel Tube Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tube

Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Main Tube *4 O-ring Fuel *5 Suction Plate *1

NOTE:





  



Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank main tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

10. REMOVE FUEL TANK VENT TUBE SET PLATE a. Remove the 8 bolts and set plate.

Fig. 45: Identifying Set Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, pull the tabs of the retainer to disengage the lock claws and pull out the fuel cut-off tube.

Fig. 46: Identifying Retainer, Fuel Cut-Off Tube And Fuel Suction Tube Set Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Fuel *2 Cut-off Tube Fuel Suction *3 Tube Set Gasket b. Remove the fuel suction tube with pump and gauge assembly from the fuel tank.

NOTE:

Make sure that the fuel sender gauge arm does not bend.

c. Remove the fuel suction tube set gasket from the fuel suction tube assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 2. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 47: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 48: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 49: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 50: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 51: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

  

Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 52: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the O-ring and spacer from the fuel pump.

Fig. 53: Identifying Fuel Pump, O-Ring & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring

*2 Spacer 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration. INSPECTION INSPECTION

1. INSPECT FUEL PUMP a. Check the fuel pump resistance.

Fig. 54: Connecting Battery Positive (+) Lead To Terminal 2 Of Connector, And Negative (-) Lead To Terminal 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 0.2 to 3.0 1-2 F) ohms If the result is not as specified, replace the fuel pump. b. Check fuel pump operation.

1. Apply battery voltage to terminals 1 and 2. Check that the pump operates. NOTE:







These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not the fuel pump side.

If the pump does not operate, replace the fuel pump. REASSEMBLY REASSEMBLY

1. INSTALL FUEL PUMP a. Apply gasoline to a new O-ring. Then install the O-ring and spacer to the fuel pump.

Fig. 55: Identifying Fuel Pump O-Ring And Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring *2 Spacer

b. Engage the 5 claws of the fuel pump.

Fig. 56: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:





Make sure that the O-ring is not cut or pinched during the installation. Engage the claws securely.



Do not remove the suction filter.

HINT: Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to INITIALIZATION . c. Engage the 2 claws of the No. 1 fuel suction support.

Fig. 57: Identifying No. 1 Fuel Suction Support Claws And Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the fuel pump harness connector. e. Engage the 2 claws of the No. 1 fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank.

Fig. 58: Identifying Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Align the groove of the fuel pump filter hose with the cutout of the fuel sub-tank and install the hose.

Fig. 59: Identifying Fuel Pump Filter Hose And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply excessive force to the fuel tube or the suction support.

g. Connect the connector of the fuel pump harness. 2. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 INSTALLATION INSTALLATION

1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Install a new fuel suction tube set gasket to the fuel suction tube.

Fig. 60: Identifying Fuel Suction Tube Set Gasket And Fuel Cut-Off Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel Suction *1 Tube Set Gasket Fuel *2 Cut-off Tube

b. Push in the fuel cut-off tube connector to the fuel suction tube assembly and push the retainer so that the claws engage. c. Install the fuel suction tube with pump and gauge assembly to the fuel tank. NOTE:

Be careful that the arm of the sender gauge does not bend.

2. INSTALL FUEL TANK VENT TUBE SET PLATE a. Align the protrusion of the fuel suction tube assembly and the cutout of the fuel tank vent tube set plate.

Fig. 61: Identifying Fuel Tank Vent Tube Set Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout *2 Protrusion b. Install the set plate with the 8 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 62: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:



 



Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tube joint cannot be pulled out.

4. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 63: Identifying Tube Joint Clip And Fuel Tube Joint Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:



 



Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tank breather tube cannot be pulled out.

5. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the fuel suction tube assembly and push the retainer so that the claws engage.

Fig. 64: Identifying Fuel Tank Vent Hose Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:





Check that there are no scratches or foreign matter around the connected parts of the fuel tank vent hose connector and fuel suction tube assembly before performing this work. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tank vent hose connector.

b. Connect the fuel pump connector. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 8. INSTALL REAR FLOOR SERVICE HOLE COVER a. Install the rear floor service hole cover with new butyl tape.

Fig. 65: Identifying Rear Floor Service Hole Cover And Butyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Butyl Tape 9. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 10. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7

FUEL TANK COMPONENTS ILLUSTRATION

Fig. 66: Identifying Fuel Tank Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 67: Identifying Fuel Tank Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 68: Identifying Fuel Tank Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 69: Identifying Fuel Tank Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. DRAIN FUEL 3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

Refer to REMOVAL 4. REMOVE NO. 1 FLOOR UNDER COVER . Refer to REMOVAL - Step 3 5. REMOVE NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) . Refer to REMOVAL - Step 2 6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 2 parking brake cable assembly.

Fig. 70: Identifying No. 2 Parking Brake Cable Assembly And No. 3 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2 Parking *1 Brake Cable Assembly No. 3 Parking *2 Brake Cable Assembly 7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 3 parking brake cable assembly. 8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET

a. Remove the 4 bolts and 2 rear No. 1 stabilizer bar brackets.

Fig. 71: Identifying No. Stabilizer Bar Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 1 FUEL TANK PROTECTOR a. Remove the 3 clips and No. 1 fuel tank protector.

Fig. 72: Identifying No. 1 Fuel Tank Protector Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 73: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank main tube sub-assembly. NOTE:





  



Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel tank main tube. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

11. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 74: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank breather elbow tube sub-assembly. NOTE:





  



Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel tank breather tube. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

12. DISCONNECT FUEL TANK VENT HOSE a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 75: Identifying Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer *2 Tab Pinch Pull NOTE:





Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank vent hose connector has an O-ring that seals the fuel pipe.

  



Only disconnect the vent hose connector by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tank vent hose. If the vent hose connector and charcoal canister are stuck, push and pull to release them.

b. Pull out the fuel tank vent hose. 13. DISCONNECT FUEL TANK TO FILLER PIPE HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank to filler pipe hose.

Fig. 76: Identifying Fuel Tank To Filler Pipe Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Retainer Pull Pull Out NOTE:





 





Remove any dirt or foreign matter on the fuel tank to filler pipe hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank to filler pipe hose connector has an O-ring that seals the fuel tank. Only disconnect the filler pipe hose connector by hand. Do not forcibly bend, twist or turn the fuel tank to filler pipe hose. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tank to filler pipe hose. If the fuel tank to filler pipe hose connector and fuel tank are stuck, push and pull to release them.

14. REMOVE FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter.

Fig. 77: Identifying Fuel Tank Support Using Engine Lift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts of the 2 fuel tank bands.

Fig. 78: Identifying Fuel Tank Bands And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Lower the engine lifter to remove the fuel tank. NOTE:

  

Slowly operate the engine lifter to lower the fuel tank. Do not drop the fuel tank. When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Disconnect the No. 1 fuel tube clamp and remove the fuel tank main tube sub-assembly.

Fig. 79: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank breather elbow tube sub-assembly.

Fig. 80: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly And No. 2 Fuel Tube

Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FUEL TANK VENT HOSE a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank vent hose sub-assembly.

Fig. 81: Identifying Fuel Tank Vent Hose Sub-Assembly And No. 2 Fuel Tube Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE NO. 1 FUEL TUBE CLAMP a. Remove the No. 1 fuel tube clamp.

Fig. 82: Identifying No. 1 Fuel Tube Clamp And No. 2 Fuel Tube Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Fuel *1 Tube Clamp No. 2 Fuel *2 Tube Clamp 19. REMOVE NO. 2 FUEL TUBE CLAMP a. Remove the No. 2 fuel tube clamp. 20. REMOVE NO. 1 FUEL TANK CUSHION a. Remove the 5 No. 1 fuel tank cushions.

Fig. 83: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 FUEL TANK CUSHION a. Install 5 new No. 1 fuel tank cushions as shown in the illustration.

Fig. 84: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 FUEL TUBE CLAMP a. Install the No. 1 fuel tube clamp. 3. INSTALL NO. 2 FUEL TUBE CLAMP a. Install the No. 2 fuel tube clamp. 4. INSTALL FUEL TANK VENT HOSE a. Install the fuel tank vent hose to the No. 2 fuel tube clamp. 5. INSTALL FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Install the fuel tank breather elbow tube sub-assembly to the No. 2 fuel tube clamp. 6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Install the fuel tank main tube sub-assembly to the No. 1 fuel tube clamp. 7. INSTALL FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter. b. Raise the engine lifter, then install the fuel tank to the vehicle. NOTE:

 

Do not drop the fuel tank. When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

c. Tighten the 4 bolts of the 2 fuel tank bands.

Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 8. CONNECT FUEL TANK TO FILLER PIPE HOSE a. Push in the fuel tank to filler pipe hose connector to the fuel tank assembly and push the retainer so that the claws engage.

Fig. 85: Identifying Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push NOTE:



Check that there are no scratches or foreign matter around the connected parts of the fuel tank to filler pipe hose connector



and tank before performing this work. After connecting the fuel tank to filler pipe hose, check that the fuel tank to filler pipe hose is securely connected by pulling on the fuel tank to filler pipe hose connector.

9. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the charcoal canister and push up the retainer so that the claws engage.

Fig. 86: Identifying Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tank vent hose connector and charcoal canister before performing this work. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tank vent hose connector and the charcoal canister.

10. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push in the fuel tube connector to the pipe and push up the retainer so that the claws engage.

Fig. 87: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Fuel Tube Connector *3 Fuel Pipe *4 O-ring Push *2

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before starting this step. After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push in the fuel tube connector to the fuel pipe and push up the retainer so that the claws engage.

Fig. 88: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Fuel Tube Connector *3 Fuel Pipe *4 O-ring Push *2

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before starting this step. After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

12. INSTALL NO. 1 FUEL TANK PROTECTOR a. Install the lower center fuel tank protector with the 3 clips. 13. INSTALL REAR NO. 1 STABILIZER BAR BRACKET a. Install the 2 rear No. 1 stabilizer bar brackets with the 4 bolts. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 14. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 3 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 15. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 2 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 16. INSTALL NO. 1 FLOOR UNDER COVER . Refer to INSTALLATION - Step 11 17. INSTALL NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) . Refer to INSTALLATION Step 10 18. INSTALL CENTER EXHAUST PIPE ASSEMBLY Refer to INSTALLATION 19. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION 20. ADD FUEL 21. INSPECT FOR EXHAUST GAS LEAK

FUEL SENDER GAUGE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 89: Identifying Fuel Sender Gauge Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY a. Disconnect the 3 harness clamps.

Fig. 90: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

b. Remove the harness protector from the wire harness.

Fig. 91: Identifying Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

c. Disconnect the connector of the fuel sender gauge assembly.

Fig. 92: Identifying Fuel Sender Gauge Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Release the lock as shown in the illustration and slide the fuel sender gauge assembly to remove it.

Fig. 93: Identifying Fuel Sender Gauge Assembly Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FUEL SENDER GAUGE ASSEMBLY a. Check that the float moves smoothly between F and E.

Fig. 94: Identifying Fuel Sender Gauge Moves Smoothly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Fuel Sender Gauge Assembly) b. Measure the resistance between terminals 1 and 2 of the connector according to the value(s) in the table below. Standard Resistance Float Resistance Level (ohms) 13.5 to F 16.5 13.5 to Between 414.5 E and F (Gradually changes) 405.5 to E 414.5 If the value is not as specified, replace the fuel sender gauge assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL SENDER GAUGE ASSEMBLY a. Install the fuel sender gauge assembly by sliding it downward.

Fig. 95: Identifying Fuel Sender Gauge Assembly Slides Downward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector of the fuel sender gauge assembly. c. Install the harness protector. NOTE:

Do not damage the wire harness.

d. Connect the 3 harness clamps.

Fig. 96: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

2. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

2012-2017 ENGINE Fuel System (Service Information) - Camry (2GR-FE)

FUEL INJECTOR COMPONENTS ILLUSTRATION

Fig. 1: Identifying Fuel Injector Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Fuel Injector Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . 1. PRECAUTION NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to REMOVAL 5. DISCONNECT FUEL TUBE SUB-ASSEMBLY a. Remove the No. 2 fuel pipe clamp.

Fig. 3: Identifying No. 2 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2

Fuel Pipe Clamp Fuel Tube *2 Connector Nylon *3 Tube *4 O-ring *5 Fuel Pipe Pinch Pull *1

b. Pinch the fuel tube connector and pull out the fuel pipe. NOTE:





   

Check that there is no dirt or other foreign objects around the fuel tube connector when disconnecting it. Clean the fuel tube connector as necessary. It is necessary to prevent dirt or foreign objects from entering the fuel tube connector. If dirt or foreign objects get in the fuel tube connector, the O-rings may not seal properly. Only disconnect the fuel tube connector by hand. Do not bend, kink or twist the nylon tubes. Protect the fuel tube connector by covering it with plastic bags. If the fuel pipe and the fuel tube connector are stuck, carefully try wiggling or pushing and pulling on the fuel tube connector to release it. Pull the fuel tube connector off carefully.

6. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY a. Disconnect the 6 fuel injector connectors.

Fig. 4: Locating Fuel Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 5 bolts and fuel delivery pipe sub-assembly together with the 6 fuel injectors.

Fig. 5: Locating Fuel Delivery Pipe And Fuel Injectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

c. Remove the 6 injector vibration insulators from the intake manifold.

Fig. 6: Locating Injector Vibration Insulators And Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FUEL INJECTOR ASSEMBLY a. Pull the 6 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

Fig. 7: Pulling Out Fuel Injector From Fuel Delivery Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the injectors are to be reused, reinstall them to the same cylinder they came from.

b. Remove the O-ring from each fuel injector assembly.

Fig. 8: Identifying O-ring Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring c. For reinstallation, attach a tag or label to each injector shaft. NOTE:

Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

INSPECTION INSPECTION

1. INSPECT FUEL INJECTOR ASSEMBLY a. Check the resistance.

Fig. 9: Inspecting Fuel Injector Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 11.6 to 1-2 F) 12.4 ohms If the result is not as specified, replace the injector assembly. b. Check the operation. WARNING: Perform the inspection in a well-ventilated area. Do not perform the inspection near a naked flame. 1. Connect SST (fuel tube connector) to SST (hose) with SST (hose band), and then connect them to the fuel pipe (vehicle side).

Fig. 10: Identifying Fuel Tube Connector To SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Fuel Tube Connector) Fuel Pipe *4 (Vehicle Side) SST: 09268-31014 09268-41500 09268-41700 95336-08070 2. Install a new O-ring onto the fuel injector assembly. 3. Connect SST (adapter and hose) to the injector assembly, and hold the injector assembly and union with SST (clamp). 

Fig. 11: Identifying Fuel Pipe Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Adapter) *4 O-ring SST *5 (Clamp) Vinyl *6 Tube SST: 09268-31014 09268-41141 09268-41410 09268-41700 95336-08070 4. Tie the clamp and adapter together with a tie band as shown in the illustration. 

Fig. 12: Identifying Fuel Pipe Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Adapter) SST *2 (Tie Band) SST *3 (Clamp) SST: 09268-31014 09268-41141 09268-41410 09268-41800 5. Set the injector assembly in a graduated cylinder. 

WARNING: Install a suitable vinyl tube onto the injector assembly to prevent gasoline from spraying. 6. Operate the fuel pump. Refer to ON-VEHICLE INSPECTION - Step 1 . 7. Connect SST (wire) to the injector assembly and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times.

Fig. 13: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Wire) *a Connect 

SST: 09842-30080

Standard Injection Volume Tester Specified Condition Connection Condition Positive (+) 76 to 91 terminal Per 15 cc (4.6 to Ground seconds 5.6 cu.in.) terminal Difference between each injector 15 cc (0.9 cu.in.) or less NOTE:

Always switch the voltage on and off on the battery side, not the injector side.

If the injection volume is not as specified, replace the injector assembly.

c. Check for leaks. 1. Disconnect the tester probes of SST (wire) from the battery and check for fuel leaks from the injector. Standard fuel drop 1 drop or less every 35 minutes INSTALLATION INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY a. Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each injector.

Fig. 14: Identifying O-ring Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring b. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts each O-ring.

Fig. 15: Identifying Fuel Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn Push c. Push and twist each fuel injector to install them into the fuel delivery pipe. d. Position each fuel injector connector outward. NOTE:

 

Be careful not to twist the O-rings. After installing a fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY a. Install 6 new injector vibration insulators to the intake manifold.

Fig. 16: Locating Injector Vibration Insulators And Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Place the fuel delivery pipe with the 6 fuel injectors in position on the intake manifold. NOTE:

Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

c. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

Fig. 17: Identifying Fuel Delivery Pipe And Fuel Injectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

d. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

Fig. 18: Locating Fuel Delivery Pipe And Fuel Injectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) e. Connect the 6 fuel injector connectors.

Fig. 19: Locating Fuel Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CONNECT FUEL TUBE SUB-ASSEMBLY a. Push in the fuel tube connector onto the pipe until the fuel tube connector makes a "click" sound.

Fig. 20: Identifying Intake Air Surge Tank Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2

Fuel Pipe Clamp *2 Retainer Fuel Tube *3 Connector *4 O-ring *5 Fuel Pipe Push *1

NOTE:





Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe. After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

b. Install the No. 2 fuel pipe clamp. 4. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to INSTALLATION 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

FUEL PRESSURE REGULATOR COMPONENTS ILLUSTRATION

Fig. 21: Identifying Fuel Pressure Regulator Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 22: Identifying Fuel Pressure Regulator Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 3. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 23: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 24: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 25: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 26: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 27: Identifying Fuel Filter And Suction Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

  

Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 28: Identifying Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the fuel pump filter seal from the fuel pump. If the fuel pump filter seal still remains in the fuel filter element, remove it using a wire tip (1 mm) that is formed as shown in the illustration.

Fig. 29: Identifying Fuel Pump Filter Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Fuel Pump *1 Filter Seal 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

h. Remove the fuel pump spacer from the fuel pump.

Fig. 30: Identifying Fuel Pump Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, remove the fuel pressure regulator assembly.

Fig. 31: Locating Fuel Pressure Regulator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Slowly pull out the fuel pressure regulator assembly because the Oring is firmly installed between the fuel pressure regulator assembly and the fuel filter.

b. Remove the 2 O-rings from the pressure regulator assembly.

Fig. 32: Identifying Pressure Regulator Assembly & O - Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSTALLATION INSTALLATION

1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY a. Apply gasoline to 2 new O-rings and then install them to the fuel pressure regulator assembly. 2. INSTALL FUEL PUMP See step 1 3. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 4. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

FUEL PUMP COMPONENTS ILLUSTRATION

Fig. 33: Identifying Fuel Pump Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 34: Identifying Fuel Pump Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 35: Identifying Fuel Pump Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:





If a malfunction such as pump lock occurs and the fuel pump is damaged, excessive current may be continuously applied to the fuel pump control ECU, damaging its internal parts. Make sure to replace the fuel pump control ECU at the same time when replacing the fuel pump. Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to INITIALIZATION .

1. PRECAUTION NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 5. REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 6. REMOVE REAR FLOOR SERVICE HOLE COVER a. Remove the rear floor service hole cover.

Fig. 36: Identifying Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump connector. 7. DISCONNECT FUEL TANK VENT HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank vent hose.

Fig. 37: Identifying Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:



Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work.



  



Do not allow any scratches or foreign matter on the parts when disconnecting them as the fuel tank vent hose connector has an O-ring that seals the pipe. Only disconnect the joint by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank vent hose. If the vent hose connector and pipe are stuck, push and pull to release them.

8. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank breather elbow tube subassembly.

Fig. 38: Identifying Fuel Tube Joint And Fuel Tank Breather Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tube

Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Breather Tube *4 O-ring Fuel *5 Suction Plate *1

NOTE:





  



Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank breather tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

9. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank main tube sub-assembly.

Fig. 39: Identifying Tube Joint Clip, Fuel Tube Joint And Fuel Tank Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tube

Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Main Tube *4 O-ring Fuel *5 Suction Plate *1

NOTE:





  



Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank main tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

10. REMOVE FUEL TANK VENT TUBE SET PLATE a. Remove the 8 bolts and set plate.

Fig. 40: Identifying Set Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, pull the tabs of the retainer to disengage the lock claws and pull out the fuel cut-off tube.

Fig. 41: Identifying Fuel Cut-Off Tube And Fuel Suction Tube Set Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Fuel *2 Cut-off Tube Fuel Suction *3 Tube Set Gasket b. Remove the fuel suction tube with pump and gauge assembly from the fuel tank.

NOTE:

Make sure that the fuel sender gauge arm does not bend.

c. Remove the fuel suction tube set gasket from the fuel suction tube assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 2. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 42: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 43: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 44: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 45: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 46: Identifying Fuel Filter And Suction Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

  

Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 47: Identifying Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the fuel pump filter seal from the fuel pump. If the fuel pump filter seal still remains in the fuel filter element, remove it using a wire tip (1 mm) that is formed as shown in the illustration.

Fig. 48: Identifying Fuel Pump Filter Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Fuel Pump *1 Filter Seal 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

h. Remove the fuel pump spacer from the fuel pump.

Fig. 49: Identifying Fuel Pump Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FUEL PUMP a. Check the fuel pump resistance.

Fig. 50: Inspect Fuel Pump Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 0.2 to 3.0 1-2 F) ohms If the result is not as specified, replace the fuel pump. b. Check fuel pump operation. 1. Apply battery voltage to terminals 1 and 2. Check that the pump operates. NOTE:







These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not the fuel pump side.

If the pump does not operate, replace the fuel pump.

REASSEMBLY REASSEMBLY

1. INSTALL FUEL PUMP a. Install the fuel pump spacer onto the fuel pump.

Fig. 51: Identifying Fuel Pump Filter Seal And Fuel Pump Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel Pump *1 Filter Seal Fuel *2 Pump Spacer b. Install a new fuel pump filter seal onto the fuel pump. c. Apply a coat of gasoline to the fuel pump filter seal. d. Engage the 5 claws of the fuel pump.

Fig. 52: Identifying Fuel Filter And Suction Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

 

Engage the claws securely. Do not remove the suction filter.

HINT: Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to

INITIALIZATION . e. Engage the 2 claws of the No. 1 fuel suction support.

Fig. 53: Identifying Claws Of No. 1 Fuel Suction Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Connect the fuel pump harness connector. g. Engage the 2 claws of the No. 1 fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank.

Fig. 54: Identifying Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Align the groove of the fuel pump filter hose with the cutout of the fuel sub-tank and install the hose.

Fig. 55: Aligning Groove Of Fuel Pump Filter And Cutout Of Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply excessive force to the fuel tube or the suction support.

i. Connect the connector of the fuel pump harness. 2. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 INSTALLATION INSTALLATION

1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Install a new fuel suction tube set gasket to the fuel suction tube.

Fig. 56: Identifying Fuel Suction Tube Set Gasket And Fuel Cut-Off Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel Suction *1 Tube Set Gasket Fuel *2 Cut-off Tube

b. Push in the fuel cut-off tube connector to the fuel suction tube assembly and push the retainer so that the claws engage. c. Install the fuel suction tube with pump and gauge assembly to the fuel tank. NOTE:

Be careful that the arm of the sender gauge does not bend.

2. INSTALL FUEL TANK VENT TUBE SET PLATE a. Align the protrusion of the fuel suction tube assembly and the cutout of the fuel tank vent tube set plate.

Fig. 57: Identifying Fuel Tank Vent Tube Set Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout *2 Protrusion b. Install the set plate with the 8 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 58: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:



 



Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tank main tube cannot be pulled out.

4. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 59: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:



 



Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tube joint cannot be pulled out.

5. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the fuel suction tube assembly and push the retainer so that the claws engage.

Fig. 60: Identifying Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:





Check that there are no scratches or foreign matter around the connected parts of the fuel tank vent hose connector and fuel suction tube assembly before performing this work. After connecting the fuel tank vent hose sub-assembly, check that the fuel tank vent hose sub-assembly is securely connected by pulling on the fuel tank vent hose connector.

b. Connect the fuel pump connector. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. INSTALL REAR FLOOR SERVICE HOLE COVER a. Install the rear floor service hole cover with new butyl tape.

Fig. 61: Identifying Rear Floor Service Hole Cover And Butyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Butyl Tape 8. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 9. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 10. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7

FUEL PUMP ECU COMPONENTS ILLUSTRATION

Fig. 62: Identifying Fuel Pump ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. 4. 5. 6. 7. 8.

REMOVE LUGGAGE COMPARTMENT FLOOR MAT REMOVE SPARE WHEEL COVER ASSEMBLY REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 REMOVE REAR FLOOR FINISH PLATE . Refer to REMOVAL - Step 4 REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to REMOVAL - Step 5 REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH . Refer to REMOVAL - Step 6 9. REMOVE FUEL PUMP CONTROL ECU ASSEMBLY a. Disconnect the connector and clamp from the fuel pump control ECU assembly.

Fig. 63: Identifying Fuel Pump Control ECU Assembly Connector, Clamp And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and fuel pump control ECU assembly.

NOTE:

Do not reuse the fuel pump control ECU if it has been dropped or subjected to a severe impact.

HINT: If a malfunction such as pump lock occurs and the fuel pump is damaged, excessive current may be continuously applied to the fuel pump control ECU, damaging its internal parts. Make sure to replace the fuel pump control ECU at the same time when replacing the fuel pump. INSTALLATION INSTALLATION

1. INSTALL FUEL PUMP CONTROL ECU ASSEMBLY a. Connect the connector and clamp. b. Install the fuel pump control ECU assembly with the 2 nuts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH . Refer to INSTALLATION - Step 6 3. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to INSTALLATION - Step 8 4. INSTALL REAR FLOOR FINISH PLATE . Refer to INSTALLATION - Step 9 5. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 10 6. INSTALL SPARE WHEEL COVER ASSEMBLY 7. INSTALL LUGGAGE COMPARTMENT FLOOR MAT 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

FUEL TANK COMPONENTS ILLUSTRATION

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

Fig. 64: Identifying Fuel Tank Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 65: Identifying Fuel Tank Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 66: Identifying Fuel Tank Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 67: Identifying Fuel Tank Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. DRAIN FUEL 3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

Refer to REMOVAL 4. REMOVE NO. 1 FLOOR UNDER COVER . Refer to REMOVAL - Step 3 5. REMOVE NO. 2 FLOOR UNDER COVER . Refer to REMOVAL - Step 2 6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 2 parking brake cable assembly.

Fig. 68: Identifying No. 2 Parking Brake Cable Assembly And No. 3 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2 Parking *1 Brake Cable Assembly No. 3 Parking *2 Brake Cable Assembly 7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 3 parking brake cable assembly. 8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET

a. Remove the 4 bolts and 2 rear No. 1 stabilizer bar brackets.

Fig. 69: Identifying No. 1 Stabilizer Bar Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 1 FUEL TANK PROTECTOR a. Remove the 3 clips and No. 1 fuel tank protector.

Fig. 70: Identifying No. 1 Fuel Tank Protector Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 71: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank main tube sub-assembly. NOTE:

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

  



Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel tank main tube. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

11. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 72: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank breather elbow tube sub-assembly. NOTE:





  



Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel tank breather tube. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

12. DISCONNECT FUEL TANK VENT HOSE a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 73: Identifying Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer *2 Tab Pinch Pull NOTE:





Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank vent hose connector has an O-ring that seals the pipe.

  



Only disconnect the vent hose connector by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tank vent hose. If the vent hose connector and charcoal canister are stuck, push and pull to release them.

b. Pull out the fuel tank vent hose. 13. DISCONNECT FUEL TANK TO FILLER PIPE HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank to filler pipe hose.

Fig. 74: Identifying Fuel Tank And Filler Pipe Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Retainer Pull Pull Out NOTE:

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

 





Remove any dirt or foreign matter on the fuel tank to filler pipe hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank to filler pipe hose connector has an O-ring that seals the fuel tank. Only disconnect the filler pipe hose connector by hand. Do not forcibly bend, twist or turn the fuel tank to filler pipe hose. Protect the disconnected part by covering it with plastic bags after disconnecting the fuel tank to filler pipe hose. If the fuel tank to filler pipe hose connector and fuel tank are stuck, push and pull to release them.

14. REMOVE FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter.

Fig. 75: Support Fuel Tank Using Engine Lifter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts of the 2 fuel tank bands.

Fig. 76: Identifying Fuel Tank Band Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Lower the engine lifter to remove the fuel tank. NOTE:

  

Slowly operate the engine lifter to lower the fuel tank. Do not drop the fuel tank. When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Disconnect the No. 1 fuel tube clamp and remove the fuel tank main tube sub-assembly.

Fig. 77: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank breather elbow tube sub-assembly.

Fig. 78: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FUEL TANK VENT HOSE a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank vent hose sub-assembly.

Fig. 79: Identifying Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE NO. 1 FUEL TUBE CLAMP a. Remove the No. 1 fuel tube clamp.

Fig. 80: Identifying Fuel Tube Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Fuel *1 Tube Clamp No. 2 Fuel *2 Tube Clamp 19. REMOVE NO. 2 FUEL TUBE CLAMP a. Remove the No. 2 fuel tube clamp. 20. REMOVE NO. 1 FUEL TANK CUSHION a. Remove the 5 No. 1 fuel tank cushions.

Fig. 81: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 FUEL TANK CUSHION a. Install 5 new No. 1 fuel tank cushions as shown in the illustration.

Fig. 82: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 FUEL TUBE CLAMP a. Install the No. 1 fuel tube clamp. 3. INSTALL NO. 2 FUEL TUBE CLAMP a. Install the No. 2 fuel tube clamp. 4. INSTALL FUEL TANK VENT HOSE a. Install the fuel tank vent hose to the No. 2 fuel tube clamp. 5. INSTALL FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Install the fuel tank breather elbow tube sub-assembly to the No. 2 fuel tube clamp. 6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Install the fuel tank main tube sub-assembly to the No. 1 fuel tube clamp. 7. INSTALL FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter. b. Raise the engine lifter, then install the fuel tank to the vehicle. NOTE:

 

Do not drop the fuel tank. When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

c. Tighten the 4 bolts of the 2 fuel tank bands.

Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 8. CONNECT FUEL TANK TO FILLER PIPE HOSE a. Push in the fuel tank to filler pipe hose connector to the fuel tank assembly and push the retainer so that the claws engage.

Fig. 83: Identifying Fuel Tank To Filler Pipe Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push NOTE:



Check that there are no scratches or foreign matter around the connected parts of the fuel tank to filler pipe hose connector



and tank before performing this work. After connecting the fuel tank to filler pipe hose, check that the fuel tank to filler pipe hose is securely connected by pulling on the fuel tank to filler pipe hose connector.

9. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the charcoal canister and push up the retainer so that the claws engage.

Fig. 84: Identifying Fuel Tank Vent Hose Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push

NOTE:

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

Check that there are no scratches or foreign matter around the connected part of the fuel tank vent hose connector and charcoal canister before performing this work. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tank vent hose connector and the charcoal canister.

10. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push in the fuel tank breather elbow tube connector to the pipe and push up the retainer so that the claws engage.

Fig. 85: Identifying Fuel Tank Breather Elbow Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Quick Connector *3 Pipe *4 O-ring Push *2

NOTE:

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

Check that there are no scratches or foreign matter around the connected part of the fuel tank breather elbow tube connector and pipe before starting this step. After connecting the fuel tank breather elbow tube connector, check that the fuel tank breather elbow tube connector is securely connected by pulling on the fuel tank breather elbow tube connector.

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage.

Fig. 86: Identifying Fuel Tank Main Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Quick Connector *3 Pipe *4 O-ring Push *2

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tank main tube connector and pipe before starting this step. After connecting the fuel tank main tube connector, check that the fuel tank main tube connector is securely connected by pulling on the fuel tube connector.

12. INSTALL NO. 1 FUEL TANK PROTECTOR a. Install the lower center fuel tank protector with the 3 clips. 13. INSTALL REAR NO. 1 STABILIZER BAR BRACKET a. Install the 2 rear No. 1 stabilizer bar brackets with the 4 bolts. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 14. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 3 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 15. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 2 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 16. INSTALL NO. 1 FLOOR UNDER COVER . Refer to INSTALLATION - Step 11 17. INSTALL NO. 2 FLOOR UNDER COVER . Refer to INSTALLATION - Step 10 18. INSTALL CENTER EXHAUST PIPE ASSEMBLY Refer to INSTALLATION 19. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION 20. ADD FUEL 21. INSPECT FOR EXHAUST GAS LEAK

FUEL SENDER GAUGE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 87: Identifying Fuel Sender Gauge Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY a. Disconnect the 3 harness clamps.

Fig. 88: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

b. Remove the harness protector from the wire harness.

Fig. 89: Identifying Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

c. Disconnect the connector of the fuel sender gauge assembly.

Fig. 90: Identifying Fuel Sender Gauge Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Release the lock as shown in the illustration and slide the fuel sender gauge assembly to remove it.

Fig. 91: Identifying Fuel Sender Gauge Assembly Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FUEL SENDER GAUGE ASSEMBLY a. Check that the float moves smoothly between F and E.

Fig. 92: Identifying Fuel Sender Gauge Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Fuel Sender Gauge Assembly) b. Measure the resistance between terminals 1 and 2 of the connector according to the value(s) in the table below. Standard Resistance Float Resistance Level (ohms) 13.5 to F 16.5 13.5 to Between 414.5 E and F (Gradually changes) 405.5 to E 414.5 If the value is not as specified, replace the fuel sender gauge assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL SENDER GAUGE ASSEMBLY a. Install the fuel sender gauge assembly by sliding it downward.

Fig. 93: Identifying Fuel Sender Gauge Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector of the fuel sender gauge assembly. c. Install the harness protector. NOTE:

Do not damage the wire harness.

d. Connect the 3 harness clamps.

Fig. 94: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

2. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

2012-2017 ENGINE Fuel System (Service Information) (Hybrid)

FUEL INJECTOR COMPONENTS ILLUSTRATION

Fig. 1: Identifying Fuel Injector Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Fuel Injector Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Fuel Injector Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . 1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. SEPARATE INTAKE MANIFOLD Refer to REMOVAL 6. DISCONNECT FUEL TUBE SUB-ASSEMBLY a. Remove the No. 1 fuel pipe clamp.

Fig. 4: Removing No. 1 Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

Fig. 5: Pulling Fuel Tube Connector Off Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Fuel Pipe Fuel Tube *2 Connector Nylon *3 Tube *4 O-ring *5 Retainer Pinch Pull NOTE:

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

 





Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe. Do not use any tools to separate the fuel tube connector and fuel pipe. Do not forcefully bend, kink or twist the nylon tube. Keep the fuel tube connector and fuel pipe free from foreign matter. If the fuel tube connector and fuel pipe are stuck, push and pull to release them. Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

c. Remove the fuel tube sub-assembly from the fuel hose clamp. 7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY a. Disconnect the 4 fuel injector connectors.

Fig. 6: Identifying Fuel Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors. NOTE:

Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

c. Remove the 2 fuel delivery spacers from the cylinder head.

Fig. 7: Identifying Fuel Delivery Spacers And Injector Vibration Insulators Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 4 injector vibration insulators from the cylinder head. 8. REMOVE FUEL INJECTOR ASSEMBLY a. Pull the 4 fuel injectors out of the fuel delivery pipe.

Fig. 8: Removing Fuel Injectors Out Of Fuel Delivery Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the O-ring from each fuel injector. c. For reinstallation, attach a tag or label to each injector shaft. NOTE:

Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

INSPECTION INSPECTION

1. INSPECT FUEL INJECTOR ASSEMBLY a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 11.6 to 1-2 F) 12.4 ohms If the result is not as specified, replace the fuel injector assembly. b. Inspect the injector injection. WARNING: Keep the injector away from sparks during the test.

1. Connect SST (fuel tube connector) to SST (hose) with SST (hose band), and then connect them to the fuel pipe (vehicle side).

Fig. 9: Identifying Fuel Pipe Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Fuel Tube Connector) Fuel Pipe *4 (Vehicle Side) SST: 09268-31014 09268-41500 09268-41700 95336-08070 2. Install a new O-ring to the fuel injector. 

Fig. 10: Identifying Hose, Fuel Pipe, SST And Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Hose) SST *2 (Hose Band) SST *3 (Adapter) *4 O-ring SST *5 (Clamp) Vinyl *6 Tube SST: 09268-31014 09268-41110 09268-41300 09268-41700 95336-08070 3. Connect SST (adapter and hose) to the injector, and hold the injector and union with SST (clamp). 4. Install a vinyl tube onto the injector. 

WARNING: Install a suitable vinyl tube onto the injector to contain any gasoline spray. 5. Tie the clamp and adapter together with a tie band as shown in the illustration.

Fig. 11: Tying SST (Clamp And Adapter) Together With SST (Tie Band) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Tie Band) SST *2 (Adapter) SST *3 (Clamp) SST: 09268-31014 09268-41110 09268-41300 09268-41800 6. Put the injector into the graduated cylinder. 7. Operate the fuel pump. Refer to ON-VEHICLE INSPECTION - Step 1 . 8. Connect SST (wire) to the injector and the auxiliary battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. 

Fig. 12: Connecting SST To Injector Assembly And Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION SST *1 (Wire) *a Connect 

SST: 09842-30080

NOTE:

Always switch the voltage on and off at the auxiliary battery side, not the injector side.

Standard Injection Volume Tester Specified Condition Connection Condition Positive 87 to 105 terminal Per 15 cc (5.3 to Ground seconds 6.4 cu.in.) terminal Difference between each injector 18 cc (1.1 cu.in.) or less

If the result is not as specified, replace the fuel injector assembly. c. Check for fuel drop. 1. In the condition above, disconnect the tester probes of SST (wire) from the auxiliary battery and check for fuel drop from the injector. Standard fuel drop 1 drop or less per 20 minutes If fuel drop is not as specified, replace the fuel injector assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL INJECTOR ASSEMBLY a. Apply a light coat of gasoline or spindle oil to new O-rings, and then install one onto each fuel injector.

Fig. 13: Identifying Fuel Injector O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring

b. Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly. c. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe subassembly.

Fig. 14: Installing Fuel Injector Assembly Onto Fuel Delivery Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the O-ring is not cracked or jammed when installing the injector. Refer to PRECAUTION .

HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to INITIALIZATION . d. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring. 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY a. Install 4 new injector vibration insulators to the cylinder head.

Fig. 15: Identifying Injector Vibration Insulators And Fuel Delivery Spacers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Delivery Spacer Fuel Delivery *a Pipe Side Cylinder *b Head Side b. Install the 2 fuel delivery spacers onto the cylinder head.

HINT: Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side. c. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.

Fig. 16: Identifying Fuel Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE:

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Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

d. Connect the 4 fuel injector connectors. 3. CONNECT FUEL TUBE SUB-ASSEMBLY a. Push the tube connector onto the pipe until the tube connector makes a "click" sound.

Fig. 17: Pushing Tube Connector Onto The Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

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Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe. After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

b. Install the No. 1 fuel pipe clamp. 4. INSTALL INTAKE MANIFOLD Refer to INSTALLATION 5. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 7. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1

FUEL PRESSURE REGULATOR COMPONENTS

ILLUSTRATION

Fig. 18: Identifying Fuel Pressure Regulator Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 19: Identifying Fuel Pressure Regulator Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 3. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 20: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 21: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 22: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 23: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 24: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

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Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 25: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the O-ring and spacer from the fuel pump.

Fig. 26: Identifying Fuel Pump, O - Ring & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring

*2 Spacer 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration. 4. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, remove the fuel pressure regulator assembly.

Fig. 27: Locating Fuel Pressure Regulator Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Slowly pull out the fuel pressure regulator assembly because the Oring is firmly installed between the regulator and the fuel filter.

b. Remove the 2 O-rings from the pressure regulator assembly.

Fig. 28: Identifying Pressure Regulator O-rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring INSTALLATION INSTALLATION

1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY a. Apply gasoline to 2 new O-rings and then install them to the fuel pressure regulator assembly. 2. INSTALL FUEL PUMP See step 1 3. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 4. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

FUEL PUMP COMPONENTS ILLUSTRATION

Fig. 29: Identifying Fuel Pump Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 30: Identifying Fuel Pump Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 31: Identifying Fuel Pump Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 32: Identifying Fuel Pump Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to INITIALIZATION . 1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

2. DISCHARGE FUEL SYSTEM PRESSURE Refer to PRECAUTION 3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 6. REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 7. REMOVE REAR FLOOR SERVICE HOLE COVER a. Remove the rear floor service hole cover.

Fig. 33: Identifying Fuel Pump Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump connector. 8. DISCONNECT FUEL TANK VENT HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank vent hose.

Fig. 34: Disconnecting Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:

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

Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work. Do not allow any scratches or foreign matter on the parts when

  



disconnecting them as the fuel tank vent hose connector has an O-ring that seals the pipe. Only disconnect the joint by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank vent hose. If the vent hose connector and pipe are stuck, push and pull to release them.

9. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank breather elbow tube subassembly.

Fig. 35: Disconnecting Fuel Tank Breather Elbow Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tube

Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Breather Elbow Tube *4 O-ring Fuel *5 Suction Plate *1

NOTE:





 





Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank breather elbow tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank main tube sub-assembly.

Fig. 36: Disconnecting Fuel Tank Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tube

Joint Clip Fuel *2 Tube Joint Fuel Tank *3 Main Tube *4 O-ring Fuel *5 Suction Plate *1

NOTE:





  



Remove any dirt or foreign matter on the fuel tube joint before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has an O-ring that seals the pipe. Only disconnect the fuel tube joint by hand. Do not forcibly bend, twist or turn the fuel tank main tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint. If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.

11. REMOVE FUEL TANK VENT TUBE SET PLATE a. Remove the 8 bolts and set plate.

Fig. 37: Identifying Fuel Tank Vent Tube Set Plate Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Using a screwdriver with its tip wrapped in protective tape, pull the tabs of the retainer to disengage the lock claws and pull out the fuel cut-off tube.

Fig. 38: Removing Fuel Cut-Off Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Fuel *2 Cut-off Tube Fuel Suction *3 Tube Set Gasket b. Remove the fuel suction tube with pump and gauge assembly from the fuel tank.

NOTE:

Make sure that the fuel sender gauge arm does not bend.

c. Remove the fuel suction tube set gasket from the fuel suction tube assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2 2. REMOVE FUEL PUMP a. Disconnect the connector of the fuel pump harness.

Fig. 39: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel pump filter hose.

Fig. 40: Identifying Fuel Pump Filter Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank.

Fig. 41: Identifying Fuel Tube And Fuel Sub-Tank

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Tube Fuel *2 Subtank NOTE:

Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to PRECAUTION .

d. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

Fig. 42: Identifying No. 1 Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump from the fuel filter.

Fig. 43: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

  

Do not damage the fuel filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump.

f. Disconnect the fuel pump harness connector.

Fig. 44: Identifying Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the O-ring and spacer from the fuel pump.

Fig. 45: Identifying Fuel Pump, O - Ring & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring

*2 Spacer 5.0 mm *a (0.197 in.) NOTE:

Be careful not to damage the sealing surface.

HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration. INSPECTION INSPECTION

1. INSPECT FUEL PUMP a. Check the fuel pump resistance.

Fig. 46: Connecting Battery Positive (+) Lead To Terminal 2 Of Connector, And Negative (-) Lead To Terminal 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 20°C (68° 0.2 to 3.0 1-2 F) ohms If the result is not as specified, replace the fuel pump. b. Check fuel pump operation.

1. Apply auxiliary battery voltage to terminals 1 and 2. Check that the pump operates. NOTE:

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



These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the auxiliary battery as possible. Always switch the voltage on and off on the auxiliary battery side, not the fuel pump side.

If the pump does not operate, replace the fuel pump. REASSEMBLY REASSEMBLY

1. INSTALL FUEL PUMP a. Apply gasoline to a new O-ring. Then install the O-ring and spacer to the fuel pump.

Fig. 47: Identifying Fuel Pump O-Ring And Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring *2 Spacer

b. Engage the 5 claws of the fuel pump.

Fig. 48: Identifying Fuel Filter, Fuel Pump Filter & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel *1 Filter Suction *2 Filter NOTE:

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

Make sure that the O-ring is not cut or pinched during the installation. Engage the claws securely.



Do not remove the suction filter.

HINT: Perform "Inspection After Repair" after replacing the fuel pump assembly. Refer to INITIALIZATION . c. Engage the 2 claws of the No. 1 fuel suction support.

Fig. 49: Identifying No. 1 Fuel Suction Support Claws And Fuel Pump Harness Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the fuel pump harness connector. e. Engage the 2 claws of the No. 1 fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank.

Fig. 50: Identifying Fuel Suction Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Align the groove of the fuel pump filter hose with the cutout of the fuel sub-tank and install the hose.

Fig. 51: Installing Fuel Pump Filter Hose

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not apply excessive force to the fuel tube or the suction support.

g. Connect the connector of the fuel pump harness. 2. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1 INSTALLATION INSTALLATION

1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY a. Install a new fuel suction tube set gasket to the fuel suction tube.

Fig. 52: Identifying Fuel Suction Tube Set Gasket and Fuel Cut-Off Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fuel Suction *1 Tube Set Gasket Fuel *2 Cut-off Tube

b. Push in the fuel cut-off tube connector to the fuel suction tube assembly and push the retainer so that the claws engage. c. Install the fuel suction tube with pump and gauge assembly to the fuel tank. NOTE:

Be careful that the arm of the sender gauge does not bend.

2. INSTALL FUEL TANK VENT TUBE SET PLATE a. Align the protrusion of the fuel suction tube assembly and the cutout of the fuel tank vent tube set plate.

Fig. 53: Identifying Fuel Tank Vent Tube Set Plate Bolts And Protrusion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cutout *2 Protrusion b. Install the set plate with the 8 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 54: Connecting Fuel Tank Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:

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Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tube joint cannot be pulled out.

4. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

Fig. 55: Connecting Fuel Tank Breather Elbow Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Tube Joint Clip Fuel Tube *2 Joint *3 O-ring *4 Collar *a CORRECT *b INCORRECT *1

NOTE:



 



Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tank breather tube cannot be pulled out.

5. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the fuel suction tube assembly and push the retainer so that the claws engage.

Fig. 56: Connecting Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:

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

Check that there are no scratches or foreign matter around the connected parts of the fuel tank vent hose connector and fuel suction tube assembly before performing this work. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tank vent hose connector.

b. Connect the fuel pump connector. 6. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 8. INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1 9. INSTALL REAR FLOOR SERVICE HOLE COVER a. Install the rear floor service hole cover with new butyl tape.

Fig. 57: Identifying Rear Floor Service Hole Cover Butyl Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Butyl Tape 10. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 11. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7

FUEL TANK COMPONENTS ILLUSTRATION

Fig. 58: Identifying Fuel Tank Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 59: Identifying Fuel Tank Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 60: Identifying Fuel Tank Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 61: Identifying Fuel Tank Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. DRAIN FUEL 3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

Refer to REMOVAL 4. REMOVE NO. 1 FLOOR UNDER COVER . Refer to REMOVAL - Step 3 5. REMOVE NO. 2 FLOOR UNDER COVER . Refer to REMOVAL - Step 2 6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 2 parking brake cable assembly.

Fig. 62: Identifying No. 2 Parking Brake Cable And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 2 Parking *1 Brake Cable Assembly No. 3 Parking *2 Brake Cable Assembly 7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 3 parking brake cable assembly. 8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET

a. Remove the 4 bolts and 2 rear No. 1 stabilizer bar brackets.

Fig. 63: Identifying Rear No. 1 Stabilizer Bar Brackets And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 1 FUEL TANK PROTECTOR a. Remove the 3 clips and No. 1 fuel tank protector.

Fig. 64: Identifying No. 1 Fuel Tank Protector Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 65: Disconnecting Fuel Tank Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank main tube sub-assembly. NOTE:





  



Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel pump tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

11. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 66: Disconnecting Fuel Tank Breather Elbow Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

*2 Tab Fuel Tube *3 Connector *4 Fuel Pipe *5 O-ring Pinch Pull b. Pull out the fuel tank breather elbow tube sub-assembly. NOTE:





  



Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has Orings that seal the fuel pipe. Only disconnect the fuel tube connector by hand. Do not forcibly bend, twist or turn the fuel tank breather tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector. If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

12. DISCONNECT FUEL TANK VENT HOSE a. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

Fig. 67: Disconnecting Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer *2 Tab Pinch Pull NOTE:

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

Remove any dirt or foreign matter on the fuel tank vent hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank vent hose connector has an O-ring that seals the pipe.

  



Only disconnect the vent hose connector by hand. Do not forcibly bend, twist or turn the fuel tank vent hose. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank vent hose. If the vent hose connector and charcoal canister are stuck, push and pull to release them.

b. Pull out the fuel tank vent hose. 13. DISCONNECT FUEL TANK TO FILLER PIPE HOSE a. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank to filler pipe hose.

Fig. 68: Disconnecting Fuel Tank To Filler Pipe Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Retainer Pull Pull Out NOTE:

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 





Remove any dirt or foreign matter on the fuel tank to filler pipe hose connector before performing this work. Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank to filler pipe hose connector has an O-ring that seals the fuel tank. Only disconnect the filler pipe hose connector by hand. Do not forcibly bend, twist or turn the fuel tank to filler pipe hose. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank to filler pipe hose. If the fuel tank to filler pipe hose connector and fuel tank are stuck, push and pull to release them.

14. REMOVE FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter.

Fig. 69: Supporting Fuel Tank Using Engine Lifter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 bolts of the 2 fuel tank bands.

Fig. 70: Identifying Fuel Tank Bands And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Lower the engine lifter to remove the fuel tank. NOTE:

  

Slowly operate the engine lifter to lower the fuel tank. Do not drop the fuel tank. When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Disconnect the No. 1 fuel tube clamp and remove the fuel tank main tube sub-assembly.

Fig. 71: Identifying Fuel Tank Main Tube Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank breather elbow tube sub-assembly.

Fig. 72: Identifying Fuel Tank Breather Elbow Tube Clamp

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FUEL TANK VENT HOSE a. Disconnect the No. 2 fuel tube clamp and remove the fuel tank vent hose sub-assembly.

Fig. 73: Identifying Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE NO. 1 FUEL TUBE CLAMP a. Remove the No. 1 fuel tube clamp.

Fig. 74: Identifying No. 1 And No. 2 Fuel Tube Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Fuel *1 Tube Clamp No. 2 Fuel *2 Tube Clamp 19. REMOVE NO. 2 FUEL TUBE CLAMP a. Remove the No. 2 fuel tube clamp. 20. REMOVE NO. 1 FUEL TANK CUSHION a. Remove the 5 No. 1 fuel tank cushions.

Fig. 75: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 FUEL TANK CUSHION a. Install 5 new No. 1 fuel tank cushions as shown in the illustration.

Fig. 76: Identifying No. 1 Fuel Tank Cushions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 1 FUEL TUBE CLAMP a. Install the No. 1 fuel tube clamp. 3. INSTALL NO. 2 FUEL TUBE CLAMP a. Install the No. 2 fuel tube clamp. 4. INSTALL FUEL TANK VENT HOSE a. Install the fuel tank vent hose to the No. 2 fuel tube clamp. 5. INSTALL FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Install the fuel tank breather elbow tube sub-assembly to the No. 2 fuel tube clamp. 6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Install the fuel tank main tube sub-assembly to the No. 1 fuel tube clamp. 7. INSTALL FUEL TANK ASSEMBLY a. Support the fuel tank using an engine lifter. b. Raise the engine lifter, then install the fuel tank to the vehicle. NOTE:

 

Do not drop the fuel tank. When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

c. Tighten the 4 bolts of the 2 fuel tank bands.

Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 8. CONNECT FUEL TANK TO FILLER PIPE HOSE a. Push in the fuel tank to filler pipe hose connector to the fuel tank assembly and push the retainer so that the claws engage.

Fig. 77: Connecting Fuel Tank To Filler Pipe Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push NOTE:



Check that there are no scratches or foreign matter around the connected parts of the fuel tank to filler pipe hose connector



and tank before performing this work. After connecting the fuel tank to filler pipe hose, check that the fuel tank to filler pipe hose is securely connected by pulling on the fuel tank to filler pipe hose connector.

9. CONNECT FUEL TANK VENT HOSE a. Push in the fuel tank vent hose connector to the charcoal canister and push up the retainer so that the claws engage.

Fig. 78: Connecting Fuel Tank Vent Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer Push

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tank vent hose connector and charcoal canister before performing this work. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tank vent hose connector and the charcoal canister.

10. CONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY a. Push in the fuel tank breather elbow tube connector to the pipe and push up the retainer so that the claws engage.

Fig. 79: Connecting Fuel Tank Breather Elbow Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Fuel Tube Connector *3 Fuel Pipe *4 O-ring Push *2

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tank fuel tube connector and fuel pipe before starting this step. After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY a. Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage.

Fig. 80: Connecting Fuel Tank Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer

Fuel Tube Connector *3 Fuel Pipe *4 O-ring Push *2

NOTE:





Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before starting this step. After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

12. INSTALL NO. 1 FUEL TANK PROTECTOR a. Install the lower center fuel tank protector with the 3 clips. 13. INSTALL REAR NO. 1 STABILIZER BAR BRACKET a. Install the 2 rear No. 1 stabilizer bar brackets with the 4 bolts. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 14. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 3 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 15. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 2 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 16. INSTALL NO. 1 FLOOR UNDER COVER . Refer to INSTALLATION - Step 11 17. INSTALL NO. 2 FLOOR UNDER COVER . Refer to INSTALLATION - Step 10 18. INSTALL CENTER EXHAUST PIPE ASSEMBLY Refer to INSTALLATION 19. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION 20. ADD FUEL 21. INSPECT FOR EXHAUST GAS LEAK

FUEL SENDER GAUGE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 81: Identifying Fuel Sender Gauge Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to REMOVAL 2. REMOVE FUEL SENDER GAUGE ASSEMBLY a. Disconnect the 3 harness clamps.

Fig. 82: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

b. Remove the harness protector from the wire harness.

Fig. 83: Identifying Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

c. Disconnect the connector of the fuel sender gauge assembly.

Fig. 84: Identifying Fuel Sender Gauge Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Release the lock as shown in the illustration and slide the fuel sender gauge assembly to remove it.

Fig. 85: Removing Fuel Sender Gauge Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FUEL SENDER GAUGE ASSEMBLY a. Check that the float moves smoothly between F and E.

Fig. 86: Inspecting Fuel Sender Gauge Float Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Fuel Sender Gauge Assembly) b. Measure the resistance between terminals 1 and 2 of the connector according to the value(s) in the table below. Standard Resistance Float Resistance Level (ohms) 13.5 to F 16.5 13.5 to Between 414.5 E and F (Gradually changes) 405.5 to E 414.5 If the value is not as specified, replace the fuel sender gauge assembly. INSTALLATION INSTALLATION

1. INSTALL FUEL SENDER GAUGE ASSEMBLY a. Install the fuel sender gauge assembly by sliding it downward.

Fig. 87: Installing Fuel Sender Gauge Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector of the fuel sender gauge assembly. c. Install the harness protector. NOTE:

Do not damage the wire harness.

d. Connect the 3 harness clamps.

Fig. 88: Identifying Fuel Sender Gauge Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the wire harness.

2. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Refer to INSTALLATION

2012-2017 ACCESSORIES & EQUIPMENT Garage Door Opener (Service Information) - Camry (Hybrid)

GARAGE DOOR OPENER SWITCH COMPONENTS ILLUSTRATION

Fig. 1: Identifying Garage Door Opener Switch Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/o Sliding Roof) . Refer to REMOVAL - Step 1 2. REMOVE ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/ Sliding Roof) . Refer to REMOVAL - Step 2 INSTALLATION INSTALLATION

1. INSTALL ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/o Sliding Roof) . Refer to INSTALLATION - Step 2 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/ Sliding Roof) . Refer to INSTALLATION - Step 3

2012-2017 ACCESSORIES & EQUIPMENT Garage Door Opener (Service Information) - Camry (Except Hybrid)

GARAGE DOOR OPENER SWITCH COMPONENTS ILLUSTRATION

Fig. 1: Identifying Garage Door Opener Switch Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/o Sliding Roof) . Refer to REMOVAL - Step 1 2. REMOVE ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/ Sliding Roof) . Refer to REMOVAL - Step 2 INSTALLATION INSTALLATION

1. INSTALL ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/o Sliding Roof) . Refer to INSTALLATION - Step 2 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (GARAGE DOOR OPENER SWITCH) (w/ Sliding Roof) . Refer to INSTALLATION - Step 3

2012-2017 ACCESSORIES & EQUIPMENT Horn (Service

HORN

Information) (Hybrid)

COMPONENTS ILLUSTRATION

Fig. 1: Identifying Horn Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE LOW PITCHED HORN ASSEMBLY a. Disconnect the connector.

Fig. 2: Identifying Low Pitched Horn Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and low pitched horn assembly. 3. REMOVE SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Disconnect the connector.

Fig. 3: Identifying Super Low Pitched Horn Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and super low pitched horn assembly. 4. REMOVE HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Disconnect the connector.

Fig. 4: Identifying High Low Pitched Horn Bolt And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and high pitched horn assembly. INSPECTION INSPECTION

1. INSPECT HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Apply an auxiliary battery voltage and check the operation of the horn according to the table below.

Fig. 5: Inspecting High Pitched Horn Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -> Terminal A4-1 Horn Auxiliary sounds battery negative (-) -> Body ground TEXT IN ILLUSTRATION Component without harness connected *a (High Pitched Horn Assembly)

If the result is not as specified, replace the high pitched horn assembly. 2. INSPECT LOW PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Apply an auxiliary battery voltage and check the operation of the horn according to the table below.

Fig. 6: Inspecting Low Pitched Horn Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -> Terminal A1-1 Horn Auxiliary sounds battery negative (-) -> Body ground TEXT IN ILLUSTRATION Component without

harness connected (Low *a Pitched Horn Assembly) If the result is not as specified, replace the low pitched horn assembly. 3. INSPECT LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Apply an auxiliary voltage and check the operation of the horn according to the table below.

Fig. 7: Inspecting Low Pitched Horn Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -> Terminal A1-1 Auxiliary battery

Horn sounds

negative (-) -> Body ground TEXT IN ILLUSTRATION Component without harness connected *a (Low Pitched Horn Assembly) If the result is not as specified, replace the low pitched horn assembly. 4. INSPECT SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Apply an auxiliary voltage and check the operation of the horn according to the table below.

Fig. 8: Inspecting Super Low Pitched Horn Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition

Auxiliary battery positive (+) -> Terminal A81-1 Auxiliary battery negative (-) -> Body ground

Horn sounds

TEXT IN ILLUSTRATION Component without harness connected *a (Super Low Pitched Horn Assembly) If the result is not as specified, replace the super low pitched horn assembly. INSTALLATION INSTALLATION

1. INSTALL LOW PITCHED HORN ASSEMBLY a. Install the low pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector. 2. INSTALL SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Install the super low pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector. 3. INSTALL HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Install the high pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector.

4. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT HORN RELAY a. Remove the horn relay.

Fig. 9: Inspecting Horn Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 3-5

Voltage is 10 kohms not or higher applied between

3-5

terminals 1 and 2 Voltage is applied Below 1 between ohms terminals 1 and 2

If the result is not as specified, replace the horn relay.

2012-2017 ACCESSORIES & EQUIPMENT Horn (Service Information) - Camry (Except Hybrid)

HORN COMPONENTS ILLUSTRATION

Fig. 1: Identifying Horn Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE LOW PITCHED HORN ASSEMBLY a. Disconnect the connector.

Fig. 2: Identifying Lower Pitched Horn Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and low pitched horn assembly. 3. REMOVE SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Disconnect the connector.

Fig. 3: Identifying Super Low Pitched Horn Assembly Connector (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and super low pitched horn assembly. 4. REMOVE HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Disconnect the connector.

Fig. 4: Identifying High Pitched Horn Assembly Connector (W/Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and high pitched horn assembly. INSPECTION INSPECTION

1. INSPECT HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Apply battery voltage and check the operation of the horn according to the table below.

Fig. 5: Applying Voltage To High Pitched Horn Assembly (W/Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal A4-1 Horn Battery sounds negative (-) -> Body ground TEXT IN ILLUSTRATION Component without harness connected *a (High Pitched Horn Assembly) If the result is not as specified, replace the high pitched horn assembly.

2. INSPECT LOW PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Apply battery voltage and check the operation of the horn according to the table below.

Fig. 6: Applying Battery Voltage To Low Pitched Horn Assembly (W/Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal A1-1 Horn Battery sounds negative (-) -> Body ground TEXT IN ILLUSTRATION Component without *a harness connected (Low

Pitched Horn Assembly) If the result is not as specified, replace the low pitched horn assembly. 3. INSPECT LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Apply battery voltage and check the operation of the horn according to the table below.

Fig. 7: Applying Battery Voltage To Low Pitched Horn Assembly (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal A1-1 Horn Battery sounds negative (-) -> Body ground

TEXT IN ILLUSTRATION Component without harness connected *a (Low Pitched Horn Assembly) If the result is not as specified, replace the low pitched horn assembly. 4. INSPECT SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Apply battery voltage and check the operation of the horn according to the table below.

Fig. 8: Applying Battery Voltage To Super Low Pitched Horn Assembly (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal

A84-1 Battery negative (-) -> Body ground

Horn sounds

TEXT IN ILLUSTRATION Component without harness connected *a (Super Low Pitched Horn Assembly) If the result is not as specified, replace the super low pitched horn assembly. INSTALLATION INSTALLATION

1. INSTALL LOW PITCHED HORN ASSEMBLY a. Install the low pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector. 2. INSTALL SUPER LOW PITCHED HORN ASSEMBLY (w/o Daytime Running Light) a. Install the super low pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector. 3. INSTALL HIGH PITCHED HORN ASSEMBLY (w/ Daytime Running Light) a. Install the high pitched horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) b. Connect the connector. 4. INSTALL RADIATOR GRILLE SUB-ASSEMBLY Refer to INSTALLATION

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT HORN RELAY a. Remove the horn relay.

Fig. 9: Identifying Horn Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition Voltage is not applied 10 kohms 3-5 between or higher terminals 1 and 2 Voltage is applied Below 1

3-5

between ohms terminals 1 and 2

If the result is not as specified, replace the horn relay.

2012-2017 ENGINE Hybrid Battery Control System (Service Information) (Hybrid)

COOLANT (FOR INVERTER) ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT FOR COOLANT LEAK (for Inverter) a. Remove the reserve tank cap. WARNING: To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot. b. Install the radiator cap tester.

Fig. 1: Pressurizing Cooling System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm2 , 17 psi), and then check that the pressure does not drop. HINT:

If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks. d. Reinstall the reserve tank cap. 2. INSPECT COOLANT LEVEL IN RESERVE TANK (for Inverter) a. The coolant should be between the LOW and FULL lines when the coolant for the inverter is cold. HINT: If the coolant level is low, check for leaks and add TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line. 3. INSPECT COOLANT (for Inverter) a. Remove the reserve tank cap. WARNING: To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot. b. Check for excessive deposits of rust or scale on and around the reserve tank cap and its opening. HINT: If excessively dirty, replace the coolant for the inverter. c. Reinstall the reserve tank cap. 4. INSPECT RESERVE TANK CAP (for Inverter) a. Inspect the reserve tank cap.

Fig. 2: Inspecting Reserve Tank Cap (For Inverter) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 O-ring *2 Rubber Packing 1. If there are water stains or foreign matter on the O-ring, clean it with water and finger scouring. NOTE:

Do not use any tools.

2. Check that the O-ring is not deformed, cracked or damaged. 3. Check that the O-ring is not swollen. b. Check the reserve tank cap operation.

Fig. 3: Checking Operation Of Reserve Tank Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Reserve Tank Cap *2 Radiator Cap Tester *a 30° or more 1. Apply coolant (for inverter) to the O-ring and rubber packing before using a radiator cap tester. 2. Install the reserve tank cap to the radiator cap tester. 3. Pump the cap tester several times, and check the maximum pressure. JUDGMENT CRITERION Standard value (for brand-new cap)

94 to 122 kPa (1.0 to 1.2 kgf/cm2 , 13.6 to 17.7 psi)

Minimum standard value (for used cap) Pump speed

94 kPa (1.0 kgf/cm2 , 13.6 psi) 1 pump per second

NOTE:

When using the cap tester, tilt it upward 30° or more.

HINT: If the maximum pressure is less than the minimum standard value, replace the reserve tank cap.

REPLACEMENT REPLACEMENT

1. DRAIN COOLANT (for Inverter) NOTE:





Do not reuse the drained coolant because it may contain foreign objects. Collect the drained coolant and measure its volume to establish a benchmark. When adding coolant, make sure to add more coolant than the measured amount.

a. Remove the reserve tank cap. WARNING: To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot. b. Using a hexagon wrench (10 mm), remove the drain plug indicated in the illustration and drain the coolant.

Fig. 4: Identifying Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Use caution when handling coolant immediately after driving or in summer because it may be hot.

c. Install the plug with a new gasket. Torque: 39 N*m (397 kgf*cm, 29 ft.*lbf) 2. ADD COOLANT (for Inverter) NOTE:





Do not reuse the drained coolant because it may contain foreign objects. If the vehicle is driven with air in the inverter cooling system, damage may occur and the following DTCs may be set. DTC Code P0A01-726

P0A04-725 P0A08-264 P0A78-284 P0A78-286 P0A7A-322 P0A7A-324 P0A93-346 P0A94-553 P0A94-557 P0AEE-277 P0AF1-276

P0BCD-315 P0BD0-314 P0C39-626 P0C3C-625

Detection Item Motor Electronics Coolant Temperature Sensor Circuit Range / Performance Motor Electronics Coolant Temperature Sensor Circuit Intermittent DC / DC Converter Status Circuit Drive Motor "A" Inverter Performance Drive Motor "A" Inverter Performance Generator Inverter Performance Generator Inverter Performance Inverter Cooling System Performance DC / DC Converter Performance DC / DC Converter Performance Motor Inverter Temperature Sensor "A" Circuit Range / Performance Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic Generator Inverter Temperature Sensor Circuit Range / Performance Generator Inverter Temperature Sensor Circuit Intermittent / Erratic DC / DC Converter Temperature Sensor "A" Range / Performance DC / DC Converter Temperature Sensor "A" Intermittent / Erratic

P0C3E-628 P0C41-627 P0C73-776

DC / DC Converter Temperature Sensor "B" Range / Performance DC / DC Converter Temperature Sensor "B" Intermittent / Erratic Motor Electronics Coolant Pump "A" Control Performance

a. Slowly pour coolant into the reserve tank until it reaches the FULL line.

Fig. 5: Identifying Reserve Tank Full Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Coolant quantity 3.2 liters (3.4 US qts, 2.8 Imp. qts.) NOTE:

To prevent foreign matter such as dust or dirt from entering the cooling system, make sure to confirm that the container used to add coolant is clean and free of foreign matter such as dust or dirt.

b. When using the Techstream: 1. Connect the Techstream to the DLC3. 2. Turn the power switch on (IG). 3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

4. Keep the coolant at the FULL line in the reserve tank to compensate for the drop in coolant level when the air bleeds. Standard Air bleeding from the inverter cooling system is completed when the noise made by the inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves. HINT: 



If free spinning of the inverter water pump is detected for approximately 5 seconds, failsafe control will be activated to suspend the operation of the pump for approximately 15 seconds and resume operation for approximately 4 seconds repeatedly. Operation of the inverter water pump will return to normal if coolant is added. Loud noise made by the inverter water pump assembly and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

HINT: Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system. c. When not using the Techstream: 1. Turn the power switch on (READY).[*1] 2. Turn the power switch off and add coolant to the FULL line because the coolant level drops as the air bleeds.[*2] NOTE:

 

Be sure to turn the power switch off before adding SLLC. Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

3. Repeat steps [*1] and [*2] until air bleeding from the cooling system is completed. Standard Air bleeding from the inverter cooling system is completed when the noise made by the inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves. HINT: Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

d. After the air is completely bled from the cooling system, tighten the reserve tank cap. e. Add coolant to the FULL line of the reserve tank.

Fig. 6: Identifying Reserve Tank Full Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT FOR COOLANT LEAK (for Inverter) See step 1

INVERTER WITH CONVERTER COMPONENTS ILLUSTRATION

Fig. 7: Identifying Inverter With Converter Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 8: Identifying Inverter With Converter Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 9: Identifying Inverter With Converter Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Identifying Inverter With Converter Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

Refer to PRECAUTION 2. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 3. DRAIN COOLANT (for Inverter) See step 1 4. REMOVE CONNECTOR COVER ASSEMBLY WARNING:





NOTE:

Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed. Wear insulated gloves.

Do not start the hybrid system with the service plug grip removed because it may cause a malfunction.

a. Remove the 2 bolts and connector cover assembly.

Fig. 11: Identifying Inverter Terminal Cover And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover. Do not allow any foreign objects or water to enter the inverter with converter assembly.

5. CHECK TERMINAL VOLTAGE WARNING: Wear insulated gloves.

NOTE:

Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

Fig. 12: Measuring Voltage Of Inverter Terminals With Voltmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard voltage

0V HINT: Use a measuring range of DC 750 V or more on the voltmeter. 6. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY WARNING: Wear insulated gloves.

a. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

Fig. 13: Identifying Connector Cover Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. 8. 9. 10. 11. 12.

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL - Step 33 REMOVE NO. 5 INVERTER BRACKET a. Remove the 2 bolts and No. 5 inverter bracket.

Fig. 14: Identifying No. 5 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 4 INVERTER BRACKET a. Remove the 3 bolts and No. 4 inverter bracket.

Fig. 15: Identifying No. 4 Inverter Bracket And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE UPPER INVERTER COVER WARNING: Wear insulated gloves.

a. Remove the 2 bolts and upper inverter cover (generator cable side).

Fig. 16: Identifying Upper Inverter Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure to pull the upper inverter cover straight up, as a connector is connected to the bottom of the cover. Do not touch the upper inverter cover waterproofing rubber.

15. DISCONNECT GENERATOR CABLE WARNING: Wear insulated gloves.

a. Using an insulated tool, remove the 3 bolts.

Fig. 17: Identifying Generator Cable Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 wire harness clamps and separate the generator cable.

Fig. 18: Identifying Generator Cable Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:



  

Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them. Do not touch the connector waterproofing rubber or terminals. Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

16. REMOVE UPPER INVERTER COVER WARNING: Wear insulated gloves.

a. Remove the 2 bolts and upper inverter cover (motor cable side).

Fig. 19: Identifying Upper Inverter Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure to pull the upper inverter cover straight up, as a connector is connected to the bottom of the cover. Do not touch the upper inverter cover waterproofing rubber.

17. DISCONNECT MOTOR CABLE WARNING: Wear insulated gloves.

a. Using an insulated tool, remove the 3 bolts.

Fig. 20: Identifying Motor Cable Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 3 wire harness clamps and separate the motor cable.

Fig. 21: Identifying Motor Cable Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  

Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them. Do not touch the connector waterproofing rubber or terminals. Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

18. REMOVE NO. 3 MOTOR CABLE BRACKET a. Disconnect the hose clamp from the No. 3 motor cable bracket.

Fig. 22: Identifying No. 3 Motor Cable Bracket Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Do not remove the hose clamp from the hose. b. Remove the 2 bolts and No. 3 motor cable bracket. 19. REMOVE CONNECTOR COVER ASSEMBLY WARNING: Wear insulated gloves.

a. Remove the bolt and connector cover assembly.

Fig. 23: Identifying Connector Cover Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover. Do not allow any foreign objects or water to enter the inverter with converter assembly.

20. DISCONNECT NO. 4 ENGINE WIRE WARNING: Wear insulated gloves.

a. Disconnect the No. 4 engine wire.

Fig. 24: Identifying No. 4 Engine Wire Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  

Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them. Do not touch the connector waterproofing rubber or terminals. Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

b. Disconnect the wire harness clamp.

Fig. 25: Identifying No. 4 Engine Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. DISCONNECT NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

a. Remove the bolt.

Fig. 26: Identifying No. 4 Floor Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the wire harness clamp and connector.

Fig. 27: Identifying No. 4 Floor Wire Harness Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:



  

Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them. Do not touch the connector waterproofing rubber or terminals. Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

22. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY WARNING: Wear insulated gloves.

a. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

Fig. 28: Identifying Connector Cover Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. DISCONNECT LOW VOLTAGE CONNECTOR NOTE:

 

Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Raise the lock lever and disconnect the 3 low voltage connectors.

Fig. 29: Raising The Lock Lever And Identifying Low Voltage Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the low voltage connector from the inverter with converter assembly. 24. DISCONNECT NO. 3 ENGINE ROOM WIRE a. Remove the relay block cover. b. Remove the nut.

Fig. 30: Identifying Relay Block Cover Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the wire harness clamp and No. 3 engine room wire. 25. REMOVE NO. 4 INVERTER COOLING HOSE a. Release the retainer and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.

Fig. 31: Disconnecting No. 4 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer b. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

Fig. 32: Covering The Pipes And Hoses With Plastic Bags Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY a. Release the retainer and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.

Fig. 33: Disconnecting No. 1 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer b. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

Fig. 34: Cover The Pipes And Hoses With Plastic Bags Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE INVERTER WITH CONVERTER ASSEMBLY WARNING: Wear insulated gloves.

a. Temporarily secure the No. 3 engine room wire with the inverter with converter assembly hook as shown in the illustration.

Fig. 35: Identifying No. 3 Engine Room Wire And Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 No. 3 Engine Room Wire *2 Hook b. Remove the 2 bolts, nut and inverter with converter assembly.

Fig. 36: Identifying Inverter With Converter Assembly Nut And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:







Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it. To prevent damage, do not hold the inverter with converter assembly by the connectors. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

c. Even after the coolant is drained, coolant remains in the inverter with converter assembly due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter to prevent coolant from spilling out or foreign matter from entering the inverter with converter.

Fig. 37: View Of Remaining Coolant After Drainage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE HIGH VOLTAGE FUSE WARNING: Wear insulated gloves.

HINT: Perform this procedure only when replacement of the high voltage fuse is necessary. a. Remove the bolt and connector cover assembly.

Fig. 38: Identifying Connector Cover Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover. Do not allow any foreign objects or water to enter the inverter with converter assembly.

b. Remove the 2 nuts and high voltage fuse.

Fig. 39: Identifying High Voltage Fuse Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

Fig. 40: Identifying Connector Cover Assembly Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE AIR CLEANER BRACKET a. Remove the bolt and air cleaner bracket.

Fig. 41: Identifying Air Cleaner Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE AIR CLEANER BRACKET a. Remove the bolt and air cleaner bracket.

Fig. 42: Identifying Air Cleaner Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE NO. 1 INVERTER BRACKET a. Remove the 2 bolts and No. 1 inverter bracket.

Fig. 43: Identifying No. 1 Inverter Bracket And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE NO. 2 INVERTER BRACKET a. Remove the 2 bolts and No. 2 inverter bracket.

Fig. 44: Identifying No. 2 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE NO. 3 INVERTER BRACKET a. Remove the 2 bolts and No. 3 inverter bracket.

Fig. 45: Identifying No. 3 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE NO. 1 MOTOR CABLE BRACKET a. Remove the 2 bolts and No. 1 motor cable bracket.

Fig. 46: Identifying No. 1 Motor Cable Bracket And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE NO. 2 MOTOR CABLE BRACKET a. Remove the 2 bolts and No. 2 motor cable bracket.

Fig. 47: Identifying No. 2 Motor Cable Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE NO. 1 INVERTER COOLING HOSE a. Release the retainer and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.

Fig. 48: Disconnecting No. 1 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer b. Remove the No. 1 inverter cooling hose. c. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

Fig. 49: Covering The Pipes And Hoses With Plastic Bags Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE NO. 3 ENGINE ROOM WIRE a. Open the cover.

Fig. 50: Identifying No. 3 Engine Room Wire Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not twist the cover excessively when opening it.

b. Remove the nut and No. 3 engine room wire. INSTALLATION INSTALLATION

NOTE:

If the inverter with converter assembly has been replaced with a new one, make sure to lock the No. 1 inverter cooling hose retainer.

Fig. 51: Locking No. 1 Inverter Cooling Hose Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer 1. INSTALL NO. 3 ENGINE ROOM WIRE a. Temporarily install the No. 3 engine room wire with the nut.

Fig. 52: Identifying No. 3 Engine Room Wire Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the nut. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Close the cover. 2. INSTALL NO. 1 INVERTER COOLING HOSE a. Connect the No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

Fig. 53: Connecting No. 1 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:

  



Insert the retainer until a click sound is heard. Pull on the hose to confirm that the hose is securely connected. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring. To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

b. Install the No. 1 inverter hose to the inverter with hose clamp. 3. INSTALL NO. 2 MOTOR CABLE BRACKET a. Install the No. 2 motor cable bracket with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 4. INSTALL NO. 1 MOTOR CABLE BRACKET a. Install the No. 1 motor cable bracket with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

5. INSTALL NO. 3 INVERTER BRACKET a. Temporarily install the No. 3 inverter bracket with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 54: Identifying No. 3 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 6. INSTALL NO. 2 INVERTER BRACKET a. Temporarily install the No. 2 inverter bracket with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 55: Identifying No. 2 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 7. INSTALL NO. 1 INVERTER BRACKET a. Temporarily install the No. 1 inverter bracket with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 56: Identifying No. 1 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 8. INSTALL AIR CLEANER BRACKET a. Install the air cleaner bracket with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 9. INSTALL AIR CLEANER BRACKET a. Install the air cleaner bracket with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 10. INSTALL HIGH VOLTAGE FUSE WARNING: Wear insulated gloves.

HINT: Perform this procedure only when replacement of the high voltage fuse is necessary. a. Remove the bolt and connector cover assembly.

NOTE:





Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover. Do not allow any foreign objects or water to enter the inverter with converter assembly.

b. Install the high voltage fuse with 2 new nuts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) NOTE:

Be sure to use a torque wrench to tighten the nuts.

c. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly. 11. INSTALL INVERTER WITH CONVERTER ASSEMBLY WARNING: Wear insulated gloves.

a. Temporarily install the inverter with converter assembly with the 2 bolts and nut.

Fig. 57: Identifying Inverter With Converter Assembly Bolts And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:







Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing the inverter with converter assembly, do not damage the parts around it. To prevent damage, do not hold the inverter with converter assembly by the connectors. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

b. Fully tighten the 2 bolts and nut in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

12. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY a. Connect the No. 1 inverter cooling hose assembly to the inverter with converter assembly and lock the hose with the retainer.

Fig. 58: Connecting No. 1 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:

  



Insert the retainer until a click sound is heard. Pull on the hose to confirm that the hose is securely connected. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring. To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

13. CONNECT NO. 4 INVERTER COOLING HOSE a. Connect the No. 4 inverter cooling hose assembly to the inverter with converter assembly and lock the hose with the retainer.

Fig. 59: Connecting No. 4 Inverter Cooling Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Retainer NOTE:

  



Insert the retainer until a click sound is heard. Pull on the hose to confirm that the hose is securely connected. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring. To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

14. CONNECT NO. 3 ENGINE ROOM WIRE a. Connect the clamp. b. Install the No. 3 engine room wire with the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the relay block cover. 15. CONNECT LOW VOLTAGE CONNECTOR a. Connect the 3 low voltage connectors and lock the connector with the lock lever.

Fig. 60: Locking Low Voltage Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Do not allow any foreign objects or water to enter the inverter with converter assembly. Make sure that the connectors are fully engaged.

16. REMOVE CONNECTOR COVER ASSEMBLY See step 19 17. CONNECT NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

NOTE:



Do not damage the terminals, connector housings or inverter with

  



converter assembly when connecting them. Do not touch the connector waterproofing rubber or terminals. Make sure that the connectors are fully engaged. Do not allow any foreign objects or water to enter the inverter with converter assembly. Make sure that the connector does not come out when its body is pulled.

a. Connect the No. 4 floor wire and wire harness clamp to the inverter with converter assembly. b. Secure the No. 4 floor wire to the inverter with converter assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 18. CONNECT NO. 4 ENGINE WIRE WARNING: Wear insulated gloves.

NOTE:



  



Do not damage the terminals, connector housings or inverter with converter assembly when connecting them. Do not touch the connector waterproofing rubber or terminals. Make sure that the connectors are fully engaged. Do not allow any foreign objects or water to enter the inverter with converter assembly. Make sure that the connector does not come out when its body is pulled.

a. Connect the No. 4 engine wire to the inverter with converter assembly. b. Connect the wire harness clamp. 19. INSTALL CONNECTOR COVER ASSEMBLY WARNING: Wear insulated gloves.

NOTE:

 

Make sure that the interlock is fully engaged. Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Install the connector cover assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

20. INSTALL NO. 3 MOTOR CABLE BRACKET a. Install the No. 3 motor cable bracket with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the hose clamp. 21. CONNECT MOTOR CABLE WARNING: Wear insulated gloves.

NOTE:



 

Do not damage the terminals, connector housings or inverter with converter assembly when connecting them. Do not touch the connector waterproofing rubber or terminals. Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Connect the motor cable to the inverter with converter assembly. b. Connect the 3 wire harness clamps. c. Using an insulated tool, install the 3 bolts and motor cable to the inverter with converter assembly. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:

 

The connector should be connected securely. The bolts should be tightened securely.

22. INSTALL UPPER INVERTER COVER WARNING: Wear insulated gloves.

a. Install the upper inverter cover (motor cable side) with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:

 



Do not touch the upper inverter cover waterproofing rubber. Visually confirm that the upper inverter cover waterproofing rubber is securely installed before installing the upper inverter cover. Make sure that the interlock is fully engaged.

23. CONNECT GENERATOR CABLE WARNING: Wear insulated gloves.

NOTE:



 

Do not damage the terminals, connector housings or inverter with converter assembly when connecting them. Do not touch the connector waterproofing rubber or terminals. Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Connect the generator cable to the inverter with converter assembly. b. Connect the 2 wire harness clamps. c. Using a insulated tool, install the 3 bolts and generator cable to the inverter with converter assembly. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:

 

The connector should be connected securely. The bolts should be tightend securely.

24. INSTALL UPPER INVERTER COVER WARNING: Wear insulated gloves.

a. Install the upper inverter cover (generator cable side) with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:

 



Do not touch the upper inverter cover waterproofing rubber. Visually confirm that the upper inverter cover waterproofing rubber is securely installed before installing the upper inverter cover. Make sure that the interlock is fully engaged.

25. INSTALL NO. 4 INVERTER BRACKET a. Temporarily install the No. 4 inverter bracket with the 3 bolts. b. Tighten the 3 bolts in the order shown in the illustration.

Fig. 61: Identifying No. 4 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 26. INSTALL NO. 5 INVERTER BRACKET a. Temporarily install the No. 5 inverter bracket with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 62: Identifying No. 5 Inverter Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 27. 28. 29. 30. 31. 32.

INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 60 INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

33. ADD COOLANT (for Inverter) See step 2 34. INSPECT FOR COOLANT LEAK (for Inverter) See step 1

BATTERY SMART UNIT COMPONENTS ILLUSTRATION

Fig. 63: Identifying Battery Smart Unit Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 64: Identifying Battery Smart Unit Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 65: Identifying Battery Smart Unit Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 66: Identifying Battery Smart Unit Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 67: Identifying Battery Smart Unit Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

Refer to PRECAUTION 2. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 3. 4. 5. 6. 7. 8.

REMOVE CONNECTOR COVER ASSEMBLY See step 4 CHECK TERMINAL VOLTAGE See step 5 INSTALL CONNECTOR COVER ASSEMBLY See step 19 REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 SEPARATE REAR SEATBACK ASSEMBLY a. Fold down the rear seatback assembly RH. b. Using a molding remover, disengage the claw and guide, and remove the No. 2 room partition cover.

Fig. 68: Identifying No. 2 Room Partition Cover Claw And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the rear seat outer belt from the rear seat center shoulder belt guide. d. Pull the cable in the direction shown in the illustration to release the rear seatback lock and then fold the rear seatback assembly LH forward.

Fig. 69: Pulling Cable To Release The Rear Seatback Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. 10. 11. 12. 13. 14.

REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT See step 9 REMOVE NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET See step 10 SEPARATE NO. 2 HYBRID BATTERY INTAKE DUCT See step 11 REMOVE BATTERY COOLING BLOWER ASSEMBLY See step 12 REMOVE BATTERY SMART UNIT WARNING: Wear insulated gloves.

a. Using the service plug grip, remove the battery cover lock striker.

Fig. 70: Removing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Service Plug Grip *2 Battery Cover Lock Striker *3 Button *a Turn *b Projection HINT: Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock. b. Disconnect the 2 connectors.

Fig. 71: Identifying Connectors And No. 2 Hybrid Vehicle Battery Shield Panel Nut And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 bolts, nut and No. 2 hybrid vehicle battery shield panel.

d. Disconnect the 3 wire harness clamps.

Fig. 72: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the connector.

Fig. 73: Identifying Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Insulate the removed terminals with insulating tape.

f. Remove the bolt.

Fig. 74: Identifying Battery Smart Unit Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the battery smart unit together with the No. 2 hybrid vehicle battery shield panel toward the rear of the vehicle.

Fig. 75: Removing Battery Smart Unit And No. 2 Hybrid Vehicle Battery Shield Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery Smart Unit *2 No. 2 Hybrid Vehicle Battery Shield Panel HINT: When removing the battery smart unit and No. 2 hybrid vehicle battery shield panel from the vehicle, they can only be removed together. INSTALLATION INSTALLATION

1. INSTALL BATTERY SMART UNIT WARNING: Wear insulated gloves.

a. Install the battery smart unit together with the No. 2 hybrid vehicle battery shield panel to the side of the HV battery from the rear of the vehicle.

Fig. 76: Installing Battery Smart Unit And No. 2 Hybrid Vehicle Battery Shield Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery Smart Unit *2 No. 2 Hybrid Vehicle Battery Shield Panel HINT: When installing the battery smart unit and No. 2 hybrid vehicle battery shield panel to the vehicle, they can only be installed together. b. Install the battery smart unit with the bolt.

Fig. 77: Identifying Battery Smart Unit Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Black Label Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE:

Check color of the label.

c. Connect the connector. NOTE:

The connector should be connected securely.

d. Install the No. 2 hybrid vehicle battery shield panel with the 2 bolts and nut. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) e. Connect the 3 wire harness clamps. f. Connect the 2 connectors. NOTE:

The connectors should be connected securely.

g. Install the battery cover lock striker, then push the button to lock it.

Fig. 78: Installing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery Cover Lock Striker *2 Button *a Push 2. 3. 4. 5. 6. 7.

INSTALL BATTERY COOLING BLOWER ASSEMBLY See step 1 INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT See step 2 INSTALL NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET See step 3 INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT See step 4 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SEATBACK ASSEMBLY a. Lift the rear seat back assembly LH. b. Engage the guide and claw to install the No. 2 room partition cover.

Fig. 79: Identifying No. 2 Room Partition Cover Claw And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the rear seat outer belt to the rear seat center shoulder belt guide. d. Lift the rear seat back assembly RH. 8. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 9. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 10. INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

HV BATTERY COMPONENTS ILLUSTRATION

Fig. 80: Identifying HV Battery Replacement Components With Torque Specifications (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 81: Identifying HV Battery Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 82: Identifying HV Battery Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 83: Identifying HV Battery Replacement Components With Torque Specifications (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 84: Identifying HV Battery Replacement Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 85: Identifying HV Battery Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 86: Identifying HV Battery Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 87: Identifying HV Battery Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

Refer to PRECAUTION 2. CHECK FOR DTCS a. Check for DTCs. Refer to DTC CHECK / CLEAR . NOTE:

Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work HV battery. If this DTC is output, perform troubleshooting for this DTC first.

3. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

REMOVE CONNECTOR COVER ASSEMBLY See step 4 CHECK TERMINAL VOLTAGE See step 5 INSTALL CONNECTOR COVER ASSEMBLY See step 19 REMOVE AUXILIARY BATTERY . Refer to REMOVAL - Step 4 REMOVE REAR FLOOR FINISH PLATE . Refer to REMOVAL - Step 4 REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to REMOVAL - Step 5 REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH . Refer to REMOVAL - Step 7 REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER RH . Refer to REMOVAL Step 8 REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 13 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 15 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to REMOVAL - Step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 20

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 REMOVE ROOF SIDE INNER GARNISH RH . Refer to REMOVAL - Step 32 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 19 REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE NO. 1 ROOM PARTITION BOARD . Refer to REMOVAL - Step 23 REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT See step 9 REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL See step 26 DISCONNECT NO. 4 FLOOR WIRE See step 27 DISCONNECT LOW VOLTAGE CONNECTOR a. Disconnect the connector and clamp.

Fig. 88: Identifying Low Voltage Connector And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 2 connectors.

Fig. 89: Identifying Low Voltage Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE HV BATTERY WARNING: Wear insulated gloves.

a. Remove the 6 bolts from the HV battery.

Fig. 90: Identifying HV Battery Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the spare wheel cover assembly upside down.

Fig. 91: Identifying Spare Wheel Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Cut and shape a piece of cardboard so that it fits the area between the HV battery bolt attachment positions, and then insert it as shown in the illustration.

Fig. 92: Inserting Cardboard Between The HV Battery Bolt Attachment Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1 *a *b *c

Cardboard Hold up Insert HV battery bolt attachment position

d. Using a tire lever to hold up the HV battery, insert the cardboard until it cannot be inserted any further. NOTE:

Secure the No. 4 floor wire with electrical tape to prevent it from getting caught when moving the battery or other parts.

HINT: Attach tape to the feet and edges of the battery to protect tools and the vehicle body. e. Pull the cardboard and HV battery together to the middle of the luggage compartment.

Fig. 93: Pulling Out Cardboard And HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cardboard *a Pull NOTE:

Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

f. Remove the 2 nuts and No. 2 hybrid vehicle battery upper cover bracket.

Fig. 94: Identifying Battery Upper Cover Bracket And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the clip.

Fig. 95: Identifying Battery Upper Cover Clip And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Disengage the 2 claws and remove the No. 2 hybrid battery intake duct. i. Disconnect the connector from the battery cooling blower assembly.

Fig. 96: Identifying Battery Cooling Blower Assembly Nuts And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Remove the 3 nuts and battery cooling blower assembly. NOTE:





k. Remove the 2 clips.

Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using the wire harness.

Fig. 97: Identifying HV battery Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Turn the cardboard and HV battery 180° together.

Fig. 98: Turning Cardboard And HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Turn 180° *b Pull m. Pull the HV battery together with the cardboard toward the rear of the vehicle. n. Using a suitable adaptor such as a rope, remove the HV battery while tilting it.

Fig. 99: Removing The HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

While lowering the HV battery from the vehicle, do not allow it to contact the vehicle.

37. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL WARNING: Wear insulated gloves.

a. Using the service plug grip, remove the battery cover lock striker.

Fig. 100: Removing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Service Plug Grip *2 Battery Cover Lock Striker *3 Button *a Turn *b Projection HINT: Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock. b. Disconnect the connector.

Fig. 101: Identifying No. 2 Hybrid Vehicle Battery Shield Panel Nut And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 bolts, nut and No. 2 hybrid vehicle battery shield panel. d. Disconnect the 3 wire harness clamps.

Fig. 102: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 38. REMOVE BATTERY SMART UNIT a. Disconnect the connector. NOTE:

Insulate the removed connector with insulating tape.

Fig. 103: Identifying Bolt And Battery Smart Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and battery smart unit. 39. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves.

a. Remove the bolt, 3 nuts and No. 1 hybrid battery shield sub-assembly.

Fig. 104: Identifying No. 1 Hybrid Battery Shield Sub-Assembly Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY See step 29 41. SEPARATE NO. 2 HYBRID BATTERY PACK WIRE

WARNING: Wear insulated gloves.

a. Disconnect the connector and 5 clamps, and remove the No. 2 hybrid battery pack wire.

Fig. 105: Identifying No. 2 Hybrid Battery Pack Wire Connector And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. REMOVE NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY a. Remove the 2 bolts and No. 1 hybrid vehicle battery carrier bracket sub-assembly.

Fig. 106: Identifying No. 1 Hybrid Vehicle Battery Carrier Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. REMOVE NO. 2 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY a. Remove the 2 bolts and No. 2 hybrid vehicle battery carrier bracket sub-assembly.

Fig. 107: Identifying No. 2 Hybrid Vehicle Battery Carrier Bracket And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY a. Install the No. 2 hybrid vehicle battery carrier bracket with the 2 bolts.

Fig. 108: Identifying No. 2 Hybrid Vehicle Battery Carrier Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Claw *b Hole

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTE:

Be sure to align the claw of the No. 2 hybrid vehicle battery carrier bracket with the hole.

2. INSTALL NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY a. Install the No. 1 hybrid vehicle battery carrier bracket with the 2 bolts.

Fig. 109: Identifying No. 1 Hybrid Vehicle Battery Carrier Bracket And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Claw *b Hole

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTE:

Be sure to align the claw of the No. 1 hybrid vehicle battery carrier bracket with the hole.

3. INSTALL NO. 2 HYBRID BATTERY PACK WIRE WARNING: Wear insulated gloves.

a. Connect the connector and 5 clamps and install the No. 2 hybrid battery pack wire. 4. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY See step 1 5. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves.

a. Install the No. 1 hybrid battery shield sub-assembly with the bolt and 3 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 6. INSTALL BATTERY SMART UNIT WARNING: Wear insulated gloves.

a. Install the battery smart unit with the bolt.

Fig. 110: Identifying Bolt And Battery Smart Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Black Label Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE:

Check color of the label.

b. Connect the connector. NOTE:

The connectors should be connected securely.

7. INSTALL NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL WARNING: Wear insulated gloves.

a. Install the No. 2 hybrid vehicle battery shield panel with the 2 bolts and nut. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Connect the 3 wire harness clamps. c. Connect the connector.

d. Install the battery cover lock striker, then push the button to lock it.

Fig. 111: Installing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery Cover Lock Striker *2 Button *a Push 8. INSTALL HV BATTERY WARNING: Wear insulated gloves.

a. Place a piece of cardboard in the luggage compartment.

Fig. 112: Identifying Piece Of Cardboard Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cardboard b. Using a suitable adaptor such as a rope, install the HV battery to the vehicle in the same direction it was facing during removal. NOTE:

Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

c. Push the cardboard and HV battery together to the middle of the luggage compartment.

Fig. 113: Pushing In Cardboard And HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Push *b Turn 180° d. Turn the cardboard and HV battery 180° together. e. Install the 2 clips. f. Install the battery cooling blower assembly with the 3 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE:





Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using the wire harness.

g. Connect the connector. h. Engage the 2 claws to install the No. 2 hybrid battery intake duct. NOTE:

Ensure that the duct is installed securely.

i. Install the clip. j. Install the No. 2 hybrid vehicle battery upper cover bracket with the 2 nuts.

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) k. Push the HV battery together with the cardboard toward the front of the vehicle.

Fig. 114: Pushing In Cardboard And HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Push NOTE:

Align the holes for the HV battery holding bolts.

l. Use a tire lever to hold up the HV battery and pull out the cardboard.

Fig. 115: Holding Up The HV Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Hold up *b Pull out m. Remove the spare wheel cover assembly. n. Install the HV battery with the 6 bolts.

Fig. 116: Identifying HV Battery Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Ground Bolt Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) HINT: Install the ground bolts to the locations shown in the illustration. 9. CONNECT LOW VOLTAGE CONNECTOR a. Connect the 3 connectors and wire harness clamp. 10. CONNECT NO. 4 FLOOR WIRE See step 3

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.

INSTALL NO. 4 HYBRID BATTERY SHIELD PANEL See step 4 INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT See step 4 INSTALL NO. 1 ROOM PARTITION BOARD . Refer to INSTALLATION - Step 3 INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 INSTALL ROOF SIDE INNER GARNISH RH . Refer to INSTALLATION - Step 28 CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 2 INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH . Refer to INSTALLATION - Step 6 INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER RH . Refer to INSTALLATION - Step 7 INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to INSTALLATION - Step 8 INSTALL REAR FLOOR FINISH PLATE . Refer to INSTALLATION - Step 10 INSTALL AUXILIARY BATTERY . Refer to INSTALLATION - Step 1 INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

CHARGING CHARGING

1. INSPECT AUXILIARY BATTERY VOLTAGE a. Measure the voltage between the terminals of the auxiliary battery. Standard voltage Approximately 11 V or more HINT: The horn should sound clearly.  If the voltage is 10 V or less, either charge the auxiliary battery (charging usually takes about 1 hour), or replace it with an auxiliary battery that is already charged. b. Check the charge level of the HV battery. 1. Check whether the HV battery warning message is shown in the multi-information display. 

Fig. 117: HV Battery Warning Message Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Confirm if the engine starts. If the engine starts, leave it idling with park (P) selected until the engine stops (self charge has completed). If the engine cannot start, follow the procedure and charge the HV battery.

HINT: Before performing external charging, always use the Techstream to perform troubleshooting.  Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.) 2. PREPARATION FOR HV BATTERY CHARGING 

WARNING:









Wear insulated gloves when working on the high voltage system. After removing the service plug grip, do not turn the power switch on (READY) as this may cause a malfunction. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system. After removing the service plug grip, wait 10 minutes before touching any of the high voltage connectors or terminals.

HINT:  

a. b. c. d. e. f. g.

Removing the service plug grip interrupts the high voltage circuit. High voltage wiring connectors are orange. Remove the service plug grip. Refer to REMOVAL. Remove the cool air intake duct seal. Refer to REMOVAL - Step 1 . Remove the inlet air cleaner assembly. Refer to REMOVAL - Step 30 . Remove the air cleaner cap sub-assembly. Refer to REMOVAL - Step 3 . Remove the air cleaner filter element sub-assembly. Remove the air cleaner case sub-assembly. Refer to REMOVAL - Step 33 . Remove the 2 bolts and connector cover assembly.

Fig. 118: Identifying Inverter Terminal Cover And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.

h. Check terminal voltage See step 5. i. Remove the bolt.

Fig. 119: Identifying No. 4 Floor Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Disconnect the wire harness clamp and connector.

Fig. 120: Identifying No. 4 Floor Wire Harness Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

k. Measure the resistance according to the value(s) in the table below.

Fig. 121: Checking No. 4 Floor Wire Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If the shield line of the No. 4 floor wire is not securely connected to body ground, the THS charger will not operate. The "FAULT" and "CABLE CONNECTION" warning lights will illuminate on the THS charger. Standard Resistance Tester Connection No. 4 floor wire connector

Condition

Specified Condition

Always

Below 1 ohms

housing - Body ground l. If the result is not as specified, inspect the connection shown in the illustration for proper installation. Refer to INSTALLATION.

Fig. 122: Inspecting No. 4 Floor Wire Connector Housing - Body Ground Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. m. Temporarily install the connector cover assembly with the 2 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

Fig. 123: Identifying Inverter Terminal Cover And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. n. Connect the THS charger in the order shown by the circled numbers in the illustration.

Fig. 124: Order To Connect THS Charger Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 EV Bonding Cable (Green Cable) *3 High Voltage Cable *5 No. 4 floor wire *7 EV Bonding Cable

*2 *4 *6 *8

Low Voltage Cable HV Battery Inverter with Converter Assembly Grounded AC 100 to 240 V Receptacle

*9 

   

THS Charger

*10

Bolt (91553-80665)

SST: 09880-10021 09881-10041 SST: 09881-10081 SST: 09881-10050 SST: 09882-10040 SST: 09882-10070

NOTE:





Make sure to connect the EV bonding cable first to prevent electrical shock. Connect all THS charger cables in the order shown in the illustration to prevent electrical shock.

o. Connect the EV bonding cable to the illustration bolt of the No. 5 inverter bracket.

Fig. 125: Identifying No. 5 Inverter Bracket Bolt And EV Bonding Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) p. Connect the EV bonding cable to the THS charger.

Fig. 126: Identifying THS Charger & EV Bonding Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. q. Connect the low voltage cable to the positions shown in the illustration, and then tighten the 2 bolts.

Fig. 127: Identifying Low Voltage Cable And Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) r. Connect the No. 4 floor wire to the high voltage cable with the bolt (91553-80665).

Fig. 128: Identifying No. 4 Floor Wire Connecting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:





The installation bolt that comes with the vehicle is too short to securely connect the No. 4 floor wire to the high voltage cable of the charger. Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the No. 4 floor wire to the vehicle.

HINT: When connecting the high voltage cable, use a bolt with a nominal diameter of 6 mm, a shaft length of 69 mm and a pitch of 1.0 mm. s. Connect the low voltage cable and high voltage cable to the THS charger in the order shown in the illustration.

Fig. 129: Identifying THS Charger, Low Voltage Cable & High Voltage Cable With Connections Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Low Voltage Cable *2 High Voltage Cable t. Install the service plug grip See step 1. u. Connect the negative auxiliary battery terminal. v. Connect the power input plug of the charger to a grounded AC 100 to 240 V receptacle. NOTE:

Always use an AC 100 to 240 V receptacle with a properly functioning ground. The ground is designed to reduce the chance of electric shock if a malfunction occurs. Do not use the charger if any of the

pins on its plug have been damaged or removed. 3. HV BATTERY CHARGING a. Turn the power switch of the vehicle on (IG). b. Connect the Techstream to the DLC3. c. Enter the following menus: Powertrain / Hybrid Control / Active Test / Battery Charge. HINT: 



During the "Battery Charge" Active Test, check "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in the Data List. If the Data List values are not as specified in the table below, turn the Techstream and the power switch off and then perform the Charge Battery procedure again.

"SMRB" and "SMRG" in Data List during "Battery Charge" Active Test

Step 1 2 3

THS charger Active Test START Battery Charge switch OFF OFF OFF --> ON OFF ON OFF --> ON

Data List System Main Relay Status SMRB OFF OFF --> ON ON

Data List System Main Relay Status SMRG OFF OFF --> ON ON

d. Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released). e. Make sure that the BREAKER is in the ON position. f. Turn the THS charger MAIN switch on.

Fig. 130: Identifying THS Charger Main Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The MAIN indicator will illuminate green. g. Press the START switch.

Fig. 131: Identifying Start Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 



When the START switch is turned on, the INITIAL CHECK indicator illuminates and an initial check starts. When the initial check completes successfully, the INITIAL CHECK indicator turns off, the CHARGING indicator illuminates and charging will start at the same time. While the INITIAL CHECK indicator is illuminated, the insulation, 400 V output,

emergency stop switch, connector connections and ground connection are inspected. h. Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off. HINT: Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)  There is very little chance of overcharging the HV battery during the second or third charging cycle. The SOC will not likely increase beyond the upper limit because it was low enough to prevent the engine from starting. Even if the SOC was to increase enough to exceed the limit, the hybrid vehicle control ECU will stop the active test to prevent overcharging.  Cranking the engine once causes the SOC to drop approximately 1%.  Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%. i. Turn the power switch off. j. Remove the THS charger and install the No. 4 floor wire. 

NOTE: 1. 2. 3. 4.

Make sure to disconnect the EV bonding cable last.

Disconnect the power inlet plug of the charger from the receptacle. Disconnect the negative terminal of the auxiliary battery. Remove the service plug grip See step 9. Disconnect the high voltage cable and low voltage cable from the THS charger in the order shown in the illustration.

Fig. 132: Identifying THS Charger, Low Voltage Cable & High Voltage Cable With Disconnection Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Low Voltage Cable *2 High Voltage Cable 5. Remove the bolt (91553-80665) and disconnect the high voltage cable from the No. 4 floor wire.

Fig. 133: Identifying No. 4 Floor Wire Connecting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the No. 4 floor wire to the vehicle.

6. Remove the 2 bolts and disconnect the low voltage cable.

Fig. 134: Identifying Low Voltage Cable And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Disconnect the EV bonding cable from the THS charger.

Fig. 135: Identifying THS Charger & EV Bonding Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

8. Disconnect the EV bonding cable from the installation bolt of the No. 5 inverter bracket.

Fig. 136: Identifying No. 5 Inverter Bracket Bolt And EV Bonding Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Tighten the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 10. Remove the connector cover assembly. 11. Connect the wire harness clamp and connector.

Fig. 137: Identifying No. 4 Floor Wire Harness Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Connect the No. 4 floor wire with the bolt.

Fig. 138: Identifying No. 4 Floor Wire Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE:

Do not use the bolt (91553-80665) used for connecting the high voltage cable of the charger.

13. Install the connector cover assembly with the 2 bolts. NOTE:

Make sure that the interlock is fully engaged.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 14. Install the air cleaner case sub-assembly. Refer to INSTALLATION - Step 60 . 15. Install the air cleaner filter element sub-assembly. 16. Install the air cleaner cap sub-assembly. Refer to INSTALLATION - Step 2 . 17. Install the inlet air cleaner assembly. Refer to INSTALLATION - Step 63 . 18. Install the cool air intake duct seal. Refer to INSTALLATION - Step 4 . 19. Install the service plug grip. Refer to INSTALLATION. k. Check if the engine starts. HINT: If the engine does not start, perform the HV battery charging operation again. 4. CHECK HV BATTERY AFTER HV BATTERY CHARGE a. Check for DTCs. b. Perform the self-charging operation. 1. Start the engine and leave park (P) selected until the engine stops idling. HINT: When the engine stops idling, this indicates that self-charging is complete. Perform any initialization required after the negative terminal of the auxiliary battery is disconnected and reconnected.

WATER PUMP WITH MOTOR COMPONENTS ILLUSTRATION

Fig. 139: Identifying Water Pump With Motor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN COOLANT (for Inverter) See step 1

2. REMOVE INVERTER RESERVE TANK ASSEMBLY a. Remove the 2 bolts and inverter reserve tank assembly.

Fig. 140: Identifying Inverter Reserve Tank Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE INVERTER WATER PUMP ASSEMBLY a. Disconnect the water hose.

Fig. 141: Identifying Inverter Water Pump Top Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Put pieces of cloth into the pipe and in the disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

b. Disconnect the connector.

Fig. 142: Identifying Inverter Water Pump Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Apply insulating tape to the connectors of the wire harness and inverter water pump assembly to prevent the entry of coolant.

c. Remove the 3 bolts. d. Disconnect the water hose and remove the inverter water pump assembly.

Fig. 143: Identifying Inverter Water Pump Side Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Put pieces of cloth into the pipe and in the disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

INSTALLATION INSTALLATION

1. INSTALL INVERTER WATER PUMP ASSEMBLY a. Connect the water hose.

Fig. 144: Identifying Inverter Water Pump Side Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Rib *b Alignment Mark *c 90° *d 2 to 7 mm (0.0787 to 0.276 in.) NOTE:

 



Make sure that the clip is positioned as shown in the illustration Make sure to align the alignment marks of the hoses with the ribs of the inverter water pump assembly. Do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

b. Install the inverter water pump assembly with the 3 bolts. Torque: 6.1 N*m (62 kgf*cm, 54 in.*lbf) NOTE:

Do not hold the inverter water pump assembly by the connector terminals when removing or installing it.

c. Connect the connector. d. Connect the water hose.

Fig. 145: Identifying Inverter Water Pump Top Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Rib *b Alignment Mark *c 220° *d 2 to 7 mm (0.0787 to 0.276 in.) NOTE:

 



Make sure that the clip is positioned as shown in the illustration Make sure to align the alignment marks of the hoses with the ribs of the inverter water pump assembly. Do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

2. INSTALL INVERTER RESERVE TANK ASSEMBLY a. Temporarily install the inverter reserve tank assembly with the 2 bolts. b. Tighten the 2 bolts in the order shown in the illustration.

Fig. 146: Identifying Inverter Reserve Tank Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. ADD COOLANT (for Inverter) See step 2 4. INSPECT FOR COOLANT LEAK (for Inverter) See step 1

SUB RADIATOR COMPONENTS ILLUSTRATION

Fig. 147: Identifying Sub Radiator Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 148: Identifying Sub Radiator Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN COOLANT (for Inverter) See step 1

2. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL 3. REMOVE FRONT BUMPER ENERGY ABSORBER . Refer to DISASSEMBLY - Step 10 4. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY . Refer to DISASSEMBLY Step 11 5. REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 6. REMOVE NO. 5 INVERTER BRACKET See step 12 7. REMOVE RADIATOR RESERVE TANK ASSEMBLY . Refer to REMOVAL - Step 13 8. REMOVE HOOD LOCK ASSEMBLY . Refer to REMOVAL - Step 9 9. REMOVE UPPER RADIATOR SUPPORT . Refer to REMOVAL - Step 18 10. REMOVE RADIATOR SIDE DEFLECTOR RH a. Disengage the 3 claws and remove the radiator side deflector RH.

Fig. 149: Identifying Radiator Side Deflector RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE RADIATOR ASSEMBLY a. Disconnect the 2 water hoses.

Fig. 150: Identifying Radiator Water Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Put pieces of cloth into the pipes and in the disconnected hoses or cover the pipes and hoses with plastic bags to prevent entry of foreign matter.

b. Remove the 4 bolts and radiator assembly.

Fig. 151: Identifying Radiator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL RADIATOR ASSEMBLY a. Install the radiator assembly with the 4 bolts.

Fig. 152: Identifying Radiator Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt A Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) b. Connect the 2 water hoses.

Fig. 153: Identifying Radiator Water Hose Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Alignment Mark *b Rib *c 120° *d 135° *e 1 to 5 mm (0.0394 to 0.197 in.) NOTE:





Make sure that the clip is positioned as shown in the illustration. Make sure to align the alignment marks of the hoses with the ribs of the radiator assembly.



Do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

2. INSTALL RADIATOR SIDE DEFLECTOR RH a. Engage the 3 claws to install the radiator side deflector RH. 3. INSTALL UPPER RADIATOR SUPPORT . Refer to INSTALLATION - Step 2 4. INSTALL HOOD LOCK ASSEMBLY . Refer to INSTALLATION - Step 2 5. INSTALL RADIATOR RESERVE TANK ASSEMBLY . Refer to INSTALLATION - Step 7 6. INSTALL NO. 5 INVERTER BRACKET See step 26 7. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 8. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY . Refer to REASSEMBLY Step 3 9. INSTALL FRONT BUMPER ENERGY ABSORBER . Refer to REASSEMBLY - Step 4 10. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION 11. ADD COOLANT (for Inverter) See step 2 12. INSPECT FOR COOLANT LEAK (for Inverter) See step 1

FRAME WIRE COMPONENTS ILLUSTRATION

Fig. 154: Identifying Frame Wire Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 155: Identifying Frame Wire Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 156: Identifying Frame Wire Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 13 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 15 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to REMOVAL - Step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 20 REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 REMOVE ROOF SIDE INNER GARNISH RH . Refer to REMOVAL - Step 32 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 19 REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE NO. 1 ROOM PARTITION BOARD . Refer to REMOVAL - Step 23 REMOVE NO. 1 FLOOR UNDER COVER . Refer to REMOVAL - Step 3 REMOVE FRONT CENTER FLOOR COVER RH a. Remove the 6 clips and front center floor cover RH.

Fig. 157: Identifying Front Center Floor Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Remove the nut and disconnect the No. 2 parking brake cable assembly.

Fig. 158: Identifying No. 2 Parking Brake Cable Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL See step 26 26. REMOVE NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

NOTE:

Insulate the removed terminals with insulating tape.

a. Disconnect the 2 connectors.

Fig. 159: Identifying No. 4 Floor Wire Connectors And Shielded Wire Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the shielded wire ground. c. Disconnect the wire harness clamp and connector.

Fig. 160: Identifying Wire Harness Clamp And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 3 claws and push the frame wire out from the floor panel.

Fig. 161: Identifying Frame Wire Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

e. Disconnect the 2 wire harness clamps.

Fig. 162: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disconnect the 2 wire harness clamps and connector.

Fig. 163: Identifying Wire Harness Clamps And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the 2 nuts. h. Remove the 2 bolts.

Fig. 164: Identifying Wire Harness Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Remove the 2 bolts and 4 nuts.

Fig. 165: Identifying Wire Harness Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Disconnect the 2 clamps and remove the No. 4 floor wire.

Fig. 166: Identifying No. 4 Floor Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When removing the clamp, break the claw on the clamp. The clamp cannot be reused. INSTALLATION INSTALLATION

1. INSTALL NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

a. Install the No. 4 floor wire with 2 new clamps shown in the illustration.

Fig. 167: Identifying No. 4 Floor Wire Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 4 nuts and 2 bolts shown in the illustration.

Fig. 168: Identifying Wire Harness Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the 2 bolts shown in the illustration.

Fig. 169: Identifying Wire Harness Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. Install the 2 nuts shown in the illustration.

Fig. 170: Identifying Wire Harness Clamps And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) e. Connect the connector and 2 wire harness clamps. f. Connect the 2 wire harness clamps shown in the illustration.

Fig. 171: Identifying Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Insert the No. 4 floor wire into the floor panel hole. h. Connect the connector and wire harness clamp.

Fig. 172: Identifying Wire Harness Clamp And Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Connect the 2 connectors.

Fig. 173: Identifying No. 4 Floor Wire Connectors And Shielded Wire Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Shielded Wire Ground *a Claw *b Hole j. Connect the shielded wire ground. NOTE:



Make sure that the ends of the No. 4 floor wire do not cross over

 



each other. The connector should be connected securely. Be sure to align the claw of the shielded wire ground with the hole. Be sure to install the shielded wire ground in the correct direction.

2. INSTALL NO. 4 HYBRID BATTERY SHIELD PANEL See step 4 3. INSTALL NO. 1 FLOOR UNDER COVER . Refer to INSTALLATION - Step 11 4. INSTALL FRONT CENTER FLOOR COVER RH a. Install the front center floor cover RH with the 6 clips. 5. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 2 parking brake cable assembly with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

INSTALL NO. 1 ROOM PARTITION BOARD . Refer to INSTALLATION - Step 3 INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 INSTALL ROOF SIDE INNER GARNISH RH . Refer to INSTALLATION - Step 28 CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 2 INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5

24. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 25. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Refer to INSTALLATION

ACCELERATOR PEDAL SENSOR COMPONENTS ILLUSTRATION

Fig. 174: Identifying Accelerator Pedal Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ACCELERATOR PEDAL SENSOR ASSEMBLY

a. Connect the Techstream to the DLC3. b. Turn the power switch on (IG). c. Enter the following menus: Powertrain / Hybrid Control / Data List / Accel Pedal Pos #1, Accel Pedal Pos #2. d. Read the Data List. Result Tester Display

Accel Pedal Pos #1

Accel Pedal Pos #2

Accelerator Pedal Condition Not depressed Fully depressed Not depressed --> Fully depressed --> Not depressed (Accelerator pedal should be operated slowly) Not depressed Fully depressed Not depressed --> Fully depressed --> Not depressed (Accelerator pedal should be operated slowly)

Specified Condition 8 to 28% 62 to 92% Value changes progressively 20 to 44% 78 to 100% Value changes progressively

REMOVAL REMOVAL

1. REMOVE ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly.

a. Disconnect the connector.

Fig. 175: Identifying Accelerator Pedal Sensor Bolts And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and accelerator pedal sensor assembly. INSTALLATION INSTALLATION

1. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE:

 

Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly.

a. Temporarily install the accelerator pedal sensor assembly with the 2 bolts.

Fig. 176: Identifying Accelerator Pedal Sensor Bolts And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Tighten the 2 bolts in the order shown in the illustration. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) c. Connect the connector.

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT IGNITION CONTROL RELAY (IGCT) a. Measure the resistance according to the value(s) in the table below.

Fig. 177: Inspecting Relay (IGCT) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection 3-5

3-5

Condition Specified Condition Auxiliary battery voltage is not applied between terminals 1 and 10 kohms or higher 2 Auxiliary battery voltage is applied between terminals 1 and Below 1 ohms 2

TEXT IN ILLUSTRATION *1 Ignition Control Relay If the result is not as specified, replace the relay. 2. INSPECT HYBRID WATER PUMP RELAY (INV W/PMP) a. Measure the resistance according to the value(s) in the table below.

Fig. 178: Identifying Hybrid Water Pump Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection 3-5

3-5

Condition Specified Condition Auxiliary battery voltage is not applied between terminals 1 and 10 kohms or higher 2 Auxiliary battery voltage is applied between terminals 1 and Below 1 ohms 2

TEXT IN ILLUSTRATION *1 Hybrid Water Pump Relay If the result is not as specified, replace the relay.

HV RELAY ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 179: Identifying HV Relay Assembly Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 180: Identifying HV Relay Assembly Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 181: Identifying HV Relay Assembly Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 182: Identifying HV Relay Assembly Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 183: Identifying HV Relay Assembly Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

Refer to PRECAUTION 2. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

REMOVE CONNECTOR COVER ASSEMBLY See step 4 CHECK TERMINAL VOLTAGE See step 5 INSTALL CONNECTOR COVER ASSEMBLY See step 19 REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 13 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 15 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to REMOVAL - Step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 20 REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 REMOVE ROOF SIDE INNER GARNISH RH . Refer to REMOVAL - Step 32 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 19 REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE NO. 1 ROOM PARTITION BOARD . Refer to REMOVAL - Step 23 REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL WARNING: Wear insulated gloves.

a. Using the service plug grip, remove the battery cover lock striker.

Fig. 184: Removing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Service Plug Grip *2 Battery Cover Lock Striker *3 Button *a Projection *b Turn HINT: Insert the projecting part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise to release the lock. b. Remove the bolt, 2 nuts and No. 4 hybrid battery shield panel.

Fig. 185: Identifying No. 4 Hybrid Battery Shield Panel Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. DISCONNECT NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

NOTE:

Insulate the disconnected connectors with insulating tape.

a. Disconnect the 2 connectors shown in the illustration.

Fig. 186: Identifying No. 4 Floor Wire Connectors And Shielded Wire Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the shielded wire ground and No. 4 floor wire. 28. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves.

a. Disconnect the connector and wire harness clamp.

Fig. 187: Identifying No. 1 Hybrid Battery Connector And Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt, 3 nuts and No. 1 hybrid battery shield sub-assembly.

Fig. 188: Identifying No. 1 Hybrid Battery Shield Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

WARNING: Wear insulated gloves.

NOTE:

Insulate the disconnected terminals with insulating tape.

a. Disengage the claw and disconnect the terminal cover.

Fig. 189: Identifying Terminal Cover Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using an insulated tool, remove the 2 bolts.

Fig. 190: Identifying Hybrid Battery Junction Block Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the connector shown in the illustration.

Fig. 191: Identifying Hybrid Battery Junction Block Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the 3 bolts and hybrid battery junction block assembly.

Fig. 192: Identifying Hybrid Battery Junction Block Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY a. Inspect SMRB. 1. Measure the resistance according to the value(s) in the table below.

Fig. 193: Identifying Hybrid Battery Junction Block Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection A-1 (+) - Q2-1 (CBI)

A-1 (+) - Q2-1 (CBI)

TEXT IN ILLUSTRATION

Condition

Specified Condition

Auxiliary battery voltage is not applied between terminals O9-1 (SMRB) and O9- 10 kohms or higher 2 (GND) Auxiliary battery voltage is applied between terminals O9-1 (SMRB) and O9- Below 1 ohms 2 (GND)

*a

Component without harness connected (Hybrid Battery Junction Block Assembly)

2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection O9-1 (SMRB) - O9-2 (GND)

Condition -40 to 80°C (-40 to 176°F)

Specified Condition 25.0 to 59.0 ohms

If the result is not as specified, replace the hybrid battery junction block assembly or electric vehicle fuse. b. Inspect SMRG. 1. Measure the resistance according to the value(s) in the table below.

Fig. 194: Identifying Hybrid Battery Junction Block Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection q1-1 (-) - Q3- 1 (CEI)

q1-1(-) - Q3- 1 (CEI)

TEXT IN ILLUSTRATION

Condition

Specified Condition

Auxiliary battery voltage is not applied between terminals O9-3 (SMRG) and O9- 10 kohms or higher 2 (GND) Auxiliary battery voltage is applied between terminals O9-3 (SMRG) and O9- Below 1 ohms 2 (GND)

*a

Component without harness connected (Hybrid Battery Junction Block Assembly)

2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection O9-3 (SMRG) - O9-2 (GND)

Condition -40 to 80°C (-40 to 176°F)

Specified Condition 25.0 to 59.0 ohms

If the result is not as specified, replace the hybrid battery junction block assembly. c. Inspect SMRP. 1. Measure the resistance according to the value(s) in the table below.

Fig. 195: Identifying Hybrid Battery Junction Block Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection q1-1 (-) - Q3- 1 (CEI)

q1-1(-) - Q3- 1(CEI)

Condition

Specified Condition

Auxiliary battery voltage is not applied between terminals O9-4 (SMRP) and O9- 10 kohms or higher 2 (GND) Auxiliary battery voltage is applied between terminals O9-4 (SMRP) and O9- 28.5 to 31.5 ohms 2 (GND)

TEXT IN ILLUSTRATION Component without harness connected *a (Hybrid Battery Junction Block Assembly) 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection O9-4 (SMRP) and O9-2 (GND)

Condition -40 to 80°C (-40 to 176°F)

Specified Condition 112 to 274 ohms

If the result is not as specified, replace the hybrid battery junction block assembly. INSTALLATION INSTALLATION

1. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY WARNING: Wear insulated gloves.

a. Install the hybrid battery junction block assembly with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Connect the connector to the hybrid battery junction block assembly. NOTE:

The connector should be connected securely.

c. Using an insulated tool, install the 2 bolts.

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTE:

Be sure to use a torque wrench to tighten the bolts.

d. Connect the terminal cover. NOTE:

The terminal cover should be connected securely.

2. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves.

a. Install the No. 1 hybrid battery shield sub-assembly with the bolt and 3 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Connect the connector. NOTE:

The connector should be connected securely.

3. CONNECT NO. 4 FLOOR WIRE WARNING: Wear insulated gloves.

a. Connect the 2 connectors. NOTE:





Make sure that the ends of the No. 4 floor wire do not cross over each other. The connector should be connected securely.

Fig. 196: Identifying No. 4 Floor Wire Connectors And Shielded Wire Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Shielded Wire Ground *a Claw *b Hole b. Connect the shielded wire ground. NOTE:





Be sure to align the claw of the shielded wire ground with the hole. Be sure to install the shielded wire ground in the correct direction.

4. INSTALL NO. 4 HYBRID BATTERY SHIELD PANEL WARNING: Wear insulated gloves.

a. Install the No. 4 hybrid battery shield panel with the bolt and 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Install the battery cover lock striker, then push the button to lock it.

Fig. 197: Installing Battery Cover Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery Cover Lock Striker *2 Button *a Push 5. 6. 7. 8.

INSTALL NO. 1 ROOM PARTITION BOARD . Refer to INSTALLATION - Step 3 INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 9. INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1

10. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 11. INSTALL ROOF SIDE INNER GARNISH RH . Refer to INSTALLATION - Step 28 12. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 2 13. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 14. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 15. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 16. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 17. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 18. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 19. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 20. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 21. INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 22. INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5 23. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 24. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 25. INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

COMBINATION SWITCH COMPONENTS ILLUSTRATION

Fig. 198: Identifying Combination Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 12 REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY)

a. Disengage the 2 claws and remove the EV drive mode switch (pattern select switch assembly).

Fig. 199: Identifying EV Drive Mode Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 200: Identifying EV Drive Mode Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection I48-4 (S) - I48-1 (E)

I48-4 (S) - I48-1 (E)

Condition Specified Condition EV drive mode switch (pattern select switch assembly) being Below 1 ohms pushed and held EV drive mode switch (pattern select switch assembly) not 10 kohms or higher pushed

TEXT IN ILLUSTRATION Component without harness connected *a (EV Drive Mode Switch (Pattern Select Switch Assembly)) If the result is not as specified, replace the EV drive mode switch (pattern select switch assembly). b. Apply Auxiliary battery voltage between the terminals of the switch, and check the illumination condition of the pattern select switch assembly.

Fig. 201: Identifying EV Drive Mode Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Measurement Condition Auxiliary battery positive (+) --> I48-3 (ILL+) Auxiliary battery negative (-) -->I48-2 (ILL-)

Specified Condition Illuminates

TEXT IN ILLUSTRATION Component without harness connected *a (EV Drive Mode Switch (Pattern Select Switch Assembly)) If the result is not as specified, replace the EV drive mode switch (pattern select switch assembly). INSTALLATION INSTALLATION

1. INSTALL EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY) a. Engage the 2 claws to install the EV drive mode switch (pattern select switch assembly). 2. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 35 3. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 36 4. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 40

5. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37

SERVICE PLUG GRIP COMPONENTS ILLUSTRATION

Fig. 202: Identifying Service Plug Grip Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION WARNING:





NOTE:

Before inspecting the high voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system. After removing the service plug grip, wait for at least 10 minutes before touching any of the high voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work. Refer to PRECAUTION .

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

HINT: Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly. 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

4. 5. 6. 7. 8.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to REMOVAL - Step 1 REMOVE SPARE WHEEL COVER ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to REMOVAL - Step 6 REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL a. Remove the 2 nuts and No. 8 hybrid vehicle battery shield panel.

Fig. 203: Identifying No. 8 Hybrid Vehicle Battery Shield Panel Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE SERVICE PLUG GRIP WARNING:

 





Wear insulating gloves. Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. All the high voltage wiring connectors are orange.

a. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.

Fig. 204: Removing Service Grip Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WARNING:





Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.

HINT: Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the inverter with converter assembly. INSPECTION INSPECTION

1. INSPECT SERVICE PLUG GRIP a. Measure the resistance according to the value(s) in the table below.

Fig. 205: Inspect Service Plug Grip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Connection Service plug grip

Condition Always

Specified Condition Below 1 ohms

If the result is not as specified, replace the service plug grip. INSTALLATION INSTALLATION

1. INSTALL SERVICE PLUG GRIP WARNING: Wear insulating gloves.

NOTE:

Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.

a. Wear insulated gloves and install the service plug grip in the order shown in the illustration.

Fig. 206: Rotating The Handle Of The Service Plug Grip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard. 2. INSTALL NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL a. Install the No. 8 hybrid vehicle battery shield panel with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 3. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to INSTALLATION Step 9 4. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 11 5. INSTALL SPARE WHEEL COVER ASSEMBLY . Refer to INSTALLATION - Step 12 6. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to INSTALLATION - Step 13 7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

BATTERY BLOWER COMPONENTS ILLUSTRATION

Fig. 207: Identifying Battery Blower Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 208: Identifying Battery Blower Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 209: Identifying Battery Blower Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to REMOVAL - Step 1

2. 3. 4. 5. 6. 7. 8. 9.

REMOVE SPARE WHEEL COVER ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to REMOVAL - Step 6 REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 SEPARATE REAR SEATBACK ASSEMBLY See step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT a. Remove the 3 clips and No. 1 hybrid battery intake duct.

Fig. 210: Identifying No. 1 Hybrid Battery Intake Duct Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET a. Remove the 2 nuts and No. 2 hybrid vehicle battery upper cover bracket.

Fig. 211: Identifying No. 2 Hybrid Vehicle Battery Upper Cover Bracket And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. SEPARATE NO. 2 HYBRID BATTERY INTAKE DUCT a. Remove the clip.

Fig. 212: Identifying Battery Upper Cover Clip And Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and separate the No. 2 hybrid battery intake duct. 12. REMOVE BATTERY COOLING BLOWER ASSEMBLY NOTE:





Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using the wire harness.

a. Disconnect the connector from the battery cooling blower assembly.

Fig. 213: Identifying Battery Cooling Blower Assembly Nuts And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and battery cooling blower assembly. INSTALLATION INSTALLATION

1. INSTALL BATTERY COOLING BLOWER ASSEMBLY NOTE:



Be sure not to touch the fan part of the battery cooling blower assembly.



Do not lift the battery cooling blower assembly using the wire harness.

a. Install the battery cooling blower assembly with the 3 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Connect the connector. 2. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT a. Engage the 2 claws to install the No. 2 hybrid battery intake duct. b. Install the clip. NOTE:

Ensure that the duct is installed securely.

3. INSTALL NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET a. Install the No. 2 hybrid vehicle battery upper cover bracket with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 4. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT a. Install the No. 1 hybrid battery intake duct with the 3 clips. NOTE: 5. 6. 7. 8. 9.

Ensure that the duct is installed securely.

INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SEATBACK ASSEMBLY See step 7 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to INSTALLATION Step 9 10. INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 11 11. INSTALL SPARE WHEEL COVER ASSEMBLY . Refer to INSTALLATION - Step 12 12. INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to INSTALLATION - Step 13

HYBRID SERVICE DISABLE PROCEDURES Toyota - Camry HV - 2012-2017-13

SAFETY PRECAUTIONS WARNING: The vehicle has a hybrid system that operates at voltages up to 650V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution. PRECAUTIONS FOR INSPECTING HYBRID CONTROL SYSTEM Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system NOTE:

After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.

After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly. Ensure the HV battery has 0 voltage. Check the voltage at the terminals in the inspection point in the inverter with converter assembly. NOTE:

Make sure to pull the converter connector cover assembly straight up, as a connector is connected to the bottom of the cover. Cover the opening with nonresidue tape to prevent entry of foreign matter or liquid after removing the connector cover

When turning the power switch on (IG) during inspections, do not press the power switch with the brake pedal depressed. WARNING: Pressing the power switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area. Turn the power switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the 12V auxiliary battery before touching any of the orange-colored wires of the high-voltage system.

NOTE:

After the power switch is turned off, the navigation receiver assembly (for Navigation Receiver type) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

Turn the power switch off before performing any resistance checks. Turn the power switch off before disconnecting or reconnecting any connectors. When performing work involving high-voltage wires, use either a tool wrapping with vinyl insulation tape or a insulated tool. When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign matter. NOTICE FOR HYBRID CONTROL SYSTEM ACTIVATION When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the power switch on (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the power switch off and reattempt to start the hybrid system. PRECAUTIONS FOR DISCONNECTING AMD TERMINAL NOTE:

The AMD terminal is connected to the positive terminal of the auxiliary battery. To prevent damage when the AMD terminal is being disconnected, use the following procedure. See Fig. 1.

Be sure to disconnect the cable from the negative (-) terminal of the auxiliary battery before disconnecting the AMD terminal from the engine room relay block and junction block assembly. NOTE:

After the power switch is turned off, the navigation receiver assembly (for Navigation Receiver type) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

Fig. 1: Identifying AMD Cable & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. After disconnecting the AMD terminal, wrap the terminal with insulation tape. Be sure to reconnect the AMD terminal to the engine room junction block assembly before reconnecting the cable of the negative (-) terminal of the auxiliary battery. CAUTION: A short circuit to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) terminal of the auxiliary battery. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse. DISPOSING OF HV BATTERY When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent. WARNING: Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent. WARNING: After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire. DISCONNECTING AND RECONNECTING 12V AUXILIARY BATTERY CABLE

NOTE:

After the power switch is turned off, the navigation receiver assembly (for Navigation Receiver type) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components. Before disconnecting and reconnecting the auxiliary battery cable, turn the power switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal. When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.

SPECIAL TOOLS NOTE:

No special tools are required for this procedure.

HIGH-VOLTAGE DISABLE CAUTION: Be sure to read the SAFETY PRECAUTIONS thoroughly before servicing.

WARNING: Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. CAUTION: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction. DISCONNECT 1. Turn the power switch off, and uncover the 12V battery. See Fig. 2. 2. Disconnect the negative terminal of the auxiliary (12-volt) battery. See Fig. 2. NOTE:

After the power switch is turned off, the navigation receiver assembly (for Navigation Receiver type) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

NOTE:

When the warning light is illuminated, or the auxiliary (12-volt) battery has been disconnected and reconnected, attempting to turn the power switch on (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the power switch off and reattempt to turn the power switch on (READY).

Fig. 2: Locating 12V Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Uncover the service plug grip, and remove. See Fig. 3 and Fig. 4 . a. Remove the 2 nuts and hybrid vehicle battery shield panel from the HV battery. b. Slide the lever (1) and release the lock. c. Raise the lever (2) and pull the service plug grip (3) to remove it.

CAUTION: After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. CAUTION: Turning the power switch on (READY) with the service plug grip removed could cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.

Fig. 3: Locating Battery Shield Panel & Service Plug Grip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Removing Battery Shield Panel & Service Plug Grip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the highvoltage connectors or terminals. Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly. 5. After waiting, check the voltage at the inspection point in the inverter with converter assembly. See Isolation Check. ISOLATION CHECK 1. Remove the 2 bolts and connector cover assembly from the inverter with converter assembly in engine compartment. See Fig. 5. NOTE:

Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover. Cover the opening with non-residue tape to prevent entry of foreign matter or liquid after removing the connector cover

Fig. 5: Identifying Inverter Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check the voltage at the terminals in the inspection point in the inverter with converter assembly. Using the voltmeter, measure the voltage between the terminals of the 2-phase connectors (N-P). Standard voltage: 0 V

CAUTION: Wear insulating gloves.

HINT: Use measuring range of DC 750 V or more on the voltmeter.

Fig. 6: Measuring Voltage Between Terminals Of 2-Phase Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Re-install inverter connector cover assembly. CONNECT CAUTION: Wear insulated gloves.

NOTE:

Before connecting the service plug grip, make sure that no parts or tools remain in the luggage compartment.

1. Install service plug grip. a. Wear insulated gloves and insert the service plug grip in the order as shown in the illustration. b. Tilt the service plug grip 90° and slide it to the left until a click sound is heard. c. Install the battery shield panel to the HV battery with the 2 nuts.

2. Connect cable to negative 12-volt battery terminal. 3. Install luggage compartment components.

2012-2017 DRIVELINE/AXLES Hybrid Transaxle (Service Information) (Hybrid)

HYBRID VEHICLE TRANSAXLE COMPONENTS ILLUSTRATION

Fig. 1: Identifying Hybrid Vehicle Transaxle Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Hybrid Vehicle Transaxle Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Hybrid Vehicle Transaxle Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

WARNING: The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the service information, or the engine lifter may suddenly drop. 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Refer to REMOVAL 2. SEPARATE WIRE HARNESS a. Remove the 3 bolts and disconnect the 4 connectors, 3 clamps and wire harness from the hybrid vehicle transaxle assembly.

Fig. 4: Identifying Wire Harness Connectors, Clamps, And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and disconnect the 3 clamps and motor cable from the hybrid vehicle transaxle assembly.

Fig. 5: Identifying Motor Cable Bolt And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FRONT FRAME ASSEMBLY . Refer to REMOVAL - Step 85 4. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

a. Using the transmission jack attachment, set the hybrid vehicle transaxle assembly on a transmission jack. NOTE:







Secure the hybrid vehicle transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment. To prevent the motor water jacket cover assembly from deforming, do not place any attachments onto the motor water jacket cover assembly of the hybrid vehicle transaxle assembly. Hold the engine assembly with a suitable adapter, such as a rope, during the operation.

b. Remove the 9 bolts and hybrid vehicle transaxle assembly.

Fig. 6: Identifying Hybrid Vehicle Transaxle Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





To avoid damage to the knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine. To prevent the splines of the damper from becoming misaligned, do not allow the transaxle to hit the damper during transaxle removal and installation.

5. REMOVE FRONT ENGINE MOUNTING BRACKET a. Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.

Fig. 7: Identifying Front Engine Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET a. Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.

Fig. 8: Identifying No. 1 Transmission Control Cable Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 2 TRANSMISSION CONTROL CABLE BRACKET a. Remove the bolt and No. 2 transmission control cable bracket from the hybrid vehicle transaxle assembly.

Fig. 9: Identifying No. 2 Transmission Control Cable Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 3 TRANSMISSION CONTROL CABLE BRACKET a. Remove the bolt and No. 3 transmission control cable bracket from the hybrid vehicle transaxle assembly.

Fig. 10: Identifying No. 3 Transmission Control Cable Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE AUTOMATIC TRANSMISSION CASE COVER a. Disengage the 2 guides and remove the automatic transmission case cover.

Fig. 11: Identifying Automatic Transmission Case Cover Guides

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 3 AUTOMATIC TRANSMISSION CASE COVER a. Remove the 2 bolts, clip and No. 3 automatic transmission case cover from the hybrid vehicle transaxle assembly.

Fig. 12: Identifying No. 3 Automatic Transmission Case Cover Clip And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE HYBRID TRANSAXLE MASS DAMPER a. Remove the hybrid transaxle mass damper and gasket from the hybrid vehicle transaxle assembly.

Fig. 13: Identifying Hybrid Transaxle Mass Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE WIRE HARNESS CLAMP BRACKET a. Remove the 3 bolts and 2 wire harness clamp brackets from the hybrid vehicle transaxle assembly.

Fig. 14: Identifying Wire Harness Clamp Bracket Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY a. Remove the No. 1 inverter cooling hose assembly from the hybrid vehicle transaxle assembly.

Fig. 15: Identifying No. 1 Inverter Cooling Hose Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 1 INVERTER COOLING HOSE ASSEMBLY a. Install the No. 1 inverter cooling hose assembly to the hybrid vehicle transaxle assembly. 2. INSTALL WIRE HARNESS CLAMP BRACKET a. Install the 2 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 3. INSTALL HYBRID TRANSAXLE MASS DAMPER a. Install a new gasket and the hybrid transaxle mass damper. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 4. INSTALL NO. 3 AUTOMATIC TRANSMISSION CASE COVER a. Install the No. 3 automatic transmission case cover to the hybrid vehicle transaxle assembly with

the 2 bolts and clip. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 5. INSTALL AUTOMATIC TRANSMISSION CASE COVER a. Engage the 2 guides and install the automatic transmission case cover. 6. INSTALL NO. 3 TRANSMISSION CONTROL CABLE BRACKET a. Install the No. 3 transmission control cable bracket to the hybrid vehicle transaxle assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 7. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET a. Install the No. 2 transmission control cable bracket to the hybrid vehicle transaxle assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 8. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET a. Install the No. 1 transmission control cable bracket to the hybrid vehicle transaxle assembly with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 9. INSTALL FRONT ENGINE MOUNTING BRACKET a. Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 10. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY a. Make sure that the knock pins are installed to the engine.

Fig. 16: Identifying Knock Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Knock

*1 Pin b. Install the hybrid vehicle transaxle assembly to the engine with the 9 bolts. Bolt

A, B

C

D

E

Bolt Torque Length 64 N*m 55 mm (653 (2.17 kgf*cm, in.) 47 ft.*lbf) 46 N*m 65 mm (469 (2.56 kgf*cm, in.) 34 ft.*lbf) 44 N*m 32 mm (449 (1.26 kgf*cm, in.) 32 ft.*lbf) 28 N*m 38 mm (286 (1.50 kgf*cm, in.) 21 ft.*lbf)

NOTE:

 

 





Do not apply grease either to the spline or to the input shaft. Make sure that the wire harness or similar items are not pinched between the contact surfaces. Do not forcibly pry on the hybrid vehicle transaxle. Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper. When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively. When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes.

HINT: Temporarily tighten bolt B first.

11. INSTALL FRONT FRAME ASSEMBLY . Refer to INSTALLATION - Step 11 12. CONNECT WIRE HARNESS a. Connect the 3 clamps and install the motor cable to the hybrid vehicle transaxle assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) b. Connect the 3 clamps, 4 connectors and install the wire harness to the hybrid vehicle transaxle assembly with the 3 bolts.

Fig. 17: Identifying Wire Harness Connectors, Clamps, And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt A

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Bolt B Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Refer to INSTALLATION

GENERATOR CABLE COMPONENTS ILLUSTRATION

Fig. 18: Identifying Generator Cable Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

Refer to REMOVAL 2. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY a. Remove the 4 bolts and inverter tray bracket sub-assembly from the body.

Fig. 19: Identifying Inverter Tray Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE GENERATOR CABLE a. Remove the 4 bolts and generator cable from the hybrid vehicle transaxle assembly.

Fig. 20: Identifying Generator Cable Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL GENERATOR CABLE a. Install the generator cable to the hybrid vehicle transaxle assembly with 4 new bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 2. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY a. Temporarily install the inverter tray bracket sub-assembly to the body with the 4 bolts.

Fig. 21: Identifying Inverter Tray Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Temporarily tighten bolt 1. b. Install the 4 bolts in the order shown in the illustration. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 3. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to INSTALLATION

MOTOR CABLE COMPONENTS ILLUSTRATION

Fig. 22: Identifying Motor Cable Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 23: Identifying Motor Cable Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE SERVICE PLUG GRIP Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8.

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE AIR CLEANER FILTER ELEMENT REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL - Step 33 REMOVE UPPER INVERTER COVER . Refer to REMOVAL - Step 14 REMOVE MOTOR CABLE WARNING: Wear insulated gloves.

a. Using an insulated tool, remove the 3 bolts.

Fig. 24: Identifying Motor Cable Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 3 wire harness clamps and separate the motor cable.

Fig. 25: Identifying Motor Cable Wire Harness Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



  

c. Disconnect the clamp.

Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them. Do not touch the connector waterproofing rubber or terminals. Insulate the removed terminals with insulating tape. Do not allow any foreign objects or water to enter the inverter with converter assembly.

Fig. 26: Identifying Motor Cable Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the bolt and disconnect the motor cable from the hybrid vehicle transaxle assembly. e. Disconnect the 2 clamps.

Fig. 27: Identifying Motor Cable Bolts And Clamps

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the 4 bolts and motor cable from the hybrid vehicle transaxle assembly. INSTALLATION INSTALLATION

1. INSTALL MOTOR CABLE WARNING: Wear insulated gloves.

NOTE:



 

Do not damage the terminals, connector housings or inverter with converter assembly when connecting them. Do not touch the connector waterproofing rubber or terminals. Do not allow any foreign objects or water to enter the inverter with converter assembly.

a. Install the motor cable to the hybrid vehicle transaxle assembly with 4 new bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) b. Connect the 2 clamps in the order shown in the illustration.

Fig. 28: Identifying Motor Cable Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the motor cable to the hybrid vehicle transaxle assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) d. e. f. g.

Connect the clamp. Connect the motor cable to the inverter with converter assembly. Connect the 3 wire harness clamps. Using an insulated tool, install the motor cable to the inverter with converter assembly with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

 

2. 3. 4. 5. 6. 7. 8.

The connector should be connected securely. The bolts should be fastened securely.

INSTALL UPPER INVERTER COVER . Refer to INSTALLATION - Step 22 INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 60 INSTALL AIR CLEANER FILTER ELEMENT INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSTALL SERVICE PLUG GRIP Refer to INSTALLATION

HYBRID TRANSAXLE FLUID ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT HYBRID TRANSAXLE FLUID a. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

Fig. 29: Identifying Hybrid Transaxle Filler Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Filler *1 Plug b. Check that the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.) NOTE:

 





Stop the vehicle on a level surface. Be sure to directly check that the transaxle fluid level is within the specified range. Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle. If the fluid was replaced or fluid was added, make sure to recheck the fluid level after driving the vehicle.

c. Check for leaks if the quantity of transaxle fluid is low. (If there are no fluid leaks but the amount of the fluid is insufficient, add fluid See step 2.) d. Using a 10 mm hexagon socket wrench, install the filler plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) REPLACEMENT

REPLACEMENT

1. REPLACE HYBRID TRANSAXLE FLUID a. Be sure that the vehicle remains level and lift the vehicle. [*1] b. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket. [*2]

Fig. 30: Identifying Hybrid Transaxle Filler And Drain Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Filler *1 Plug Drain *2 Plug c. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket to drain the hybrid transaxle fluid. [*3] d. Using a 10 mm hexagon socket wrench, temporarily install the drain plug and gasket. [*4] HINT: Because the drain plug will be removed again, the gasket can be reused at this time. e. Add transaxle fluid until the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. [*5]

Fig. 31: Identifying Hybrid Transaxle Filler Plug And Filler Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Filler *1 Nozzle Filler *2 Plug NOTE:

 







Use Toyota Genuine ATF WS. Be sure to fully insert the filler nozzle into the filler plug opening. Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening. Be sure to directly check that the transaxle fluid level is within the specified range. Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

f. Using a 10 mm hexagon socket wrench, temporarily install the filler plug and gasket. [*6] HINT: Because the filler plug will be removed again, the gasket can be reused at this time.

g. h. i. j. k. l. m. n.

Lower the vehicle. [*7] Connect the Techstream to the DLC3 and turn the power switch on (IG). [*8] Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE . [*9] Idle the engine for 30 seconds with the power switch on (READY). [*10] Turn the power switch off. [*11] Repeat steps [*1] to [*11]. Repeat steps [*1] to [*3]. Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

2. ADD HYBRID TRANSAXLE FLUID See step 2 3. INSPECT HYBRID TRANSAXLE FLUID See step 3 ADJUSTMENT ADJUSTMENT

1. DRAIN HYBRID TRANSAXLE FLUID a. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

Fig. 32: Identifying Hybrid Transaxle Filler And Drain Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Filler Plug Drain *2 Plug *1

b. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket to drain the hybrid transaxle fluid. c. Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 2. ADD HYBRID TRANSAXLE FLUID a. Add transaxle fluid until the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening.

Fig. 33: Identifying Hybrid Transaxle Filler Plug And Filler Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Filler *1 Nozzle Filler *2 Plug NOTE:



Stop the vehicle on a level surface.

 







Use Toyota Genuine ATF WS. Be sure to fully insert the filler nozzle into the filler plug opening. Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening. Be sure to directly check that the transaxle fluid level is within the specified range. Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

Reference 3.7 liters (3.9 US qts, 3.2 Imp. qts) b. After adding fluid, leave it for 30 seconds so that the fluid surface can become still again, and then check that the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.) NOTE:

After adding fluid, make sure to check the fluid level.

3. INSPECT HYBRID TRANSAXLE FLUID a. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

Fig. 34: Identifying Hybrid Transaxle Filler Plug

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Filler *1 Plug b. Check that the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.) NOTE:

 





Stop the vehicle on a level surface. Be sure to directly check that the transaxle fluid level is within the specified range. Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle. If the fluid was replaced or fluid was added, make sure to recheck the fluid level after driving the vehicle.

c. Check for leaks if the quantity of transaxle fluid is low. d. Using a 10 mm hexagon socket wrench, install the filler plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

TRANSMISSION CONTROL CABLE COMPONENTS ILLUSTRATION

Fig. 35: Identifying Transmission Control Cable Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 36: Identifying Transmission Control Cable Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4.

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 30 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE AIR CLEANER FILTER ELEMENT

5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL - Step 33 6. REMOVE AIRBAG SENSOR ASSEMBLY Refer to REMOVAL - Step 17 7. REMOVE ACCELERATOR PEDAL SENSOR ASSEMBLY . Refer to REMOVAL - Step 1 8. DISCONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY a. Turn back the floor carpet. b. Remove the bolt and nut, and disconnect the No. 1 parking brake cable assembly.

Fig. 37: Identifying No. 1 Parking Brake Cable Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY a. Move the shift lever to N. b. Disconnect the end of the transmission control cable from the lower shift lever assembly.

Fig. 38: Identifying Transmission Control Cable Assembly End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 claws and disconnect the transmission control cable assembly from the lower shift lever assembly. d. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

Fig. 39: Identifying Transmission Control Cable Assembly Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket. f. Remove the clip from the transmission control cable assembly. g. Disconnect the transmission control cable assembly from the 2 transmission control brackets.

Fig. 40: Identifying Transmission Control Cable Assembly Control Brackets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the bolt and disconnect the No. 1 parking brake cable assembly from the body.

Fig. 41: Identifying No. 1 Parking Brake Cable Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION No. 1 parking *1 brake cable assembly Transmission *2 control cable assembly i. Turn back the dash panel insulator. j. Remove the 2 bolts and pull out the transmission control cable assembly from the body. ADJUSTMENT ADJUSTMENT

1. INSPECT SHIFT LEVER POSITION a. While moving the shift lever from the N position to each position, check that the lever moves smoothly and that the shift position indicator comes on properly according to the shift lever position. b. Put the vehicle into the READY-on state and check the following: 1. When the shift lever is moved to the D position, the vehicle moves forward. 2. When the shift lever is moved to the R position, the vehicle moves in reverse. NOTE:

The vehicle should not move when the shift position indicator is off.

2. ADJUST SHIFT LEVER POSITION a. Move the shift lever to N. b. Remove the console box. Refer to REMOVAL . c. Disconnect the end of the transmission control cable assembly from the lower shift lever assembly.

Fig. 42: Identifying Transmission Control Cable Assembly End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Slide the slider of the transmission control cable assembly in the direction indicated by the arrow and pull the lock piece outward.

Fig. 43: Identifying Transmission Control Cable Assembly Slider Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Slider Lock *2 Piece *a Slide *b Pull e. Install the end of the transmission control cable assembly to the lower shift lever assembly.

Fig. 44: Installing End Of Transmission Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Piece NOTE:

 

Check that the lock piece is pulled up. Install the cable end all the way to the base of the pin.

f. Push the lock piece into the adjuster case. NOTE:



Check that the park/neutral position switch and the shift lever are in neutral.



Securely push in the lock piece until the slider lock is engaged.

g. After adjusting the shift lever position, check the operation and function of the shift lever. If there is a problem, adjust the position again. h. Install the console box. Refer to INSTALLATION . INSTALLATION INSTALLATION

1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY NOTE:

Before installing the transmission control cable assembly, check that the shift lever position sensor and the shift lever are in neutral.

a. Pass the transmission control cable assembly from the cabin to the engine compartment. b. Install the transmission control cable assembly with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) c. d. e. f.

Install the dash panel insulator to the original position. Connect the transmission control cable assembly to the 2 transmission control cable brackets. Install a new clip to the No. 1 transmission control cable bracket. Install the transmission control cable assembly to the No. 1 transmission control cable bracket

Fig. 45: Identifying Transmission Control Cable Assembly And Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 1 Transmission *1 control cable assembly No. 1 transmission *2 control cable bracket *a Claw A *b Claw B

NOTE:





Make sure that the claws A on the clip are securely fit into the bracket holes. Make sure that the cable is securely installed inside of the claws B of the clip.

g. Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) h. Engage the 2 claws to connect the transmission control cable assembly. i. Slide the slider of the transmission control cable in the direction indicated by the arrow and pull the lock piece outward.

Fig. 46: Identifying Transmission Control Cable Assembly Slider Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Slider Lock *2 Piece *a Slide *b Pull j. Install the end of transmission control cable assembly to the lower shift lever assembly.

Fig. 47: Installing End Of Transmission Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Piece

NOTE:

 

Check that the lock piece is pulled up. Install the cable end all the way to the base of the pin.

k. Push the lock piece into the adjuster case. NOTE:





Check that the shift lever position sensor and the shift lever are in neutral. Securely push in the lock piece until the slider lock is engaged.

2. CONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 1 parking brake cable assembly with the bolt and nut. Bolt Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) Nut Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) b. Install the floor carpet to the original position. 3. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY . Refer to INSTALLATION - Step 1 4. INSTALL AIRBAG SENSOR ASSEMBLY Refer to INSTALLATION - Step 1 5. 6. 7. 8. 9. 10. 11.

INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 60 INSTALL AIR CLEANER FILTER ELEMENT INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 3 INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 63 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4 INSPECT SHIFT LEVER POSITION See step 1 ADJUST SHIFT LEVER POSITION See step 2

HYBRID TRANSAXLE OIL SEAL COMPONENTS ILLUSTRATION

Fig. 48: Identifying Hybrid Transaxle Oil Seal Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 49: Identifying Hybrid Transaxle Oil Seal Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 50: Identifying Hybrid Transaxle Oil Seal Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

HINT:

 

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. REMOVE FRONT WHEELS REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN HYBRID TRANSAXLE FLUID See step 1 REMOVE FRONT AXLE SHAFT NUT . Refer to REMOVAL - Step 9 SEPARATE FRONT STABILIZER LINK ASSEMBLY . Refer to REMOVAL - Step 4 SEPARATE FRONT SPEED SENSOR . Refer to REMOVAL - Step 3 SEPARATE TIE ROD ASSEMBLY . Refer to REMOVAL - Step 5 SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to REMOVAL - Step 10 SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to REMOVAL - Step 15 REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to REMOVAL - Step 16 REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REMOVAL - Step 17 REMOVE DRIVE SHAFT BEARING BRACKET . Refer to REMOVAL - Step 90 REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL a. Remove the left side oil seal. 1. Using SST, remove the hybrid vehicle transaxle assembly type T oil seal from the hybrid vehicle transaxle assembly.

Fig. 51: Removing Hybrid Vehicle Transaxle Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09514-35011

TEXT IN ILLUSTRATION *a Hold *b Turn b. Remove the right side oil seal. 1. Using SST, remove the hybrid vehicle transaxle assembly type T oil seal from the hybrid vehicle transaxle assembly.

Fig. 52: Removing Hybrid Vehicle Transaxle Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09612-30012

TEXT IN ILLUSTRATION *a Hold *b Turn 20. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL a. Install a new left side oil seal. 1. Using SST and a hammer, tap in a new hybrid vehicle transaxle assembly type T oil seal.

Fig. 53: Installing Hybrid Vehicle Transaxle Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09223-15020 SST: 09950-70010 09951-07150

Oil seal installation depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease. b. Install a new RH side oil seal. 1. Using SST and a hammer, tap in a new hybrid vehicle transaxle assembly type T oil seal.

Fig. 54: Installing Hybrid Vehicle Transaxle Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09710-30050 SST: 09950-70010 09951-07150

Oil seal installation depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease. 21. INSTALL DRIVE SHAFT BEARING BRACKET . Refer to INSTALLATION - Step 7 22. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to REASSEMBLY - Step 13 23. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to INSTALLATION - Step 1

24. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to INSTALLATION - Step 2 25. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY . Refer to INSTALLATION - Step 8 26. CONNECT TIE ROD ASSEMBLY . Refer to INSTALLATION - Step 8 27. INSTALL FRONT SPEED SENSOR . Refer to INSTALLATION - Step 11 28. INSTALL FRONT STABILIZER LINK ASSEMBLY . Refer to INSTALLATION - Step 10 29. INSTALL FRONT AXLE SHAFT NUT . Refer to INSTALLATION - Step 7 30. ADD HYBRID TRANSAXLE FLUID See step 2 31. INSPECT HYBRID TRANSAXLE FLUID See step 3 32. INSPECT FOR TRANSAXLE FLUID LEAK 33. INSTALL FRONT WHEELS . Refer to INSTALLATION - Step 8 34. ADJUST FRONT WHEEL ALIGNMENT Refer to ADJUSTMENT 35. 36. 37. 38. 39. 40. 41.

INSTALL FRONT FENDER APRON SEAL LH INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH CHECK FOR SPEED SENSOR SIGNAL Refer to TEST MODE PROCEDURE

INPUT SHAFT OIL SEAL COMPONENTS ILLUSTRATION

Fig. 55: Identifying Input Shaft Oil Seal Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to REMOVAL 2. REMOVE INPUT SHAFT TYPE T OIL SEAL a. Using a screwdriver with its tip taped, remove the input shaft type T oil seal.

Fig. 56: Removing Input Shaft Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Vinyl *a Tape NOTE:

When removing the input shaft type T oil seal, make sure not to damage the input shaft or hybrid vehicle transaxle housing.

3. INSTALL INPUT SHAFT TYPE T OIL SEAL a. Coat the lip of a new input shaft type T oil seal with MP grease.

Fig. 57: Installing Input Shaft Type T Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a hammer, tap in the input shaft type T oil seal.  SST: 09388-40010 Oil seal installation depth 1.0 to 1.8 mm (0.0394 to 0.0709 in.) NOTE:





Ensure that no foreign matter adheres to the input shaft type T oil seal lip. Ensure that the input shaft type T oil seal is not at an angle.

4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

Refer to INSTALLATION

MOTOR WATER JACKET COVER ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 58: Identifying Motor Water Jacket Cover Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DRAIN COOLANT (for Inverter) . Refer to REPLACEMENT - Step 1

2. REMOVE NO. 2 MOTOR WATER JACKET COVER ASSEMBLY a. Remove the 5 bolts.

Fig. 59: Identifying No. 2 Motor Water Jacket Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the blade of an oil pan seal cutter between the transaxle housing. Cut through the applied sealer and remove the No. 2 motor water jacket cover assembly. NOTE:

Be careful not to damage the contact surfaces of the transaxle housing where the motor water jacket cover is installed.

3. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to REMOVAL 4. REMOVE FRONT ENGINE MOUNTING BRACKET See step 5 5. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET See step 6 6. REMOVE AUTOMATIC TRANSMISSION CASE COVER a. Remove the 2 bolts, clip and automatic transmission case cover from the hybrid vehicle transaxle assembly.

Fig. 60: Identifying Automatic Transmission Case Cover Clip And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 1 MOTOR WATER JACKET COVER ASSEMBLY a. Remove the 8 bolts.

Fig. 61: Identifying No. 1 Motor Water Jacket Cover Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the blade of an oil pan seal cutter between the transaxle housing. Cut through the applied sealer and remove the No. 1 motor water jacket cover assembly. NOTE:

Be careful not to damage the contact surfaces of the transaxle housing where the motor water jacket cover is installed.

INSTALLATION INSTALLATION

1. INSTALL NO. 1 MOTOR WATER JACKET COVER ASSEMBLY a. Remove any remaining seal packing from the transaxle housing installation surface and bolt holes. NOTE:

 

Clean and degrease the installation surface and bolt holes. Do not allow any remaining seal packing to enter the coolant path when cleaning.

b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 62: Applying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent Standard seal diameter 1.5 mm (0.059 in.) or more. NOTE:

Remove any oil from the contact surface.

c. Install a new No. 1 motor water jacket cover assembly to the hybrid vehicle transaxle with 8 new bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:







Install the motor water jacket cover assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. Do not add coolant within 2 hours after installing the motor water jacket cover assembly. Do not start the engine for at least 2 hours after installing the motor water jacket cover assembly.

2. INSTALL AUTOMATIC TRANSMISSION CASE COVER a. Install the automatic transmission case cover to the hybrid vehicle transaxle with the 2 bolts and clip. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 3. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 4. INSTALL FRONT ENGINE MOUNTING BRACKET 5. INSTALL NO. 2 MOTOR WATER JACKET COVER ASSEMBLY a. Remove any remaining seal packing from the transaxle housing installation surface and bolt holes. NOTE:

 

Clean and degrease the installation surface and bolt holes. Do not allow any remaining seal packing to enter the coolant path when cleaning.

b. Apply seal packing in a continuous line as shown in the illustration.

Fig. 63: Applying Seal Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent Standard seal diameter 1.5 mm (0.059 in.) or more. NOTE:

Remove any oil from the contact surface.

c. Install a new No. 2 motor water jacket cover assembly to the hybrid vehicle transaxle with 5 new bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:







Install the motor water jacket cover assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. Do not add coolant within 2 hours after installing the motor water jacket cover assembly. Do not start the engine for at least 2 hours after installing the motor water jacket cover assembly.

6. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to INSTALLATION

SHIFT LEVER COMPONENTS ILLUSTRATION

Fig. 64: Identifying Shift Lever Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 65: Identifying Shift Lever Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 66: Identifying Shift Lever Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 67: Identifying Shift Lever Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. INSPECT LOWER SHIFT LEVER ASSEMBLY a. Inspect shift lock operation. 1. Move the shift lever to P. 2. Turn the power switch off. 3. Check that the shift lever cannot be moved from P to any other position. 4. Turn the power switch on (READY), depress the brake pedal, and check that the shift lever can be moved from P to any other position. If the operation cannot be done as specified, inspect the lower shift lever assembly. b. Inspect shift lock release button operation. 1. Move the shift lever to P. 2. Turn the power switch off. 3. When moving the shift lever with the shift lock release button pressed, check that the shift lever can be moved from P to any other position. If the operation cannot be done as specified, inspect the shift lock control unit. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL - Step 10 2. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 4. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 5. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 6. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 7. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 14 8. REMOVE FRONT DOOR SCUFF PLATE RH . Refer to REMOVAL - Step 8 9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH . Refer to REMOVAL - Step 9 10. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 33 11. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 34 12. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to

13. 14. 15. 16. 17. 18. 19. 20.

REMOVAL - Step 35 REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 37 REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 REMOVE FRONT NO. 2 CONSOLE BOX INSERT . Refer to REMOVAL - Step 47 REMOVE CONSOLE BOX INSERT . Refer to REMOVAL - Step 48 REMOVE FLOOR CARPET BRACKET LH . Refer to REMOVAL - Step 26 REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET a. Remove the screw and No. 1 console box mounting bracket from the lower shift lever assembly.

Fig. 68: Identifying No. 1 Console Box Mounting Bracket Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE NO. 1 CONSOLE BOX DUCT a. Remove the clip and No. 1 console box duct.

Fig. 69: Identifying No. 1 Console Box Duct Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE LOWER SHIFT LEVER ASSEMBLY a. Disconnect the end of transmission control cable assembly from the lower shift lever assembly.

Fig. 70: Identifying Transmission Control Cable Assembly End

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and disconnect the transmission control cable assembly from the lower shift lever assembly. c. Disconnect the 3 clamps and connector.

Fig. 71: Identifying Transmission Control Cable Assembly Claws And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 4 bolts and lower shift lever assembly.

Fig. 72: Identifying Lower Shift Lever Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE SHIFT LEVER SUPPORT a. Remove the 4 bolts and shift lever support.

Fig. 73: Identifying Shift Lever Support Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE LOWER POSITION INDICATOR HOUSING a. Disengage the 5 claws to remove the lower position indicator housing.

Fig. 74: Identifying Lower Position Indicator Housing Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SHIFT LOCK RELEASE BUTTON (Lower Shift Lever Assembly Side) a. Disengage the 2 claws to remove the shift lock release button and shift lock release spring.

Fig. 75: Identifying Shift Lock Release Button Claws And Shift Lock Release Spring Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE SHIFT POSITION INDICATOR a. Remove the 4 screws and shift position indicator.

Fig. 76: Identifying Shift Position Indicator Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE SHIFT LOCK RELEASE BUTTON COVER a. Disengage the 2 claws to remove the shift lock release button cover.

Fig. 77: Identifying Shift Lock Release Button Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE SHIFT LOCK RELEASE BUTTON (Shift Position Indicator Side) a. Disengage the 2 claws to remove the position indicator plate.

Fig. 78: Identifying Position Indicator Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw to remove the shift lock release button and shift lock release spring.

Fig. 79: Identifying Shift Lock Release Button Claw And Shift Lock Release Spring Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY a. Separate the bulb socket, 2 guides and clamp, and remove the indicator light wire sub-assembly from the upper position indicator housing.

Fig. 80: Removing Indicator Light Wire Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bulb from the indicator light wire sub-assembly. c. Remove the cap from the bulb. 7. REMOVE POSITION INDICATOR SLIDE COVER a. Remove the position indicator slide cover from the upper position indicator housing.

Fig. 81: Removing Position Indicator Slide Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 2 POSITION INDICATOR SLIDE COVER a. Remove the No. 2 position indicator slide cover from the position indicator slide cover.

Fig. 82: Identifying No. 2 Position Indicator Slide Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE UPPER POSITION INDICATOR HOUSING a. Disengage the 4 claws to remove the position indicator lens.

Fig. 83: Identifying Position Indicator Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LOWER SHIFT LEVER ASSEMBLY a. Measure the voltage according to the value(s) in the table below.

Fig. 84: Identifying Shift Lock Control ECU Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Voltage Tester Specified Condition Connection Condition Power switch on 11 to 14 V 5 (IG) (IG) Body ground Power Below 1 switch off V Brake pedal 11 to 14 V depressed 4 (STP) Body

ground

Brake pedal released

Below 1 V

TEXT IN ILLUSTRATION Component with harness *a connected (Shift Lock Control ECU) HINT: Do not disconnect the shift lock control unit assembly connector. b. Measure the resistance according to the value(s) in the table below.

Fig. 85: Identifying Shift Lock Control ECU Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (E) Below 1 Body Always ohms ground TEXT IN ILLUSTRATION Component with *a harness connected

(Shift Lock Control ECU) HINT: Do not disconnect the shift lock control unit assembly connector. c. Inspect shift lock solenoid 1. Disconnect the shift lock solenoid connector.

Fig. 86: Identifying Shift Lock Solenoid Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position.

Fig. 87: Measure The Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Shift Tester Specified Lever Connection Condition Position 4 (P) - 3 10 kohms P (E2) or higher 4 (P) - 3 Other Below 1 (E2) than P ohms TEXT IN ILLUSTRATION Front view of wire harness *a connector (to Shift Lock Solenoid)  

If the result is not as specified, replace the shift lock control unit assembly. If the shift lock does not operate when the power source of the shift lock control unit assembly is normal and the resistance between the body ground and the shift lock

solenoid is as specified, replace the shift lock control unit assembly. 3. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 1 (SLS+) Always 112 ohms 2 (SLS-)  

If the result is not as specified, replace the shift lock control unit assembly. If the shift lock does not operate when the power source of the shift lock control unit assembly is normal and the resistance between the body ground and the shift lock solenoid is as specified, replace the shift lock control unit assembly.

REASSEMBLY REASSEMBLY

1. INSTALL UPPER POSITION INDICATOR HOUSING a. Engage the 4 claws to install the position indicator lens.

Fig. 88: Identifying Position Indicator Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 POSITION INDICATOR SLIDE COVER

a. Install the No. 2 position indicator slide cover to the position indicator slide cover.

Fig. 89: Identifying No. 2 Position Indicator Slide Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL POSITION INDICATOR SLIDE COVER a. Install the position indicator slide cover to the upper position indicator housing.

Fig. 90: Installing Position Indicator Slide Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY a. Install the cap to the bulb. b. Install the bulb to the indicator light wire sub-assembly. c. Connect the 2 guides, clamp and bulb socket to install the indicator light wire sub-assembly to the upper position indicator housing.

Fig. 91: Installing Indicator Light Wire Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL SHIFT LOCK RELEASE BUTTON (Shift Position Indicator Side) a. Engage the claw to install the shift lock release button with the shift lock release spring.

Fig. 92: Identifying Shift Lock Release Button Claw And Shift Lock Release Spring Claw

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 claws to install the position indicator plate.

Fig. 93: Identifying Position Indicator Plate Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL SHIFT LOCK RELEASE BUTTON COVER a. Engage the 2 claws to install the shift lock release button cover.

Fig. 94: Identifying Shift Lock Release Button Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL SHIFT POSITION INDICATOR a. Install the shift position indicator with the 4 screws in the sequence shown in the illustration.

Fig. 95: Identifying Shift Position Indicator Screws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. INSTALL SHIFT LOCK RELEASE BUTTON (Lower Shift Lever Assembly Side) a. Engage the 2 claws to install the shift lock release button with the shift lock release spring.

Fig. 96: Identifying Shift Lock Release Button Claws And Shift Lock Release Spring Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL LOWER POSITION INDICATOR HOUSING a. Engage the 5 claws to install the lower position indicator housing.

Fig. 97: Identifying Lower Position Indicator Housing Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL SHIFT LEVER SUPPORT a. Install the shift lever support with the 4 bolts in the sequence shown in the illustration.

Fig. 98: Identifying Shift Lever Support Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSTALL LOWER SHIFT LEVER ASSEMBLY NOTE:

Check that the park/neutral position switch and the shift lever are in neutral.

a. Install the lower shift lever assembly with the 4 bolts in the sequence shown in the illustration.

Fig. 99: Identifying Lower Shift Lever Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) b. Connect the 3 clamps and connector. c. Slide the slider of the transmission control cable in the direction indicated by the arrow and pull the lock piece outward.

Fig. 100: Identifying Transmission Control Cable Assembly Slider Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Slider Lock *2 Piece *a Slide *b Pull d. Install the end of the transmission control cable to the shift lever assembly.

Fig. 101: Installing End Of Transmission Control Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Piece NOTE:

 

Check that the lock piece is pulled up. Install the cable end all the way to the base of the pin.

e. Push the lock piece into the adjuster case. NOTE:



Check that the park/neutral position switch and the shift lever are in neutral.



Securely push in the lock piece until the slider lock is engaged.

3. INSTALL NO. 1 CONSOLE BOX DUCT a. Install the No. 1 console box duct to the lower shift lever assembly with the clip. 4. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET a. Install the No. 1 console box mounting bracket to the lower shift lever assembly with the screw. 5. INSTALL FLOOR CARPET BRACKET LH . Refer to INSTALLATION - Step 10 6. INSTALL CONSOLE BOX INSERT . Refer to INSTALLATION - Step 4 7. INSTALL FRONT NO. 2 CONSOLE BOX INSERT . Refer to INSTALLATION - Step 5 8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 9. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 10. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 11. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 12. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 13. INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 47 15. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH . Refer to INSTALLATION - Step 48 16. INSTALL FRONT DOOR SCUFF PLATE RH . Refer to INSTALLATION - Step 49 17. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 38 18. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39 19. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 20. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 21. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 22. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 23. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION - Step 1 24. INSPECT SHIFT LEVER POSITION See step 1

SHIFT LEVER POSITION SENSOR COMPONENTS

ILLUSTRATION

Fig. 102: Identifying Shift Lever Position Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER LH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE ENGINE UNDER COVER RH SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY a. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

Fig. 103: Identifying Transmission Control Cable Assembly Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket. c. Remove the clip from the transmission control cable assembly. 6. REMOVE SHIFT LEVER POSITION SENSOR a. Disconnect the connector from the shift lever position sensor.

Fig. 104: Identifying Shift Lever Position Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the nut, washer, and control shaft lever from the manual valve shaft.

Fig. 105: Identifying Control Shaft Lever Washer And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using a screwdriver, pry the tabs of the lock plate.

Fig. 106: Identifying Lock Plate Tabs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Plate d. Remove the lock nut and lock plate from the manual valve shaft.

Fig. 107: Identifying Lock Nut And Lock Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Nut Lock *2 Plate e. Remove the 2 bolts and pull out the shift lever position sensor from the manual valve shaft.

Fig. 108: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT SHIFT LEVER POSITION SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 109: Shift Lever Position Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Shift Tester Specified Lever Connection Condition Position Below 1 D ohms 8 (+B) - 1 (D) Except 10 kohms D or higher Below 1 N ohms 8 (+B) - 2 (N) Except 4.2 to 5.2 N kohms Below 1 P ohms 8 (+B) - 3 (P) Except 10 kohms P or higher Below 1 R ohms 8 (+B) - 4 (R) Except 10 kohms R or higher 8 (+B) - 5 Below 1 ALL (MJ) ohms

Below 1 D or B ohms 8 (+B) - 6 (FD) Except 10 kohms D and B or higher Below 1 B ohms 8 (+B) - 7 (B) Except 10 kohms B or higher Below 1 R ohms 8 (+B) - 9 (RV) Except 10 kohms R or higher TEXT IN ILLUSTRATION Component without harness connected *a (Shift Lever Position Sensor) If the result is not as specified, replace the shift lever position sensor. ADJUSTMENT ADJUSTMENT

1. INSPECT SHIFT LEVER POSITION SENSOR POSITION a. Apply the parking brake. b. Lock the wheels with chocks to secure the vehicle. c. Turn the power switch on (READY). d. Move the shift lever to D and release the brake. NOTE:

Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

e. Slowly move the shift lever to N and measure moving distance (A) of the shift lever from the original point to the gear activation point.

Fig. 110: Measure Moving Distance To The Gear Activation Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Gear *a Activation Point N *b Position *c R Position D *d Position NOTE:

Be sure to move the shift lever slowly.

f. Move the shift lever to R and release the brake. NOTE:

Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

g. Slowly move the shift lever to N and measure moving distance (B) of the shift lever from the original point to the vehicle activation point. NOTE:

Be sure to move the shift lever slowly.

h. Check that moving distances (A) and (B) shown in the illustration are almost the same. HINT: If moving distances (A) and (B) are almost the same, adjustment of the shift lever position is not necessary.  If moving distance (A) is shorter than (B), perform adjustment of the shift lever position [*1].  If moving distance (B) is shorter than (A), perform adjustment of the shift lever position [*2]. 2. ADJUST SHIFT LEVER POSITION SENSOR POSITION a. If moving distance (A) is shorter than (B).[*1] 1. Move the shift lever to N. 2. Loosen the 2 bolts. 

Fig. 111: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Slightly turn the shift lever position sensor counterclockwise.

Fig. 112: Identifying Shift Lever Position Sensor Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If the shift lever is moved from R to N, the moving distance of the shift lever from the original point to the gear activation point becomes longer. 4. Tighten the 2 bolts in the order shown in the illustration.

Fig. 113: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 5. Recheck the shift lever position sensor. b. If moving distance (B) is shorter than (A) [*2] 1. Move the shift lever to N. 2. Loosen the 2 bolts.

Fig. 114: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Slightly turn the shift lever position sensor clockwise.

Fig. 115: Identifying Shift Lever Position Sensor Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HINT: If the shift lever is moved from D to N, the moving distance of the shift lever from the original point to the gear activation point becomes longer. 4. Tighten the 2 bolts in the order shown in the illustration.

Fig. 116: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 5. Recheck the shift lever position sensor. INSTALLATION INSTALLATION

1. INSTALL SHIFT LEVER POSITION SENSOR a. Install the shift lever position sensor to the manual valve shaft. b. Temporarily install the 2 bolts. c. Install a new lock plate and tighten the nut. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) d. Temporarily install the control shaft lever to the manual valve shaft.

e. Turn the lever clockwise until it stops, then turn it counterclockwise 2 notches.

Fig. 117: Turning Control Shaft Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the control shaft lever from the manual valve shaft. g. Align the protruding part with the neutral basic line.

Fig. 118: Aligning Protruding Part With Neutral Basic Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Neutral *a Basic Line *b Protruding Range of *c Play NOTE:

There is play on the nut stopper side (protruding part). Align the center point of the range of the play with the neutral basic line.

h. Tighten the 2 bolts in the order shown in the illustration.

Fig. 119: Identifying Shift Lever Position Sensor Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) i. Using a screwdriver, secure the nut with the lock plate. j. Install the control shaft lever, washer, and nut to the manual valve shaft. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) k. Connect the connector to the shift lever position sensor. 2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY a. Move the shift lever to the N position. b. Install a new clip to the control bracket. c. Install the transmission control cable assembly to the control bracket.

Fig. 120: Installing Transmission Control Cable Assembly To Control Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Transmission Control *1 Cable Assembly No. 1 Transmission *2 Control Cable Bracket *a Claw A *b Claw B

NOTE:





Make sure that the A claws on the clip are securely fit into the bracket holes. Make sure that the cable is securely installed inside the B claws of the clip.

d. Install the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 3. 4. 5. 6. 7. 8. 9. 10.

INSPECT SHIFT LEVER POSITION SENSOR POSITION See step 1 ADJUST SHIFT LEVER POSITION SENSOR POSITION See step 2 INSPECT SHIFT LEVER POSITION See step 1 ADJUST SHIFT LEVER POSITION See step 2 INSTALL ENGINE UNDER COVER RH INSTALL FRONT WHEEL OPENING EXTENSION PAD RH INSTALL ENGINE UNDER COVER LH INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

2012-2017 ENGINE Ignition System (Inspection) - Camry (2AR-FE)

IGNITION SYSTEM PARTS LOCATION ILLUSTRATION

Fig. 1: Identifying Ignition System Components Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Identifying Ignition System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. PERFORM SPARK TEST

a. Check for DTCs. Refer to DTC CHECK / CLEAR . NOTE:

If any DTC is output, perform troubleshooting procedures for that DTC.

b. Remove the ignition coil assemblies and spark plugs. Refer to REMOVAL . c. Disconnect the 4 injector connectors.

Fig. 3: Identifying Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the spark plug into the ignition coil assembly, and then connect the ignition coil connector. e. Ground the spark plug.

Fig. 4: Checking Spark Occurs At Each Spark Plug While Engine Is Being Cranked Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Check that spark occurs at each spark plug while the engine is being cranked. NOTE:

 

Be sure to ground the spark plugs when checking them. Do not crank the engine for more than 2 seconds. Cranking will stop if the engine switch is pushed again for models with cranking holding function.

 

If a spark plug has been struck or dropped, replace it. If an ignition coil assembly has been struck or dropped, replace it.

HINT: If spark does not occur for any cylinder, perform the following Inspect Ignition Coil and Spark Test procedure. g. Connect the 4 fuel injector connectors. h. Install the spark plugs and ignition coil assemblies. Refer to INSTALLATION . i. Check for DTCs. Refer to DTC CHECK / CLEAR . j. Clear the DTCs. Refer to DTC CHECK / CLEAR . 2. INSPECT IGNITION COIL AND SPARK TEST HINT: Perform "Inspection After Repair" after replacing the spark plug and ignition coil assembly. Refer to INITIALIZATION . a. Check that the wire harness side connector of the ignition coil assembly is securely connected. RESULT Result Action Connect NG securely Go to OK next step b. Perform a spark test on each ignition coil assembly. 1. Replace the ignition coil assembly with a known good one. 2. Perform the spark test again.

RESULT Result Action Go to NG next step Replace ignition OK coil assembly c. Perform a spark test on each spark plug. 1. Replace the spark plug with a known good one. 2. Perform the spark test again. RESULT Result Action Inspect the ignition system. Refer to DTC P0351: Ignition Coil "A" Primary / Secondary Circuit; DTC P0352: Ignition Coil "B" NG Primary / Secondary Circuit; DTC P0353: Ignition Coil "C" Primary / Secondary Circuit; DTC P0354: Ignition Coil "D" Primary / Secondary

Circuit . Replace OK spark plug 3. CHECK SPARK PLUG NOTE:

 

Do not use a wire brush for cleaning. Do not adjust the electrode gap of a used spark plug.

HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . a. Check the electrode using a megohmmeter:

Fig. 5: Electrode Using A Megohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Ground 1. Using a megohmmeter, measure the insulation resistance. Standard Insulation Resistance Tester

Specified

Connection Condition Condition Spark plug 10 (terminal Always Mohms or part) - Body higher ground HINT: If the result is not as specified, clean the spark plug with a spark plug cleaner and measure the resistance again.  If a megohmmeter is not available, perform the following simple inspection instead. b. Alternative inspection method: 

Fig. 6: Identifying Spark Plug Condition Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Quickly accelerate the engine to 4000 rpm 5 times. 2. Remove the spark plug. Refer to REMOVAL . 3. Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. 4. Install the spark plug. Refer to INSTALLATION . c. Check the spark plug for any damage to its thread and insulator.

If there is any damage, replace the spark plug. Recommended Spark Plug Manufacturer DENSO

Spark Plug Type SK16HR11

d. Reference: 1. Check the spark plug electrode gap.

Fig. 7: Checking Spark Plug Electrode Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum electrode gap for a used spark plug 1.3 mm (0.0512 in.) If the gap is more than the maximum, replace the spark plug. NOTE:

Never attempt to adjust the gap of a used plug.

Electrode gap for a new spark plug 1.0 to 1.1 mm (0.0394 to 0.0433 in.)

TEXT IN ILLUSTRATION Spark plug *a electrode gap e. Clean the spark plugs.

Fig. 8: Cleaning Electrode With Spark Plug Cleaner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard air pressure 588 kPa (6.0 kgf/cm2 , 85 psi) Standard duration 20 seconds or less HINT: Only use a spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner.

2012-2017 ENGINE Ignition System (Inspection) - Camry (2GR-FE)

IGNITION SYSTEM PARTS LOCATION ILLUSTRATION

Fig. 1: Identifying Ignition System Components Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Identifying Ignition System Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. PERFORM SPARK TEST

a. Check for DTCs. Refer to DTC CHECK / CLEAR . NOTE:

If any DTC is present, perform troubleshooting in accordance with the procedure for that DTC.

b. Remove the ignition coils and spark plugs. Refer to REMOVAL . c. Disconnect the 6 fuel injector connectors.

Fig. 3: Identifying Fuel Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the spark plug into the ignition coil, and then connect the ignition coil connector.

Fig. 4: Checking Ground Spark Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Ground the spark plug. f. Check that spark occurs at each spark plug while the engine is being cranked. NOTE:

 

Be sure to ground the spark plugs when checking them. Do not crank the engine for more than 2 seconds. Cranking will stop if the engine switch is pushed again for models with cranking holding function.

 

If a spark plug has been struck or dropped, replace it. If an ignition coil has been struck or dropped, replace it.

HINT: If spark does not occur for any cylinder, perform the following inspect Ignition Coil and Spark Test procedure. g. Connect the 6 fuel injector connectors. h. Install the spark plugs and ignition coils. Refer to INSTALLATION . i. Clear the DTCs. Refer to DTC CHECK / CLEAR . 2. INSPECT IGNITION COIL AND SPARK TEST

HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . a. Check that the wire harness side connector of the ignition coil is securely connected. Result Result Action Connect NG securely Go to OK next step b. Perform a spark test on each ignition coil. 1. Replace the ignition coil with a known good one. 2. Perform the spark test again. Result Result Action Go to NG next step Replace OK ignition coil c. Perform a spark test on each spark plug. 1. Replace the spark plug with a known good one. 2. Perform the spark test again. Result Result

Proceed to Inspect the ignition system. Refer to DTC P0351: Ignition Coil "A"

NG

OK

Primary / Secondary Circuit; DTC P0352: Ignition Coil "B" Primary / Secondary Circuit; DTC P0353: Ignition Coil "C" Primary / Secondary Circuit; DTC P0354: Ignition Coil "D" Primary / Secondary Circuit; DTC P0355: Ignition Coil "E" Primary / Secondary Circuit; DTC P0356: Ignition Coil "F" Primary / Secondary Circuit . Replace spark plug

3. CHECK SPARK PLUG NOTE:

 

HINT:

Do not use a wire brush for cleaning. Do not adjust the electrode gap of a spark plug.

Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . a. Check the electrode using a megohmmeter.

Fig. 5: Checking Electrode Using Megohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Ground 1. Using a megohmmeter, measure the insulation resistance. Standard Insulation Resistance Tester Specified Condition Connection Condition Spark plug 10 (terminal Always Mohms or part) - Body more ground HINT: If the result is not as specified, clean the spark plug with a spark plug cleaner and measure the resistance again.  If a megohmmeter is not available, perform the following simple inspection instead. b. Alternative inspection method. 

1. Quickly accelerate the engine to 4000 rpm 5 times. 2. Remove the spark plug. Refer to REMOVAL . 3. Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. 4. Install the spark plug. Refer to INSTALLATION . c. Check the spark plug for any damage to its threads and insulator. If there is any damage, replace the spark plug. Recommended Spark Plug Manufacturer DENSO

Spark Plug Type FK20HR11

d. Reference. 1. Check the spark plug electrode gap.

Fig. 6: Checking Spark Plug Electrode Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum Electrode Gap for Used Spark Plug 1.4 mm (0.0551 in.)

If the gap is greater than the maximum, replace the spark plug. NOTE:

Never attempt to adjust the gap of a used

Electrode Gap for New Spark Plug 1.0 to 1.1 mm (0.0394 to 0.0433 in.) e. Clean the spark plugs.

Fig. 7: Cleaning Electrode With Spark Plug Cleaner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard Air Pressure 588 kPa (6.0 kgf/cm2 , 85 psi) Standard Duration 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil,

use gasoline to clean off the oil before using the spark plug cleaner.

2012-2017 ENGINE Ignition System (Inspection) (Hybrid)

IGNITION SYSTEM PARTS LOCATION ILLUSTRATION

Fig. 1: Identifying Ignition System Components Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Ignition System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. PERFORM SPARK TEST

a. Check for DTCs. Refer to DTC CHECK / CLEAR . NOTE:

If any DTC is output, perform troubleshooting procedures for that DTC.

b. Remove the ignition coil assemblies and spark plugs. Refer to REMOVAL . c. Disconnect the 4 injector connectors.

Fig. 3: Identifying Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the spark plug into the ignition coil assembly, and then connect the ignition coil connector. e. Ground the spark plug.

Fig. 4: Identifying Spark Plug In Ignition Coil Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Check that spark occurs at each spark plug while the engine is being cranked. NOTE:

 

Be sure to ground the spark plugs when checking them. Do not crank the engine for more than 2 seconds. Cranking will stop if the power switch is pushed again for models with cranking holding function.

 

If a spark plug has been struck or dropped, replace it. If an ignition coil assembly has been struck or dropped, replace it.

HINT: If spark does not occur for any cylinder, perform the following Inspect Ignition Coil and Spark Test procedure. g. Connect the 4 fuel injector connectors.

Fig. 5: Identifying Injector Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Install the spark plugs and ignition coil assemblies. Refer to INSTALLATION . i. Check for DTCs. Refer to DTC CHECK / CLEAR . j. Clear the DTCs. Refer to DTC CHECK / CLEAR . 2. INSPECT IGNITION COIL AND SPARK TEST HINT: Perform "Inspection After Repair" after replacing the spark plug and ignition coil assembly. Refer to INITIALIZATION . a. Check that the wire harness side connector of the ignition coil assembly is securely connected.

RESULT Result Action Connect NG securely Go to OK next step b. Perform a spark test on each ignition coil assembly. 1. Replace the ignition coil assembly with a known good one. 2. Perform the spark test again. RESULT Result Action Go to NG next step Replace ignition OK coil assembly c. Perform a spark test on each spark plug. 1. Replace the spark plug with a known good one. 2. Perform the spark test again. RESULT Result Action Inspect the ignition system. Refer to DTC P0351: Ignition Coil "A" NG Primary / Secondary Circuit; DTC P0352: Ignition Coil "B" Primary / Secondary Circuit;

DTC P0353: Ignition Coil "C" Primary / Secondary Circuit; DTC P0354: Ignition Coil "D" Primary / Secondary Circuit . Replace OK spark plug 3. CHECK SPARK PLUG NOTE:

 

Do not use a wire brush for cleaning. Do not adjust the electrode gap of a used spark plug.

HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to INITIALIZATION . a. Check the electrode using a megohmmeter:

Fig. 6: Electrode Using A Megohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Ground 1. Using a megohmmeter, measure the insulation resistance. Standard Insulation Resistance Tester Specified Condition Connection Condition Spark plug 10 (terminal Always Mohms or part) - Body higher ground HINT: If the result is not as specified, clean the spark plug with a spark plug cleaner and measure the resistance again.  If a megohmmeter is not available, perform the following simple inspection instead. b. Alternative inspection method: 

Fig. 7: Identifying Spark Plug Condition Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Quickly accelerate the engine to 4000 RPM 5 times. 2. Remove the spark plug. Refer to REMOVAL . 3. Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. c. Check the spark plug for any damage to its thread and insulator. If there is any damage, replace the spark plug. Recommended Spark Plug Spark Manufacturer Plug Type FK16HRDENSO A8 d. Reference: 1. Check the spark plug electrode gap.

Fig. 8: Checking Spark Plug Electrode Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Maximum electrode gap for a used spark plug 1.1 mm (0.0433 in.) If the gap is more than the maximum, replace the spark plug. NOTE:

Never attempt to adjust the gap of a used plug.

Electrode gap for a new spark plug 0.7 to 0.8 mm (0.0276 to 0.0315 in.) TEXT IN ILLUSTRATION Spark plug *a electrode gap e. Clean the spark plugs.

Fig. 9: Cleaning Electrode With Spark Plug Cleaner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard air pressure 588 kPa (6.0 kgf/cm2 , 85 psi) Standard duration 20 seconds or less HINT: Only use a spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. f. Install the spark plug. Refer to INSTALLATION .

2012-2017 ACCESSORIES & EQUIPMENT Interior Trim (Service Information) (Hybrid) - Camry

INSTRUMENT PANEL SAFETY PAD PRECAUTION PRECAUTION

1. PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER a. Some operations in this service information may affect the SRS airbags. Prior to performing the corresponding operations, read the precautions regarding the SRS airbags.  for Separate Type Yaw Rate Sensor: Refer to PRECAUTION  for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION 2. TABLE OF BOLT, SCREW AND NUT HINT: All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with their alphabet codes in the table below. Code Shape





COMPONENTS ILLUSTRATION

Size Code Shape Size = 8 mm = 8 mm (0.315 in.) (0.315 in.)

Length = 20 mm Length = 15 mm (0.787 in.) (0.591 in.) = 6 mm = 5 mm (0.236 in.) (0.197 in.)

Length = 20 mm Length = 15 mm (0.787 in.) (0.591 in.) = 5 mm = 3 mm (0.197 in.) (0.118 in.)

Length = 16 mm Length = 12 mm (0.630 in.) (0.472 in.) = 6 mm = 6 mm

(0.236 in.) (0.236 in.)

Fig. 1: Identifying Instrument Panel Safety Pad Replacement Components (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Instrument Panel Safety Pad Replacement Components (2 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Instrument Panel Safety Pad Replacement Components (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Instrument Panel Safety Pad Replacement Components (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Identifying Instrument Panel Safety Pad Replacement Components With Torque Specifications (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Identifying Instrument Panel Safety Pad Replacement Components With Torque Specifications (6 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Identifying Instrument Panel Safety Pad Replacement Components (7 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE LH See step 4 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH See step 5 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the front door opening trim weatherstrip LH.

Fig. 8: Identifying Front Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE INSTRUMENT SIDE PANEL LH a. Using a molding remover, disengage the 4 claws as shown in the illustration.

Fig. 9: Disengaging Instrument Side Panel LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 guides and remove the instrument side panel LH as shown in the illustration.

Fig. 10: Disengaging Instrument Side Panel LH Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Disengage the 3 clips to remove the No. 1 instrument cluster finish panel garnish as shown in the illustration.

Fig. 11: Removing No. 1 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 12: Identifying Protective Tape Around No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Disengage the 2 clips as shown in the illustration.

Fig. 13: Removing No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a molding remover, disengage the 2 clips to remove the No. 1 instrument panel register assembly.

Fig. 14: Identifying No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Operate the tilt and telescopic lever to fully extend and lower the steering column assembly. b. Using a molding remover, disengage the 2 claws, 4 clips and 2 guides.

Fig. 15: Disengaging Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 5 claws, 5 clips and 2 guides.

Fig. 16: Identifying Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector. e. Remove the instrument cluster finish panel assembly as shown in the illustration.

Fig. 17: Removing Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE COMBINATION METER ASSEMBLY . Refer to REMOVAL - Step 9 12. REMOVE FRONT PANEL GARNISH LH a. Disengage the 3 claws, 2 clips and 8 guides to remove the front panel garnish LH.

Fig. 18: Identifying Front Panel Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Disengage the claw and 2 guides to disconnect the hood lock control lever sub-assembly.

Fig. 19: Identifying Hood Lock Control Lever Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Remove the bolt and screw or .

Fig. 20: Identifying Lower No. 1 Instrument Panel Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws, 9 clips and 3 guides to remove the lower No. 1 instrument panel finish panel assembly.

Fig. 21: Identifying Lower No. 1 Instrument Panel Finish Panel Assembly Claws, Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE FRONT PANEL GARNISH RH a. Disengage the 3 claws, 2 clips and 8 guides to remove the front panel garnish RH.

Fig. 22: Identifying Front Panel Garnish RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY a. Turn the shift lever knob sub-assembly counterclockwise and remove the shift lever knob subassembly.

Fig. 23: Removing Shift Lever Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY a. Open the upper console panel sub-assembly door. b. Move the shift lever to N. c. Disengage the 4 clips.

Fig. 24: Identifying Rear Console Upper Panel Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

18. 19. 20. 21. 22.

d. Disconnect each connector and remove the rear console upper panel sub-assembly. REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY See step 7 REMOVE NO. 4 CONSOLE BOX DUCT See step 8 REMOVE CONSOLE BOX CARPET See step 9 REMOVE REAR CONSOLE BOX ASSEMBLY See step 10 REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Using a molding remover, disengage the 2 claws and 2 clips as shown in the illustration.

Fig. 25: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a molding remover, disengage the 2 claws and 2 clips as shown in the illustration.

Fig. 26: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 3 claws and 2 clips as shown in the illustration.

Fig. 27: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the clamp.

Fig. 28: Locating Center Instrument Cluster Finish Panel Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the connector to remove the center instrument cluster finish panel assembly. 23. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY a. Pull the No. 2 instrument panel register assembly in the direction indicated by the arrow to disengage the 6 clips to remove the No. 2 instrument panel register assembly.

Fig. 29: Removing No. 2 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE BOX BOTTOM MAT a. Remove the box bottom mat.

Fig. 30: Identifying Box Bottom Mat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 31: Locating Upper Console Panel Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and guide as shown in the illustration.

Fig. 32: Removing Upper Console Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

26. 27. 28. 29.

c. Disconnect each connector to remove the upper console panel sub-assembly. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY

a. Disengage the 8 clips as shown in the illustration.

Fig. 33: Removing No. 1 Speaker Opening Cover Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector to remove the No. 1 speaker opening cover assembly. 30. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 16 31. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side See step 4. 32. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT: Use the same procedure as for the LH side See step 5. 33. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH a. Disconnect the front door opening trim weatherstrip RH.

Fig. 34: Identifying Front Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE INSTRUMENT SIDE PANEL RH a. Using a molding remover, disengage the 4 claws as shown in the illustration.

Fig. 35: Disengaging Instrument Side Panel RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 guides to remove the instrument side panel RH as shown in the illustration.

Fig. 36: Disengaging Instrument Side Panel RH Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY a. Disengage the 4 claws and 2 guides.

Fig. 37: Identifying No. 2 Instrument Panel Under Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the No. 2 instrument panel under cover sub-assembly. 36. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 37. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 38: Locating Lower Instrument Panel Sub-Assembly Lower Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Open the lower instrument panel door. c. Remove the 3 screws or .

Fig. 39: Locating Lower Instrument Panel Sub-Assembly Upper Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 clips and 3 guides.

Fig. 40: Identifying Lower Instrument Panel Door Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the glove compartment light as shown in the illustration.

Fig. 41: Removing Glove Compartment Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disconnect each connector and remove the lower instrument panel sub-assembly. 38. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Disengage the 5 clips to remove the No. 2 instrument cluster finish panel garnish as shown in the illustration.

Fig. 42: Removing No. 2 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 43: Identifying Protective Tape Around No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Disengage the 2 clips as shown in the illustration.

Fig. 44: Removing No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a molding remover, disengage the 2 clips to remove the No. 3 instrument panel register assembly.

Fig. 45: Removing No. 3 Instrument Panel Register Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE FRONT PILLAR GARNISH LH See step 7 41. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 46: Identifying Protective Tape Around No. 1 Instrument Panel Speaker Panel SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a molding remover, disengage the 2 clips and 3 claws.

Fig. 47: Identifying No. 1 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides to remove the No. 1 instrument panel speaker panel sub-assembly. 42. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) . Refer to REMOVAL - Step 5 43. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side See step 7. 44. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 48: Identifying Protective Tape Around No. 2 Instrument Panel Speaker Panel SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a molding remover, disengage the 2 clips and 3 claws.

Fig. 49: Identifying No. 2 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides to remove the No. 2 instrument panel speaker panel sub-assembly. 45. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 5 . 46. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Disengage the 4 clips and guide.

Fig. 50: Identifying Lower Instrument Panel Finish Panel Clips And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the lower instrument panel finish panel assembly. 47. REMOVE FRONT NO. 2 CONSOLE BOX INSERT a. Disengage the 2 claws to disconnect the room temperature sensor from the front No. 2 console box insert.

Fig. 51: Locating Room Temperature Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 screws or .

Fig. 52: Identifying Front No. 2 Console Box Insert Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clip and 3 guides to remove the front No. 2 console box insert as shown in the illustration.

Fig. 53: Removing Front No. 2 Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 48. REMOVE CONSOLE BOX INSERT a. Remove the 2 screws or .

Fig. 54: Identifying Console Box Insert Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clip and 3 guides to remove the console box insert as shown in the illustration.

Fig. 55: Removing Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 49. REMOVE NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Disengage the 10 clips to remove the No. 1 instrument panel garnish sub-assembly as shown in the illustration.

Fig. 56: Removing No. 1 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 50. DISCONNECT NO. 2 INSTRUMENT PANEL WIRE . Refer to REMOVAL - Step 3 51. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY a. Disconnect each connector.

Fig. 57: Locating Instrument Panel Safety Pad Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage each clamp. c. Remove the 2 passenger airbag bolts or .

Fig. 58: Locating Instrument Panel Safety Pad Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Passenger Airbag Bolt *1 *2 Bolt

or Nut *3 *4 Clip or d. Remove the 3 bolts and nut or . e. Remove the 2 clips. f. Disengage the 5 guides and remove the instrument panel safety pad assembly as shown in the illustration.

Fig. 59: Removing Instrument Panel Safety Pad Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not damage the instrument panel safety pad assembly. Do not allow the wire harnesses to interfere with the surrounding parts.

DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 INSTRUMENT PANEL PIN a. Remove the 4 screws or and 4 No. 1 instrument panel pins.

Fig. 60: Locating No. 1 Instrument Panel Pin Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY . Refer to REMOVAL Step 5 3. REMOVE NO. 1 HEATER TO REGISTER DUCT a. Remove the clip.

Fig. 61: Locating No. 1 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws or and No. 1 heater to register duct. 4. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT a. Remove the screw or .

Fig. 62: Locating No. 1 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the No. 1 side defroster nozzle duct. 5. REMOVE NO. 3 HEATER TO REGISTER DUCT a. Remove the clip.

Fig. 63: Locating No. 3 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws or and No. 3 heater to register duct. 6. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT a. Remove the screw or .

Fig. 64: Locating No. 2 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the No. 2 side defroster nozzle duct. 7. REMOVE ANTENNA CORD SUB-ASSEMBLY . Refer to REMOVAL - Step 4 8. REMOVE DEFROSTER NOZZLE ASSEMBLY a. Remove the 3 screws or .

Fig. 65: Locating Defroster Nozzle Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the defroster nozzle assembly. 9. REMOVE NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) . Refer to REMOVAL Step 7 10. REMOVE NO. 2 HEATER TO REGISTER DUCT a. Remove the 2 screws or and No. 2 heater to register duct.

Fig. 66: Locating No. 2 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 2 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 67: Locating No. 2 Instrument Panel Garnish Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply protective tape to the areas shown in the illustration.

Fig. 68: Identifying Protective Tape Around No. 2 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 -Tape c. Disengage the 5 clips as shown in the illustration.

d. Using a molding remover, disengage the 8 clips to remove the No. 2 instrument panel garnish subassembly as shown in the illustration. REASSEMBLY REASSEMBLY

1. INSTALL NO. 2 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Engage the 13 clips.

Fig. 69: Identifying No. 2 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 2 instrument panel garnish sub-assembly with the 2 screws or .

Fig. 70: Locating No. 2 Instrument Panel Garnish Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 HEATER TO REGISTER DUCT a. Install the No. 2 heater to register duct with the 2 screws or .

Fig. 71: Locating No. 2 Heater To Register Duct Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) . Refer to INSTALLATION - Step 1 4. INSTALL DEFROSTER NOZZLE ASSEMBLY a. Engage the 2 guides.

Fig. 72: Locating Defroster Nozzle Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the defroster nozzle assembly with the 3 screws or . 5. INSTALL ANTENNA CORD SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 6. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT a. Engage the 2 claws.

Fig. 73: Locating No. 2 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 2 side defroster nozzle duct with the screw or . 7. INSTALL NO. 3 HEATER TO REGISTER DUCT a. Install the No. 3 heater to register duct with the 3 screws or .

Fig. 74: Locating No. 3 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clip. 8. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT a. Engage the 2 claws.

Fig. 75: Locating No. 1 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 1 side defroster nozzle duct with the screw or . 9. INSTALL NO. 1 HEATER TO REGISTER DUCT a. Install the No. 1 heater to register duct with the 3 screws or .

Fig. 76: Locating No. 1 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clip. 10. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 2 11. INSTALL NO. 1 INSTRUMENT PANEL PIN a. Install the 4 No. 1 instrument panel pins with the 4 screws or .

Fig. 77: Locating No. 1 Instrument Panel Pin Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION

INSTALLATION

1. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY a. Engage the 5 guides and temporarily install the instrument panel safety pad assembly as shown in the illustration.

Fig. 78: Installing Instrument Panel Safety Pad Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not damage the instrument panel safety pad assembly. Do not allow the wire harnesses to interfere with the surrounding parts.

b. Install the 2 clips. c. Install the 3 bolts and nut or . d. Install the 2 passenger airbag bolts or . Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) e. Engage each clamp. f. Connect each connector. 2. CONNECT NO. 2 INSTRUMENT PANEL WIRE . Refer to INSTALLATION - Step 4 3. INSTALL NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Engage the 10 clips to install the No. 1 instrument panel garnish sub-assembly.

Fig. 79: Installing No. 1 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL CONSOLE BOX INSERT a. Engage the clip and 3 guides.

Fig. 80: Installing Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the console box insert with the 2 screws or . 5. INSTALL FRONT NO. 2 CONSOLE BOX INSERT a. Engage the 2 claws to connect the room temperature sensor. b. Engage the clip and 3 guides.

Fig. 81: Installing Front No. 2 Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the front No. 2 console box insert with the 2 screws or . 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Connect the connector. b. Engage the 4 clips and guide to install the lower instrument panel finish panel assembly. 7. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) . Refer to INSTALLATION - Step 1 8. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Engage the 2 guides.

Fig. 82: Identifying No. 1 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws and 2 clips to install the No. 1 instrument panel speaker panel sub-assembly. 9. INSTALL FRONT PILLAR GARNISH LH See step 42 10. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 1 . 11. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Engage the 2 guides.

Fig. 83: Identifying No. 2 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws and 2 clips to install the No. 2 instrument panel speaker panel sub-assembly. 12. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side See step 42. 13. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 4 clips to install the No. 3 instrument panel register assembly.

Fig. 84: Identifying No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Engage the 5 clips to install the No. 2 instrument cluster finish panel garnish.

Fig. 85: Identifying No. 2 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY a. Connect each connector. b. Engage the glove compartment light as shown in the illustration.

Fig. 86: Installing Glove Compartment Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 3 guides and 2 clips.

Fig. 87: Identifying Glove Compartment Guides And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the lower instrument panel sub-assembly with the 5 screws or . 16. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 17. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY a. Connect the connector. b. Engage the 2 guides and 4 claws to install the No. 2 instrument panel under cover sub-assembly. 18. INSTALL INSTRUMENT SIDE PANEL RH a. Engage the 3 guides. b. Engage the 4 claws to install the instrument side panel RH as shown in the illustration.

Fig. 88: Engaging Instrument Side Panel RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH See step 47 20. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side See step 44. 21. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side See step 45.

22. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION Step 5 23. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY a. Connect the connector. b. Engage the 8 clips to install the No. 1 speaker opening cover assembly.

Fig. 89: Identifying No. 1 Speaker Opening Cover Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 25. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 26. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7

27. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY a. Connect each connector. b. Engage the 4 clips and guide. c. Install the upper console panel sub-assembly with the 2 screws or . 28. INSTALL BOX BOTTOM MAT a. Install the box bottom mat. 29. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 6 clips to install the No. 2 instrument panel register assembly.

Fig. 90: Identifying No. 2 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When installing the No. 2 instrument panel register assembly, check that the wire harness is not caught between the No. 2 instrument

panel register assembly and duct. 30. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Connect the connector. b. Engage the clamp. c. Engage the 6 clips and 7 claws to install the center instrument cluster finish panel assembly.

Fig. 91: Identifying Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. 32. 33. 34. 35.

INSTALL REAR CONSOLE BOX ASSEMBLY See step 1 INSTALL CONSOLE BOX CARPET See step 2 INSTALL NO. 4 CONSOLE BOX DUCT See step 3 INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY See step 4 INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY a. Connect each connector. b. Engage the 4 clips and install the rear console upper panel sub-assembly. c. Move the shift lever to P. 36. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY a. Turn the shift lever knob sub-assembly clockwise to install the shift lever knob sub-assembly.

Fig. 92: Installing Shift Lever Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. INSTALL FRONT PANEL GARNISH RH a. Engage the 3 claws, 2 clips and 8 guides to install the front panel garnish RH. 38. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Engage the 4 claws, 9 clips and 3 guides. b. Install the lower No. 1 instrument panel finish panel assembly with the bolt and screw or . 39. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Engage the claw and 2 guides to connect the hood lock control lever sub-assembly. 40. INSTALL FRONT PANEL GARNISH LH a. Engage the 3 claws, 2 clips and 8 guides to install the front panel garnish LH. 41. INSTALL COMBINATION METER ASSEMBLY . Refer to INSTALLATION - Step 1 42. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Temporarily install the instrument cluster finish panel assembly as shown in the illustration.

Fig. 93: Installing Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect each connector. c. Engage the 5 claws, 5 clips and 2 guides, and install the instrument cluster finish panel assembly. d. Engage the 2 claws, 4 clips and 2 guides.

Fig. 94: Engaging Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 4 clips to install the No. 1 instrument panel register assembly.

Fig. 95: Identifying No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 44. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Engage the 3 clips to install the No. 1 instrument cluster finish panel garnish.

Fig. 96: Identifying No. 1 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 45. INSTALL INSTRUMENT SIDE PANEL LH a. Engage the 3 guides. b. Engage the 4 claws to install the instrument side panel LH as shown in the illustration.

Fig. 97: Engaging Instrument Side Panel LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 46. 47. 48. 49.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH See step 43 INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH See step 44 INSTALL FRONT DOOR SCUFF PLATE LH See step 45 CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

50. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 51. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

FRONT CONSOLE BOX COMPONENTS ILLUSTRATION

Fig. 98: Identifying Front Console Box Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 99: Identifying Front Console Box Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH See step 12 REMOVE FRONT PANEL GARNISH RH See step 15 REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See step 16 REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY See step 17 REMOVE CONSOLE BOX CUP HOLDER a. Remove the console box cup holder from the rear console upper panel sub-assembly.

Fig. 100: Identifying Console Box Cup Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE INSTRUMENT PANEL CUP HOLDER TRAY a. Remove the 6 screws and instrument panel cup holder tray.

Fig. 101: Locating Instrument Panel Cup Holder Tray Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front console upper panel garnish. 7. REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY a. Remove the 2 screws.

Fig. 102: Identifying Upper Console Box Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and 2 guides remove the upper console box sub-assembly as shown in the illustration.

Fig. 103: Removing Upper Console Box Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clamp.

Fig. 104: Locating Upper Console Box Sub-Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the connector to remove the upper console box sub-assembly. 8. REMOVE NO. 4 CONSOLE BOX DUCT a. Disengage the claw and remove the No. 4 console box duct.

Fig. 105: Locating No. 4 Console Box Duct (w/ Rear Register Duct) Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE CONSOLE BOX CARPET a. Remove the console box carpet.

Fig. 106: Identifying Console Box Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE REAR CONSOLE BOX ASSEMBLY a. Remove the 2 bolts and 2 screws.

Fig. 107: Identifying Rear Console Box Bolts And Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the rear console box assembly in the direction indicated by the arrow to disengage the 4 guides and remove the rear console box assembly.

Fig. 108: Removing The Rear Console Box Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY a. Disengage the 4 claws and 4 clips to remove the console rear end panel sub-assembly.

Fig. 109: Identifying Console Rear End Panel Claws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE REAR CONSOLE ARMREST ASSEMBLY a. Using a screwdriver, remove the 2 E-rings.

Fig. 110: Locating Rear Console Armrest Assembly E-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to allow the E-rings to pop out when removing them.

b. Using a screwdriver, pull out the 2 box door hinge shafts.

Fig. 111: Removing Rear Console Armrest Assembly Hinge Shafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use.  The illustration is for the LH side.  Use the same procedure for the RH side and LH side. c. Remove the rear console armrest assembly. 3. REMOVE CONSOLE COMPARTMENT DOOR LOCK SUB-ASSEMBLY a. Remove the 2 screws. 

Fig. 112: Locating Console Compartment Door Lock Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 8 claws.

Fig. 113: Locating Console Compartment Door Lock Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. c. Disengage the 2 guides to remove the console compartment door lock sub-assembly as shown in the illustration.

Fig. 114: Removing Console Compartment Door Lock Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE CONSOLE COMPARTMENT DOOR CUSHION a. Remove the 4 console compartment door cushions from the console compartment door lock subassembly.

Fig. 115: Locating Console Compartment Door Cushion Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL CONSOLE COMPARTMENT DOOR CUSHION a. Install the 4 console compartment door cushions to the console compartment door lock subassembly.

Fig. 116: Locating Console Compartment Door Cushion Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL CONSOLE COMPARTMENT DOOR LOCK SUB-ASSEMBLY a. Engage the 2 guides and temporarily install the console compartment door lock sub-assembly as shown in the illustration.

Fig. 117: Installing Console Compartment Door Lock Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 8 claws.

Fig. 118: Locating Console Compartment Door Lock Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the console compartment door lock sub-assembly with the 2 screws.

Fig. 119: Locating Console Compartment Door Lock Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR CONSOLE ARMREST ASSEMBLY a. Temporarily install the rear console armrest assembly. b. Push in the 2 box door hinge shafts by hand as far as possible.

Fig. 120: Installing Rear Console Armrest Assembly Hinge Shafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The illustration is for the LH side.  Use the same procedure for the RH side and LH side. c. Using pliers, push in the 2 box door hinge shafts completely. 

Fig. 121: Installing Rear Console Armrest Assembly Hinge Shafts Using Pliers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the tips of the pliers before use.  The illustration is for the LH side.  Use the same procedure for the RH side and LH side. d. Install the rear console armrest assembly with the 2 E-rings. 

Fig. 122: Locating Rear Console Armrest Assembly E-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY a. Engage the 4 claws and 4 clips to install the console rear end panel sub-assembly.

Fig. 123: Identifying Console Rear End Panel Claws And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL REAR CONSOLE BOX ASSEMBLY a. Engage the 4 guides as shown in the illustration.

Fig. 124: Installing The Rear Console Box Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear console box assembly with the 2 bolts and 2 screws. 2. INSTALL CONSOLE BOX CARPET a. Install the console box carpet. 3. INSTALL NO. 4 CONSOLE BOX DUCT a. Engage the claw to install the No. 4 console box duct. 4. INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY a. Connect the connector and engage the clamp. b. Engage the 2 guides and 4 clips as shown in the illustration.

Fig. 125: Installing Upper Console Box Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5.

6. 7. 8. 9. 10.

c. Install the upper console box sub-assembly with the 2 screws. INSTALL INSTRUMENT PANEL CUP HOLDER TRAY a. Install the front console upper panel garnish. b. Install the instrument panel cup holder tray with the 6 screws. INSTALL CONSOLE BOX CUP HOLDER a. Install the console box cup holder to the rear console upper panel sub-assembly. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY See step 35 INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See step 36 INSTALL FRONT PANEL GARNISH RH See step 37 INSTALL FRONT PANEL GARNISH LH See step 40

ROOF HEADLINING COMPONENTS ILLUSTRATION

Fig. 126: Identifying Roof Headlining Replacement Components (1 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 127: Identifying Roof Headlining Replacement Components (2 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 128: Identifying Roof Headlining Replacement Components (3 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 129: Identifying Roof Headlining Replacement Components With Torque Specifications (4 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 130: Identifying Roof Headlining Replacement Components With Torque Specifications (5 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 131: Identifying Roof Headlining Replacement Components With Torque Specifications (6 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 132: Identifying Roof Headlining Replacement Components (7 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 133: Identifying Roof Headlining Replacement Components (8 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 134: Identifying Roof Headlining Replacement Components (9 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 135: Identifying Roof Headlining Replacement Components With Torque Specifications (10 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 136: Identifying Roof Headlining Replacement Components (11 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 137: Identifying Roof Headlining Replacement Components (12 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 138: Identifying Roof Headlining Replacement Components (13 Of 13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE LH a. Disengage the 10 claws and remove the front door scuff plate LH.

Fig. 139: Identifying Front Door Scuff Plate LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH a. Remove the clip.

Fig. 140: Removing Cowl Side Trim Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the cowl side trim sub-assembly LH in the direction indicated by the arrow shown in the illustration to disengage the 2 clips and remove the cowl side trim sub-assembly LH. 6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Remove the front door opening trim weatherstrip LH. 7. REMOVE FRONT PILLAR GARNISH LH a. Pull the upper part of the garnish toward the inside of the cabin and disengage the garnish from the base of the 2 clips.

Fig. 141: Identifying Front Pillar Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Pillar *1 Garnish Clip HINT: Make the front pillar garnish LH hang down from the front pillar garnish clip. b. While pushing the tabs on the front pillar garnish clip in the direction indicated by the arrow (1) shown in the illustration, disengage the front pillar garnish clip.

Fig. 142: Removing Front Pillar Garnish LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the garnish in the direction indicated by the arrow (2) shown in the illustration to disengage the 2 guides and remove the front pillar garnish LH. d. Protect the curtain shield airbag assembly.

Fig. 143: Identifying Curtain Shield Airbag Assembly With Protective Cover And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Adhesive *1 Tape Protective *2 Cover Curtain Shield *3 Airbag Assembly 1. Cover the airbag with a piece of cloth or nylon and secure the edges of the cover with tape as shown in the illustration. NOTE:

Cover the curtain shield airbag with a protective cover as soon as the front pillar garnish is removed.

8. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT: Use the same procedure as for the LH side. 10. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side. 11. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. 12. 13. 14. 15. 16. 17. 18. 19.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 REMOVE REAR DOOR SCUFF PLATE LH a. Disengage the 6 claws and remove the rear door scuff plate LH.

Fig. 144: Identifying Rear Door Scuff Plate LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Disengage the claws from the rear side of the scuff plate. 20. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Remove the rear door opening trim weatherstrip LH. 21. REMOVE LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to REMOVAL - Step 8 22. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 9 23. REMOVE CENTER PILLAR LOWER GARNISH LH a. Disengage the 2 claws and 3 clips, and remove the center pillar lower garnish LH.

Fig. 145: Identifying Center Pillar Lower Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE CENTER PILLAR UPPER GARNISH LH a. Remove the 2 screws.

Fig. 146: Locating Center Pillar Upper Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clip. c. Pass the floor anchor of the front seat outer seat belt assembly LH through the center pillar upper garnish LH and remove the center pillar upper garnish LH. 25. REMOVE ROOF SIDE INNER GARNISH LH a. Disengage the 5 clips.

Fig. 147: Identifying Roof Side Inner Garnish LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the roof side inner garnish LH. 26. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 27. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side.

28. REMOVE LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedure as for the LH side. 29. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 30. REMOVE CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedure as for the LH side. 31. REMOVE CENTER PILLAR UPPER GARNISH RH HINT: Use the same procedure as for the LH side. 32. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 33. REMOVE FRONT SEAT ASSEMBLY LH for Manual Seat. Refer to REMOVAL for Power Seat. Refer to REMOVAL 34. REMOVE FRONT SEAT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 35. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to REMOVAL 36. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) . Refer to

37. 38. 39. 40. 41. 42.

REMOVAL - Step 2 REMOVE PROTECTOR . Refer to REMOVAL - Step 1 REMOVE ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) . Refer to REMOVAL - Step 1 REMOVE ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) . Refer to REMOVAL - Step 2 REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) . Refer to REMOVAL - Step 1 REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) . Refer to REMOVAL - Step 2 REMOVE ASSIST GRIP SUB-ASSEMBLY a. Using a screwdriver, disengage the 4 claws and remove the 2 assist grip covers.

Fig. 148: Identifying Assist Grip Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Do not forcibly pry the assist grip covers to prevent them from being deformed.

HINT: Tape the screwdriver tip before use. b. Disengage the 2 clips and remove the assist grip sub-assembly.

Fig. 149: Identifying Assist Grip Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 clips from the vehicle body. HINT: Use the same procedure for the RH side. 43. REMOVE REAR ASSIST GRIP ASSEMBLY LH a. Using a screwdriver, disengage the 4 claws and remove the 2 assist grip covers.

Fig. 150: Removing Rear Assist Grip Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Do not forcibly pry the assist grip covers to prevent them from being deformed.

HINT: Tape the screwdriver tip before use. b. Disengage the 2 clips and remove the rear assist grip assembly LH.

Fig. 151: Identifying Rear Assist Grip Assembly LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 clips from the vehicle body. 44. REMOVE REAR ASSIST GRIP ASSEMBLY RH HINT: Use the same procedure as for the LH side. 45. REMOVE SLIDING ROOF OPENING TRIM MOLDING (w/ Sliding Roof) a. Remove the sliding roof opening trim molding. 46. REMOVE VISOR BRACKET COVER (for LH Side) a. Using a molding remover, disengage the 4 claws and remove the visor bracket cover.

Fig. 152: Removing Visor Bracket Cover (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 47. REMOVE VISOR ASSEMBLY LH a. Remove the 2 screws and visor assembly LH.

Fig. 153: Identifying Visor Assembly LH Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 48. REMOVE VISOR BRACKET COVER (for RH Side) HINT: Use the same procedure as for the LH side. 49. REMOVE VISOR ASSEMBLY RH HINT: Use the same procedure as for the LH side. 50. REMOVE VISOR HOLDER a. Turn the visor holder approximately 45° and pull it out as shown in the illustration.

Fig. 154: Removing Visor Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and remove the visor holder.

HINT: Use the same procedure for the other visor holder. 51. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) a. w/ EC Mirror 1. Disconnect the connector from the inner rear view mirror assembly. b. Disconnect the connector from the air conditioning thermistor assembly. c. Remove the bolt and disconnect the bracket from the front pillar RH.

Fig. 155: Removing Roof Headlining Assembly (W/O Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. Disengage the 3 clamps from the front pillar RH. e. Disengage the 4 clamps from the front pillar LH.

f. w/o Satellite Radio: 1. Disengage the 2 clamps and disconnect the connector from the rear pillar RH. g. w/ Satellite Radio: 1. Disengage the 2 clamps and disconnect the 2 connectors from the rear pillar RH. h. Remove the 2 clips. i. Slide the roof headlining assembly to disengage the 2 clips as shown in the illustration. HINT: Leave the 2 clips in the vehicle. j. Remove the roof headlining assembly from the vehicle through the front door RH.

Fig. 156: Removing Roof Headlining Assembly From Vehicle (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

k. Remove the 2 clips from the vehicle body as shown in the illustration.

Fig. 157: Removing Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 52. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) a. w/ EC Mirror 1. Disconnect the connector from the inner rear view mirror assembly. b. Disconnect the connector from the air conditioning thermistor assembly. c. Disconnect the connector from the sliding roof drive gear assembly.

Fig. 158: Removing Roof Headlining Assembly (W/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. e. f. g. h. i. j. k.

Remove the bolt and disconnect the bracket from the front pillar RH. Disengage the 3 clamps from the front pillar RH. Disengage the 4 clamps from the front pillar LH. w/o Satellite Radio: 1. Disengage the 2 clamps and disconnect the connector from the rear pillar RH. w/ Satellite Radio: 1. Disengage the 2 clamps and disconnect the 2 connectors from the rear pillar RH. Remove the 2 clips. Disengage the 2 fasteners. Slide the roof headlining assembly to disengage the 2 clips as shown in the illustration.

HINT: Leave the 2 clips in the vehicle. l. Remove the roof headlining assembly from the vehicle through the front door RH.

Fig. 159: Removing Roof Headlining Assembly From Vehicle (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

m. Remove the 2 clips from the vehicle body as shown in the illustration.

Fig. 160: Removing Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE VANITY LIGHT ASSEMBLY (w/ Sliding Roof) a. Remove the vanity light assembly. Refer to REMOVAL - Step 2 . HINT: Use the same procedure for the other vanity light. 2. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY . Refer to REMOVAL - Step 6 3. REMOVE NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) a. Remove the 3 No. 4 roof silencer pads.

Fig. 161: Identifying No. 4 Roof Silencer Pads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE NO. 1 ROOF WIRE a. Remove the adhesive tape from the roof headlining assembly.

Fig. 162: Identifying Roof Headlining Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof w/o EC w/ EC *C *D Mirror Mirror Adhesive *1 - Tape b. w/ Sliding Roof: 1. Turn the visor connectors counterclockwise approximately 45° and separate the connectors from the roof headlining assembly. c. Remove the No. 1 roof wire from the roof headlining assembly.

Fig. 163: Identifying No. 1 Roof Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A w/o *B w/ Sliding Sliding

Roof

Roof

5. REMOVE NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) a. Remove the No. 2 roof silencer pad.

Fig. 164: Identifying No. 2 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) a. Align the markings on the roof headlining assembly with the No. 2 roof silencer pad and install a new pad using hot-melt glue as shown in the illustration.

Fig. 165: Identifying No. 2 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hot-

*1 Marking *2

melt Glue

2. INSTALL NO. 1 ROOF WIRE a. Apply double-sided tape as shown in the illustration.

Fig. 166: Identifying Double-Sided Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof Double*1 Marking *2 sided Tape

b. Peel off the release paper from the double-sided tape. c. Attach the No. 1 roof wire along the double-sided tape so that the marking surface of the wire harness faces downward. d. Align the pink marking tape (A) on the No. 1 roof wire with the vehicle front side tab on the roof headlining.

Fig. 167: Aligning The Pink Marking Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ w/o Sliding *A *B Sliding Roof Roof Pink Pink Marking *1 Marking *2 Tape Tape (A) (B) Pink *3 Marking *4 Marking Tape (C)

*5

Adjustment - Area

e. w/ Sliding Roof: 1. Turn the visor connector LH clockwise approximately 45° to install it to the roof headlining assembly. f. Align the edge of the pink marking tape (A) on the No. 1 roof wire with the markings on the roof headlining. g. Attach the No. 1 roof wire, starting from the pink marking tape (B) to the pink marking tape (A) while aligning it with the double-sided tape. NOTE:





Securely attach the No. 1 roof wire before the hot-melt glue cools. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

h. w/ Sliding Roof: 1. Turn the visor connector RH clockwise approximately 45° to install it to the roof headlining assembly. 2. Attach the No. 1 roof wire, starting from the visor connector RH to the pink marking tape (B) while aligning it with the double-sided tape. NOTE:

 

Securely attach the No. 1 roof wire. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

i. Align the edge of the pink marking tape (C) on the No. 1 roof wire with the markings on the roof headlining. j. Attach the No. 1 roof wire, starting from the pink marking tape (A) to the pink marking tape (C) while aligning it with the double-sided tape. NOTE:

 

Securely attach the No. 1 roof wire. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

HINT: Secure the extra length of the No. 1 roof wire in the adjustment area. k. Apply adhesive tape by aligning it with the markings on the roof headlining as shown in the

illustration.

Fig. 168: Identifying Adhesive Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tape w/o Attachment *A *B Sliding Location Roof (Reference) w/ Sliding w/o EC *C *D Roof Mirror w/ EC *E - Mirror Adhesive *1 *2 Marking Tape

Adhesive Tape Size X 20 mm (0.787 in.) Y 80 mm (3.15 in.) 3. INSTALL NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) a. Align the markings on the roof headlining assembly with the 3 No. 4 roof silencer pads and install 3 new pads using hot-melt glue as shown in the illustration.

Fig. 169: Identifying No. 4 Roof Silencer Pads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hot*1 Marking *2 melt Glue 4. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 5. INSTALL VANITY LIGHT ASSEMBLY (w/ Sliding Roof) a. Install the vanity light assembly. Refer to INSTALLATION - Step 1 . HINT: Use the same procedure for the other vanity light. INSTALLATION INSTALLATION

1. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) a. Install the 2 clips to the roof headlining assembly.

Fig. 170: Identifying Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1 (Black) Clip *2 (White) b. Put the roof headlining assembly into the vehicle through the front door RH.

Fig. 171: Installing Roof Headlining Assembly From Vehicle (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

c. Engage the 2 clips.

Fig. 172: Identifying Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. e. f. g.

Install the roof headlining assembly with the 2 clips. Engage the 4 clamps to the front pillar LH. Engage the 3 clamps to the front pillar RH. Connect the bracket with the bolt to the front pillar RH. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

h. w/o Satellite Radio: 1. Engage the 2 clamps and connect the connector to the rear pillar RH. i. w/ Satellite Radio: 1. Engage the 2 clamps and connect the 2 connectors to the rear pillar RH. j. Connect the connector to the air conditioning thermistor assembly.

k. w/ EC Mirror 1. Connect the connector to the inner rear view mirror assembly. 2. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) a. Install the 2 clips to the roof headlining assembly.

Fig. 173: Identifying Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1 (Black) Clip *2 (White) b. Put the roof headlining assembly into the vehicle through the front door RH.

Fig. 174: Installing Roof Headlining Assembly From Vehicle (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

c. Engage the 2 clips and 2 fasteners.

Fig. 175: Identifying Roof Headlining Assembly Clips And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. e. f. g.

Install the roof headlining assembly with the 2 clips. Engage the 4 clamps to the front pillar LH. Engage the 3 clamps to the front pillar RH. Connect the bracket with the bolt to the front pillar RH. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

h. w/o Satellite Radio: 1. Engage the 2 clamps and connect the connector to the rear pillar RH. i. w/ Satellite Radio: 1. Engage the 2 clamps and connect the 2 connectors to the rear pillar RH. j. Connect the connector to the sliding roof drive gear assembly.

k. Connect the connector to the air conditioning thermistor assembly. l. w/ EC Mirror 1. Connect the connector to the inner rear view mirror. 3. INSTALL VISOR HOLDER a. Engage the 2 claws.

Fig. 176: Installing Visor Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push in the visor holder as shown in the illustration. HINT: Use the same procedure for the other visor holder. 4. INSTALL VISOR ASSEMBLY LH a. Install the visor assembly LH with the 2 screws. 5. INSTALL VISOR BRACKET COVER (for LH Side) a. Engage the 4 claws to install the visor bracket cover.

Fig. 177: Identifying Visor Bracket Cover (For LH Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL VISOR ASSEMBLY RH HINT: Use the same procedure as for the LH side. 7. INSTALL VISOR BRACKET COVER (for RH Side) HINT: Use the same procedure as for the LH side. 8. INSTALL SLIDING ROOF OPENING TRIM MOLDING (w/ Sliding Roof) a. Align the alignment mark on the molding with the notch of the roof headlining to install the sliding roof opening trim molding.

Fig. 178: Identifying Sliding Roof Opening Trim Molding (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Notch Alignment *2 Mark NOTE:

After installation, check that the corners fit correctly.

9. INSTALL ASSIST GRIP SUB-ASSEMBLY a. Put a assist grip sub-assembly together as shown in the illustration.

Fig. 179: Identifying Assist Grip Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 clips to install the assist grip sub-assembly.

Fig. 180: Identifying Assist Grip Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 4 claws to install the 2 assist grip covers

Fig. 181: Identifying Assist Grip Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side. 10. INSTALL REAR ASSIST GRIP ASSEMBLY LH a. Put a rear assist grip assembly LH together as shown in the illustration.

Fig. 182: Identifying Rear Assist Grip Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 clips to install the rear assist grip assembly LH.

Fig. 183: Identifying Rear Assist Grip Assembly LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 4 claws to install the 2 assist grip covers

Fig. 184: Identifying Rear Assist Grip Assembly LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL REAR ASSIST GRIP ASSEMBLY RH HINT: Use the same procedure as for the LH side. 12. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) . Refer to INSTALLATION - Step 1 13. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) . Refer to INSTALLATION - Step 2 14. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) . Refer to INSTALLATION Step 2 15. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) . Refer to INSTALLATION Step 3 16. INSTALL PROTECTOR . Refer to INSTALLATION - Step 2 17. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) . Refer to INSTALLATION - Step 3 18. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION 19. INSTALL FRONT SEAT ASSEMBLY LH

for Manual Seat. Refer to INSTALLATION for Power Seat. Refer to INSTALLATION 20. INSTALL FRONT SEAT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 21. INSTALL ROOF SIDE INNER GARNISH LH a. Engage the guide. b. Engage the 5 clips to install the roof side inner garnish LH. 22. INSTALL CENTER PILLAR UPPER GARNISH LH a. Pass the floor anchor of the front seat outer seat belt assembly LH through the center pillar upper garnish LH. b. Engage the clip. c. Install the center pillar upper garnish LH with the 2 screws. 23. INSTALL CENTER PILLAR LOWER GARNISH LH a. Engage the 2 claws and 3 clips to install the center pillar lower garnish LH. 24. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 25. INSTALL LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to INSTALLATION Step 7 26. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Align the alignment mark (Pink) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the rear door opening trim weatherstrip LH.

Fig. 185: Identifying Rear Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Pink)

NOTE:

After installation, check that the corners fit correctly.

27. INSTALL REAR DOOR SCUFF PLATE LH a. Engage the 6 claws to install the rear door scuff plate LH. HINT: Engage the claws from the rear side of the scuff plate. 28. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 29. INSTALL CENTER PILLAR UPPER GARNISH RH HINT: Use the same procedure as for the LH side. 30. INSTALL CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedure as for the LH side. 31. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 32. INSTALL LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedure as for the LH side. 33. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH a. Align the alignment mark (Blue) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the rear door opening trim weatherstrip RH.

Fig. 186: Identifying Rear Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Blue)

NOTE:

After installation, check that the corners fit correctly.

34. INSTALL REAR DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 35. 36. 37. 38. 39. 40. 41. 42.

INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 INSTALL FRONT PILLAR GARNISH LH a. Remove the protective cover. b. Make sure that the front pillar garnish clip is not damaged. NOTE:

If there is any damage, replace the garnish clip with a new one.

c. Install the front pillar garnish clip to front pillar garnish LH.

Fig. 187: Installing Front Pillar Garnish LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Install the front pillar garnish clip so that it faces as shown in the illustration. d. Engage the 2 guides as shown in the illustration. e. Engage the 2 clips to install the front pillar garnish LH.

Fig. 188: Identifying Front Pillar Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 43. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Align the alignment mark (Yellow) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip LH.

Fig. 189: Identifying Front Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Yellow)

NOTE:

After installation, check that the corners fit correctly.

44. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH a. Insert the 2 clips in the direction indicated by the arrows shown in the illustration to engage them.

Fig. 190: Identifying Cowl Side Trim Sub-Assembly LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the cowl side trim sub-assembly LH with the clip. 45. INSTALL FRONT DOOR SCUFF PLATE LH a. Engage the 10 claws to install the front door scuff plate LH. 46. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. 47. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH a. Align the alignment mark (White) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip RH.

Fig. 191: Identifying Front Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (White)

NOTE:

After installation, check that the corners fit correctly.

48. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. 49. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 50. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

51. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 52. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

2012-2017 ACCESSORIES & EQUIPMENT Interior Trim (Service Information) (Except Hybrid) - Camry

INSTRUMENT PANEL SAFETY PAD PRECAUTION PRECAUTION

1. PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER a. Some operations in this information may affect the SRS airbags. Prior to performing the corresponding operations, read the precautions regarding the SRS airbags.  For Separate Type Yaw Rate Sensor. Refer to PRECAUTION .  For Built-in Type Yaw Rate Sensor. Refer to PRECAUTION . 2. TABLE OF BOLT, SCREW AND NUT HINT: All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with their alphabet codes in the table below. Code Shape





COMPONENTS ILLUSTRATION

Size Code Shape Size = 8 mm = 6 mm (0.315 in.) (0.236 in.)

Length = 15 mm Length = 20 mm (0.591 in.) (0.787 in.) = 5 mm = 5 mm (0.197 in.) (0.197 in.)

Length = 15 mm Length = 16 mm (0.591 in.) (0.630 in.) = 3 mm (0.118 in.) = 6 mm

Length = 12 mm (0.236 in.) (0.472 in.) = 6 mm (0.236 in.)

Fig. 1: Identifying Instrument Panel Safety Pad Replacement Components (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Instrument Panel Safety Pad Replacement Components (2 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Instrument Panel Safety Pad Replacement Components (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Instrument Panel Safety Pad Replacement Components (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 5: Identifying Instrument Panel Safety Pad Replacement Components With Torque Specifications (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 6: Identifying Instrument Panel Safety Pad Replacement Components With Torque Specifications (6 Of 7)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 7: Identifying Instrument Panel Safety Pad Replacement Components (7 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION Refer to PRECAUTION. NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE LH . See step 3. 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . See step 4. 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the front door opening trim weatherstrip LH.

Fig. 8: Identifying Front Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE INSTRUMENT SIDE PANEL LH a. Using a moulding remover, disengage the 4 claws as shown in the illustration.

Fig. 9: Disengaging Instrument Side Panel LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 guides and remove the instrument side panel LH as shown in the illustration.

Fig. 10: Disengaging Instrument Side Panel LH Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Disengage the 3 clips to remove the No. 1 instrument cluster finish panel garnish as shown in the illustration.

Fig. 11: Removing No. 1 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 12: Identifying Protective Tape Around No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Disengage the 2 clips as shown in the illustration.

Fig. 13: Removing No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a moulding remover, disengage the 2 clips to remove the No. 1 instrument panel register assembly.

Fig. 14: Identifying No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Operate the tilt and telescopic lever to fully extend and lower the steering column assembly. b. Using a moulding remover, disengage the 2 claws, 4 clips and 2 guides.

Fig. 15: Disengaging Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 5 claws, 5 clips and 2 guides.

Fig. 16: Identifying Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector. e. Remove the instrument cluster finish panel assembly as shown in the illustration.

Fig. 17: Removing Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE COMBINATION METER ASSEMBLY . Refer to REMOVAL - Step 8 . 11. REMOVE FRONT PANEL GARNISH LH a. Disengage the 3 claws, 2 clips and 8 guides to remove the front panel garnish LH.

Fig. 18: Identifying Front Panel Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Disengage the claw and 2 guides to disconnect the hood lock control lever sub-assembly.

Fig. 19: Identifying Hood Lock Control Lever Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Remove the bolt and screw or .

Fig. 20: Identifying Lower No. 1 Instrument Panel Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws, 9 clips and 3 guides to remove the lower No. 1 instrument panel finish panel assembly.

Fig. 21: Identifying Lower No. 1 Instrument Panel Finish Panel Assembly Claws, Clips And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE FRONT PANEL GARNISH RH a. Disengage the 3 claws, 2 clips and 8 guides to remove the front panel garnish RH.

Fig. 22: Identifying Front Panel Garnish RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY a. Turn the shift lever knob sub-assembly counterclockwise and remove the shift lever knob subassembly.

Fig. 23: Removing Shift Lever Knob Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY a. Move the shift lever to N. b. Disengage the 4 clips.

Fig. 24: Identifying Rear Console Upper Panel Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. w/ Seat heater System: 1. Disconnect the 2 connectors. d. Disconnect the connector and remove the rear console upper panel sub-assembly. 17. REMOVE CONSOLE BOX CUP HOLDER a. Remove the console box cup holder from the rear console upper panel sub-assembly.

Fig. 25: Identifying Console Box Cup Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE INSTRUMENT PANEL CUP HOLDER TRAY a. Remove the 6 screws and instrument panel cup holder tray.

Fig. 26: Locating Instrument Panel Cup Holder Tray Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

19. 20. 21. 22. 23.

b. Remove the front console upper panel garnish. REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY . See step 5. REMOVE NO. 4 CONSOLE BOX DUCT (w/ Rear Register Duct) . See step 6. REMOVE CONSOLE BOX CARPET . See step 7. REMOVE REAR CONSOLE BOX ASSEMBLY . See step 8. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Using a moulding remover, disengage the 2 claws and 2 clips as shown in the illustration.

Fig. 27: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a moulding remover, disengage the 2 claws and 2 clips as shown in the illustration.

Fig. 28: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 3 claws and 2 clips as shown in the illustration.

Fig. 29: Removing Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the clamp.

Fig. 30: Locating Center Instrument Cluster Finish Panel Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the connector to remove the center instrument cluster finish panel assembly. 24. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY a. Pull the No. 2 instrument panel register assembly in the direction indicated by the arrow to disengage the 6 clips to remove the No. 2 instrument panel register assembly.

Fig. 31: Removing No. 2 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE BOX BOTTOM MAT a. Remove the box bottom mat.

Fig. 32: Identifying Box Bottom Mat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 33: Locating Upper Console Panel Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and guide as shown in the illustration.

Fig. 34: Removing Upper Console Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

27. 28. 29. 30.

c. Disconnect each connector to remove the upper console panel sub-assembly. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 8 . REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 9 . REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 8 . REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY

a. Disengage the 8 clips as shown in the illustration.

Fig. 35: Removing No. 1 Speaker Opening Cover Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector to remove the No. 1 speaker opening cover assembly. 31. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) . Refer to REMOVAL - Step 15 . 32. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. See step 3. 33. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT: Use the same procedure as for the LH side. See step 4. 34. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH a. Disconnect the front door opening trim weatherstrip RH.

Fig. 36: Identifying Front Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE INSTRUMENT SIDE PANEL RH a. Using a moulding remover, disengage the 4 claws as shown in the illustration.

Fig. 37: Disengaging Instrument Side Panel RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 guides to remove the instrument side panel RH as shown in the illustration.

Fig. 38: Disengaging Instrument Side Panel RH Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 36. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY a. Disengage the 4 claws.

Fig. 39: Identifying No. 2 Instrument Panel Under Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the No. 2 instrument panel under cover sub-assembly. 37. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 8 . 38. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 40: Locating Lower Instrument Panel Sub-Assembly Lower Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Open the lower instrument panel door. c. Remove the 3 screws or .

Fig. 41: Locating Lower Instrument Panel Sub-Assembly Upper Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 clips and guide.

Fig. 42: Removing Lower Instrument Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage the glove compartment light as shown in the illustration.

Fig. 43: Removing Glove Compartment Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disconnect each connector and remove the lower instrument panel sub-assembly. 39. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Disengage the 5 clips to remove the No. 2 instrument cluster finish panel garnish as shown in the illustration.

Fig. 44: Removing No. 2 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 40. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 45: Identifying Protective Tape Around No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Disengage the 2 clips as shown in the illustration.

Fig. 46: Removing No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a moulding remover, disengage the 2 clips to remove the No. 3 instrument panel register assembly.

Fig. 47: Removing No. 3 Instrument Panel Register Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 41. REMOVE FRONT PILLAR GARNISH LH . See step 6. 42. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 48: Identifying Protective Tape Around No. 1 Instrument Panel Speaker Panel SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a moulding remover, disengage the 2 clips and 3 claws.

Fig. 49: Identifying No. 1 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides to remove the No. 1 instrument panel speaker panel sub-assembly. 43. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) . Refer to REMOVAL - Step 5 . 44. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. See step 6. 45. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 50: Identifying Protective Tape Around No. 2 Instrument Panel Speaker Panel SubAssembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Using a moulding remover, disengage the 2 clips and 3 claws.

Fig. 51: Identifying No. 2 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 guides to remove the No. 2 instrument panel speaker panel sub-assembly. 46. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 5 . 47. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Disengage the 4 clips to remove the lower instrument panel finish panel assembly.

Fig. 52: Identifying Lower Instrument Panel Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. w/ Smart Key System: 1. Disconnect the connector. 48. REMOVE FRONT NO. 2 CONSOLE BOX INSERT a. Disengage the 2 claws to disconnect the room temperature sensor from the front No. 2 console box insert.

Fig. 53: Locating Room Temperature Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 screws or .

Fig. 54: Identifying Front No. 2 Console Box Insert Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clip and 3 guides to remove the front No. 2 console box insert as shown in the illustration.

Fig. 55: Removing Front No. 2 Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 49. REMOVE CONSOLE BOX INSERT a. Remove the 2 screws or .

Fig. 56: Identifying Console Box Insert Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clip and 3 guides to remove the console box insert as shown in the illustration.

Fig. 57: Removing Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 50. REMOVE NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Disengage the 10 clips to remove the No. 1 instrument panel garnish sub-assembly as shown in the illustration.

Fig. 58: Removing No. 1 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 51. DISCONNECT NO. 2 INSTRUMENT PANEL WIRE . Refer to REMOVAL - Step 3 . 52. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY a. Disconnect each connector.

Fig. 59: Locating Instrument Panel Safety Pad Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage each clamp. c. Remove the 2 passenger airbag bolts .

Fig. 60: Locating Instrument Panel Safety Pad Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Passenger Bolt *1 Airbag *2

Bolt Nut *3 *4 Clip or d. Remove the 3 bolts and nut or . e. Remove the 2 clips. f. Disengage the 5 guides and remove the instrument panel safety pad assembly as shown in the illustration.

Fig. 61: Removing Instrument Panel Safety Pad Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not damage the instrument panel safety pad assembly. Do not allow the wire harnesses to interfere with the surrounding parts.

DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 INSTRUMENT PANEL PIN a. Remove the 4 screws or and 4 No. 1 instrument panel pins.

Fig. 62: Locating No. 1 Instrument Panel Pin Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY . Refer to REMOVAL Step 5 . 3. REMOVE NO. 1 HEATER TO REGISTER DUCT a. Remove the clip.

Fig. 63: Locating No. 1 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws or and No. 1 heater to register duct. 4. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT a. Remove the screw or .

Fig. 64: Locating No. 1 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the No. 1 side defroster nozzle duct. 5. REMOVE NO. 3 HEATER TO REGISTER DUCT a. Remove the clip.

Fig. 65: Locating No. 3 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 screws or and No. 3 heater to register duct. 6. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT a. Remove the screw or .

Fig. 66: Locating No. 2 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the No. 2 side defroster nozzle duct. 7. REMOVE ANTENNA CORD SUB-ASSEMBLY . Refer to REMOVAL - Step 4 . 8. REMOVE DEFROSTER NOZZLE ASSEMBLY a. Remove the 3 screws or .

Fig. 67: Locating Defroster Nozzle Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the defroster nozzle assembly. 9. REMOVE NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) . Refer to REMOVAL Step 7 . 10. REMOVE NO. 2 HEATER TO REGISTER DUCT a. Remove the 2 screws or and No. 2 heater to register duct.

Fig. 68: Locating No. 2 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 2 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Remove the 2 screws or .

Fig. 69: Locating No. 2 Instrument Panel Garnish Sub-Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply protective tape to the areas shown in the illustration.

Fig. 70: Identifying Protective Tape Around No. 2 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 -Tape c. Disengage the 5 clips as shown in the illustration.

d. Using a moulding remover, disengage the 8 clips to remove the No. 2 instrument panel garnish subassembly as shown in the illustration. REASSEMBLY REASSEMBLY

1. INSTALL NO. 2 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Engage the 13 clips.

Fig. 71: Identifying No. 2 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 2 instrument panel garnish sub-assembly with the 2 screws or .

Fig. 72: Locating No. 2 Instrument Panel Garnish Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 HEATER TO REGISTER DUCT a. Install the No. 2 heater to register duct with the 2 screws or .

Fig. 73: Locating No. 2 Heater To Register Duct Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) . Refer to INSTALLATION - Step 1 . 4. INSTALL DEFROSTER NOZZLE ASSEMBLY a. Engage the 2 guides.

Fig. 74: Locating Defroster Nozzle Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the defroster nozzle assembly with the 3 screws or . 5. INSTALL ANTENNA CORD SUB-ASSEMBLY . Refer to INSTALLATION - Step 3 . 6. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT a. Engage the 2 claws.

Fig. 75: Locating No. 2 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 2 side defroster nozzle duct with the screw or . 7. INSTALL NO. 3 HEATER TO REGISTER DUCT a. Install the No. 3 heater to register duct with the 3 screws or .

Fig. 76: Locating No. 3 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clip. 8. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT a. Engage the 2 claws.

Fig. 77: Locating No. 1 Side Defroster Nozzle Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 1 side defroster nozzle duct with the screw or . 9. INSTALL NO. 1 HEATER TO REGISTER DUCT a. Install the No. 1 heater to register duct with the 3 screws or .

Fig. 78: Locating No. 1 Heater To Register Duct Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the clip. 10. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 2 . 11. INSTALL NO. 1 INSTRUMENT PANEL PIN a. Install the 4 No. 1 instrument panel pins with the 4 screws or .

Fig. 79: Locating No. 1 Instrument Panel Pin Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION

INSTALLATION

1. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY a. Engage the 5 guides and temporarily install the instrument panel safety pad assembly as shown in the illustration.

Fig. 80: Installing Instrument Panel Safety Pad Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not damage the instrument panel safety pad assembly. Do not allow the wire harnesses to interfere with the surrounding parts.

b. Install the 2 clips. c. Install the 3 bolts and nut or . d. Install the 2 passenger airbag bolts . Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) e. Engage each clamp. f. Connect each connector. 2. CONNECT NO. 2 INSTRUMENT PANEL WIRE . Refer to INSTALLATION - Step 4 . 3. INSTALL NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY a. Engage the 10 clips to install the No. 1 instrument panel garnish sub-assembly.

Fig. 81: Installing No. 1 Instrument Panel Garnish Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL CONSOLE BOX INSERT a. Engage the clip and 3 guides.

Fig. 82: Installing Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the console box insert with the 2 screws or . 5. INSTALL FRONT NO. 2 CONSOLE BOX INSERT a. Engage the clip and 3 guides.

Fig. 83: Installing Front No. 2 Console Box Insert Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the front No. 2 console box insert with the 2 screws or . c. Engage the 2 claws to connect the room temperature sensor. 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. w/ Smart Key System: 1. Connect the connector. b. Engage the 4 clips to install the lower instrument panel finish panel assembly. 7. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) . Refer to INSTALLATION - Step 1. 8. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Engage the 2 guides.

Fig. 84: Identifying No. 1 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws and 2 clips to install the No. 1 instrument panel speaker panel sub-assembly. 9. INSTALL FRONT PILLAR GARNISH LH . See step 41. 10. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 1 . 11. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY a. Engage the 2 guides.

Fig. 85: Identifying No. 2 Instrument Panel Speaker Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 3 claws and 2 clips to install the No. 2 instrument panel speaker panel sub-assembly. 12. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. See step 41. 13. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 4 clips to install the No. 3 instrument panel register assembly.

Fig. 86: Identifying No. 3 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Engage the 5 clips to install the No. 2 instrument cluster finish panel garnish.

Fig. 87: Identifying No. 2 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY a. Connect each connector. b. Engage the glove compartment light as shown in the illustration.

Fig. 88: Installing Glove Compartment Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the guide and 2 clips.

Fig. 89: Identifying Lower Instrument Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the lower instrument panel sub-assembly with the 5 screws or . 16. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 17. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY a. Engage the 2 guides and 4 claws to install the No. 2 instrument panel under cover sub-assembly. 18. INSTALL INSTRUMENT SIDE PANEL RH a. Engage the 3 guides. b. Engage the 4 claws to install the instrument side panel RH as shown in the illustration.

Fig. 90: Engaging Instrument Side Panel RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH . See step 46. 20. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. See step 43. 21. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. See step 44.

22. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) . Refer to INSTALLATION Step 5 . 23. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY a. Connect the connector. b. Engage the 8 clips to install the No. 1 speaker opening cover assembly.

Fig. 91: Identifying No. 1 Speaker Opening Cover Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 . 25. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 . 26. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 .

27. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY a. Connect each connector. b. Engage the 4 clips and guide. c. Install the upper console panel sub-assembly with the 2 screws or . 28. INSTALL BOX BOTTOM MAT a. Install the box bottom mat. 29. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 6 clips to install the No. 2 instrument panel register assembly.

Fig. 92: Identifying No. 2 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When installing the No. 2 instrument panel register assembly, check that the wire harness is not caught between the No. 2 instrument

panel register assembly and duct. 30. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Connect the connector. b. Engage the clamp. c. Engage the 6 clips and 7 claws to install the center instrument cluster finish panel assembly.

Fig. 93: Identifying Center Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. 32. 33. 34. 35.

INSTALL REAR CONSOLE BOX ASSEMBLY . See step 1. INSTALL CONSOLE BOX CARPET . See step 2. INSTALL NO. 4 CONSOLE BOX DUCT (w/ Rear Register Duct) . See step 3. INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY . See step 4. INSTALL CONSOLE BOX CUP HOLDER a. Install the console box cup holder to the instrument panel cup holder tray. 36. INSTALL INSTRUMENT PANEL CUP HOLDER TRAY a. Install the front console upper panel garnish. b. Install the instrument panel cup holder tray and front console upper panel garnish with the 6 screws or . 37. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY a. Connect the connector. b. w/ Seat Heater System:

1. Connect the 2 connectors. c. Engage the 4 clips and install the rear console upper panel sub-assembly. d. Move the shift lever to P. 38. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY a. Turn the shift lever knob sub-assembly clockwise to install the shift lever knob sub-assembly.

Fig. 94: Installing Shift Lever Knob Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 39. INSTALL FRONT PANEL GARNISH RH a. Engage the 3 claws, 2 clips and 8 guides to install the front panel garnish RH. 40. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY a. Engage the 4 claws, 9 clips and 3 guides. b. Install the lower No. 1 instrument panel finish panel assembly with the bolt and screw or . 41. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY a. Engage the claw and 2 guides to connect the hood lock control lever sub-assembly. 42. INSTALL FRONT PANEL GARNISH LH a. Engage the 3 claws, 2 clips and 8 guides to install the front panel garnish LH. 43. INSTALL COMBINATION METER ASSEMBLY . Refer to INSTALLATION - Step 1 . 44. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY a. Temporarily install the instrument cluster finish panel assembly as shown in the illustration.

Fig. 95: Installing Instrument Cluster Finish Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect each connector. c. Engage the 5 claws, 5 clips and 2 guides, and install the instrument cluster finish panel assembly. d. Engage the 2 claws, 4 clips and 2 guides.

Fig. 96: Engaging Instrument Cluster Finish Panel Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 45. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY a. Engage the 4 clips to install the No. 1 instrument panel register assembly.

Fig. 97: Identifying No. 1 Instrument Panel Register Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 46. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH a. Engage the 3 clips to install the No. 1 instrument cluster finish panel garnish.

Fig. 98: Identifying No. 1 Instrument Cluster Finish Panel Garnish Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 47. INSTALL INSTRUMENT SIDE PANEL LH a. Engage the 3 guides. b. Engage the 4 claws to install the instrument side panel LH as shown in the illustration.

Fig. 99: Engaging Instrument Side Panel LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 48. 49. 50. 51.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . See step 42. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . See step 43. INSTALL FRONT DOOR SCUFF PLATE LH . See step 44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

52. INSPECT SRS WARNING LIGHT  For Separate Type Yaw Rate Sensor. Refer to DIAGNOSIS SYSTEM .  For Built-in Type Yaw Rate Sensor. Refer to DIAGNOSIS SYSTEM .

FRONT CONSOLE BOX COMPONENTS ILLUSTRATION

Fig. 100: Identifying Front Console Box Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 101: Identifying Front Console Box Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH . See step 11. REMOVE FRONT PANEL GARNISH RH . See step 14. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . See step 15. REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . See step 16. REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY a. Remove the 2 screws.

Fig. 102: Locating Upper Console Box Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 clips and remove the upper console box sub-assembly as shown in the illustration.

Fig. 103: Removing Upper Console Box Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. w/ Power Outlet Socket: 1. Disengage the clamp.

Fig. 104: Locating Upper Console Box Sub-Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect the connector to remove the upper console box sub-assembly. 6. REMOVE NO. 4 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Disengage the claw and remove the No. 4 console box duct.

Fig. 105: Locating No. 4 Console Box Duct (w/ Rear Register Duct) Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE CONSOLE BOX CARPET a. Remove the console box carpet.

Fig. 106: Identifying Console Box Carpet Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR CONSOLE BOX ASSEMBLY a. Remove the 2 bolts and 2 screws.

Fig. 107: Locating Rear Console Box Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the rear console box assembly in the direction indicated by the arrow to disengage the 4 guides and remove the rear console box assembly.

Fig. 108: Removing Rear Console Box Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY a. Disengage the 4 claws and 4 clips to remove the console rear end panel sub-assembly.

Fig. 109: Identifying Console Rear End Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE REAR CONSOLE ARMREST ASSEMBLY a. Using a screwdriver, remove the 2 E-rings.

Fig. 110: Locating Rear Console Armrest Assembly E-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to allow the E-rings to pop out when removing them.

b. Using a screwdriver, pull out the 2 box door hinge shafts.

Fig. 111: Removing Rear Console Armrest Assembly Hinge Shafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use.  The illustration is for the LH side.  Use the same procedure for the RH side and LH side. c. Remove the rear console armrest assembly. 3. REMOVE CONSOLE COMPARTMENT DOOR LOCK SUB-ASSEMBLY a. Remove the 2 screws. 

Fig. 112: Locating Console Compartment Door Lock Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 8 claws.

Fig. 113: Locating Console Compartment Door Lock Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Tape the screwdriver tip before use. c. Disengage the 2 guides to remove the console compartment door lock sub-assembly as shown in the illustration.

Fig. 114: Removing Console Compartment Door Lock Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE CONSOLE COMPARTMENT DOOR CUSHION a. Remove the 4 console compartment door cushions from the console compartment door lock subassembly.

Fig. 115: Locating Console Compartment Door Cushion Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL CONSOLE COMPARTMENT DOOR CUSHION a. Install the 4 console compartment door cushions to the console compartment door lock subassembly.

Fig. 116: Locating Console Compartment Door Cushion Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL CONSOLE COMPARTMENT DOOR LOCK SUB-ASSEMBLY a. Engage the 2 guides and temporarily install the console compartment door lock sub-assembly as shown in the illustration.

Fig. 117: Installing Console Compartment Door Lock Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 8 claws.

Fig. 118: Locating Console Compartment Door Lock Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the console compartment door lock sub-assembly with the 2 screws.

Fig. 119: Locating Console Compartment Door Lock Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR CONSOLE ARMREST ASSEMBLY a. Temporarily install the rear console armrest assembly. b. Push in the 2 box door hinge shafts by hand as far as possible.

Fig. 120: Installing Rear Console Armrest Assembly Hinge Shafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The illustration is for the LH side.  Use the same procedure for the RH side and LH side. c. Using pliers, push in the 2 box door hinge shafts completely. 

Fig. 121: Installing Rear Console Armrest Assembly Hinge Shafts Using Pliers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the tips of the pliers before use.  The illustration is for the LH side.  Use the same procedure for the RH side and LH side. d. Install the rear console armrest assembly with the 2 E-rings. 

Fig. 122: Locating Rear Console Armrest Assembly E-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY a. Engage the 4 claws and 4 clips to install the console rear end panel sub-assembly.

Fig. 123: Identifying Console Rear End Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL REAR CONSOLE BOX ASSEMBLY a. Engage the 4 guides as shown in the illustration.

Fig. 124: Installing Rear Console Box Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear console box assembly with the 2 bolts and 2 screws. 2. INSTALL CONSOLE BOX CARPET a. Install the console box carpet. 3. INSTALL NO. 4 CONSOLE BOX DUCT (w/ Rear Register Duct) a. Engage the claw to install the No. 4 console box duct. 4. INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY a. w/ Power Outlet Socket: 1. Connect the connector. 2. Engage the clamp. b. Engage the 4 clips as shown in the illustration.

Fig. 125: Installing Upper Console Box Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5. 6. 7. 8.

c. Install the upper console box sub-assembly with the 2 screws. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . See step 37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . See step 38. INSTALL FRONT PANEL GARNISH RH . See step 39. INSTALL FRONT PANEL GARNISH LH . See step 42.

ROOF HEADLINING COMPONENTS ILLUSTRATION

Fig. 126: Identifying Roof Headlining Replacement Components (1 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 127: Identifying Roof Headlining Replacement Components (2 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 128: Identifying Roof Headlining Replacement Components With Torque Specifications (3 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 129: Identifying Roof Headlining Replacement Components With Torque Specifications (4 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 130: Identifying Roof Headlining Replacement Components With Torque Specifications (5 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 131: Identifying Roof Headlining Replacement Components (6 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 132: Identifying Roof Headlining Replacement Components (7 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 133: Identifying Roof Headlining Replacement Components (8 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 134: Identifying Roof Headlining Replacement Components With Torque Specifications (9 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 135: Identifying Roof Headlining Replacement Components (10 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 136: Identifying Roof Headlining Replacement Components (11 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 137: Identifying Roof Headlining Replacement Components (12 Of 12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore,

make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE LH a. Disengage the 10 claws and remove the front door scuff plate LH.

Fig. 138: Identifying Front Door Scuff Plate LH Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH a. Remove the clip.

Fig. 139: Removing Cowl Side Trim Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clips and remove the cowl side trim sub-assembly LH. 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Remove the front door opening trim weatherstrip LH. 6. REMOVE FRONT PILLAR GARNISH LH a. Pull the upper part of the garnish toward the inside of the cabin and disengage the garnish from the base of the 2 clips.

Fig. 140: Identifying Front Pillar Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Pillar *1 Garnish Clip HINT: Make the front pillar garnish LH hang down from the front pillar garnish clip. b. While pushing the tabs on the front pillar garnish clip in the direction indicated by the arrow (A) shown in the illustration, disengage the front pillar garnish clip.

Fig. 141: Removing Front Pillar Garnish LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the garnish in the direction indicated by the arrow (B) shown in the illustration to disengage the 2 guides and remove the front pillar garnish LH. d. Protect the curtain shield airbag assembly.

Fig. 142: Identifying Curtain Shield Airbag Assembly With Protective Cover And Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Adhesive *1 Tape Protective *2 Cover Curtain Shield *3 Airbag Assembly 1. Cover the airbag with a piece of cloth or nylon and secure the edges of the cover with tape as shown in the illustration. NOTE:

Cover the curtain shield airbag with a protective cover as soon as the front pillar garnish is removed.

7. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT: Use the same procedure as for the LH side. 9. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side. 10. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. 11. 12. 13. 14. 15. 16. 17. 18.

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 7 . REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR DOOR SCUFF PLATE LH a. Disengage the 6 claws and remove the rear door scuff plate LH.

Fig. 143: Identifying Rear Door Scuff Plate LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Disengage the claws from the rear side of the scuff plate. 19. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Remove the rear door opening trim weatherstrip LH. 20. REMOVE LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to REMOVAL - Step 7 . 21. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 8 . 22. REMOVE CENTER PILLAR LOWER GARNISH LH a. Disengage the 2 claws and 3 clips, and remove the center pillar lower garnish LH.

Fig. 144: Identifying Center Pillar Lower Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE CENTER PILLAR UPPER GARNISH LH a. Remove the 2 screws.

Fig. 145: Locating Center Pillar Upper Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clip. c. Pass the floor anchor of the front seat outer seat belt assembly LH through the center pillar upper garnish LH and remove the center pillar upper garnish LH. 24. REMOVE ROOF SIDE INNER GARNISH LH a. Disengage the 5 clips.

Fig. 146: Identifying Roof Side Inner Garnish LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the roof side inner garnish LH. 25. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 26. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side.

27. REMOVE LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedure as for the LH side. 28. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 29. REMOVE CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedure as for the LH side. 30. REMOVE CENTER PILLAR UPPER GARNISH RH HINT: Use the same procedure as for the LH side. 31. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 32. REMOVE FRONT SEAT ASSEMBLY LH For TMMK Made Manual Seat. Refer to REMOVAL . For TMMK Made Power Seat. Refer to REMOVAL . For SIA Made Manual Seat. Refer to REMOVAL . For SIA Made Power Seat. Refer to REMOVAL . 33. REMOVE FRONT SEAT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 34. REMOVE INSTRUMENT PANEL ASSEMBLY

Refer to REMOVAL. 35. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) . Refer to REMOVAL - Step 2 . 36. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) . Refer to REMOVAL - Step 1 . 37. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) . Refer to REMOVAL - Step 2 . 38. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) . Refer to REMOVAL - Step 1 . 39. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) . Refer to REMOVAL - Step 2 . 40. REMOVE ASSIST GRIP SUB-ASSEMBLY a. Using a screwdriver, disengage the 4 claws and remove the 2 assist grip covers.

Fig. 147: Identifying Assist Grip Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Do not forcibly pry the assist grip covers to prevent them from being deformed.

HINT: Tape the screwdriver tip before use.

b. Disengage the 2 clips and remove the assist grip sub-assembly.

Fig. 148: Identifying Assist Grip Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 clips from the vehicle body. HINT: Use the same procedure for the RH side. 41. REMOVE REAR ASSIST GRIP ASSEMBLY LH a. Using a screwdriver, disengage the 4 claws and remove the 2 assist grip covers.

Fig. 149: Removing Rear Assist Grip Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Do not forcibly pry the assist grip covers to prevent them from being deformed.

HINT: Tape the screwdriver tip before use. b. Disengage the 2 clips and remove the rear assist grip assembly LH.

Fig. 150: Identifying Rear Assist Grip Assembly LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 clips from the vehicle body. 42. REMOVE REAR ASSIST GRIP ASSEMBLY RH HINT: Use the same procedure as for the LH side. 43. REMOVE SLIDING ROOF OPENING TRIM MOULDING (w/ Sliding Roof) a. Remove the sliding roof opening trim moulding. 44. REMOVE VISOR BRACKET COVER (for LH Side) a. Using a moulding remover, disengage the 4 claws and remove the visor bracket cover.

Fig. 151: Removing Visor Bracket Cover (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 45. REMOVE VISOR ASSEMBLY LH a. Remove the 2 screws and visor assembly LH.

Fig. 152: Identifying Visor Assembly LH Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 46. REMOVE VISOR BRACKET COVER (for RH Side) HINT: Use the same procedure as for the LH side. 47. REMOVE VISOR ASSEMBLY RH HINT: Use the same procedure as for the LH side. 48. REMOVE VISOR HOLDER a. Turn the visor holder approximately 45° and pull it out as shown in the illustration.

Fig. 153: Removing Visor Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and remove the visor holder.

HINT: Use the same procedure for the other visor holder. 49. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) a. w/ EC Mirror 1. Disconnect the connector from the inner rear view mirror. b. Remove the bolt and disconnect the bracket from the front pillar RH.

Fig. 154: Removing Roof Headlining Assembly (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio c. Disengage the 3 clamps from the front pillar RH. d. Disengage the 4 clamps from the front pillar LH. e. w/o Satellite Radio:

1. Disengage the 2 clamps and disconnect the connector from the rear pillar RH. f. w/ Satellite Radio: 1. Disengage the 2 clamps and disconnect the 2 connectors from the rear pillar RH. g. Remove the 2 clips. h. Slide the roof headlining assembly to disengage the 2 clips as shown in the illustration. HINT: Leave the 2 clips in the vehicle. i. Remove the roof headlining assembly from the vehicle through the front door RH.

Fig. 155: Removing Roof Headlining Assembly From Vehicle (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

j. Remove the 2 clips from the vehicle body as shown in the illustration.

Fig. 156: Removing Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 50. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) a. w/ EC Mirror 1. Disconnect the connector from the inner rear view mirror. b. Disconnect the connector from the sliding roof drive gear assembly.

Fig. 157: Removing Roof Headlining Assembly (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio c. d. e. f. g. h. i. j.

Remove the bolt and disconnect the bracket from the front pillar RH. Disengage the 3 clamps from the front pillar RH. Disengage the 4 clamps from the front pillar LH. w/o Satellite Radio: 1. Disengage the 2 clamps and disconnect the connector from the rear pillar RH. w/ Satellite Radio: 1. Disengage the 2 clamps and disconnect the 2 connectors from the rear pillar RH. Remove the 2 clips. Disengage the 2 fasteners. Slide the roof headlining assembly to disengage the 2 clips as shown in the illustration.

HINT: Leave the 2 clips in the vehicle. k. Remove the roof headlining assembly from the vehicle through the front door RH.

Fig. 158: Removing Roof Headlining Assembly From Vehicle (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

l. Remove the 2 clips from the vehicle body as shown in the illustration.

Fig. 159: Removing Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE VANITY LIGHT ASSEMBLY (w/ Sliding Roof) a. Remove the vanity light assembly. Refer to REMOVAL - Step 2 . HINT: Use the same procedure for the other vanity light. 2. REMOVE NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) a. Remove the 3 No. 4 roof silencer pads.

Fig. 160: Identifying No. 4 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY . Refer to REMOVAL - Step 6 . 4. REMOVE NO. 1 ROOF WIRE a. Remove the adhesive tape from the roof headlining assembly.

Fig. 161: Identifying No. 1 Roof Wire Adhesive Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof w/o EC w/ EC *C *D Mirror Mirror Adhesive *1 - Tape b. w/ Sliding Roof: 1. Turn the visor connectors counterclockwise approximately 45° and separate the connectors from the roof headlining assembly. c. Remove the No. 1 roof wire from the roof headlining assembly.

Fig. 162: Identifying No. 1 Roof Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A w/o *B w/ Sliding Sliding

Roof

Roof

5. REMOVE NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) a. Remove the No. 2 roof silencer pad.

Fig. 163: Identifying No. 2 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) a. Align the markings on the roof headlining assembly with the No. 2 roof silencer pad and install the pad using hot-melt glue as shown in the illustration.

Fig. 164: Identifying No. 2 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hot-

*1 Marking *2

melt Glue

2. INSTALL NO. 1 ROOF WIRE a. Apply double-sided tape as shown in the illustration.

Fig. 165: Identifying No. 1 Roof Wire Double-Sided Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Sliding *B Sliding Roof Roof Hot*1 Marking *2 melt Glue

b. Peel off the release paper from the double-sided tape. c. Attach the No. 1 roof wire along the double-sided tape so that the marking surface of the wire harness faces downward. d. Align the pink marking tape (A) on the No. 1 roof wire with the vehicle front side tab on the roof headlining.

Fig. 166: Identifying No. 1 Roof Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/ w/o Sliding *A *B Sliding Roof Roof Pink Pink Marking *1 Marking *2 Tape Tape (A) (B) Pink *3 Marking *4 Marking Tape (C)

*5

Adjustment - Area

e. w/ Sliding Roof: 1. Turn the visor connector LH clockwise approximately 45° to install it to the roof headlining assembly. f. Align the edge of the pink marking tape (A) on the No. 1 roof wire with the markings on the roof headlining. g. Attach the No. 1 roof wire, starting from the pink marking tape (B) to the pink marking tape (A) while aligning it with the double-sided tape. NOTE:





Securely attach the No. 1 roof wire before the hot-melt glue cools. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

h. w/ Sliding Roof: 1. Turn the visor connector RH clockwise approximately 45° to install it to the roof headlining assembly. 2. Attach the No. 1 roof wire, starting from the visor connector RH to the pink marking tape (B) while aligning it with the double-sided tape. NOTE:

 

Securely attach the No. 1 roof wire. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

i. Align the edge of the pink marking tape (C) on the No. 1 roof wire with the markings on the roof headlining. j. Attach the No. 1 roof wire, starting from the pink marking tape (A) to the pink marking tape (C) while aligning it with the double-sided tape. NOTE:

 

Securely attach the No. 1 roof wire. If any of the No. 1 roof wire is left loose, this will cause abnormal noise. Make sure to attach the No. 1 roof wire without leaving any of it loose.

HINT: Secure the extra length of the No. 1 roof wire in the adjustment area. k. Apply adhesive tape by aligning it with the markings on the roof headlining as shown in the

illustration.

Fig. 167: Identifying No. 1 Roof Wire Double-Sided Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tape w/o Attachment *A *B Sliding Location Roof (Reference) w/ Sliding w/o EC *C *D Roof Mirror w/ EC *E - Mirror Adhesive *1 *2 Marking Tape

Adhesive Tape Size X 20 mm (0.787 in.) Y 80 mm (3.15 in.) 3. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY . Refer to INSTALLATION - Step 1 . 4. INSTALL NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) a. Align the markings on the roof headlining assembly with the 3 No. 4 roof silencer pads and install the pads using hot-melt glue as shown in the illustration.

Fig. 168: Identifying No. 4 Roof Silencer Pad (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hot*1 Marking *2 melt Glue 5. INSTALL VANITY LIGHT ASSEMBLY (w/ Sliding Roof) a. Install the vanity light assembly. Refer to INSTALLATION - Step 1 . HINT: Use the same procedure for the other vanity light. INSTALLATION INSTALLATION

1. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) a. Install the 2 clips to the roof headlining assembly.

Fig. 169: Identifying Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1 (Black) Clip *2 (White) b. Put the roof headlining assembly into the vehicle through the front door RH.

Fig. 170: Installing Roof Headlining Assembly From Vehicle (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

c. Engage the 2 clips.

Fig. 171: Identifying Roof Headlining Assembly (w/o Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. e. f. g.

Install the roof headlining assembly with the 2 clips. Engage the 4 clamps to the front pillar LH. Engage the 3 clamps to the front pillar RH. Connect the bracket with the bolt to the front pillar RH. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

h. w/o Satellite Radio: 1. Engage the 2 clamps and connect the connector to the rear pillar RH. i. w/ Satellite Radio: 1. Engage the 2 clamps and connect the 2 connectors to the rear pillar RH. j. w/ EC Mirror

1. Connect the connector to the inner rear view mirror. 2. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) a. Install the 2 clips to the roof headlining assembly.

Fig. 172: Identifying Roof Headlining Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clip *1 (Black) Clip *2 (White) b. Put the roof headlining assembly into the vehicle through the front door RH.

Fig. 173: Installing Roof Headlining Assembly From Vehicle (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the roof headlining assembly or body interior.

c. Engage the 2 clips and 2 fasteners.

Fig. 174: Identifying Roof Headlining Assembly (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ *A Satellite *B Satellite Radio Radio d. e. f. g.

Install the roof headlining assembly with the 2 clips. Engage the 4 clamps to the front pillar LH. Engage the 3 clamps to the front pillar RH. Connect the bracket with the bolt to the front pillar RH. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

h. w/o Satellite Radio: 1. Engage the 2 clamps and connect the connector to the rear pillar RH. i. w/ Satellite Radio: 1. Engage the 2 clamps and connect the 2 connectors to the rear pillar RH. j. Connect the connector to the sliding roof drive gear assembly.

k. w/ EC Mirror 1. Connect the connector to the inner rear view mirror. 3. INSTALL VISOR HOLDER a. Engage the 2 claws.

Fig. 175: Installing Visor Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push in the visor holder as shown in the illustration. HINT: Use the same procedure for the other visor holder. 4. INSTALL VISOR ASSEMBLY LH a. Install the visor assembly LH with the 2 screws. 5. INSTALL VISOR BRACKET COVER (for LH Side) a. Engage the 4 claws to install the visor bracket cover.

Fig. 176: Identifying Visor Bracket Cover (For LH Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL VISOR ASSEMBLY RH HINT: Use the same procedure as for the LH side. 7. INSTALL VISOR BRACKET COVER (for RH Side) HINT: Use the same procedure as for the LH side. 8. INSTALL SLIDING ROOF OPENING TRIM MOULDING (w/ Sliding Roof) a. Align the alignment mark on the moulding with the notch of the roof headlining to install the sliding roof opening trim moulding.

Fig. 177: Identifying Sliding Roof Opening Trim Moulding (w/ Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Notch Alignment *2 Mark NOTE:

After installation, check that the corners fit correctly.

9. INSTALL ASSIST GRIP SUB-ASSEMBLY a. Put a assist grip sub-assembly together as shown in the illustration.

Fig. 178: Identifying Assist Grip Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 clips to install the assist grip sub-assembly.

Fig. 179: Identifying Assist Grip Sub-Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 4 claws to install the 2 assist grip covers

Fig. 180: Identifying Assist Grip Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side. 10. INSTALL REAR ASSIST GRIP ASSEMBLY LH a. Put a rear assist grip assembly LH together as shown in the illustration.

Fig. 181: Identifying Rear Assist Grip Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 clips to install the rear assist grip assembly LH.

Fig. 182: Identifying Rear Assist Grip Assembly LH Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Engage the 4 claws to install the 2 assist grip covers

Fig. 183: Identifying Rear Assist Grip Assembly LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL REAR ASSIST GRIP ASSEMBLY RH HINT: Use the same procedure as for the LH side. 12. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) . Refer to INSTALLATION - Step 1. 13. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) . Refer to INSTALLATION - Step 2 . 14. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) . Refer to INSTALLATION Step 2 . 15. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) . Refer to INSTALLATION Step 3 . 16. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) . Refer to INSTALLATION - Step 3 . 17. INSTALL INSTRUMENT PANEL ASSEMBLY Refer to INSTALLATION. 18. INSTALL FRONT SEAT ASSEMBLY LH

For TMMK Made Manual Seat. Refer to INSTALLATION . For TMMK Made Power Seat. Refer to INSTALLATION . For SIA Made Manual Seat. Refer to INSTALLATION . For SIA Made Power Seat. Refer to INSTALLATION . 19. INSTALL FRONT SEAT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 20. INSTALL ROOF SIDE INNER GARNISH LH a. Engage the guide. b. Engage the 5 clips to install the roof side inner garnish LH. 21. INSTALL CENTER PILLAR UPPER GARNISH LH a. Pass the floor anchor of the front seat outer seat belt assembly LH through the center pillar upper garnish LH. b. Engage the clip. c. Install the center pillar upper garnish LH with the 2 screws. 22. INSTALL CENTER PILLAR LOWER GARNISH LH a. Engage the 2 claws and 3 clips to install the center pillar lower garnish LH. 23. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 . 24. INSTALL LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to INSTALLATION Step 7 . 25. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Align the alignment mark (Pink) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the rear door opening trim weatherstrip LH.

Fig. 184: Identifying Rear Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Pink)

NOTE:

After installation, check that the corners fit correctly.

26. INSTALL REAR DOOR SCUFF PLATE LH a. Engage the 6 claws to install the rear door scuff plate LH. HINT: Engage the claws from the rear side of the scuff plate. 27. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 28. INSTALL CENTER PILLAR UPPER GARNISH RH HINT: Use the same procedure as for the LH side. 29. INSTALL CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedure as for the LH side. 30. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 31. INSTALL LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedure as for the LH side. 32. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH a. Align the alignment mark (Blue) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the rear door opening trim weatherstrip RH.

Fig. 185: Identifying Rear Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Blue)

NOTE:

After installation, check that the corners fit correctly.

33. INSTALL REAR DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 3 . INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 39. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 40. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 41. INSTALL FRONT PILLAR GARNISH LH a. Remove the protective cover. b. Make sure that the front pillar garnish clip is not damaged. 34. 35. 36. 37. 38.

NOTE:

If there is any damage, replace the garnish clip with a new one.

c. Install the front pillar garnish clip to front pillar garnish LH.

Fig. 186: Installing Front Pillar Garnish LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Install the front pillar garnish clip so that it faces as shown in the illustration. d. Engage the 2 guides as shown in the illustration. e. Engage the 2 clips to install the front pillar garnish LH.

Fig. 187: Identifying Front Pillar Garnish LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 42. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH a. Align the alignment mark (Yellow) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip LH.

Fig. 188: Identifying Front Door Opening Trim Weatherstrip LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (Yellow)

NOTE:

After installation, check that the corners fit correctly.

43. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH a. Engage the 2 clips. b. Install the cowl side trim sub-assembly LH with the clip. 44. INSTALL FRONT DOOR SCUFF PLATE LH a. Engage the 10 claws to install the front door scuff plate LH. 45. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedure as for the LH side. 46. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH a. Align the alignment mark (White) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip RH.

Fig. 189: Identifying Front Door Opening Trim Weatherstrip RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment

*1

Mark (White)

NOTE:

After installation, check that the corners fit correctly.

47. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. 48. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. 49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

50. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 GENERAL INFORMATION Introduction - Camry (Except Hybrid)

HOW TO USE THIS SERVICE INFORMATION GENERAL INFORMATION GENERAL INFORMATION

1. GENERAL DESCRIPTION a. This service information is written in accordance with SAE J2008. b. Repair operations can be separated mainly into the following 3 processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection c. The following procedure is omitted from this service information. However, this procedure must be performed. 1. Use a jack or lift to perform operations. 2. Clean all removed parts. 3. Perform a visual check before and after performing any work. 2. PREPARATION a. Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the work procedure properly. A list of SST and SSM is in the appropriate "PREPARATION" articles of this service information. 3. REPAIR PROCEDURES a. A component illustration is placed under the title where necessary. b. Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example.

Fig. 1: Identifying Replacement Components With Torque Specifications (Example) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. d. Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration Task heading

What to do and where to do it What work will be performed 

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Explanation text

How to perform the task Information such as specifications and warnings, which are written in boldface text

e. Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. f. Procedures are presented in a step-by-step format. 4. SERVICE SPECIFICATIONS a. Specifications are presented in boldface text throughout the service information. The specifications are also found in the appropriate "SERVICE SPECIFICATIONS" article for reference. 5. TERM DEFINITIONS Possibility of injury to CAUTION you or other people. Possibility of damage to NOTICE components being repaired. Provides additional information HINT to help you perform repairs. 6. INTERNATIONAL SYSTEM OF UNITS a. The units used in this service information comply with the International System of Units (SI UNIT) standard. Other units from the metric system and the English systems are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION AND SERIAL NUMBERS

1. VEHICLE IDENTIFICATION NUMBER a. The vehicle identification number is stamped on the vehicle body and on the certification label as shown in the illustration. A

Vehicle Identification Number B Certification Label C Vehicle Identification Number* *: w/ Outer rear view mirror type side turn signal light

Fig. 2: Identifying Vehicle Identification Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER a. The engine serial number is stamped on the cylinder block of the engine as shown in the illustration.

Fig. 3: Identifying Engine Identification Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A

2GR-FE Engine Serial Number B 2AR-FE Engine Serial Number b. The transaxle serial number is stamped on the case as shown in the illustration.

Fig. 4: Identifying Transaxle Serial Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A U660E and U760E Transaxle Serial Number

REPAIR INSTRUCTION

PRECAUTION PRECAUTION

1. BASIC REPAIR HINT a. HINTS ON OPERATIONS

Fig. 5: Identifying Basic Repair Hints & Precautions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Always wear a clean uniform.  A hat and safety shoes must be worn. Prepare a grille cover, fender cover, seat cover and floor mat before starting work. 

1 Attire

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Vehicle protection

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When working with 2 or more persons, be sure to check the safety of one another.

When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.  If working on high temperature, high pressure, rotating, moving or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.  When jacking up the vehicle, be sure to support the specified locations with safety stands.  When lifting up the vehicle, use appropriate safety equipment. Before starting work, prepare a tool stand, SST, measuring equipment, oil, and any replacement parts required. 

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Safety procedures

Preparation of tools and 4 measuring equipment

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Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing any parts, check the general condition of the assembly and for deformation and damage. If the procedure is

Removal and installation, 5 disassembly and assembly operations 

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6

Removed parts

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complicated, take notes. For example, note the total number of electrical connections, bolts or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. Place the removed parts in a separate box to avoid mixing them up with new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings and self-locking nuts, replace them with new ones as instructed in this service information. Retain the removed parts for customer inspection, if requested. Make sure that removed and installed parts (oil filler cap, level

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Checks to perform 7* after work is finished

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dipstick, floor mat, etc.) are properly installed/tightened. Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle. Check that there are no oil leaks.

WARNING: *: Be sure to perform these checks properly, Notperforming these checks properly after finishing work can lead to serious accident or injury. b. JACKING UP AND SUPPORTING THE VEHICLE 1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. c. PRECOATED PARTS

Fig. 6: Identifying Precoated Parts With Seal Lock Adhesive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Seal *a Lock Adhesive 1. Precoated parts are bolts and nuts that are coated with seal lock adhesive at the factory. 2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. 3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part. 4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. d. GASKETS 1. When necessary, use a sealer on gaskets to prevent leaks. e. BOLTS, NUTS AND SCREWS 1. Carefully follow all the specifications for tightening torque. Always use a torque wrench. f. FUSES

Fig. 7: Identifying Incorrect/Correct Fuse Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT *b CORRECT 1. When inspecting a fuse, check that the wire of the fuse is not broken.

2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit. 3. When a fuse is replaced, a fuse with the same amperage rating must be used. Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT M-FUSE FUSE HIGH CURRENT H-FUSE FUSE FUSIBLE FL LINK CIRCUIT CB BREAKER g. CLIPS 1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clips with new ones. Shape Removal/Installation (Example) Remove the clips with a clip remover or pliers. Remove the clips with a clip remover or screwdriver. Remove the clips with a wide scraper to prevent panel damage. Remove the clips by pushing the center pin through and prying out the shell. Remove the clips by unscrewing the center pin and prying out the shell.

Remove the clips by prying out the pin and then prying out the shell. h. CLAWS 1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one. Shape Illustration Procedure (Example) Using a screwdriver, disengage the claws and remove the cap or cover. Using a screwdriver, disengage the claws and remove the cap or cover. Using a screwdriver, disengage the claws and remove the cap or cover. i. HINGES, GUIDES, CLAMPS, PINS, ETC. 1. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below. HINT: If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

Shape Removal/Installation (Example)

j. REMOVAL AND INSTALLATION OF VACUUM HOSES 1. To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.

Fig. 8: Precaution For Removal/Installation Of Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT *b CORRECT 2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

Fig. 9: Identifying Tag On Vacuum Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. 4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary. k. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL

Fig. 10: Identifying Length Of Extension Tool & Torque Wrench (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.

Fig. 11: Identifying Length Of Extension Tool & Torque Wrench (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Formula T' = (L2/(L1 + L2))*T Reading of torque wrench T' {N*m (kgf*cm, ft.*lbf)} Torque {N*m T (kgf*cm, ft.*lbf)} Length of SST or L1 extension tool {cm (in.)} Length of torque L2 wrench {cm (in.)} NOTE:

If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this service information, the actual torque will be excessive and parts will be damaged.

2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER This vehicle is equipped with a Supplemental Restraint System (SRS). WARNING:

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Before performing pre-disposal deployment of any SRS component, review and closely follow all applicable environmental and hazardous material regulations. Predisposal deployment may be considered hazardous material treatment. Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including

removal or installation of parts, inspection or replacement), be sure to read the following information carefully. a. GENERAL NOTICE 1. As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check for DTCs before disconnecting the battery. 2. Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, the clock and audio system memory will be cleared. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. WARNING: Never use a back-up power source (battery or other) to avoid clearing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy. 3. If the vehicle has been involved in a minor collision where the SRS does not deploy, the steering pad, front passenger airbag assembly, knee airbag assembly, seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle. 4. Never use SRS parts from another vehicle. When replacing parts, use new ones. 5. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs. 6. Never disassemble and attempt to repair any airbag sensor assemblies or airbag assemblies. a. Steering pad b. Front passenger airbag assembly c. Knee airbag assembly d. Seat side airbag assembly e. Curtain shield airbag assembly f. Front seat outer belt assembly 7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present. 8. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames. 9. Use a voltmeter/ohmmeter with high impedance (minimum = 10 kohms) for troubleshooting electrical circuits.

b.

c.

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10. Information labels are attached to the SRS components. Follow the instructions on the labels. 11. After work on the SRS is completed, check the SRS warning light. SPIRAL CABLE 1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position. Otherwise, cable damage and other problems may occur. Refer to the information about correct installation of the steering wheel. Refer to INSTALLATION . STEERING PAD 1. Always place a removed or new steering pad with the surface facing upward as shown in the illustration. Placing the steering pad with the pad surface facing downward could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad. 2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. 3. Grease or detergents of any kind should not be applied to the steering pad. 4. Store the steering pad in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. 6. When disposing of the vehicle or the steering pad by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise. FRONT PASSENGER AIRBAG ASSEMBLY 1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys. 2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. 3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly. 4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. 6. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise. KNEE AIRBAG ASSEMBLY 1. Always place a removed or new knee airbag assembly with the airbag deployment direction facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys. 2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which

could cause serious injury. 3. Grease or detergents of any kind should not be applied to the knee airbag assembly. 4. Store the knee airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. 6. When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL (for driver side). Refer to DISPOSAL (for front passenger side)). Deploy the airbag in a safe place away from electrical noise. f. SEAT SIDE AIRBAG ASSEMBLY 1. Always place a removed or new seat side airbag assembly with the airbag deployment direction facing upward. 2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. 3. Grease or detergents of any kind should not be applied to the seat side airbag assembly. 4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. 6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL (for front side). Refer to DISPOSAL (for rear side)). Deploy the airbag in a safe place away from electrical noise. g. CURTAIN SHIELD AIRBAG ASSEMBLY 1. Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. WARNING: The plastic bag should be disposed of after use.

NOTE:

Never disassemble the curtain shield airbag assembly.

2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. 3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly. 4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.

6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise. h. FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) 1. Never measure the resistance of the front seat outer belt assembly. This may cause the pretensioner of the front seat outer belt assembly to activate, which could cause serious injury. 2. Never disassemble the front seat outer belt assembly. 3. Never install the front seat outer belt assembly on another vehicle. 4. Store the seat outer belt assembly in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. 5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. 6. When disposing of a vehicle or the front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal. Refer to DISPOSAL . Activate the front seat outer belt assembly in a safe place away from electrical noise. 7. As the front seat outer belt assembly is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the front seat outer belt assembly. 8. Grease, detergents, oil or water should not be applied to the front seat outer belt assembly. i. CENTER AIRBAG SENSOR ASSEMBLY 1. Never reuse a center airbag sensor assembly that has been involved in a collision where the SRS has deployed. 2. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the center airbag sensor assembly is not installed, the SRS may activate. 3. Work must be started at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the bolts of the center airbag sensor assembly. j. WIRE HARNESS AND CONNECTOR 1. All the connectors in the system are a standard yellow color. If an SRS wire harness has an open circuit or a connector is broken, replace it. 3. ELECTRONIC CONTROL

Fig. 12: Identifying Battery Terminal And Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cable Negative (-) *2 Battery Terminal NOTE:

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Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. After the ignition switch is turned off, the navigation receiver assembly (for Navigation Receiver Type) or radio and display receiver assembly (for Radio and Display Type with Intuitive Parking Assist System) records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

a. DISCONNECTING AND RECONNECTING NEGATIVE BATTERY CABLE 1. Before performing work on electronic components, disconnect the cable from the negative (-) battery terminal to prevent damage to the electrical system or components. 2. When disconnecting the cable, turn the ignition switch and headlight switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.

3. Clock settings, radio settings, audio system memory, DTCs and other data will be cleared when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. b. HANDLING OF ELECTRONIC PARTS

Fig. 13: Precaution For Handling Electronic Parts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT 1. Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. 2. Do not pull on the wires when disconnecting electronic connectors. Pull on the connector itself. 3. Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. 4. When cleaning the engine components with steam, protect the electronic components, air filter and emission-related components from water. 5. Never use an impact wrench to remove or install temperature switches or temperature sensors. 6. When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent the terminals from bending. 4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS a. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS

1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources nearby. 2. Never work in a pit or near a pit as fuel vapors will collect there. b. REMOVING AND INSTALLING FUEL SYSTEM PARTS 1. Prepare a fire extinguisher before starting work. 2. To prevent static electricity, install a ground wire between the fuel changer and vehicle, and do not spray the surrounding area with water. Be careful when performing work in this area, as the floor surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. 3. Avoid using electric motors, work lights and other electric equipment that can cause sparks or high temperatures. 4. Avoid using iron hammers as they may create sparks. 5. Dispose of fuel-contaminated cloth separately using a fire resistant container. 5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS a. If any metal particles enter intake system parts, this may damage the engine.

Fig. 14: Identifying Cover Of Openings Of Removed Parts And Engine Openings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. When removing and installing intake system parts, cover the openings of the removed parts and engine openings. Use adhesive tape or other suitable materials. c. When installing intake system parts, check that no metal particles have entered the engine or installed parts. 6. HANDLING OF HOSE CLAMPS

Fig. 15: Identifying Clamp Track And Spring Type Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Clamp *1 Track Spring *2 Type Clamp a. b. c. d.

Before removing a hose, check the clamp position so that it can be reinstalled in the same position. Replace any deformed or dented clamps with new ones. When reusing a hose, attach the clamp on the clamp track portion of the hose. For a spring type clamp, it may be necessary to spread the tabs slightly after installation by pushing them in the direction of the arrows as shown in the illustration. 7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

Fig. 16: Identifying Antenna For Vehicles Equipped With Mobile Communication Systems Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible. b. Install the antenna and feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the article on the applicable components. c. Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice versa. d. Check that the antenna and feeder are correctly adjusted. e. Do not install a high-powered mobile communication system. 8. HEADLIGHT INSPECTION OR MAINTENANCE a. When the headlight dimmer switch assembly is set to head, do not touch the discharge headlight high-voltage socket area. NOTE:

When performing inspection or maintenance, the discharge headlight precautions must be followed.

b. When the headlights are illuminated, do not cover the headlights for 3 minutes or more.

Fig. 17: Identifying Headlight Inspection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Illumination for 3 minutes or *a more prohibited if covered NOTE:

As the headlight's outer lens is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.

9. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TR(A)C) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter inspection mode and disable the TR(A)C and VSC systems. Refer to PRECAUTION . HINT: 

The vehicle may slip unexpectedly out of the dynamometer because of TR(A)C and VSC operation.

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Pressing the VSC OFF switch (for vehicles with a VSC OFF switch) does not disable TR(A)C and VSC operation completely.

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Make sure that the VSC warning light is blinking. Secure the vehicle with chains for safety.

10. PRECAUTIONS FOR TOWING FRONT WHEEL DRIVE VEHICLES a. Use one of the following methods to tow the vehicle. b. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

Fig. 18: Identifying Precautions For Towing Front Wheel Drive Vehicles

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use any towing method other than those shown above.

c. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30 km/h (19 mph). A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition. NOTE:

If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with the front wheels on the ground, the transaxle may be damaged.

1. Emergency towing procedure a. Turn the ignition switch ON. b. Depress the brake pedal and move the shift lever to N. c. Release the parking brake. d. Release the brake pedal slowly. NOTE:

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Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains. Do not turn off the ignition switch. Turning off the ignition switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.

d. The towing methods shown below are dangerous and can damage the vehicle, so do not use them.

Fig. 19: Illustrations Of How NOT TO Tow Front Wheel Drive Vehicles

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Do not tow the vehicle facing rearward with the front wheels on the ground. NOTE:

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If the vehicle is towed facing rearward with the front wheels on the ground, the drivetrain may overheat and be damaged. In addition, if the vehicle is equipped with the VSC system, the system may apply the brakes to the rotating wheels.

2. Do not use a sling-type towing method either from the front or rear. NOTE:

If a sling-type tow truck is used, damage may occur to the vehicle body.

11. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER WARNING: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause converter overheating and create a fire hazard. To prevent this, observe the following precautions: a. Use only unleaded gasoline. b. Avoid performing unnecessary spark tests. 1. Perform a spark test only when absolutely necessary. Perform this test as rapidly as possible. 2. While testing, never race the engine unless instructed. c. Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. d. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 12. EXPRESSIONS OF IGNITION SWITCH a. The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this service information. Ignition Engine Expression Switch Switch (position) (condition) Ignition LOCK Off switch off Ignition switch to ACC On (ACC) ACC Ignition

switch to ON Engine start

ON

On (IG)

START

Start

VEHICLE LIFT AND SUPPORT LOCATIONS VEHICLE LIFT AND SUPPORT LOCATIONS

1. NOTICE ABOUT VEHICLE CONDITION WHEN RAISING VEHICLE a. The vehicle must be unloaded before jacking up or raising the vehicle. Never jack up or raise a heavily loaded vehicle. b. When removing any heavy components like the engine or transaxle, the vehicle center of gravity will shift. To stabilize the vehicle, place a balance weight in a location that will prevent the vehicle from rolling or shifting, or place a transmission jack under the appropriate jack position at the opposite end of the vehicle. 2. NOTICE FOR USING 4 POST LIFT a. Follow the safety procedures outlined in the lift's instruction manual. b. Do not damage the tires or wheels while driving onto the lift. c. Use wheel chocks to secure the vehicle. 3. NOTICE FOR USING JACK AND SAFETY STANDS a. Work on a level surface. Use wheel chocks at all times. b. Use safety stands with rubber attachments as shown in the illustration.

Fig. 20: Notice For Using Jack And Safety Stands

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Attachment c. Set the jack and safety stands exactly under the specified locations on the vehicle. d. Do not work on or leave the vehicle supported only by a jack. Be sure to support the vehicle with safety stands. e. When jacking up the vehicle, first release the parking brake and move the shift lever to N. f. When jacking up the entire vehicle: 1. When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. 2. When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. g. When jacking up only the front or rear wheels of the vehicle: 1. Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. 2. Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. h. When lowering a vehicle that only has its front or rear wheels jacked up.

Fig. 21: Identifying Vehicle Support Locations & Center Of Gravity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. 2. Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. 4. NOTICE FOR USING A SWING ARM TYPE LIFT a. Follow the safety procedures outlined in the lift's instruction manual. b. Use swing arms equipped with rubber attachments as shown in the illustration. c. Position the vehicle so that its center of gravity is centered on the lift (length of "L" in the illustration should be as short as possible). d. Ensure that the rubber cushions or swing arms do not contact the body cladding or lower mouldings. e. Be sure to lock the swing arms before raising the vehicle (if equipped with arm locks). f. Use the lift to raise the vehicle until the tires are off the ground, then stop the lift and shake the front and rear of the vehicle to make sure that it is stable.

Fig. 22: Identifying Vehicle Support Locations & Center Of Gravity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. NOTICE FOR USING PLATE TYPE LIFT

a. Follow the safety procedures outlined in the lift's instruction manual. b. Use plate lift attachments (rubber lifting blocks) on top of the plates. c. Be sure to set the vehicle to the specified position described in the following chart and shown in the following illustration. Right and left set position

Front and rear set position

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Center the vehicle on the lift.

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Align the plate cushion ends with the lower ends of the attachments (A). Be sure to set the attachment to position (B) as shown in the illustration.

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d. Ensure that the plate lift or rubber lifting blocks do not contact the body cladding or lower mouldings. e. Use the lift to raise the vehicle until the tires are off the ground, then stop the lift and shake the front and rear of the vehicle to make sure that it is stable.

Fig. 23: Identifying Plate Type Lift Attachments Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CUSTOMIZE PARAMETERS CUSTOMIZE PARAMETERS

1. CUSTOMIZE INTUITIVE PARKING ASSIST SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 2. CUSTOMIZE POWER DOOR LOCK CONTROL SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 3. CUSTOMIZE WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) . Refer to CUSTOMIZE PARAMETERS - Step 1 4. CUSTOMIZE WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) . Refer to CUSTOMIZE PARAMETERS - Step 1 5. CUSTOMIZE SMART KEY SYSTEM (for Entry Function) . Refer to CUSTOMIZE PARAMETERS - Step 1 6. CUSTOMIZE SMART KEY SYSTEM (for Start Function) . Refer to CUSTOMIZE PARAMETERS - Step 1 7. CUSTOMIZE THEFT DETERRENT SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 8. CUSTOMIZE REMOTE ENGINE STARTER SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 9. CUSTOMIZE LIGHTING SYSTEM (INT) . Refer to CUSTOMIZE PARAMETERS - Step 1 10. CUSTOMIZE METER / GAUGE SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 11. CUSTOMIZE SEAT BELT WARNING SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 12. CUSTOMIZE AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System) . Refer to CUSTOMIZE PARAMETERS - Step 1

13. CUSTOMIZE AIR CONDITIONING SYSTEM (for Manual Air Conditioning System) . Refer to CUSTOMIZE PARAMETERS - Step 1 14. CUSTOMIZE POWER WINDOW CONTROL SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 15. CUSTOMIZE SLIDING ROOF SYSTEM . Refer to CUSTOMIZE PARAMETERS - Step 1 16. CUSTOMIZE LIGHTING SYSTEM (EXT) . Refer to CUSTOMIZE PARAMETERS - Step 1 INITIALIZATION INITIALIZATION

1. PROCEDURES NECESSARY WHEN BATTERY TERMINAL IS DISCONNECTED/RECONNECTED Effect/Inoperative Function When Necessary Necessary See Procedures Procedures are not Performed Correct the steering Parking assist Refer to angle monitor system INITIALIZATION neutral point NOTE:

After the ignition switch is turned off, the navigation receiver assembly (for Navigation Receiver Type) or radio and display receiver assembly (for Radio and Display Type with Intuitive Parking Assist System) records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

2. PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE REPLACED

Replacement Part

ECM

Necessary Procedure

Effect/Inoperative Function when Necessary Procedures are not Performed

Vehicle Identification Number (VIN) MIL comes on registration

See

Refer to REGISTRATION for 2AR-FE Refer to REGISTRATION for 2GR-FE

ECU communication ID registration Engine start (Engine immobiliser system)

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Refer to REGISTRATION *1 Refer to REGISTRATION *2

Throttle with motor body assembly Cleaning the deposits from the throttle with motor body assembly Engine assembly Cylinder head subassembly Camshaft (for intake or exhaust camshaft)

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Camshaft timing gear assembly Camshaft timing Inspection after exhaust gear repair assembly Piston or piston ring Mass air flow meter subassembly Fuel injector assembly Fuel pump Air fuel ratio sensor Engine coolant temperature sensor Spark plug Ignition coil assembly Air leaks from intake system

Poor idle, engine starting, etc

Refer to INITIALIZATION for 2AR-FE Refer to INITIALIZATION for 2GR-FE

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Gas leaks from exhaust system Knock control sensor

Automatic transaxle assembly

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Valve body assembly Shift solenoid valve SL3 and/or SL4

a. Reset memory b. Input transaxle compensation code into TCM c. Perform road test to allow TCM to learn a. Reset memory b. Reset transaxle compensation code c. Perform road test to allow TCM to learn

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Shift solenoid valve SL1 Perform road test to and/or SL2 allow TCM to learn

Possible

a. Reset memory b. Transfer transaxle compensation code c. Perform road test to allow TCM to learn

Impossible

a. Reset memory b. Reset transaxle compensation code c. Perform road test to allow TCM to learn

TCM (If possible, read the transaxle compensation code from the previous TCM)

Automatic transaxle

a. Reset memory b. Input transaxle compensation code into ECM

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Large shift shock Deterioration of fuel efficiency

Large shift shock Deterioration of fuel efficiency Large shift shock Deterioration of fuel efficiency

Large shift shock Deterioration of fuel efficiency

Large shift shock Deterioration of fuel efficiency

Large shift shock Deterioration

Refer to INITIALIZATION for U660E Initialization Refer to REGISTRATION for U660E Registration

assembly

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of fuel efficiency

c. Perform road test to allow ECM to learn

Valve body assembly Shift solenoid valve SL3 and/or SL4

a. Reset memory b. Reset transaxle compensation code c. Perform road test to allow ECM to learn

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Shift solenoid valve SL1 Perform road test to and/or SL2 allow ECM to learn

Possible

a. Reset memory b. Transfer transaxle compensation code c. Perform road test to allow ECM to learn

Impossible

a. Reset memory b. Reset transaxle compensation code c. Perform road test to allow ECM to learn

ECM (If possible, read the transaxle compensation code from the previous ECM)

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Door control and tire pressure monitoring system receiver assembly

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Transmitter ID registration Initialization

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Large shift shock Deterioration of fuel efficiency Large shift shock Deterioration of fuel efficiency

Large shift shock Deterioration of fuel efficiency

Refer to INITIALIZATION for U760E Initialization Refer to REGISTRATION for U760E Registration

Large shift shock Deterioration of fuel efficiency

When DTC detection conditions of "transmitter ID Refer to not received" INITIALIZATION DTC are met, for Initialization TPWS Refer to indicator REGISTRATION blinks for 1 for Registration minute, and then illuminates. Tire pressure

warning function Code registration (Wireless door lock system)

Wireless door lock control system 

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Tire pressure monitor receiver assembly Tire pressure warning valve and transmitter

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Transmitter ID registration Initialization

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Skid control ECU (Brake actuator assembly)

Perform system variant learning

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Power steering ECU assembly 

Electric power steering column sub-assembly (containing the torque sensor)*3*4 

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Spiral cable with sensor assembly Spiral cable subassembly Steering sensor

Radio and display receiver assembly

Torque sensor zero point calibration*3*4 Assist map writing

Torque sensor zero point calibration

Correct steering angle neutral point  Steering angle setting Radio and display receiver assembly initialization

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Refer to REGISTRATION

When DTC detection conditions of "transmitter ID not received" Refer to DTC are met, INITIALIZATION TPWS for Initialization indicator Refer to blinks for 1 REGISTRATION minute, and for Registration then illuminates. Tire pressure warning function Slip indicator light illumination Refer to VSC disabled CALIBRATION or malfunctioning P/S warning light comes on EPS control

Steering effort is different between turning steering wheel to left and right

Refer to CALIBRATION *3 Refer to CALIBRATION *4 Refer to CALIBRATION *5

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Parking assist monitor system Refer to CALIBRATION Parking assist monitor system

Rear television camera assembly

Back camera position Parking assist setting monitor system Re-registration of codes in the garage  Roof console box door opener system assembly*6 Garage door opener  Register  Garage door system transmitter opener code transmitter*6  Rolling code systems DCM (Telematics Safety connect DCM activation Transceiver) system 

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Certification ECU (smart key ECU assembly)*1 Steering lock ECU Code registration (steering lock (Engine immobiliser actuator assembly) system) *1 Electrical key transmitter subassembly*1

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Refer to REGISTRATION

Refer to DCM ACTIVATION

Wireless door lock control system Smart key Refer to system REGISTRATION Engine start Steering lock system

Transponder key ECU assembly*2 Code registration Door control (Engine immobiliser Engine start transmitter system) assembly*2 Key*3

Refer to REGISTRATION

Door control transmitter assembly*2 Door control receiver

Code registration (Wireless door lock system)

Refer to REGISTRATION

Remote engine starter ECU*7 Certification ECU (smart key ECU assembly)*7

Registration of remote engine starter Refer to Remote engine start ID (Remote engine REGISTRATION starter system)

Wireless door lock control system

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Occupant classification system Passenger

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Occupant Zero point calibration classification ECU and sensitivity check. Front passenger (Occupant classification system) seat

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No. 1 air conditioning radiator damper servo subassembly*8*9 Initialization servo No. 2 air motor (Air DTCs are output conditioning conditioning system) radiator damper servo subassembly*8 No. 1 blower damper servo subassembly*8*9 

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Power window regulator motor assembly Door window regulator subassembly Door glass Door glass run

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Initialize power window control system 

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airbag ON/OFF indicator Airbag system (Front Refer to passenger INITIALIZATION side) Seat belt warning system (Front passenger)

Sliding roof ECU (sliding roof drive

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Refer to INITIALIZATION *8 Refer to INITIALIZATION *9

Auto up/down function Jam protection function Operation function after Refer to ignition switch INITIALIZATION is turned off Key-linked function Wireless transmitterlinked function Automatic slide open/close and tilt up/down function of sliding roof Jam protection

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gear subassembly) Sliding roof glass sub-assembly Sliding roof drive Initialize sliding roof cable subECU (pulse sensor assembly initial position setting)

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Perform headlight Headlight leveling ECU leveling ECU assembly assembly initialization Perform headlight leveling ECU Rear height control assembly sensor sub-assembly initialization

function Operation function after ignition switch is turned off Key-linked Refer to function INITIALIZATION Wireless transmitterlinked function Sliding roof open warning

Headlight leveling function Refer to INITIALIZATION Headlight leveling function

*1: w/ Smart Key System *2: w/o Smart Key System *3: for 2AR-FE without Wireless Door Lock *4: for 2AR-FE with Wireless Door Lock *5: for 2GR-FE *6: w/ Garage Door Opener System *7: w/ Remote Engine Starter System *8: for Automatic Air Conditioning System *9: for Manual Air Conditioning System

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION GENERAL INFORMATION

A large number of ECU controlled systems are used in this vehicle. In general, ECU controlled systems

are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnosis and necessary repairs. (For using the Techstream*) HINT: *: The Techstream is the name for the diagnostic tester in North America.  

Before using the Techstream, read the operator's manual thoroughly. If the Techstream cannot communicate with the ECU controlled systems when connected to the DLC3 with the ignition switch ON and the Techstream turned on, there is a problem on the vehicle side or the Techstream side. 1. If communication is possible when the Techstream is connected to another vehicle, inspect the diagnosis data link line (bus (+) line), CANH and CANL lines, and the power circuits for the vehicle ECUs. 2. If communication is still not possible when the Techstream is connected to another vehicle, the problem is probably in the Techstream itself. Perform the Self Test procedure outlined in the Techstream operator's manual.

1. TROUBLESHOOTING PROCEDURES  The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. Procedure Troubleshooting Details Type Method The malfunctioning part is identified based on the The DTC detection diagnosis conditions using DTC procedure a process of Based is based elimination. Diagnosis on the The possible DTC that trouble areas are is stored. eliminated oneby-one by use of the Techstream and inspection of related parts. The malfunctioning part is identified

based on the problem symptoms using The a process of Symptom diagnosis elimination. procedure Based The possible Diagnosis is based trouble areas are (No DTCs on eliminated oneproblem stored) by-one by use of symptoms. the Techstream and inspection of related parts. Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced.  It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved.  In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom.  To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. 2. DESCRIPTION a. The data of each system and Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream to check for malfunctions and perform repairs. 3. CHECK DLC3 a. The vehicle ECUs use ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. 

Fig. 24: Identifying DLC3 Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Terminal Reference Name Result Condition No. Terminal Bus 5 - Signal Pulse During SIL 7 "+" line ground generation transmission Chassis Body 1 ohms or CG 4 Always ground ground less Signal Body 1 ohms or SG 5 Always ground ground less Battery Body 11 to 14 BAT 16 Always positive ground V 14 54 to 69 Ignition CANL ohms switch off* CAN Battery 6 kohms Ignition CANH 6 "High" positive or higher switch off* line 200 ohms Ignition 4 - CG or higher switch off* Battery 6 kohms Ignition CAN positive or higher switch off* CANL 14 "Low" 200 ohms Ignition line 4 - CG or higher switch off*

Symbol

NOTE:

*: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches

or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness or connector. ELECTRONIC CIRCUIT INSPECTION PROCEDURE ELECTRONIC CIRCUIT INSPECTION PROCEDURE

1. BASIC INSPECTION a. WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS 1. Unless otherwise stated, all resistance measurements are standard values measured at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. b. HANDLING CONNECTORS

Fig. 25: Identifying Correct/Incorrect Way To Handle Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT

*b CORRECT 1. When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector. 2. When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. 3. Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals. 4. When connecting a connector, press firmly until it locks with a "click" sound. 5. If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTE:

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As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. Do not damage the terminals by moving the inserted tester needle.

c. CHECKING CONNECTORS

Fig. 26: Identifying Core Wire, Looseness of Crimping & Terminal Deformation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Core Wire Looseness

*b of Crimping Terminal *c Deformation *d Pull Lightly 1. Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. 2. Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Visually check for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated or deformed terminals. 3. Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTE:

When testing a gold-plated female terminal, always use a goldplated male terminal.

Fig. 27: Checking Contact Pressure Of Terminal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. CONNECTOR TERMINAL REPAIR METHOD

Fig. 28: Identifying Correct/Incorrect Connector Terminal Repair Method Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT 1. If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off. 2. If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. 3. Damaged, deformed or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. e. WIRE HARNESS HANDLING

Fig. 29: Identifying Incorrect Wire Harness Handling Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a INCORRECT 1. If removing a wire harness, check the wiring and clamps before proceeding so that it can be restored in the same way. 2. Never twist, pull or slacken the wire harness more than necessary. 3. The wire harness should never come into contact with any high temperature part, rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. 4. When installing parts, never pinch the wire harness. 5. Never cut or break the cover of the wire harness. If it is cut or broken, repair it with insulating tape or replace the wire harness.

2. CHECK FOR OPEN CIRCUIT a. For an open circuit in the wire harness in Fig. 1, measure the resistance and voltage as follows:

Fig. 30: Checking For Open Circuit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the resistance.

Fig. 31: Measuring Resistance Between Terminals Of Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disconnect connectors A and C and measure the resistance between the terminals of the connectors. Standard Resistance (Fig. 2) Tester Specified Connection Condition Connector A terminal 110 kohms Connector or higher C terminal 1 Connector A terminal 2Below 1 Connector ohms C terminal 2 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the values specified above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. 2. Disconnect connector B and measure the resistance between the terminals of the connectors.

Fig. 32: Measuring Resistance Between Terminals Of Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance (Fig. 3) Tester Specified Connection Condition Connector A terminal 1Below 1 Connector ohms B1 terminal 1 Connector B2 terminal 110 kohms Connector or higher C terminal 1 If the results match the values specified above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. c. Check the voltage.

Fig. 33: Measuring Voltage Between Body Ground And Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between body ground and the following terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard Voltage (Fig. 4) Tester Specified Connection Condition Connector A terminal 5V 1 - Body ground Connector B terminal 5V 1 - Body ground Connector C terminal Below 1 1 - Body V ground

If the results match the values specified above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT a. If a wire in the harness is shorted to ground (Fig. 5), locate the shorted section by measuring the resistance as follows:

Fig. 34: Checking For Short Circuit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the resistance to body ground.

Fig. 35: Measuring Resistance Between Connectors A And C Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disconnect connectors A and C and measure the resistance. Standard Resistance (Fig. 6) Tester Specified Connection Condition Connector A terminal Below 1 1 - Body ohms ground Connector A terminal 10 kohms 2 - Body or higher ground HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the values specified above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. 2. Disconnect connector B and measure the resistance.

Fig. 36: Measuring Connector Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance (Fig. 7) Tester Specified Connection Condition Connector A terminal 10 kohms 1 - Body or higher ground Connector B2 terminal Below 1 1 - Body ohms ground If the results match the values specified above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTE:

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The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON.

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Check that the connectors are fully seated. Check for loose, corroded or broken wires.

a. First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. 1. Measure the resistance between the ECU ground terminal and body ground.

Fig. 37: Identifying ECU Ground Terminal & Body Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Ground Standard resistance Below 1 ohms 2. Disconnect the ECU connector. Check the ground terminals on the ECU side and wire harness side for bent terminals, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals.

Fig. 38: Checking The Contact Pressure Of The Female Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without *a harness connected (ECU) *b Ground Front view of wire *c harness connector (to ECU) *d Ground HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING

1. OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedure below. The following is an outline of basic troubleshooting procedure. Confirm the troubleshooting procedure for the circuit you are working on

before beginning troubleshooting. a. VEHICLE BROUGHT TO WORKSHOP NEXT: Go to next step b. CUSTOMER PROBLEM ANALYSIS 1. Ask the customer about the conditions and environment when the problem occurred. NEXT: Go to next step c. INSPECT BATTERY VOLTAGE Standard voltage 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT: Go to next step d. SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK 1. Visually check the wire harnesses, connectors and fuses for open and short circuits. 2. Warm up the engine to the normal operating temperature. 3. Confirm the problem symptoms and conditions, and check for DTCs. Result Result DTC is output DTC is not output

Proceed to A

B

B --> GO TO STEP f A: Go to next step e. DTC CHART 1. Find the output DTC in the DTC chart. Look at the Trouble Area column for a list of potentially malfunctioning circuits and/or parts.

NEXT --> GO TO STEP g f. PROBLEM SYMPTOMS CHART 1. Find the problem symptoms in the problem symptoms table. Look at the Suspected Area column for a list of potentially malfunctioning circuits and/or parts. NEXT: Go to next step g. CIRCUIT INSPECTION OR PARTS INSPECTION 1. Identify the malfunctioning circuit or part. NEXT: Go to next step h. ADJUST, REPAIR OR REPLACE 1. Adjust, repair or replace the malfunctioning circuit or parts. NEXT: Go to next step i. CONFIRMATION TEST 1. After the adjustment, repairs or replacement of components, confirm that the malfunction no longer exists. If the malfunction does not recur, perform a confirmation test under the same conditions and in the same environment as when the malfunction first occurred. NEXT --> END 2. CUSTOMER PROBLEM ANALYSIS HINT: 

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When troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. The following 5 items are important points for problem analysis:

What

When Where

Vehicle model, system name Date, time, occurrence frequency Road

conditions Driving Under conditions, what weather conditions? conditions How did it Problem happen? symptoms 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in this vehicle has various functions. 

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The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting can be more effective. Diagnostic functions are incorporated in the following systems of this vehicle.

System

Symptom Confirmation and Diagnostic Trouble Code Sensor DTC DTC Check/Test Check Check Mode Data Active (Normal (Check (Input List Test Mode) Mode) Signal Check)

SFI System o (2AR-FE) Ignition System (2AR-FE) SFI System o (2GR-FE) Ignition System (2GR-FE) Fuel System (2AR-FE) Fuel System (2GR-FE) Emission Control System

o

-

o

o

-

-

-

-

o

-

o

o

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

(2AR-FE) Emission Control System (2GR-FE) Intake System (2AR-FE) Intake System (2GR-FE) Cooling Fan System (2AR- FE) Cooling Fan System (2GR- FE) Starting System (2AR-FE) Starting System (2GR-FE) Cruise Control o System Automatic Transaxle o System (U660E) Automatic Transaxle o System (U760E) Tire Pressure Warning o System Vehicle Stability o Control System Power Steering System (for 2AR-FE o without Wireless Door Lock) Power Steering System (for 2AR-FE with o Wireless Door Lock)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

o

o

o

-

o

o

o

-

o

o

-

o

o

o

-

o

o

o

-

-

o

-

-

-

o

-

Power Steering System (for 2GR-FE) Steering Lock System Audio and Visual System (for Radio Receiver Type) Audio and Visual System (for Radio and Display Type with intuitive Parking Assist System) Audio and Visual System (for Radio and Display Type without intuitive Parking Assist System) Navigation System (for Radio and Display Type) Navigation System (for Navigation Receiver Type) Intuitive Parking Assist System Parking Assist Monitor System Rear View Monitor System Blind Spot Monitor System Garage Door Opener System

o

-

-

o

-

o

-

-

o

-

-

-

-

-

-

o

-

-

o

-

o

-

-

o

-

o

-

-

o

-

o

-

-

o

-

o

-

-

o

o

o

-

-

o

-

-

-

-

-

-

o

-

o

o

-

-

-

-

-

-

Safety Connect o System Charging System (2AR- FE) Charging System (2GR- FE) LIN Communication o System CAN Communication o System Power Door Lock Control System Wireless Door Lock Control System (w/ o Smart Key System) Wireless Door Lock Control System (w/o o Smart Key System) Key Reminder Warning System Smart Key System (for o Entry Function) Smart Key System (for o Start Function) Engine Immobiliser System (w/ o Smart Key System) Engine Immobiliser System (w/o o Smart Key System)

-

-

o

-

-

-

-

-

-

-

-

-

-

-

o

-

-

-

-

-

-

-

o

o

-

-

o

o

-

-

o

o

-

-

o

-

-

-

o

o

-

-

o

o

-

-

o

o

-

-

o

o

Theft Deterrent System Remote Engine Starter System Lighting System (INT) Meter / Gauge System Clock System Airbag System (for Separate Type Yaw Rate Sensor) Airbag System (for Built-in Type Yaw Rate Sensor) Occupant Classification System Front Power Seat Control System Seat Heater System Seat Belt Warning System Air Conditioning System (for Automatic Air Conditioning System) Air Conditioning System (for Manual Air Conditioning System) Power Window Control System Window Defogger System

-

-

-

o

o

o

-

-

o

-

-

-

-

o

o

o

-

-

o

o

-

-

-

-

-

o

o

-

o

-

o

o

-

o

-

o

-

-

o

-

-

-

-

-

-

-

-

-

-

-

-

-

-

o

o

o

-

-

o

o

o

-

-

o

o

o

-

-

o

o

-

-

-

-

o

Sliding Roof System Power Mirror Control System Wiper and Washer System Lighting System (EXT) Automatic Headlight Beam Level Control System Manual Headlight Beam Level Control System Horn System

o

-

-

o

o

-

-

-

-

o

-

-

-

-

-

o

-

-

o

o

o

-

-

o

o

-

-

-

-

-

-

-

-

-

-

In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1) still occurs, or 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below.  Never skip the DTC check. Failing to check for DTCs, depending on the case, may result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedure listed in the flowchart in the correct order.  The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. a. DTC CHECK 

NEXT: Go to next step b. MAKE A NOTE OF DTC DISPLAYED AND THEN CLEAR DTCs NEXT: Go to next step c. SYMPTOM CONFIRMATION Result Result

Proceed to

No symptoms

A

exist Symptoms exist

B

B --> GO TO STEP e A: Go to next step d. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT: Go to next step e. DTC CHECK Result Result

Proceed to

DTC is not output DTC is output

A

B

B --> TROUBLESHOOT FOR PROBLEM INDICATED BY DTC A: Go to next step f. SYMPTOM CONFIRMATION Result Result Symptoms exist No symptoms exist

Proceed to A B

If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B --> END

A --> TROUBLESHOOT FOR EACH PROBLEM SYMPTOM If problem symptoms are present, but no DTCs were stored again after they were cleared, then the problem causing the symptom may be occurring for something that does not store DTCs (the DTC that was displayed in the initial DTC check may have been from a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The following symptom simulation tests are effective substitutes for the conditions and can be applied to a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to Problem Symptoms Table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. a. VIBRATION METHOD: When a malfunction seems to occur as a result of vibration.

Fig. 39: Identifying Vibration Method Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a

Vibrate

Slightly Shake *b Slightly 1. PARTS OR SENSORS Apply slight vibration with a finger to the part or sensor suspected to be the cause of the problem, and check whether the malfunction occurs. NOTE:

Applying strong vibration to relays may open the relays.

2. CONNECTORS Slightly shake the connector vertically and horizontally. 3. WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. b. HEAT METHOD: When a malfunction seems to occur when the area in question is heated. 1. Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTE:





Do not heat components to more than 60°C (140°F). Exceeding this temperature may damage the components. Do not apply heat directly to parts in an ECU.

c. WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in highhumidity.

Fig. 40: Identifying Water Sprinkling Method Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Sprinkle water onto the vehicle and check if the malfunction occurs. NOTE:





Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. Never apply water directly onto the electronic components.

HINT: If the vehicle has or had a water leak problem, the leak may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. d. HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is high.

Fig. 41: Turning On Heater Blower, Headlight, Rear Window Defogger And All Other Electrical Loads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1. Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction recurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate article's Diagnostic Trouble Code chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is shown in the table below. Item

Description Indicates the DTC No. diagnostic trouble code. Indicates the system Detection or details of Item the problem. Indicates the Trouble suspected Area areas of the problem. Indicates the article where the inspection procedure for each See circuit is to be found, or gives instruction for checking and repairs. 6. PROBLEM SYMPTOMS TABLE When no DTC is output but the problem still occurs, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are shown in the table. The suspected areas are listed in order of probability. A description of each of the table columns is shown in the following table. HINT:

In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs. It is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem occurs in a completely different system. Item Description Symptom Indicates the circuit Suspected or part which Area needs to be checked. Indicates the article where the See inspection procedure is located. 7. INSPECTION A description of the main points for inspection of suspected areas is shown in the following table. Item

Description The major role and operation of the circuit or Description system and its component parts are explained. Indicates the diagnostic DTC No., trouble DTC codes, DTC Detection detection Condition conditions and and Trouble suspected Area areas for a problem. This is a wiring diagram for

Wiring Diagram

the circuit or system. This diagram can be used together with the Electrical Wiring Diagram to thoroughly understand the circuit. Wire colors are indicated by alphabetical codes. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe.

This shows the procedure not only to determine Inspection whether the Procedure circuit is normal or abnormal, but also to determine

whether the problem is located in the sensors, actuators, wire harness or ECU. The illustration shows whether the connector being checked is connected or disconnected. The connections for an electrical Illustration tester are of the ECU indicated by connector (+) or (-) during the after the check terminal name. For inspections between a connector and body ground, information about the ground is not shown in the illustration.

TERMS ABBREVIATIONS USED IN THIS SERVICE INFORMATION ABBREVIATIONS USED IN THIS SERVICE INFORMATION

Abbreviation ABS A/C

Meaning Anti-Lock Brake System Air Conditioner

AC ACC ACIS ACM ACSD ACT A.D.D ADM A/F AFS AHC AID ALR ALT AMP ANT ASG ASL ASSB A/T, ATM A-TRAC, A-TRC ATDC ATF AUTO AUX AVG AVS AWD B+, +B BA BACS BATT BDC B/L B/S BTDC BVSV Calif. CAN CB CCM

Alternating Current Accessory Acoustic Control Induction System Active Control Engine Mount Automatic Cold Start Device Actuator Automatic Disconnecting Differential P.T. Astra Daihatsu Motor Air-Fuel Ratio Adaptive Front-Lighting System Active Height Control Suspension Air Injection Control Driver Automatic Locking Retractor Alternator Amplifier Antenna Automated Sequential Gearbox Automatic Sound Levelizer Assembly Services Sdn. Bhd. Automatic Transmission (Transaxle) Active Traction Control After Top Dead Center Automatic Transmission Fluid Automatic Auxiliary Average Adaptive Variable Suspension All Wheel Drive Battery Voltage Brake Assist Boost Altitude Compensation System Battery Bottom Dead Center Bi-Level Bore-Stroke Ratio Before Top Dead Center Bimetallic Vacuum Switching Valve California Controller Area Network Circuit Breaker Carbon Ceramic Material

CCV CD CF CG CH CKD COMB. CPS CPU CRAWL CRS CTR C/V CV CVT CW DC DEF DFL DIFF. DIFF. LOCK D/INJ DLC DLI DOHC DP DS DSP DTC DVD EBD EC ECAM ECD ECDY ECT ECU ED EDU EDIC

Catalytic Converter for Oxidation Canister Closed Valve Compact Disc Cornering Force Center of Gravity Channel Complete Knock Down Combination Combustion Pressure Sensor Central Processing Unit Crawl Control Child Restraint System Center Check Valve Control Valve Continuously Variable Transmission (Transaxle) Curb Weight Direct Current Defogger Deflector Differential Differential Lock Direct Injection Data Link Connector Distributorless Ignition Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatile Disc Electric Brake Force Distribution Electrochromic Engine Control And Measurement System Electronically Controlled Diesel Eddy Current Dynamometer Electronic Controlled Automatic Transmission Electronic Control Unit Electro-Deposited Electronic Driving Unit Electric Diesel Injection Control

E/G EGR ELR EMPS EPS ENG ES ESA EVAP E-VRV EX FE FF F/G FIPG FL F/P FR F/W FW/D FWD GAS GND GPS GSA GTMC H/B H-FUSE HID HPU HSG HT HV HWS IC IDI IFS IG

Electronic Fuel Injection Engine Exhaust Gas Recirculation Emergency Locking Retractor Electric Motor Power Steering Electric Power Steering Engine Easy & Smooth Electronic Spark Advance Evaporative Emission Control Electric Vacuum Regulating Valve Exhaust Fuel Economy Front-Engine-Front-Wheel-Drive Fuel Gauge Formed In Place Gasket Fusible Link Front Left Fuel Pump Front Front Right Flywheel Flywheel Damper Front Wheel Drive Gasoline Ground Global Positioning System Gear Shift Actuator Gac Toyota Motor Co., Ltd. Hatchback High Current Fuse High Intensity Discharge (Headlight) Hydraulic Power Unit Housing Hard Top Hybrid Vehicle Heated Windshield System Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition

IIA IMC IN INT I/P IRS ISC ISCV KD KDSS LAN LCD LED LEV LH LHD LIN L/H/W LLC LNG LPG LSD LSP & BV LSPV MAP MAX. MIC MIL MIN. MG1 MG2 MMT MP MPI MPX M/T MT MTG N NA NO.

Integrated Ignition Assembly INDUS Motor Company Ltd. Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Idle Speed Control Valve Kick-Down Kinetic Dynamic Suspension System Local Area Network Liquid Crystal Display Light Emitting Diode Low Emission Vehicle Left-Hand Left-Hand Drive Local Interconnect Network Length, Height, Width Long-Life Coolant Liquefied Natural Gas Liquefied Petroleum Gas Limited Slip Differential Load Sensing Proportioning and Bypass Valve Load Sensing Proportioning Valve Manifold Absolute Pressure Maximum Microphone Malfunction Indicator Lamp Minimum Motor Generator No. 1 Motor Generator No. 2 Multi-mode Manual Transmission Multipurpose Multipoint Electronic Injection Multiplex Communication System Manual Transmission (Transaxle) Mount Mounting Neutral Natural Aspiration Number

OC OCV O/D OEM OPT ORVR O/S P & BV PBD PCS PCV PKB PPS PROM PS PSD PTC PTO PZEV P/W R&P RAM RBS REAS R/F RFS RH RHD RL ROM RR RRS RSE RWD SC SCV SFTM

Oxygen Sensor Oxidation Catalyst Oil Control Valve Overdrive Original Equipment Manufacturing Option On-board Refilling Vapor Recovery Oversize Proportioning and Bypass Valve Power Back Door Power Control System Pre-crash Safety System/Pre-collision System Positive Crankcase Ventilation Parking Brake Progressive Power Steering Programmable Read Only Memory Power Steering Power Slide Door Positive Temperature Coefficient Power Take-Off Partial Zero Emission Vehicle Power Window Rack and Pinion Random Access Memory Recirculating Ball Type Steering Relative Absorber System Reinforcement Rigid Front Suspension Right-Hand Right-Hand Drive Rear Left Read Only Memory Rear Rear Right Rigid Rear Suspension Rear Seat Entertainment Rear Wheel Drive Supercharger Swirl Control Valve (for gasoline engine) Suction Control Valve (for diesel engine) Sichuan Faw Toyota Motor Co., Ltd.

SIA SICS SLLC SOC SOHC SPEC SPI SPV SRS SSM SST STD STJ SULEV T/A TACH TASA TCAP TCM TCV TDB TDC TDV TEMP. TFT TFTM THS ll TIS T/M TMC TMCA TMMBC TMMC TMMF TMMI TMMIN TMMK TMMR TMMT

Subaru of Indiana Automotive, Inc. Starting Injection Control System Super Long Life Coolant State Of Charge Single Overhead Camshaft Specification Single Point Injection Spill Control Valve Supplemental Restraint System Special Service Materials Special Service Tools Standard Cold-Start Fuel Injection Super Ultra Low Emission Vehicle Transaxle Tachometer Toyota Argentina S.A. Toyota Caetano Portugal, S.A. Transmission Control Module Timing Control Valve (for diesel engine) Tumble Control Valve (for gasoline engine) Toyota do Brasil Ltda. Top Dead Center Toyota de Venezuela, C.A. Temperature TOYOTA Free-Tronic Tianjin Faw Toyota Motor Co., Ltd. TOYOTA Hybrid System ll Total Information System for Vehicle Development Transmission Toyota Motor Corporation Toyota Motor Corporation Australia Ltd. Toyota Motor Manufacturing de Baja California, S. de R.L. de C.V. Toyota Motor Manufacturing Canada Inc. Toyota Motor Manufacturing France S.A.S. Toyota Motor Manufacturing, Indiana, Inc. P.T. Toyota Motor Manufacturing Indonesia TOYOTA Motor Manufacturing Kentucky, Inc. Toyota Motor Manufacturing Russia Toyota Motor Manufacturing Turkey Inc.

TMMTX TMUK TMP TMT TMV TPCA TRAC/TRC TSAM TVIP TWC U/D U/S VCV VDIM VENT VGRS VIM VIN VLC VPS VSC VSV VTV VVT-i W/, w/ WGN W/H W/O, w/o X-REAS 1ST, 1st 2ND, 2nd 2WD 3RD, 3rd 4TH, 4th 4WD 4WS 5TH, 5th 6TH, 6th 7TH, 7th 8TH, 8th

Toyota Motor Manufacturing, Texas, Inc. Toyota Motor Manufacturing (UK) Ltd. Toyota Motor Philippines Corp. Toyota Motor Thailand Co. Ltd. Toyota Motor Vietnam Co., Ltd. Toyota Peugeot Citroen Automobiles Czech, s.r.o. Traction Control System Toyota South Africa Motors (Pty) Ltd. TOYOTA Vehicle Intrusion Protection Three-Way Catalyst Underdrive Undersize Vacuum Control Valve Vehicle Dynamics Integrated Management Ventilator Variable Gear Ratio Steering Vehicle Interface Module Vehicle Identification Number Valve Lift Control Variable Power Steering Vehicle Stability Control Vacuum Switching Valve Vacuum Transmitting Valve Variable Valve Timing-intelligent With Wagon Wire Harness Without X-Relative Absorber System First Second Two Wheel Drive Vehicle (4 x 2) Third Fourth Four Wheel Drive Vehicle (4 x 4) Four Wheel Steering System Fifth Sixth Seventh Eighth

GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this service information in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE Abbreviation A/C ACL AIR AP B+ BARO CAC CARB CFI CKP CL CMP CPP CTOX CTP DFI DI DLC3 DTC DTM ECL ECM ECT EEPROM EFE EGR EI EM

TOYOTA Term ()-Abbreviation Air Conditioning Air Conditioner Air Cleaner Air Cleaner, A/CL Secondary Air Injection Air Injection (AI) Accelerator Pedal Battery Positive Voltage +B, Battery Voltage Barometric Pressure HAC Charge Air Cooler Intercooler Carburetor Carburetor Continuous Fuel Injection Crankshaft Position Crank Angle Closed Loop Closed Loop Camshaft Position Cam Angle Clutch Pedal Position Continuous Trap Oxidizer Closed Throttle Position LL ON, Idle ON Direct Fuel Injection Direct Injection (DI./INJ) Distributor Ignition Data Link Connector 3 OBD II Diagnostic Connector Diagnostic Trouble Code Diagnostic Trouble Code Diagnostic Test Mode Engine Coolant Level Engine Electronic Control Unit Engine Control Module (ECU) Coolant Temperature, Water Engine Coolant Temperature Temperature (THW) Electrically Erasable Electrically Erasable Programmable Read Only Memory Programmable Read Only Memory (EEPROM) Cold Mixture Heater (CMH), Heat Early Fuel Evaporation Control Valve (HCV) Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) Electronic Ignition Distributorless Ignition (DLI) Engine Modification Engine Modification (EM) SAE Term

Erasable Programmable Read Only Programmable Read Only Memory

EPROM

Memory

EVAP

Evaporative Emission

FC

Fan Control Flash Electrically Erasable Programmable Read Only Memory Flash Erasable Programmable Read Only Memory Flexible Fuel Fuel Pump Fuel Pump Generator Alternator Ground Ground (GND) Heated Oxygen Sensor (HO2 S) Heated Oxygen Sensor Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel-Shutoff Idle Speed Control Knock Sensor Knock Sensor Mass Airflow Air Flow Meter Manifold Absolute Pressure Manifold Pressure Intake Vacuum Electric Bleed Air Control Valve (EBCV) Mixture Control Mixture Control Valve (MCV) Electric Air Control Valve (EACV) Manifold Differential Pressure Multiport Fuel Injection Electronic Fuel Injection (EFI) Malfunction Indicator Lamp Check Engine Light Manifold Surface Temperature Manifold Vacuum Zone Non-Volatile Random Access Memory Oxygen Sensor, O2 Sensor (O2 S) Oxygen Sensor On-Board Diagnostic System On-Board Diagnostic (OBD) Oxidation Catalytic Convert (OC), Oxidation Catalytic Converter CCo Open Loop Open Loop Pulsed Secondary Air Injection Air Suction (AS) Powertrain Control Module -

FEEPROM FEPROM FF FP GEN GND HO2S IAC IAT ICM IFI IFS ISC KS MAF MAP

MC

MDP MFI MIL MST MVZ NVRAM O2S OBD OC OL PAIR PCM

(PROM) Evaporative Emission Control (EVAP) -

PNP PROM PSP PTOX RAM RM ROM RPM SC SCB SFI SPL SRI SRT ST TB TBI TC TCC TCM TP TR TVV

TWC TWC+OC VAF VR VSS WOT WU-OC WU-TWC

Park/Neutral Position Programmable Read Only Memory Power Steering Pressure Diesel Particulate Filter (DPF) Periodic Trap Oxidizer Diesel Particulate Trap (DPT) Random Access Memory Random Access Memory (RAM) Relay Module Read Only Memory Read Only Memory (ROM) Engine Speed Engine Speed Supercharger Supercharger Supercharger Bypass E-ABV Electronic Fuel Injection (EFI), Sequential Multiport Fuel Injection Sequential Injection Smoke Puff Limiter Service Reminder Indicator System Readiness Test Scan Tool Throttle Body Throttle Body Single Point Injection Throttle Body Fuel Injection Central Fuel Injection (Ci) Turbocharger Turbocharger Torque Converter Clutch Torque Converter Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three-Way Catalytic (TWC) Manifold Converter Three-Way Catalytic Converter CCRO Three-Way + Oxidation Catalytic Converter Volume Airflow Voltage Regulator Vehicle Speed Sensor Wide Open Throttle Warm Up Oxidation Catalytic Converter Warm Up Three-Way Catalytic Converter

CCR + CCo Air Flow Meter Voltage Regulator Vehicle Speed Sensor Full Throttle -

3GR 4GR

Third Gear Fourth Gear

-

2012-2017 ACCESSORIES & EQUIPMENT Lighting System (Exterior) (Service Information) (Except Hybrid) - Camry

HEADLIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 1: Identifying Headlight Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Headlight Assembly Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION (for HID Headlight) Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before

disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for HID Headlight) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL . 4. REMOVE HEADLIGHT ASSEMBLY a. Remove the 3 screws and bolt.

Fig. 3: Identifying Headlight Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp.

Fig. 4: Identifying Headlight Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect each connector and remove the headlight assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 HEADLIGHT BULB a. Turn the No. 1 headlight bulb in the direction indicated by the arrow shown in the illustration, and remove it.

Fig. 5: Removing No. 1 Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

2. REMOVE NO. 2 HEADLIGHT BULB (for Halogen Headlight) a. Turn the No. 2 headlight bulb in the direction indicated by the arrow shown in the illustration, and remove it.

Fig. 6: Removing No. 2 Headlight Bulb (For Halogen Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

3. REMOVE HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY (for HID Headlight) a. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 7: Removing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force using a tool. Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

b. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 8: Removing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

c. Disengage the clamp.

Do not apply excessive force using a tool. Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

Fig. 9: Removing Headlight Light Control ECU Sub-Assembly Clamp (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and remove it. NOTE:

Do not pull the headlight light control ECU sub-assembly with the socket connected.

4. REMOVE DISCHARGE HEADLIGHT BULB (for HID Headlight) a. Release the set spring as shown in the illustration and remove the discharge headlight bulb.

Fig. 10: Removing Discharge Headlight Bulb (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

5. REMOVE HEADLIGHT SOCKET COVER a. for Halogen Headlight: 1. Remove the 2 headlight socket covers from the headlight unit. b. for HID Headlight: 1. Remove the headlight socket cover from the headlight unit. 6. REMOVE FRONT TURN SIGNAL LIGHT BULB a. Turn the front turn signal light socket with the front turn signal light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 11: Removing Front Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front turn signal light bulb from the front turn signal light socket. 7. REMOVE FRONT SIDE MARKER LIGHT BULB a. Turn the front side marker light socket with the front side marker light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 12: Removing Front Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front side marker light bulb from the front side marker light socket. ADJUSTMENT ADJUSTMENT

HINT: It is possible that a bulb is incorrectly installed, affecting headlight aim. Bulb installation should be considered prior to performing the adjustment procedure. 1. PREPARE VEHICLE FOR HEADLIGHT AIM ADJUSTMENT a. Prepare the vehicle:  Ensure that there is no damage or deformation to the body around the headlights.  Fill the fuel tank.  Make sure that the oil is filled to the specified level.  Make sure that the engine coolant is filled to the specified level.  Inflate the tires to the appropriate pressure.  Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.  Sit a person of average weight (68 kg, 150 lb) in the driver's seat.  Vehicles with manual headlight beam level control system should be adjusted to "0".

Fig. 13: Adjusting Halogen Headlight To "0" For Headlight Aim Adjustment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. PREPARE FOR HEADLIGHT AIMING (Using a headlight aim test machine) a. Adjust the headlight aim in accordance with the headlight aim test machine instructions. 3. PREPARE FOR HEADLIGHT AIMING (Using a Screen) a. Prepare the vehicle:

Fig. 14: Identifying Headlight Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

    

Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot. Place the vehicle at a 90° angle to the wall. Create a 7.62 m (25 ft.) distance between the vehicle (headlight bulb center) and the wall. Make sure that the vehicle is on a level surface. Position the front wheels straight ahead. Bounce the vehicle up and down several times to settle the suspension.

NOTE:

A distance of 7.62 m (25 ft.) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of headlight aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

b. Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen. c. Draw a vertical line down the center of the screen (V line). d. Set the screen as shown in the illustration.

Fig. 15: Identifying Headlight Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Stand the screen perpendicular to the ground.  Align the V line on the screen with the center of the vehicle. e. Draw base lines (H, V LH and V RH lines) on the screen as shown in the illustration. 

Fig. 16: Identifying V LH Line, V RH Line Graph

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION V LH *a Line *b V Line V RH *c Line *d H Line *e Ground HINT: The base lines differ for "low beam inspection" and "high beam inspection".  Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb as the center mark. 1. H Line (Headlight height): 

Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low beam headlights. 2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam headlight bulbs). 4. INSPECT HEADLIGHT AIMING a. Cover the headlight or disconnect the connector of the headlight/ECU on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection. WARNING: Do not disconnect the HID high voltage connector for the bulb when performing this aiming inspection. NOTE:

Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

HINT: When checking the aim of the high beam, cover the low beam or disconnect the connector. b. Start the engine.

c. Turn on the headlights and check the aiming of each beam. HINT:  

Preferred position for the low beam: Matches preferred cutoff line shown in the illustration. Preferred position for the high beam: Matches center of intensity shown in the illustration.

Fig. 17: Identifying Preferred Beam Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 



Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure. If the alignment distance is 7.62 m (25 ft.): The low beam cutoff line should be within 101 mm (3.97 in.) above or below the H line as well as 101 mm (3.97 in.) left or right of the V line (SAE J599).



If the alignment distance is 3 m (9.84 ft.):

The low beam cutoff line should be within 39 mm (1.56 in.) above or below the H line as well as 39 mm (1.56 in.) left or right of the V line (SAE J599). 

If the alignment distance is 7.62 m (25 ft.): The high beam center of intensity should be within 101 mm (3.97 in.) above or below the H line as well as left and right of the V line (SAE J599).



If the alignment distance is 3 m (9.84 ft.): The high beam center of intensity should be within 39 mm (1.56 in.) above or below the H line as well as 39 mm (1.56 in.) left or right of the V line (SAE J599).

5. ADJUST HEADLIGHT AIMING a. Adjust the aim vertically:

Fig. 18: Adjusting Headlight Aim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for for HID *A Halogen *B Headlight Headlight Aiming *1 Screw Adjust the aim of each headlight to the specified range by turning aiming screw with a screwdriver. NOTE:

HINT:

The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.







The low beam light and the high beam light are a unit. Adjusting the aim on the low beam to the correct position should also result in the high beam adjustment being correct. If it is not possible to correctly adjust the headlight aim, check the bulbs, headlight unit and headlight unit reflector installation. The headlight aim moves up when turning the aiming screw counterclockwise, and moves down when turning the aiming screw clockwise.

REASSEMBLY REASSEMBLY

1. INSTALL FRONT SIDE MARKER LIGHT BULB a. Install the front side marker light bulb to the front side marker light socket. b. Turn the front side marker light socket with the front side marker light bulb in the direction indicated by the arrow shown in the illustration and install them as a unit.

Fig. 19: Installing Front Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT TURN SIGNAL LIGHT BULB a. Install the front turn signal light bulb to the front turn signal light socket. b. Turn the front turn signal light socket with the front turn signal light bulb in the direction indicated by the arrow shown in the illustration and install them as a unit.

Fig. 20: Installing Front Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL HEADLIGHT SOCKET COVER a. for Halogen Headlight: 1. Install the 2 headlight socket covers to the headlight unit. b. for HID Headlight: 1. Install the headlight socket cover to the headlight unit. 4. INSTALL NO. 2 HEADLIGHT BULB (for Halogen Headlight) a. Turn the No. 2 headlight bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 21: Installing No. 2 Headlight Bulb (For Halogen Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

5. INSTALL DISCHARGE HEADLIGHT BULB (for HID Headlight) a. Set the discharge headlight bulb to the headlight unit. NOTE:

Do not touch the bulb glass.

b. Lock the set spring to install the discharge headlight bulb as shown in the illustration.

Fig. 22: Installing Discharge Headlight Bulb (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY (for HID Headlight) a. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration to connect it.

Fig. 23: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:







Check that the O-ring is installed on the headlight light control ECU sub-assembly. Check that the O-ring is not damaged or contaminated with foreign matter. If there is any damage, replace the O-ring with a new one. Do not pull the headlight light control ECU sub-assembly with the socket connected.

b. Check that the red line on the output harness is not twisted and store the harness in the headlight assembly securely so that the output harness is not pinched. TEXT IN ILLUSTRATION Red *1 Line c. Engage the clamp.

Fig. 24: Installing Headlight Light Control ECU Sub-Assembly Clamp (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 25: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

e. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 26: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

7. INSTALL NO. 1 HEADLIGHT BULB a. Turn the No. 1 headlight bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 27: Installing No. 1 Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL HEADLIGHT ASSEMBLY a. Connect each connector. b. Engage the clamp. c. Install the headlight assembly with the 3 screws and bolt. Screw Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) Bolt Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf)

2. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION . 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for HID Headlight) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT. 5. ADJUST FOG LIGHT AIMING (w/ Fog Light) Refer to ADJUSTMENT.

HIGH INTENSITY DISCHARGE HEADLIGHT BULB COMPONENTS ILLUSTRATION

Fig. 28: Identifying High Intensity Discharge Headlight Bulb Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT DISCHARGE HEADLIGHT BULB NOTE:

Confirm the following items before replacing a discharge headlight bulb. If a malfunction is discovered and repaired, perform the inspection again to confirm the repair. 



Make sure that the high voltage socket of the light control ECU and discharge headlight bulb are connected normally. Make sure that there is no damage to the high voltage socket of the light control ECU or discharge headlight bulb connector.

HINT: Even if a bulb seems to turn on normally, it may not be normal. Perform all the following steps in order because an abnormal condition might otherwise not be easy to duplicate. a. Prepare the vehicle: Before performing the following inspection procedure, turn off the discharge headlight bulbs for more than 10 minutes to allow them to cool down sufficiently. HINT: Since it is necessary to find the cause of a malfunction that causes a discharge headlight bulb not to turn on, the discharge headlight bulbs should be inspected starting from a cooled off state. 1. Turn on the discharge headlights for more than 25 minutes, and check that the bulbs illuminate normally when they are turned on. HINT: Leave the headlights on for more than 25 minutes to stabilize the discharge headlight bulb arc tube voltage.  A discharge headlight bulb that has almost reached the end of its life may turn off due to a headlight control ECU fail-safe function because the arc tube voltage is high. 2. Repeatedly turn the discharge headlights off for 15 seconds and on for 15 seconds (5 times for each). Check that the bulbs illuminate normally. 

HINT: This inspection confirms the ability of the bulbs to start when hot. 3. Turn off the discharge headlights for 3 minutes, and then turn on the discharge headlights for 3 minutes. Check that the bulbs illuminate normally when they are turned on. HINT:





A characteristic of discharge headlight bulbs is that their starting voltage is highest when 3 minutes have elapsed after being turned off. This is the most difficult situation for discharge bulbs to start in. This inspection is further confirmation of the ability of the bulbs to start when hot.

Fig. 29: Identifying Discharge Headlight Bulb Inspection Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard The discharge headlight bulbs illuminate normally in all steps. 4. Remove the discharge headlight bulb and perform a visual inspection of the arc tube. Standard The inside of the arc tube is not bulging or deformed and is not clouded. However, a dull brown coloration inside the arc tube is normal.

Fig. 30: Identifying Arc Tube Coloration Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Discharge Discharge Headlight Headlight Bulb at *A *B Bulb is End of Normal Usable Life *1 Arc Tube - Distortion / Inside of Clouded Arc Tube Area REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before

disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY WARNING: The headlight light control ECU sub-assembly may be hot when the light control switch is in the HEAD position or right after it is turned off. Check that the headlight light control ECU sub-assembly is not hot before starting work. a. Disconnect the connector. b. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 31: Removing Headlight Light Control ECU Sub-Assembly (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Do not apply excessive force using a tool.



Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

c. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 32: Removing Headlight Light Control ECU Sub-Assembly (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Do not apply excessive force using a tool.



d. Disengage the clamp.

Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

Fig. 33: Removing Headlight Light Control ECU Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and remove it.

NOTE:

Do not pull the headlight light control ECU sub-assembly with the socket connected.

4. REMOVE DISCHARGE HEADLIGHT BULB a. Release the set spring as shown in the illustration and remove the discharge headlight bulb.

Fig. 34: Removing Discharge Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL DISCHARGE HEADLIGHT BULB a. Set the discharge headlight bulb to the headlight unit. NOTE:

Do not touch the bulb glass.

b. Lock the set spring to install the discharge headlight bulb as shown in the illustration.

Fig. 35: Installing Discharge Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY a. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the

arrow shown in the illustration to connect it.

Fig. 36: Installing Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:







Check that the O-ring is installed on the headlight light control ECU sub-assembly. Check that the O-ring is not damaged or contaminated with foreign matter. If there is any damage, replace the O-ring with a new one. Do not pull the headlight light control ECU sub-assembly with the socket connected.

b. Check that the red line on the output harness is not twisted and store the harness in the headlight assembly securely so that the output harness is not pinched. TEXT IN ILLUSTRATION Red *1 Line c. Engage the clamp.

Fig. 37: Installing Headlight Light Control ECU Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 38: Installing Headlight Light Control ECU Sub-Assembly (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock

*1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

e. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 39: Installing Headlight Light Control ECU Sub-Assembly (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock

*1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

f. Connect the connector. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

FOG LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 40: Identifying Fog Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL . 2. REMOVE FOG LIGHT ASSEMBLY a. Remove the screw.

Fig. 41: Identifying Fog Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides and remove the fog light assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE FOG LIGHT BULB a. Turn the fog light bulb in the direction indicated by the arrow shown in the illustration and remove it.

Fig. 42: Removing Fog Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

ADJUSTMENT ADJUSTMENT

HINT: It is possible that a bulb is incorrectly installed, affecting fog light aim. Bulb installation should be considered prior to performing the adjustment procedure. 1. PREPARE VEHICLE FOR FOG LIGHT AIM ADJUSTMENT a. Prepare the vehicle:  Ensure there is no damage or deformation to the body around the fog lights.  Fill the fuel tank.  Make sure that the oil is filled to the specified level.  Make sure that the coolant is filled to the specified level.  Inflate the tires to the appropriate pressure.  Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.  Sit a person of average weight (68 kg, 150 lb) in the driver's seat. 2. PREPARE FOR FOG LIGHT AIMING

a. Prepare the vehicle:

Fig. 43: Identifying Fog Light Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

    

Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot. Place the vehicle at a 90° angle to the wall. Create a 7.62 m (25 ft.) distance between the vehicle (fog light bulb center) and the wall. Make sure that the vehicle is on a level surface. Position the front wheels straight ahead. Bounce the vehicle up and down to settle the suspension. NOTE:

A distance of 7.62 m (25 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

b. Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen. c. Draw a vertical line down the center of the screen (V line). d. Set the screen as shown in the illustration.

Fig. 44: Identifying Fog Light Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Stand the screen perpendicular to the ground.  Align the V line on the screen with the center of the vehicle. e. Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration. 

Fig. 45: Identifying V LH Line, V RH Line Graph

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION V LH *a Line *b V Line V RH *c Line *d H Line *e Ground HINT: Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb. 1. H Line (Fog light height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights. 2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the fog light bulbs). 3. INSPECT FOG LIGHT AIMING a. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection. b. Start the engine. c. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration.

Fig. 46: Inspecting Fog Light Aiming Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 

If the alignment distance is 7.62 m (25 ft.): The upper edge of the hot zone for the fog light should be 229 mm (9.02 in.) below the H line.



If the alignment distance is 3 m (9.84 ft.): The upper edge of the hot zone for the fog light should be 90 mm (3.54 in.) below the H line.

4. ADJUST FOG LIGHT AIMING a. Adjust the aim vertically: Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.

Fig. 47: Adjusting Fog Light Aim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Aiming *1 Screw NOTE:

The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

HINT: If it is not possible to correctly adjust fog light aim, check bulb, fog light unit and fog light unit reflector installation.

REASSEMBLY REASSEMBLY

1. INSTALL FOG LIGHT BULB a. Turn the fog light bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 48: Installing Fog Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL FOG LIGHT ASSEMBLY a. Engage the 2 guides. b. Install the fog light assembly with the screw. Torque: 1.6 N*m (16 kgf*cm, 14 in.*lbf)

2. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION .

SIDE TURN SIGNAL LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 49: Identifying Side Turn Signal Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: 

Use the same procedure for the RH and LH sides.



The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR . Refer to REMOVAL - Step 2 . 2. REMOVE OUTER MIRROR COVER . Refer to REMOVAL - Step 4 . 3. REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY a. Disengage the 2 claws.

Fig. 50: Identifying Side Turn Signal Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the side turn signal light assembly. INSPECTION INSPECTION

1. INSPECT SIDE TURN SIGNAL LIGHT ASSEMBLY LH a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 51: Identifying Turn Signal Light Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the side turn signal light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (Side Turn Signal Light Assembly LH) If the result is not as specified, replace the side turn signal light assembly LH. 2. INSPECT SIDE TURN SIGNAL LIGHT ASSEMBLY RH a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 52: Identifying Turn Signal Light Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the side turn signal light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (Side Turn Signal Light Assembly RH) If the result is not as specified, replace the side turn signal light assembly RH. INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY a. Connect the connector. b. Engage the 2 claws to install the side turn signal light assembly. 2. INSTALL OUTER MIRROR COVER . Refer to INSTALLATION - Step 2 . 3. INSTALL OUTER REAR VIEW MIRROR . Refer to INSTALLATION - Step 2 .

REAR COMBINATION LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 53: Identifying Rear Combination Light Assembly Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 54: Identifying Rear Combination Light Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REAR COMBINATION LIGHT ASSEMBLY LH

a. Disconnect the connector from the rear combination light assembly LH.

Fig. 55: Inspecting Rear Combination Light Assembly LH Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition Turn signal Below 1 switch in V neutral T8-1 (B)- position T8-2 (E) Turn 11 to 14 V signal (60 to 120 switch in times per left turn minute) position Light Below 1 control V switch off T9-2 (TL) - Light T9-1 (E) control switch in 11 to 14 V tail position Brake Below 1 pedal V T9-3 (STP) released - T9-1 (E) Brake 11 to 14 V pedal depressed Light Below 1 control V switch off T19-2 (B) - Light T19-1 (E) control switch in 11 to 14 V tail position TEXT IN ILLUSTRATION Front view of wire *a harness connector (to Rear Combination

Light Assembly LH) If the result is not as specified, repair or replace the wire harness or connector. 2. INSPECT REAR COMBINATION LIGHT ASSEMBLY RH a. Disconnect the connector from the rear combination light assembly RH.

Fig. 56: Inspecting Rear Combination Light Assembly RH Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below.

Standard Voltage Tester Switch Specified Connection Condition Condition Turn signal Below 1 switch in V neutral T13-1 (B) - position T13-2 (E) Turn 11 to 14 V signal (60 to 120 switch in times per right turn minute) position Light Below 1 control V switch off T12-2 (TL) Light - T12-1 (E) control switch in 11 to 14 V tail position Brake Below 1 pedal V T12-3 released (STP) T12-1 (E) Brake pedal 11 to 14 V depressed Light Below 1 control V switch off T20-2 (B) - Light T20-1 (E) control switch in 11 to 14 V tail position TEXT IN ILLUSTRATION Front view of wire harness *a connector (to Rear Combination Light Assembly

RH) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL . 2. 3. 4. 5. 6. 7. 8.

REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to REMOVAL - Step 1 . REMOVE SPARE WHEEL COVER ASSEMBLY . Refer to REMOVAL - Step 2 . REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 . REMOVE REAR FLOOR FINISH PLATE . Refer to REMOVAL - Step 4 . REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to REMOVAL - Step 22 . REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER . Refer to REMOVAL - Step 6 . REMOVE REAR COMBINATION LIGHT ASSEMBLY a. Disconnect each connector.

Fig. 57: Identifying Rear Combination Light Assembly Connectors And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. c. Remove the 4 nuts and rear combination light assembly.

Fig. 58: Identifying Rear Combination Light Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR COMBINATION LIGHT PACKING a. Remove the rear combination light packing.

Fig. 59: Identifying Rear Combination Light Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be sure to remove all the traces of the old packing from the body. Do not reuse the removed packing. Be sure to install a new rear combination light packing to prevent water ingress.

2. REMOVE REAR SIDE MARKER LIGHT BULB a. Turn the rear side marker light socket with the rear side marker light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 60: Removing Rear Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear side marker light bulb from the rear side marker light socket. 3. REMOVE REAR TURN SIGNAL LIGHT BULB a. Turn the rear turn signal light socket with the rear turn signal light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 61: Removing Rear Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear turn signal light bulb from the rear turn signal light socket. 4. REMOVE TAIL AND STOP LIGHT BULB a. Turn the tail and stop light socket with the tail and stop light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 62: Removing Tail And Stop Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail and stop light bulb from the tail and stop light socket. 5. REMOVE REAR BUMPER UPPER SIDE RETAINER a. Using a screwdriver, disengage the claw and remove the rear bumper upper side retainer as shown in the illustration.

Fig. 63: Removing Rear Bumper Upper Side Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL REAR BUMPER UPPER SIDE RETAINER a. Engage the claw to install the rear bumper upper side retainer as shown in the illustration.

Fig. 64: Installing Rear Bumper Upper Side Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL TAIL AND STOP LIGHT BULB a. Install the tail and stop light bulb to the tail and stop light socket. b. Turn the tail and stop light socket with the tail and stop light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 65: Installing Tail And Stop Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR TURN SIGNAL LIGHT BULB a. Install the rear turn signal light bulb to the rear turn signal light socket. b. Turn the rear turn signal light socket with the rear turn signal light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 66: Installing Rear Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL REAR SIDE MARKER LIGHT BULB a. Install the rear side marker light bulb to the rear side marker light socket. b. Turn the rear side marker light socket with the rear side marker light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 67: Installing Rear Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL REAR COMBINATION LIGHT PACKING a. Install a new rear combination light packing.

Fig. 68: Identifying Rear Combination Light Packing

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR COMBINATION LIGHT ASSEMBLY a. Install the rear combination light assembly with the 4 nuts. Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf)

2. 3. 4. 5. 6. 7. 8.

b. Engage the clamp. c. Connect each connector. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER . Refer to INSTALLATION Step 6 . INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to INSTALLATION - Step 4. INSTALL REAR FLOOR FINISH PLATE . Refer to INSTALLATION - Step 9 . INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 10 . INSTALL SPARE WHEEL COVER ASSEMBLY . Refer to INSTALLATION - Step 11 . INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to INSTALLATION - Step 12 . INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION .

REAR LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 69: Identifying Rear Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REAR LIGHT ASSEMBLY LH

a. Disconnect the connector from the rear light assembly LH.

Fig. 70: Inspecting Rear Light Assembly LH Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Engine started Below 1 and the V shift lever T18-2 not in R (B/U) T18-1 (E) Engine started and the 11 to 14 V shift lever in R TEXT IN ILLUSTRATION Front view of wire

harness connector (to Rear *a Light Assembly LH) If the result is not as specified, repair or replace the wire harness or connector. 2. INSPECT REAR LIGHT ASSEMBLY RH a. Disconnect the connector from the rear light assembly RH.

Fig. 71: Inspecting Rear Light Assembly RH Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Engine started Below 1 and the V shift lever T17-2 not in R (B/U) -

T17-1 (E)

Engine started 11 to 14 V and the shift lever in R

TEXT IN ILLUSTRATION Front view of wire harness *a connector (to Rear Light Assembly RH) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 . 2. REMOVE REAR LIGHT ASSEMBLY a. Disconnect the connector.

Fig. 72: Identifying Rear Light Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and rear light assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR LIGHT GASKET a. Remove the rear light gasket.

Fig. 73: Identifying Rear Light Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Be sure to remove all the traces of the old gasket from the body. Do not reuse the removed gasket. Be sure to install a new rear light gasket to prevent water ingress.

2. REMOVE BACK-UP LIGHT BULB a. Turn the back-up light socket with the back-up light bulb in the direction indicated by the arrow shown in the illustration and remove them as a unit.

Fig. 74: Removing Back-Up Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the back-up light bulb from the back-up light socket. REASSEMBLY REASSEMBLY

1. INSTALL BACK-UP LIGHT BULB a. Install the back-up light bulb to the back-up light socket. b. Turn the back-up light socket with the back-up light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 75: Installing Back-Up Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL REAR LIGHT GASKET a. Install a new rear light gasket.

Fig. 76: Identifying Rear Light Gasket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR LIGHT ASSEMBLY a. Install the rear light assembly with the 3 nuts.

Fig. 77: Identifying Rear Light Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Nut (A) Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) Nut (B) Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) b. Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 12 .

LICENSE PLATE LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 78: Identifying License Plate Light Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL .

2. REMOVE LICENSE PLATE LIGHT ASSEMBLY a. Disconnect the connector.

Fig. 79: Locating License Plate Light Assembly Connector And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and remove the license plate light assembly. 3. REMOVE LICENSE PLATE LIGHT PACKING a. Remove the license plate light packing.

Fig. 80: Identifying License Plate Light Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not reuse the removed packing. Be sure to install a new license plate light packing to prevent water ingress.

INSPECTION INSPECTION

1. INSPECT LICENSE PLATE LIGHT ASSEMBLY a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 81: Identifying License Plate Light Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the license plate light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness *a connected (License Plate Light Assembly) If the result is not as specified, replace the bulb or license plate light socket and wire. INSTALLATION INSTALLATION

HINT: 

Use the same procedure for the RH and LH sides.



The procedure described below is for the LH side.

1. INSTALL LICENSE PLATE LIGHT PACKING a. Install a new license plate light packing. 2. INSTALL LICENSE PLATE LIGHT ASSEMBLY a. Engage the 2 claws to install the license plate light assembly. b. Connect the connector. 3. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION .

HIGH MOUNTED STOP LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 82: Identifying High Mounted Stop Light Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CENTER STOP LIGHT SET a. Slide the center stop light set in the order and directions shown by the arrows in the illustration while pushing it towards the rear of the vehicle to disengage the 4 claws.

Fig. 83: Removing Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the center stop light set 180 degrees as shown by the arrow in the illustration.

Fig. 84: Turning Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This makes it easier to disconnect the connector. c. Disconnect the connector and remove the center stop light set. INSPECTION INSPECTION

1. INSPECT CENTER STOP LIGHT SET a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 85: Identifying Center Stop Light Set Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the center stop light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Center Stop Light Set) If the result is not as specified, replace the center stop light set. INSTALLATION INSTALLATION

1. INSTALL CENTER STOP LIGHT SET a. Connect the connector. b. Temporarily install the center stop light set.

c. Slide the center stop light set in the order and directions shown by the arrows in the illustration while pushing it towards the rear of the vehicle to engage the 4 claws.

Fig. 86: Installing Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HEADLIGHT DIMMER SWITCH COMPONENTS ILLUSTRATION

Fig. 87: Identifying Headlight Dimmer Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY Refer to REMOVAL . 2. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY . Refer to REMOVAL - Step 3 . 3. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 88: Identifying Headlight Dimmer Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 3 claws and remove the headlight dimmer switch assembly. INSPECTION INSPECTION

1. INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 89: Inspecting Headlight Dimmer Switch Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance LIGHT CONTROL SWITCH (W/ DRL OFF FUNCTION) Tester Switch Specified Connection Condition Condition 18 (T) - 15 Light 10 kohms (EL) or higher control 19 (H) - 15 switch off 10 kohms (EL) (DRL or higher 20 (A) - 15 OFF 10 kohms position) or higher (EL) Light control 20 (A) - 15 Below 1 switch in (EL) ohms AUTO position Light control 18 (T) - 15 Below 1 switch in (EL) ohms tail position 18 (T) - 15 Light (EL) control

Below 1 ohms

switch in 19 (H) - 15 Below 1 head (EL) ohms position LIGHT CONTROL SWITCH (W/O DRL OFF FUNCTION) Tester Switch Specified Connection Condition Condition 18 (T) - 15 10 kohms (EL) or higher Light 19 (H) - 15 10 kohms control (EL) or higher switch off 20 (A) - 15 10 kohms (EL) or higher Light control 18 (T) - 15 Below 1 switch in (EL) ohms tail position 18 (T) - 15 Light Below 1 control (EL) ohms switch in 19 (H) - 15 head Below 1 (EL) position ohms Light control 20 (A) - 15 Below 1 switch in (EL) ohms AUTO position DIMMER SWITCH Tester Switch Specified Connection Condition Condition Dimmer 14 (HU) - switch in Below 1 15 (EL) high ohms position 14 (HU) - Dimmer Below 1 switch in ohms 15 (EL) high 17 (HF) - flasher Below 1 15 (EL) position ohms TURN SIGNAL SWITCH Tester Switch Specified Connection Condition Condition

12 (TR) 15 (EL) 11 (TL) 15 (EL) 12 (TR) 15 (EL) 11 (TL) 15 (EL)

10 kohms or higher Neutral 10 kohms or higher Below 1 Right turn ohms Below 1 Left turn ohms

FRONT FOG LIGHT SWITCH*1 Tester Switch Specified Connection Condition Condition Front fog 8 (LFG) - 9 10 kohms light (BFG) or higher switch off Front fog 8 (LFG) - 9 Below 1 light (BFG) ohms switch on *1: w/ Front Fog Light TEXT IN ILLUSTRATION Component without harness connected *a (Headlight Dimmer Switch Assembly) If the result is not as specified, replace the headlight dimmer switch assembly. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY a. Engage the 3 claws to install the headlight dimmer switch assembly. b. Connect the connector. 2. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY . Refer to INSTALLATION - Step 1 . 3. INSTALL SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY Refer to INSTALLATION .

HAZARD WARNING SWITCH COMPONENTS ILLUSTRATION

Fig. 90: Identifying Hazard Warning Switch Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 91: Identifying Hazard Warning Switch Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 92: Identifying Hazard Warning Switch Replacement Components (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 93: Identifying Hazard Warning Switch Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 94: Identifying Hazard Warning Switch Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 . 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 . 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 8 . 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 9 . 11. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 8 . 12. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 10 . 13. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 11 . 14. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 12 . 15. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 13 . 16. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 14 . 17. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 15 . 18. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 . 19. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 10 . 20. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) . Refer to

REMOVAL - Step 20 . INSPECTION INSPECTION

1. INSPECT AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) a. Measure the resistance according to the value(s) in the table below.

Fig. 95: Inspecting Air Conditioning Control Assembly (Hazard Switch) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Hazard 10 kohms 4 (HAZ) - 6 switch off or higher (GND) Hazard Below 1 switch on ohms TEXT IN ILLUSTRATION Component without harness

connected (Air Conditioning *a Control Assembly (Hazard Switch)) If the result is not as specified, replace the air conditioning control assembly. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) . Refer to INSTALLATION - Step 1 . 2. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 8. 3. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 9. 4. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 10 . 5. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 11 . 6. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 12 . 7. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 . 8. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 5 . 9. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 6 . 10. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 . 11. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 . 12. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 . 13. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 . 14. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 . 15. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . 16. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 .

17. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION . 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

HEADLIGHT LEVELING SWITCH COMPONENTS ILLUSTRATION

Fig. 96: Identifying Headlight Leveling Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 . 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 7 . 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 8. 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 9.

6. REMOVE HEADLIGHT LEVELING SWITCH a. Disengage the 2 claws and remove the headlight leveling switch.

Fig. 97: Identifying Headlight Leveling Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT HEADLIGHT LEVELING SWITCH a. Voltage Check 1. Connect a positive (+) lead from the battery to terminal 1 (B) and a negative (-) lead to terminal 5 (E).

Fig. 98: Inspecting Headlight Leveling Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the voltage according to the value(s) in the table below. Standard Voltage Specified Condition Tester Switch (Battery Condition Position voltage is 12 V) 10.44 to 0 11.16 V 9.16 to 1 9.88 V 7.88 to 2 8.60 V 2 (T) - 5 (E) 6.6 to 7.32 3 V 5.32 to 4 6.04 V 4.04 to 5 4.76 V TEXT IN ILLUSTRATION

Component without harness *a connected (Headlight Leveling Switch) If the result is not as specified, replace the headlight leveling switch. b. LED Illumination Inspection

Fig. 99: Inspecting Headlight Leveling Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply battery voltage to the headlight leveling switch and check that the switch illuminates. OK Tester Specified Connection Condition Battery positive (+) --> Illuminates Terminal 3 (ILL+) Battery

negative (-) --> Terminal 4 (ILL-) TEXT IN ILLUSTRATION Component without harness *a connected (Headlight Leveling Switch) If the result is not as specified, replace the headlight leveling switch. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT LEVELING SWITCH a. Engage the 2 claws to install the headlight leveling switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 44 . 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 45 . 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 46 . 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 .

STOP LIGHT SWITCH COMPONENTS ILLUSTRATION

Fig. 100: Identifying Stop Light Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STOP LIGHT SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 101: Locating Stop Light Switch Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the stop light switch assembly counterclockwise and remove it.

Fig. 102: Removing Stop Light Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT STOP LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 103: Inspecting Stop Light Switch Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms Pushed or higher

1-2

Not pushed Pushed

3-4

Not pushed

Below 0.1 ohms Below 200 ohms 10 kohms or higher

TEXT IN ILLUSTRATION Component without harness *a connected (Stop Light Switch Assembly) *b Not Pushed *c Pushed If the result is not as specified, replace the stop light switch assembly. INSTALLATION INSTALLATION

1. INSTALL STOP LIGHT SWITCH ASSEMBLY a. Insert the stop light switch assembly until the threaded sleeve hits the pedal.

Fig. 104: Inserting Stop Light Switch Assembly Until Rod Hits Pedal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

b. Make a quarter turn clockwise to install the stop light switch assembly.

Fig. 105: Turning Stop Light Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less NOTE:

When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

c. Connect the connector. d. Check the protrusion of the plunger. PROTRUSION OF THE PLUNGER Area Measurement 1.5 to 2.5 mm a (0.0591 to 0.0984 in.) If the protrusion is not as specified, recheck switch installation and inspect brake pedal adjustment if necessary. Refer to ADJUSTMENT . NOTE:

Do not depress or support the brake pedal.

AUTOMATIC LIGHT CONTROL SENSOR

COMPONENTS ILLUSTRATION

Fig. 106: Identifying Automatic Light Control Sensor Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 107: Identifying Automatic Light Control Sensor Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 . 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 . 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 8 . 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 9 . 11. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 8 . 12. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to REMOVAL - Step 30 . 13. REMOVE AUTOMATIC LIGHT CONTROL SENSOR a. Disengage the 2 claws and remove the automatic light control sensor.

Fig. 108: Identifying Automatic Light Control Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (for Automatic Air Conditioning System) a. Disconnect the I61 automatic light control sensor connector.

Fig. 109: Inspecting I61 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage and resistance according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition Ignition Below 1 I61-6 switch off V (CLTB) Ignition I61-3 switch 11 to 14 V (CLTE) ON Standard Resistance Tester Specified Condition Connection Condition I61-3 (CLTE) Below 1 Always Body ohms ground TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Automatic Light Control Sensor) If the result is not as specified, there may be a malfunction on the wire harness side. c. Reconnect the I61 automatic light control sensor connector.

Fig. 110: Inspecting I61 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Connect an oscilloscope to the automatic light control sensor connector. TEXT IN ILLUSTRATION Component with harness connected *a (Automatic Light Control Sensor) e. Check the waveform.

Fig. 111: Identifying Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Tool Switch Specified Connection Setting Condition Condition I61-3 5 Ignition Correct (CLTE) - V/DIV., switch I61-5 5 ON, light waveform is as (CLTS) ms./DIV control switch in shown

AUTO position

above

HINT: If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, the automatic light control sensor may have a malfunction. 2. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (for Manual Air Conditioning System) a. Disconnect the I132 automatic light control sensor connector.

Fig. 112: Inspecting I132 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage and resistance according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition Ignition Below 1 I132-3 switch off V (CLTB) Ignition I132-5 switch 11 to 14 V (CLTE) ON

Standard Resistance Tester Specified Condition Connection Condition I132-5 (CLTE) Below 1 Always Body ohms ground TEXT IN ILLUSTRATION Front view of wire harness connector *a (to Automatic Light Control Sensor) If the result is not as specified, there may be a malfunction on the wire harness side. c. Reconnect the I132 automatic light control sensor connector.

Fig. 113: Inspecting I132 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect an oscilloscope to the automatic light control sensor connector. TEXT IN ILLUSTRATION Component with harness connected *a (Automatic Light Control Sensor) e. Check the waveform.

Fig. 114: Identifying Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Tool Switch Specified Connection Setting Condition Condition Ignition switch Correct I132-5 5 ON, light waveform (CLTE) - V/DIV., control is as I132-4 5 switch in shown (CLTS) ms./DIV AUTO above position HINT: If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, the automatic light control sensor may have a malfunction. INSTALLATION INSTALLATION

1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR a. Engage the 2 claws to install the automatic light control sensor.

2. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to INSTALLATION - Step 23 . 3. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 . 4. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 . 5. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 . 6. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 . 7. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 . 8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . 9. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . 10. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION . 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

HEIGHT CONTROL SENSOR COMPONENTS ILLUSTRATION

Fig. 115: Identifying Height Control Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Disconnect the connector.

Fig. 116: Locating Rear Height Control Sensor Sub-Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the nut and 2 bolts. c. Disengage the clamp and remove the rear height control sensor sub-assembly. NOTE:

Do not drop the rear height control sensor sub-assembly. If it is dropped, replace it with a new one.

INSPECTION INSPECTION

1. INSPECT REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Connect 3 dry cell batteries (1.5 V) in series. NOTE:

Do not use rechargeable batteries as they may not output a voltage of 1.5 V.

Fig. 117: Inspecting Rear Height Control Sensor Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the batteries to terminal 3 (SHB) and the negative (-) lead from the batteries to terminal 1 (SHG).

c. Measure the voltage between terminals 2 (SHRR) and 1 (SHG) while slowly moving the link up and down. Standard Voltage Tester Specified Condition Connection Condition 2 (SHRR) - +37.9° 3.77 V 1 (SHG) (High) 2 (SHRR) - 0° 2.25 V 1 (SHG) (Normal) 2 (SHRR) - -36.9° 0.77 V 1 (SHG) (Low) TEXT IN ILLUSTRATION Component without harness connected (Rear *a Height Control Sensor Subassembly) If the result is not as specified, replace the rear height control sensor sub-assembly. INSTALLATION INSTALLATION

1. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Engage the clamp. b. Install the rear height control sensor sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) d. Connect the connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. INITIALIZE HEIGHT CONTROL SENSOR SIGNAL Refer to INITIALIZATION . 4. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT.

HEADLIGHT LEVELING ECU COMPONENTS ILLUSTRATION

Fig. 118: Identifying Headlight Leveling ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Refer to REMOVAL . 2. REMOVE HEADLIGHT LEVELING ECU ASSEMBLY a. Disconnect the connector.

Fig. 119: Locating Headlight Leveling ECU Assembly Connector And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. TEXT IN ILLUSTRATION *1 Clamp *2 Guide c. Remove the bolt. d. Disengage the 2 guides and remove the headlight leveling ECU assembly. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT LEVELING ECU ASSEMBLY a. Engage the 2 guides. b. Install the headlight leveling ECU assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

c. Engage the clamp. d. Connect the connector. 2. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION . 3. INITIALIZE HEIGHT CONTROL SENSOR SIGNAL Refer to INITIALIZATION . 4. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT.

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT H-LP RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 120: Identifying H-LP Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard Resistance Tester Specified Condition Connection Condition Voltage is not applied 10 kohms 3-5 between or higher terminals 1 and 2 Voltage is applied Below 1 3-5 between ohms terminals 1 and 2 If the result is not as specified, replace the H-LP relay.

2012-2017 ACCESSORIES & EQUIPMENT Lighting System (Interior) (Service Information) (Hybrid)

VANITY LIGHT COMPONENTS ILLUSTRATION

Fig. 1: Identifying Vanity Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 2. REMOVE VANITY LIGHT ASSEMBLY a. Tilt the tab to disengage the 2 claws and separate the bulb holder from the vanity light as shown in the illustration.

Fig. 2: Removing Vanity Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tab Claw *2

Bulb *3 Holder Claw *4

b. Disengage the claw and remove the vanity light assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL VANITY LIGHT ASSEMBLY a. Engage the claw to install the vanity light assembly.

Fig. 3: Installing Vanity Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Claw *1

Claw *2

Bulb *3 Holder b. Engage the 2 claws to install the bulb holder to the vanity light assembly. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION

PERSONAL LIGHT

COMPONENTS ILLUSTRATION

Fig. 4: Identifying Personal Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Using a molding remover, disengage the 4 clips.

Fig. 5: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the roof console box assembly. 2. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Using a molding remover, disengage the 4 clips.

Fig. 6: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the roof console box assembly. 3. REMOVE MAP LIGHT BULB a. Turn the 2 map light sockets with the 2 map light bulbs in the direction indicated by the arrows in the illustration and remove them as a unit.

Fig. 7: Removing Map Light Bulbs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 map light bulbs from the 2 map light sockets. INSPECTION INSPECTION

1. INSPECT ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Inspect the personal lights.

Fig. 8: Identifying Roof Console Box Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the auxiliary battery to terminal 9 (B) and a negative (-) lead to terminal 1 (GND). Result Tester Specified Condition Connection Condition Personal Personal light LH light and RH switches do not off come on Personal 9 (B) - 1 Personal light (GND) light LH switch LH comes on on Personal Personal light light RH switch RH comes on on TEXT IN ILLUSTRATION Component

without harness connected *a (Roof Console Box Assembly) If the result is not as specified, replace the bulb or roof console box assembly. 2. INSPECT ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Inspect the personal lights.

Fig. 9: Identifying Roof Console Box Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the auxiliary battery to terminal 9 (B) and a negative (-) lead to terminal 1 (GND) or 6 (CTY). Result Tester Specified Condition Connection Condition Interior light on/off

Personal

9 (B) - 1 (GND)

9 (B) - 6 (CTY)

switch off light LH and and RH personal do not light come on switches off Interior light on/off switch off Personal and light LH personal comes on light switch LH on Interior light on/off switch off Personal and light RH personal comes on light switch RH on Interior light on/off Personal switch on light LH and and RH personal comes on light switches off Interior light door Personal switch off light LH and and RH personal do not light come on switches off Interior light door switch off and personal light

Personal light LH and RH do not come on

switches on Interior light door switch on and personal light switches off

Personal light LH and RH comes on

TEXT IN ILLUSTRATION Component without harness connected *a (Roof Console Box Assembly) If the result is not as specified, replace the bulb or roof console box assembly. b. Inspect the center console spot light. 1. Connect a positive (+) lead from the auxiliary battery to terminal 8 (ILLB) and a negative (-) lead to terminal 1 (GND). Result Tester Specified Condition Connection Condition Auxiliary battery positive (+) --> Terminal Center 1 (GND) - 8 (ILLB) console 8 (ILLB) Auxiliary spot light battery comes on negative (-) --> Terminal 1 (GND) If the result is not as specified, replace the roof console box assembly.

c. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition Personal light switches off and 10 kohms interior or higher light on/off 1 (GND) - switch off 10 (RRMP) Personal light switches off and Below 1 interior ohms light on/off switch on Interior 10 kohms light door or higher 6 (CTY) - switch off 10 (RRMP) Interior Below 1 light door ohms switch on If the result is not as specified, replace the roof console box assembly. INSTALLATION INSTALLATION

1. INSTALL MAP LIGHT BULB a. Install the 2 map light bulbs to the 2 map light sockets. b. Turn the 2 map light sockets with the 2 map light bulbs in the direction indicated by the arrows in the illustration and install them as a unit.

Fig. 10: Installing Map Light Bulbs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Connect the connector. b. Engage the 4 clips to install the roof console box assembly.

Fig. 11: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Connect the connector. b. Engage the 4 clips to install the roof console box assembly.

Fig. 12: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ROOM LIGHT COMPONENTS ILLUSTRATION

Fig. 13: Identifying Room Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) a. Using a screwdriver with its tip wrapped with protective tape, disengage the 4 claws and remove the No. 1 room light lens.

Fig. 14: Removing No. 1 Room Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front b. Using a screwdriver with its tip wrapped with protective tape, disengage the 4 claws as shown in the illustration and remove the No. 1 room light housing.

Fig. 15: Removing No. 1 Room Light Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front c. Using a screwdriver, disengage the 4 claws and disconnect the room light switch base from the No. 1 room light housing.

Fig. 16: Identifying Claws & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Room Light *1 Switch Base 2. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) a. Using a screwdriver with its tip wrapped with protective tape, disengage the 8 claws and remove the 2 spot light lenses.

Fig. 17: Removing The Spot Light Lenses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front b. Using a screwdriver with its tip wrapped with protective tape and molding remover, disengage the 2 claws .

Fig. 18: Disconnecting The Spot Light Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Claw *2

Claw *3

Claw *4

*a Front c. Disengage the 2 claws and 2 claws , and disconnect the spot light housing.

d. Using a screwdriver, disengage the 8 claws and disconnect the 2 map light sub-assemblies from the spot light housing.

Fig. 19: Disconnecting The Map Light Sub-Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Map Light *1 Subassembly INSTALLATION INSTALLATION

1. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) a. Align the switch parts shown in the illustration and engage the 4 claws to install the room light switch base to the No. 1 room light housing.

Fig. 20: Installing No. 1 Room Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Switch Part of Room *a Light Switch Base Switch Part of No. 1 *b Room Light Housing b. Engage the 4 claws to install the No. 1 room light housing.

Fig. 21: Installing No. 1 Room Light Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front c. Engage the 4 claws to install the No. 1 room light lens.

Fig. 22: Installing No. 1 Room Light Lens Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front 2. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) a. Engage the 8 claws to install the 2 map light sub-assemblies to the spot light housing as shown in the illustration.

Fig. 23: Installing The Map Light Sub-Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front b. Engage the 6 claws to install the spot light housing.

Fig. 24: Installing Spot Light Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front c. Engage the 8 claws to install the 2 spot light lenses.

Fig. 25: Installing Spot Light Lenses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front

LUGGAGE COMPARTMENT ROOM LIGHT COMPONENTS ILLUSTRATION

Fig. 26: Identifying Luggage Compartment Room Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY a. Disengage the 2 claws.

Fig. 27: Identifying No. 1 Luggage Compartment Light Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the No. 1 luggage compartment light assembly. INSPECTION INSPECTION

1. INSPECT NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY a. Connect a positive (+) lead from the auxiliary battery to terminal 2 and a negative (-) lead to terminal 1.

Fig. 28: No. 1 Luggage Compartment Light Assembly Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the No. 1 luggage compartment light comes on. OK No. 1 luggage compartment light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (No. 1 Luggage Compartment Light Assembly) If the result is not as specified, replace the bulb or No. 1 luggage compartment light assembly. INSTALLATION INSTALLATION

1. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

a. Connect the connector. b. Engage the 2 claws to install the No. 1 luggage compartment light assembly.

DOOR COURTESY LIGHT COMPONENTS ILLUSTRATION

Fig. 29: Identifying Door Courtesy Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COURTESY LIGHT ASSEMBLY a. Using a screwdriver with its tip wrapped with protective tape, disengage the claw.

Fig. 30: Removing The Courtesy Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for LH

*A Side for RH *B Side Protective *1 Tape b. Disconnect the connector and remove the courtesy light assembly. INSPECTION INSPECTION

1. INSPECT COURTESY LIGHT ASSEMBLY LH a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 31: Identifying Courtesy Light Assembly LH Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the courtesy light comes on. OK Courtesy light comes on. TEXT IN ILLUSTRATION

Component without harness connected *a (Courtesy Light Assembly LH) If the result is not as specified, replace the bulb or courtesy light assembly LH. 2. INSPECT COURTESY LIGHT ASSEMBLY RH a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 32: Identifying Courtesy Light Assembly RH Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the courtesy light comes on. OK Courtesy light comes on. TEXT IN ILLUSTRATION Component without

harness connected (Courtesy *a Light Assembly RH) If the result is not as specified, replace the bulb or courtesy light assembly RH. INSTALLATION INSTALLATION

1. INSTALL COURTESY LIGHT ASSEMBLY a. Connect the connector. b. Engage the claw to install the courtesy light assembly.

Fig. 33: Installing Courtesy Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

LH Side for *B RH Side

*A

VANITY LIGHT SWITCH COMPONENTS ILLUSTRATION

Fig. 34: Identifying Vanity Light Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE VISOR BRACKET COVER . Refer to REMOVAL - Step 46 2. REMOVE VISOR ASSEMBLY . Refer to REMOVAL - Step 47 INSPECTION INSPECTION

1. INSPECT VISOR ASSEMBLY LH a. Inspect the vanity light switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 35: Inspecting Visor Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 10 kohms 1-2 Visor up or higher Mirror cover 10 kohms fully 1-2 or higher closed with visor down Mirror cover Below 1 fully open 1-2 ohms with visor down TEXT IN ILLUSTRATION Component without harness *a connected (Visor Assembly LH) *b Visor up Visor *c down Mirror *1 Cover If the result is not as specified, replace the visor assembly LH. 2. INSPECT VISOR ASSEMBLY RH a. Inspect the vanity light switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 36: Inspecting Visor Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Specified Condition Connection Condition 10 kohms 1-2 Visor up or higher Mirror cover 10 kohms fully 1-2 or higher closed with visor down Mirror cover Below 1 1-2 fully open ohms with visor down TEXT IN ILLUSTRATION Component without harness *a connected (Visor Assembly RH) *b Visor up Visor *c down Mirror *1 Cover If the result is not as specified, replace the visor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL VISOR ASSEMBLY . Refer to INSTALLATION - Step 4 2. INSTALL VISOR BRACKET COVER . Refer to INSTALLATION - Step 5

FRONT DOOR COURTESY SWITCH

COMPONENTS ILLUSTRATION

Fig. 37: Identifying Front Door Courtesy Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 4

2. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 5 3. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 19 4. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 7 5. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 23 6. REMOVE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Disconnect the connector. b. Using a T30 "TORX" socket wrench, remove the screw and front door courtesy light switch assembly.

Fig. 38: Identifying Front Door Courtesy Light Switch Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 39: Identifying Front Door Courtesy Light Switch Connector Terminal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Not Below 1 pushed ohms 1 - Switch (ON) body Pushed 10 kohms (OFF) or higher TEXT IN ILLUSTRATION Component without harness connected (Front *a Door Courtesy Light Switch Assembly) Switch *1 Body

If the result is not as specified, replace the front door courtesy light switch assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Using a T30 "TORX" socket wrench, install the front door courtesy light switch assembly with the screw. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) HINT: There are 2 diameters for the "TORX" screws: 6 mm (0.236 in.) and 7 mm (0.276 in.). The diameter of a supplied "TORX" screw is 7 mm (0.276 in.). b. Connect the connector. 2. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 23 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 26 for RH Side: Refer to INSTALLATION - Step 33 4. INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 27 5. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 43 for RH Side: Refer to INSTALLATION - Step 47 6. INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 45

REAR DOOR COURTESY SWITCH COMPONENTS ILLUSTRATION

Fig. 40: Identifying Rear Door Courtesy Switch Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 41: Identifying Rear Door Courtesy Switch Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. Refer to PRECAUTION . NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Disconnect the connector. b. Using a T30 "TORX" socket wrench, remove the screw and rear door courtesy light switch assembly.

Fig. 42: Identifying Rear Door Courtesy Light Switch Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 43: Identifying Rear Door Courtesy Light Switch Connector Terminal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Not Below 1 pushed ohms 1 - Switch (ON) body Pushed 10 kohms (OFF) or higher TEXT IN ILLUSTRATION Component without *a harness connected (Rear Door

Courtesy Light Switch Assembly) Switch *1 Body If the result is not as specified, replace the rear door courtesy light switch assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Using a T30 "TORX" socket wrench, install the rear door courtesy light switch assembly with the screw. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) HINT: There are 2 diameters for the "TORX" screws: 6 mm (0.236 in.) and 7 mm (0.276 in.). The diameter of a supplied "TORX" screw is 7 mm (0.276 in.).

2. 3. 4. 5.

b. Connect the connector. INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 7. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

BACK DOOR COURTESY SWITCH COMPONENTS ILLUSTRATION

Fig. 44: Identifying Back Door Courtesy Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY . Refer to REMOVAL Step 2 INSPECTION INSPECTION

1. INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Check the operation of the door lock motor. 1. Move the door lock to the close (lock) position.

Fig. 45: Checking Operation Of The Door Lock Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage to the door lock motor and check operation of the door lock motor. OK Measurement Specified Condition Condition Auxiliary

battery positive (+) -> 1 (B) Auxiliary battery negative (-) -> 2 (E)

Luggage compartment door lock motor open (unlock) operation

TEXT IN ILLUSTRATION Component without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. b. Check the operation of the door courtesy switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 46: Inspecting Luggage Compartment Door Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Door Specified Lock Condition Condition Close 10 kohms 2 (E) - 3 (D+) (Lock) or higher Open Below 1 2 (E) - 3 (D+) (Unlock) ohms

Measurement Condition

TEXT IN ILLUSTRATION Component

without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY . Refer to INSTALLATION - Step 1 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 10

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT LIGHT CUT RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 47: Inspecting Light Cut Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Voltage is not applied 10 kohms 3-5 between or higher terminals 1 and 2 Voltage is applied Below 1 3-5 between ohms terminals 1 and 2 If the result is not as specified, replace the light cut relay.

2012-2017 ACCESSORIES & EQUIPMENT Lighting System (Interior) (Service Information) - Camry (Except Hybrid)

VANITY LIGHT COMPONENTS ILLUSTRATION

Fig. 1: Identifying Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 2. REMOVE VANITY LIGHT ASSEMBLY a. Tilt the tab to disengage the 2 claws and separate the bulb holder from the vanity light as shown in the illustration.

Fig. 2: Identifying Vanity Light Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Tab Claw *2

Bulb *3 Holder Claw *4

b. Disengage the claw and remove the vanity light assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL VANITY LIGHT ASSEMBLY a. Engage the claw to install the vanity light assembly.

Fig. 3: Identifying Vanity Light Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Claw *1

Claw *2

Bulb *3 Holder b. Engage the 2 claws to install the bulb holder to the vanity light assembly. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION

PERSONAL LIGHT

COMPONENTS ILLUSTRATION

Fig. 4: Identifying Personal Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Using a moulding remover, disengage the 4 clips.

Fig. 5: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the roof console box assembly. 2. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Using a moulding remover, disengage the 4 clips.

Fig. 6: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the roof console box assembly. 3. REMOVE MAP LIGHT BULB a. Turn the 2 map light sockets with the 2 map light bulbs in the direction indicated by the arrows in the illustration and remove them as a unit.

Fig. 7: Removing Map Light Bulbs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 map light bulbs from the 2 map light sockets. INSPECTION INSPECTION

1. INSPECT ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Inspect the personal lights.

Fig. 8: Roof Console Box Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the battery to terminal 9 (B) and a negative (-) lead to terminal 1 (GND). Result Tester Specified Condition Connection Condition Personal Personal light LH light and RH switches do not off come on Personal 9 (B) - 1 Personal light (GND) light LH switch LH comes on on Personal Personal light light RH switch RH comes on on TEXT IN ILLUSTRATION Component

without harness connected *a (Roof Console Box Assembly) If the result is not as specified, replace the bulb or roof console box assembly. 2. INSPECT ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Inspect the personal lights.

Fig. 9: Roof Console Box Assembly Connector Terminal Identification (W/Sliding Roof) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the battery to terminal 9 (B) and a negative (-) lead to terminal 1 (GND) or 6 (CTY). Result Tester Specified Condition Connection Condition Interior light on/off

Personal

9 (B) - 1 (GND)

9 (B) - 6 (CTY)

switch off light LH and and RH personal do not light come on switches off Interior light on/off switch off Personal and light LH personal comes on light switch LH on Interior light on/off switch off Personal and light RH personal comes on light switch RH on Interior light on/off Personal switch on light LH and and RH personal comes on light switches off Interior light door Personal switch off light LH and and RH personal do not light come on switches off Interior light door switch off and personal light

Personal light LH and RH do not come on

switches on Interior light door switch on and personal light switches off

Personal light LH and RH comes on

TEXT IN ILLUSTRATION Component without harness connected *a (Roof Console Box Assembly) If the result is not as specified, replace the bulb or roof console box assembly. b. Inspect the center console spot light. 1. Connect a positive (+) lead from the battery to terminal 8 (ILLB) and a negative (-) lead to terminal 1 (GND). Result Tester Specified Condition Connection Condition Battery positive (+) --> Terminal Center 1 (GND) - 8 (ILLB) console 8 (ILLB) Battery spot light positive (- comes on ) --> Terminal 1 (GND) If the result is not as specified, replace the roof console box assembly. c. Measure the resistance according to the value(s) in the table below.

Standard Resistance Tester Specified Condition Connection Condition Personal light switches off and 10 kohms interior or higher light on/off 1 (GND) - switch off 10 (RRMP) Personal light switches off and Below 1 interior ohms light on/off switch on Interior 10 kohms light door or higher 6 (CTY) - switch off 10 (RRMP) Interior Below 1 light door ohms switch on If the result is not as specified, replace the roof console box assembly. INSTALLATION INSTALLATION

1. INSTALL MAP LIGHT BULB a. Install the 2 map light bulbs to the 2 map light sockets. b. Turn the 2 map light sockets with the 2 map light bulbs in the direction indicated by the arrows in the illustration and install them as a unit.

Fig. 10: Installing Map Light Bulbs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof) a. Connect the connector. b. Engage the 4 clips to install the roof console box assembly.

Fig. 11: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof) a. Connect the connector. b. Engage the 4 clips to install the roof console box assembly.

Fig. 12: Identifying Roof Console Box Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ROOM LIGHT COMPONENTS ILLUSTRATION

Fig. 13: Identifying Room Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) a. Using a screwdriver with its tip wrapped with protective tape, disengage the 4 claws and remove the No. 1 room light lens.

Fig. 14: Identifying No. 1 Room Light Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front b. Using a screwdriver with its tip wrapped with protective tape, disengage the 4 claws as shown in the illustration and remove the No. 1 room light housing.

Fig. 15: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front c. Using a screwdriver, disengage the 4 claws and disconnect the room light switch base from the No. 1 room light housing.

Fig. 16: Identifying Claws & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Room Light *1 Switch Base 2. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) a. Using a screwdriver with its tip wrapped with protective tape, disengage the 8 claws and remove the 2 spot light lenses.

Fig. 17: Identifying Spot Light Lenses Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape *a Front b. Using a screwdriver with its tip wrapped with protective tape and moulding remover, disengage the 2 claws .

Fig. 18: Disconnecting Spot Light Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Claw *2

Claw *3

Claw *4

*a Front c. Disengage the 2 claws and 2 claws , and disconnect the spot light housing.

d. Using a screwdriver, disengage the 8 claws and disconnect the 2 map light sub-assemblies from the spot light housing.

Fig. 19: Identifying Map Light Sub-Assemblies Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Map Light *1 Subassembly INSTALLATION INSTALLATION

1. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) a. Align the switch parts shown in the illustration and engage the 4 claws to install the room light switch base to the No. 1 room light housing.

Fig. 20: Installing No. 1 Room Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Switch Part of Room *a Light Switch Base Switch Part of No. 1 *b Room Light Housing b. Engage the 4 claws to install the No. 1 room light housing.

Fig. 21: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front c. Engage the 4 claws to install the No. 1 room light lens.

Fig. 22: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front 2. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) a. Engage the 8 claws to install the map light sub-assembly to the spot light housing as shown in the illustration.

Fig. 23: Identifying Map Light Sub-Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front b. Engage the 6 claws to install the spot light housing.

Fig. 24: Identifying Spot Light Housing Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front c. Engage the 8 claws to install the 2 spot light lenses.

Fig. 25: Identifying Spot Light Lenses Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Front

LUGGAGE COMPARTMENT ROOM LIGHT COMPONENTS ILLUSTRATION

Fig. 26: Identifying Luggage Compartment Room Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY a. Disengage the 2 claws.

Fig. 27: Identifying No. 1 Luggage Compartment Light Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the No. 1 luggage compartment light assembly. INSPECTION INSPECTION

1. INSPECT NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY a. Connect a positive (+) lead from the battery to terminal 2 and a negative (-) lead to terminal 1.

Fig. 28: No. 1 Luggage Compartment Light Assembly Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the No. 1 luggage compartment light comes on. OK No. 1 luggage compartment light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (No. 1 Luggage Compartment Light Assembly) If the result is not as specified, replace the bulb or No. 1 luggage compartment light assembly. INSTALLATION INSTALLATION

1. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

a. Connect the connector. b. Engage the 2 claws to install the No. 1 luggage compartment light assembly.

DOOR COURTESY LIGHT COMPONENTS ILLUSTRATION

Fig. 29: Identifying Door Courtesy Light Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE COURTESY LIGHT ASSEMBLY a. Using a screwdriver with its tip wrapped with protective tape, disengage the claw.

Fig. 30: Identifying Courtesy Light Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for LH

*A Side for RH *B Side Protective *1 Tape b. Disconnect the connector and remove the courtesy light assembly. INSPECTION INSPECTION

1. INSPECT COURTESY LIGHT ASSEMBLY LH a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 31: Courtesy Light Assembly RH Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the courtesy light comes on. OK Courtesy light comes on. TEXT IN ILLUSTRATION Component

without harness connected *a (Courtesy Light Assembly LH) If the result is not as specified, replace the bulb or courtesy light assembly LH. 2. INSPECT COURTESY LIGHT ASSEMBLY RH a. Connect a positive (+) lead from the battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 32: Courtesy Light Assembly Connector Terminal Identification RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the courtesy light comes on. OK Courtesy light comes on. TEXT IN ILLUSTRATION Component without harness connected

(Courtesy Light *a Assembly RH) If the result is not as specified, replace the bulb or courtesy light assembly RH. INSTALLATION INSTALLATION

1. INSTALL COURTESY LIGHT ASSEMBLY a. Connect the connector. b. Engage the claw to install the courtesy light assembly.

Fig. 33: Identifying Courtesy Light Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION for

LH Side for *B RH Side

*A

IGNITION KEY CYLINDER LIGHT COMPONENTS ILLUSTRATION

Fig. 34: Identifying Transponder Key Amplifier Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LOWER STEERING COLUMN COVER . Refer to REMOVAL - Step 1 2. REMOVE TRANSPONDER KEY AMPLIFIER . Refer to REMOVAL - Step 2 INSPECTION INSPECTION

1. INSPECT TRANSPONDER KEY AMPLIFIER a. Connect a positive (+) lead from the battery to terminal 2 (ILL+) and a negative (-) lead to terminal 6 (ILL-).

Fig. 35: Transponder Key Amplifier Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the ignition key cylinder light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Transponder Key Amplifier) If the result is not as specified, replace the transponder key amplifier. INSTALLATION INSTALLATION

1. INSTALL TRANSPONDER KEY AMPLIFIER . Refer to INSTALLATION - Step 1 2. INSTALL LOWER STEERING COLUMN COVER . Refer to INSTALLATION - Step 3

VANITY LIGHT SWITCH COMPONENTS ILLUSTRATION

Fig. 36: Identifying Vanity Light Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE VISOR BRACKET COVER . Refer to REMOVAL - Step 44 2. REMOVE VISOR ASSEMBLY . Refer to REMOVAL - Step 45 INSPECTION INSPECTION

1. INSPECT VISOR ASSEMBLY LH a. Inspect the vanity light switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 37: Inspecting Visor Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Switch Specified Connection Condition Condition 10 kohms 1-2 Visor up or higher Mirror cover 10 kohms fully 1-2 or higher closed with visor down Mirror cover Below 1 1-2 fully open ohms with visor down TEXT IN ILLUSTRATION Component without harness *a connected (Visor Assembly LH) *b Visor up Visor *c down Mirror *1 Cover If the result is not as specified, replace the visor assembly LH. 2. INSPECT VISOR ASSEMBLY RH a. Inspect the vanity light switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 38: Inspecting Visor Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Switch Specified Connection Condition Condition 10 kohms 1-2 Visor up or higher Mirror cover 10 kohms fully 1-2 or higher closed with visor down Mirror cover Below 1 1-2 fully open ohms with visor down TEXT IN ILLUSTRATION Component without harness *a connected (Visor Assembly RH) *b Visor up Visor *c down Mirror *1 Cover If the result is not as specified, replace the visor assembly RH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL VISOR ASSEMBLY . Refer to INSTALLATION - Step 4 2. INSTALL VISOR BRACKET COVER . Refer to INSTALLATION - Step 5

FRONT DOOR COURTESY SWITCH

COMPONENTS ILLUSTRATION

Fig. 39: Identifying Front Door Courtesy Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 3

2. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 4 3. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 18 4. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP . Refer to REMOVAL - Step 6 5. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 22 6. REMOVE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Disconnect the connector. b. Using a T30 "TORX" socket wrench, remove the screw and front door courtesy light switch assembly.

Fig. 40: Identifying Front Door Courtesy Light Switch Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 41: Rear Door Courtesy Light Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Not Below 1 pushed ohms 1 - Switch (ON) body Pushed 10 kohms (OFF) or higher TEXT IN ILLUSTRATION Component without harness connected (Front *a Door Courtesy Light Switch Assembly) Switch *1 Body

If the result is not as specified, replace the front door courtesy light switch assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Using a T30 "TORX" socket wrench, install the front door courtesy light switch assembly with the screw. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) HINT: There are 2 diameters for the "TORX" screws: 6 mm (0.236 in.) and 7 mm (0.276 in.). The diameter of a supplied "TORX" screw is 7 mm (0.276 in.). b. Connect the connector. 2. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 22 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 25 for RH Side: Refer to INSTALLATION - Step 32 4. INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 26 5. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 42 for RH Side: Refer to INSTALLATION - Step 46 6. INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 44

REAR DOOR COURTESY SWITCH COMPONENTS ILLUSTRATION

Fig. 42: Identifying Rear Door Courtesy Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery

terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 8 REMOVE REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Disconnect the connector. b. Using a T30 "TORX" socket wrench, remove the screw and rear door courtesy light switch assembly.

Fig. 43: Identifying Rear Door Courtesy Light Switch Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 44: Rear Door Courtesy Light Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Not Below 1 pushed ohms 1 - Switch (ON) body Pushed 10 kohms (OFF) or higher TEXT IN ILLUSTRATION Component without harness connected *a (Rear Door Courtesy Light Switch Assembly)

*1

Switch Body

If the result is not as specified, replace the rear door courtesy light switch assembly. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY a. Using a T30 "TORX" socket wrench, install the rear door courtesy light switch assembly with the screw. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf) HINT: There are 2 diameters for the "TORX" screws: 6 mm (0.236 in.) and 7 mm (0.276 in.). The diameter of a supplied "TORX" screw is 7 mm (0.276 in.).

2. 3. 4. 5.

b. Connect the connector. INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

BACK DOOR COURTESY SWITCH COMPONENTS ILLUSTRATION

Fig. 45: Identifying Luggage Compartment Door Lock Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) . Refer to REMOVAL - Step 2 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to REMOVAL - Step 3 4. REMOVE LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to REMOVAL - Step 4 INSPECTION

INSPECTION

1. INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY a. Check the operation of the door lock motor. 1. Move the door lock to the close (lock) position.

Fig. 46: Checking Operation Of Door Lock Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage to the door lock motor and check operation of the door lock motor. OK Measurement Specified Condition Condition

Battery positive (+) -> 1 (B) Battery negative (-) -> 2 (E)

Luggage compartment door lock motor open (unlock) operation

TEXT IN ILLUSTRATION Component without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. b. Check the operation of the door courtesy switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 47: Inspecting Luggage Compartment Door Lock Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard resistance Door Specified Lock Condition Condition Close 10 kohms 2 (E) - 3 (D+) (Lock) or higher Open Below 1 2 (E) - 3 (D+) (Unlock) ohms

Measurement Condition

TEXT IN ILLUSTRATION Component

without harness connected: *a (Luggage Compartment Door Lock Assembly) *b Close (Lock) Open *c (Unlock) If the result is not as specified, replace the luggage compartment door lock assembly. INSTALLATION INSTALLATION

1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/ Wireless Door Lock Control System) . Refer to INSTALLATION - Step 1 2. INSTALL LUGGAGE DOOR LOCK CONTROL CABLE SUB-ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to INSTALLATION - Step 2 3. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (w/o Wireless Door Lock Control System) . Refer to INSTALLATION - Step 3 4. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 12

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT LIGHT CUT RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 48: Light Cut Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Voltage is not applied 10 kohms 3-5 between or higher terminals 1 and 2 Voltage is applied Below 1 3-5 between ohms terminals 1 and 2 TEXT IN ILLUSTRATION Component without harness *a connected (Light Cut Relay)

If the result is not as specified, replace the light cut relay.

2012-2017 ACCESSORIES & EQUIPMENT Lighting System (Exterior) (Service Information) (Hybrid)

HEADLIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 1: Identifying Headlight Assembly Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Headlight Assembly Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Headlight Assembly Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION (for HID Headlight) Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before

disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER (for HID Headlight) . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for HID Headlight) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL 5. REMOVE HEADLIGHT ASSEMBLY a. Remove the 3 screws and bolt.

Fig. 4: Identifying Headlight Assembly Screws And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp.

Fig. 5: Identifying Headlight Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect each connector and remove the headlight assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 HEADLIGHT BULB a. Turn the No. 1 headlight bulb in the direction indicated by the arrow shown in the illustration, and remove it.

Fig. 6: Removing No. 1 Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

2. REMOVE NO. 2 HEADLIGHT BULB (for Halogen Headlight) a. Turn the No. 2 headlight bulb in the direction indicated by the arrow shown in the illustration, and remove it.

Fig. 7: Removing No. 2 Headlight Bulb (For Halogen Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

3. REMOVE HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY (for HID Headlight) a. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 8: Removing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not apply excessive force using a tool. Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

b. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 9: Removing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

c. Disengage the clamp.

Do not apply excessive force using a tool. Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

Fig. 10: Removing Headlight Light Control ECU Sub-Assembly Clamp (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and remove it. NOTE:

Do not pull the headlight light control ECU sub-assembly with the socket connected.

4. REMOVE DISCHARGE HEADLIGHT BULB (for HID Headlight) a. Release the set spring as shown in the illustration and remove the discharge headlight bulb.

Fig. 11: Removing Discharge Headlight Bulb (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

5. REMOVE HEADLIGHT SOCKET COVER a. for Halogen Headlight: 1. Remove the 2 headlight socket covers from the headlight unit. b. for HID Headlight: 1. Remove the headlight socket cover from the headlight unit. 6. REMOVE FRONT TURN SIGNAL LIGHT BULB a. Turn the front turn signal light socket with the front turn signal light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 12: Removing Front Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front turn signal light bulb from the front turn signal light socket. 7. REMOVE FRONT SIDE MARKER LIGHT BULB a. Turn the front side marker light socket with the front side marker light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 13: Removing Front Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front side marker light bulb from the front side marker light socket. ADJUSTMENT ADJUSTMENT

HINT: It is possible that a bulb is incorrectly installed, affecting headlight aim. Bulb installation should be considered prior to performing the adjustment procedure. 1. PREPARE VEHICLE FOR HEADLIGHT AIM ADJUSTMENT a. Prepare the vehicle:  Ensure that there is no damage or deformation to the body around the headlights.  Fill the fuel tank.  Make sure that the oil is filled to the specified level.  Make sure that the engine coolant is filled to the specified level.  Inflate the tires to the appropriate pressure.  Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.  Sit a person of average weight (68 kg, 150 lb) in the driver's seat.  Vehicles with manual headlight beam level control system should be adjusted to "0".

Fig. 14: Adjusting Halogen Headlight To "0" For Headlight Aim Adjustment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. PREPARE FOR HEADLIGHT AIMING (Using a headlight aim test machine) a. Adjust the headlight aim in accordance with the headlight aim test machine instructions. 3. PREPARE FOR HEADLIGHT AIMING (Using a Screen) a. Prepare the vehicle:

Fig. 15: Identifying Headlight Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

    

Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot. Place the vehicle at a 90° angle to the wall. Create a 7.62 m (25 ft.) distance between the vehicle (headlight bulb center) and the wall. Make sure that the vehicle is on a level surface. Position the front wheels straight ahead. Bounce the vehicle up and down several times to settle the suspension.

NOTE:

A distance of 7.62 m (25 ft.) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of headlight aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

b. Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen. c. Draw a vertical line down the center of the screen (V line). d. Set the screen as shown in the illustration.

Fig. 16: Identifying Headlight Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Stand the screen perpendicular to the ground.  Align the V line on the screen with the center of the vehicle. e. Draw base lines (H, V LH and V RH lines) on the screen as shown in the illustration. 

Fig. 17: Identifying V LH Line, V RH Line Graph

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION V LH *a Line *b V Line V RH *c Line *d H Line *e Ground HINT: The base lines differ for "low beam inspection" and "high beam inspection".  Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb as the center mark. 1. H Line (Headlight height): 

Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low beam headlights. 2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam headlight bulbs). 4. INSPECT HEADLIGHT AIMING a. Cover the headlight or disconnect the connector of the headlight/ECU on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection. WARNING: Do not disconnect the HID high voltage connector for the bulb when performing this aiming inspection. NOTE:

Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

HINT: When checking the aim of the high beam, cover the low beam or disconnect the connector. b. Start the engine.

c. Turn on the headlights and check the aiming of each beam. HINT:  

Preferred position for the low beam: Matches preferred cutoff line shown in the illustration. Preferred position for the high beam: Matches center of intensity shown in the illustration.

Fig. 18: Alignment Distance Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 



Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure. If the alignment distance is 7.62 m (25 ft.): The low beam cutoff line should be within 53 mm (2.09 in.) above the H line.



If the alignment distance is 3 m (9.84 ft.): The low beam cutoff line should be within 20 mm (0.82 in.) above the H line.



If the alignment distance is 7.62 m (25 ft.): The high beam center of intensity should be within 101 mm (3.97 in.) above or below the H line as well as left and right of the V line (SAE J599).



If the alignment distance is 3 m (9.84 ft.): The high beam center of intensity should be within 39 mm (1.56 in.) above or below the H line as well as 39 mm (1.56 in.) left or right of the V line (SAE J599).



If the alignment distance is 7.62 m (25 ft.): The right half of the low beam cutoff line should be on the H line (preferred cutoff line target).



If the alignment distance is 3 m (9.84 ft.): The right half of the low beam cutoff line should be on the H line (preferred cutoff line target).



If the alignment distance is 7.62 m (25 ft.): The high beam center of intensity should be on the H line (preferred center of intensity).



If the alignment distance is 3 m (9.84 ft.): The high beam center of intensity should be on the H line (preferred center of intensity).

5. ADJUST HEADLIGHT AIMING a. Adjust the aim vertically:

Fig. 19: Adjusting Headlight Aim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION for for HID *A Halogen *B Headlight Headlight Aiming *1 Screw Adjust the aim of each headlight to the specified range by turning aiming screw with a screwdriver. NOTE:

The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

HINT: 





The low beam light and the high beam light are a unit. Adjusting the aim on the low beam to the correct position should also result in the high beam adjustment being correct. If it is not possible to correctly adjust the headlight aim, check the bulbs, headlight unit and headlight unit reflector installation. The headlight aim moves up when turning the aiming screw counterclockwise, and moves down when turning the aiming screw clockwise.

REASSEMBLY REASSEMBLY

1. INSTALL FRONT SIDE MARKER LIGHT BULB a. Install the front side marker light bulb to the front side marker light socket. b. Turn the front side marker light socket with the front side marker light bulb in the direction indicated by the arrow shown in the illustration and install them as a unit.

Fig. 20: Installing Front Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT TURN SIGNAL LIGHT BULB a. Install the front turn signal light bulb to the front turn signal light socket. b. Turn the front turn signal light socket with the front turn signal light bulb in the direction indicated by the arrow shown in the illustration and install them as a unit.

Fig. 21: Installing Front Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL HEADLIGHT SOCKET COVER a. for Halogen Headlight: 1. Install the 2 headlight socket covers to the headlight unit. b. for HID Headlight: 1. Install the headlight socket cover to the headlight unit. 4. INSTALL NO. 2 HEADLIGHT BULB (for Halogen Headlight) a. Turn the No. 2 headlight bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 22: Installing No. 2 Headlight Bulb (For Halogen Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

5. INSTALL DISCHARGE HEADLIGHT BULB (for HID Headlight) a. Set the discharge headlight bulb to the headlight unit. NOTE:

Do not touch the bulb glass.

b. Lock the set spring to install the discharge headlight bulb as shown in the illustration.

Fig. 23: Installing Discharge Headlight Bulb (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY (for HID Headlight) a. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration to connect it.

Fig. 24: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:







Check that the O-ring is installed on the headlight light control ECU sub-assembly. Check that the O-ring is not damaged or contaminated with foreign matter. If there is any damage, replace the O-ring with a new one. Do not pull the headlight light control ECU sub-assembly with the socket connected.

b. Check that the red line on the output harness is not twisted and store the harness in the headlight assembly securely so that the output harness is not pinched. TEXT IN ILLUSTRATION Red *1 Line c. Engage the clamp.

Fig. 25: Installing Headlight Light Control ECU Sub-Assembly Clamp (For HID Headlight) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 26: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

e. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 27: Installing Headlight Light Control ECU Sub-Assembly (For HID Headlight) (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

7. INSTALL NO. 1 HEADLIGHT BULB a. Turn the No. 1 headlight bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 28: Installing No. 1 Headlight Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL HEADLIGHT ASSEMBLY a. Connect each connector. b. Engage the clamp. c. Install the headlight assembly with the 3 screws and bolt. Screw Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) Bolt Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf)

2. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION 3. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for HID Headlight) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HID Headlight) . Refer to INSTALLATION - Step 3 5. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT 6. ADJUST FOG LIGHT AIMING (w/ Fog Light) Refer to ADJUSTMENT

HIGH INTENSITY DISCHARGE HEADLIGHT BULB COMPONENTS ILLUSTRATION

Fig. 29: Identifying High Intensity Discharge Headlight Bulb Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 30: Identifying High Intensity Discharge Headlight Bulb Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT DISCHARGE HEADLIGHT BULB NOTE:

Confirm the following items before replacing a discharge headlight bulb. If a malfunction is discovered and repaired, perform the inspection again to confirm the repair. 



Make sure that the high voltage socket of the light control ECU and discharge headlight bulb are connected normally. Make sure that there is no damage to the high voltage socket of the light control ECU or discharge headlight bulb connector.

HINT: Even if a bulb seems to turn on normally, it may not be normal. Perform all the following steps in order because an abnormal condition might otherwise not be easy to duplicate. a. Prepare the vehicle: Before performing the following inspection procedure, turn off the discharge headlight bulbs for more than 10 minutes to allow them to cool down sufficiently.

HINT: Since it is necessary to find the cause of a malfunction that causes a discharge headlight bulb not to turn on, the discharge headlight bulbs should be inspected starting from a cooled off state. 1. Turn on the discharge headlights for more than 25 minutes, and check that the bulbs illuminate normally when they are turned on. HINT: Leave the headlights on for more than 25 minutes to stabilize the discharge headlight bulb arc tube voltage.  A discharge headlight bulb that has almost reached the end of its life may turn off due to a headlight control ECU fail-safe function because the arc tube voltage is high. 2. Repeatedly turn the discharge headlights off for 15 seconds and on for 15 seconds (5 times for each). Check that the bulbs illuminate normally. 

HINT: This inspection confirms the ability of the bulbs to start when hot. 3. Turn off the discharge headlights for 3 minutes, and then turn on the discharge headlights for 3 minutes. Check that the bulbs illuminate normally when they are turned on. HINT: 



A characteristic of discharge headlight bulbs is that their starting voltage is highest when 3 minutes have elapsed after being turned off. This is the most difficult situation for discharge bulbs to start in. This inspection is further confirmation of the ability of the bulbs to start when hot.

Fig. 31: Identifying Discharge Headlight Bulb Inspection Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard The discharge headlight bulbs illuminate normally in all steps. 4. Remove the discharge headlight bulb and perform a visual inspection of the arc tube. Standard The inside of the arc tube is not bulging or deformed and is not clouded. However, a dull brown coloration inside the arc tube is normal.

Fig. 32: Identifying Arc Tube Coloration Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Discharge Discharge Headlight Headlight Bulb at *A *B Bulb is End of Normal Usable Life *1 Arc Tube - Distortion / Inside of Clouded Arc Tube Area REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. PRECAUTION Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY WARNING: The headlight light control ECU sub-assembly may be hot when the light control switch is in the HEAD position or right after it is turned off. Check that the headlight light control ECU sub-assembly is not hot before starting work. a. Disconnect the connector. b. for LH Side: 1. Using a screwdriver, disengage the claw and disconnect the wire harness.

Fig. 33: Identifying Wire Harness Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Move the wire harness as shown in the illustration.

Fig. 34: Moving The Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 35: Turning The Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

 

Do not apply excessive force using a tool. Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

c. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and disconnect it.

Fig. 36: Turning The Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Do not apply excessive force using a tool.



d. Disengage the clamp.

Do not damage the O-ring or allow it to become contaminated with foreign matter. If the O-ring is damaged or contaminated, water may get into the headlight assembly, resulting in a malfunction of the headlight light control ECU sub-assembly.

Fig. 37: Turning The Socket Of Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration, and remove it.

NOTE:

Do not pull the headlight light control ECU sub-assembly with the socket connected.

5. REMOVE DISCHARGE HEADLIGHT BULB a. Release the set spring as shown in the illustration and remove the discharge headlight bulb.

Fig. 38: Releasing Discharge Headlight Bulb Set Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL DISCHARGE HEADLIGHT BULB a. Set the discharge headlight bulb to the headlight unit. NOTE:

Do not touch the bulb glass.

b. Lock the set spring to install the discharge headlight bulb as shown in the illustration.

Fig. 39: Locking Discharge Headlight Bulb Set Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY a. Turn the socket of the headlight light control ECU sub-assembly in the direction indicated by the

arrow shown in the illustration to connect it.

Fig. 40: Turning The Socket Of Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:







Check that the O-ring is installed on the headlight light control ECU sub-assembly. Check that the O-ring is not damaged or contaminated with foreign matter. If there is any damage, replace the O-ring with a new one. Do not pull the headlight light control ECU sub-assembly with the socket connected.

b. Check that the red line on the output harness is not twisted and store the harness in the headlight assembly securely so that the output harness is not pinched. TEXT IN ILLUSTRATION Red *1 Line c. Engage the clamp.

Fig. 41: Engaging The Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for LH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 42: Turning The Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock

*1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

2. Engage the claw and connect the wire harness.

Fig. 43: Identifying Wire Harness Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. for RH Side: 1. Turn the headlight light control ECU sub-assembly in the direction indicated by the arrow shown in the illustration until the lock marks are aligned to install it.

Fig. 44: Turning The Headlight Light Control ECU Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock

*1 Mark NOTE:





To prevent incomplete installation, make sure to fully push in and turn the headlight light control ECU sub-assembly until the lock marks are aligned. Do not apply excessive force using a tool.

f. Connect the connector. 3. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

FOG LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 45: Identifying Fog Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL 2. REMOVE FOG LIGHT ASSEMBLY a. Remove the screw.

Fig. 46: Identifying Fog Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides and remove the fog light assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE FOG LIGHT BULB a. Turn the fog light bulb in the direction indicated by the arrow shown in the illustration and remove it.

Fig. 47: Removing Fog Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

ADJUSTMENT ADJUSTMENT

HINT: It is possible that a bulb is incorrectly installed, affecting fog light aim. Bulb installation should be considered prior to performing the adjustment procedure. 1. PREPARE VEHICLE FOR FOG LIGHT AIM ADJUSTMENT a. Prepare the vehicle:  Ensure there is no damage or deformation to the body around the fog lights.  Fill the fuel tank.  Make sure that the oil is filled to the specified level.  Make sure that the coolant is filled to the specified level.  Inflate the tires to the appropriate pressure.  Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.  Sit a person of average weight (68 kg, 150 lb) in the driver's seat. 2. PREPARE FOR FOG LIGHT AIMING

a. Prepare the vehicle:

Fig. 48: Identifying Fog Light Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

    

Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot. Place the vehicle at a 90° angle to the wall. Create a 7.62 m (25 ft.) distance between the vehicle (fog light bulb center) and the wall. Make sure that the vehicle is on a level surface. Position the front wheels straight ahead. Bounce the vehicle up and down to settle the suspension. NOTE:

A distance of 7.62 m (25 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

b. Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen. c. Draw a vertical line down the center of the screen (V line). d. Set the screen as shown in the illustration.

Fig. 49: Identifying Fog Light Aiming Distance (Using A Screen) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Stand the screen perpendicular to the ground.  Align the V line on the screen with the center of the vehicle. e. Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration. 

Fig. 50: Identifying V LH Line, V RH Line Graph

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION V LH *a Line *b V Line V RH *c Line *d H Line *e Ground HINT: Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb. 1. H Line (Fog light height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights. 2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the fog light bulbs). 3. INSPECT FOG LIGHT AIMING a. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection. b. Start the engine. c. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration.

Fig. 51: Inspecting Fog Light Aiming Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 

If the alignment distance is 7.62 m (25 ft.): The upper edge of the hot zone for the fog light should be 229 mm (9.02 in.) below the H line.



If the alignment distance is 3 m (9.84 ft.): The upper edge of the hot zone for the fog light should be 90 mm (3.54 in.) below the H line.

4. ADJUST FOG LIGHT AIMING a. Adjust the aim vertically: Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.

Fig. 52: Adjusting Fog Light Aim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Aiming *1 Screw NOTE:

The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

HINT: If it is not possible to correctly adjust fog light aim, check bulb, fog light unit and fog light unit reflector installation.

REASSEMBLY REASSEMBLY

1. INSTALL FOG LIGHT BULB a. Turn the fog light bulb in the direction indicated by the arrow shown in the illustration to install it.

Fig. 53: Installing Fog Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the bulb glass.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL FOG LIGHT ASSEMBLY a. Engage the 2 guides to temporarily install the fog light assembly. b. Install the fog light assembly with the screw. Torque: 1.6 N*m (16 kgf*cm, 14 in.*lbf)

2. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION

SIDE TURN SIGNAL LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 54: Identifying Side Turn Signal Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: 

Use the same procedure for the RH and LH sides.



The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR . Refer to REMOVAL - Step 2 2. REMOVE OUTER MIRROR COVER . Refer to REMOVAL - Step 4 3. REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY a. Disengage the 2 claws.

Fig. 55: Identifying Side Turn Signal Light Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and remove the side turn signal light assembly. INSPECTION INSPECTION

1. INSPECT SIDE TURN SIGNAL LIGHT ASSEMBLY LH a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 56: Turn Signal Light Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the side turn signal light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (Side Turn Signal Light Assembly LH) If the result is not as specified, replace the side turn signal light assembly LH. 2. INSPECT SIDE TURN SIGNAL LIGHT ASSEMBLY RH a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 57: Turn Signal Light Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the side turn signal light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness connected *a (Side Turn Signal Light Assembly RH) If the result is not as specified, replace the side turn signal light assembly RH. INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY a. Connect the connector. b. Engage the 2 claws to install the side turn signal light assembly. 2. INSTALL OUTER MIRROR COVER . Refer to INSTALLATION - Step 2 3. INSTALL OUTER REAR VIEW MIRROR . Refer to INSTALLATION - Step 2

REAR COMBINATION LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 58: Identifying Rear Combination Light Assembly Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 59: Identifying Rear Combination Light Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REAR COMBINATION LIGHT ASSEMBLY LH

a. Disconnect the connector from the rear combination light assembly LH.

Fig. 60: Inspecting Rear Combination Light Assembly LH Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition Turn signal Below 1 switch in V neutral T8-1 (B)- position T8-2 (E) Turn 11 to 14 V signal (60 to 120 switch in times per left turn minute) position Light Below 1 control V switch off T9-2 (TL) - Light T9-1 (E) control switch in 11 to 14 V tail position Brake Below 1 pedal V T9-3 (STP) released - T9-1 (E) Brake 11 to 14 V pedal depressed Light Below 1 control V switch off T19-2 (B) - Light T19-1 (E) control switch in 11 to 14 V tail position TEXT IN ILLUSTRATION Front view of wire *a harness connector (to Rear Combination

Light Assembly LH) If the result is not as specified, repair or replace the wire harness or connector. 2. INSPECT REAR COMBINATION LIGHT ASSEMBLY RH a. Disconnect the connector from the rear combination light assembly RH.

Fig. 61: Inspecting Rear Combination Light Assembly RH Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below.

Standard Voltage Tester Switch Specified Connection Condition Condition Turn signal Below 1 switch in V neutral T13-1 (B) - position T13-2 (E) Turn 11 to 14 V signal (60 to 120 switch in times per right turn minute) position Light Below 1 control V switch off T12-2 (TL) Light - T12-1 (E) control switch in 11 to 14 V tail position Brake Below 1 pedal V T12-3 released (STP) T12-1 (E) Brake pedal 11 to 14 V depressed Light Below 1 control V switch off T20-2 (B) - Light T20-1 (E) control switch in 11 to 14 V tail position TEXT IN ILLUSTRATION Front view of wire harness *a connector (to Rear Combination Light Assembly

RH) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8. 9.

REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to REMOVAL - Step 1 REMOVE SPARE WHEEL COVER ASSEMBLY . Refer to REMOVAL - Step 2 REMOVE BAGGAGE HOLDER NET (w/ Partition Net) . Refer to REMOVAL - Step 3 REMOVE REAR FLOOR FINISH PLATE . Refer to REMOVAL - Step 4 REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to REMOVAL - Step 18 REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to REMOVAL - Step 6 REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER . Refer to REMOVAL - Step 7 REMOVE REAR COMBINATION LIGHT ASSEMBLY a. Disconnect each connector.

Fig. 62: Identifying Rear Combination Light Assembly Connectors And Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. c. Remove the 4 nuts and rear combination light assembly.

Fig. 63: Identifying Rear Combination Light Assembly Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR COMBINATION LIGHT PACKING a. Remove the rear combination light packing.

Fig. 64: Identifying Rear Combination Light Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be sure to remove all the traces of the old packing from the body. Do not reuse the removed packing. Be sure to install a new rear combination light packing to prevent water ingress.

2. REMOVE REAR SIDE MARKER LIGHT BULB a. Turn the rear side marker light socket with the rear side marker light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 65: Removing Rear Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear side marker light bulb from the rear side marker light socket. 3. REMOVE REAR TURN SIGNAL LIGHT BULB a. Turn the rear turn signal light socket with the rear turn signal light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 66: Removing Rear Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear turn signal light bulb from the rear turn signal light socket. 4. REMOVE TAIL AND STOP LIGHT BULB a. Turn the tail and stop light socket with the tail and stop light bulb in the direction indicated by the arrow shown in the illustration, and remove them as a unit.

Fig. 67: Removing Tail And Stop Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the tail and stop light bulb from the tail and stop light socket. 5. REMOVE REAR BUMPER UPPER SIDE RETAINER a. Using a screwdriver, disengage the claw and remove the rear bumper upper side retainer as shown in the illustration.

Fig. 68: Removing Rear Bumper Upper Side Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL REAR BUMPER UPPER SIDE RETAINER a. Engage the claw to install the rear bumper upper side retainer as shown in the illustration.

Fig. 69: Installing Rear Bumper Upper Side Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL TAIL AND STOP LIGHT BULB a. Install the tail and stop light bulb to the tail and stop light socket. b. Turn the tail and stop light socket with the tail and stop light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 70: Installing Tail And Stop Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR TURN SIGNAL LIGHT BULB a. Install the rear turn signal light bulb to the rear turn signal light socket. b. Turn the rear turn signal light socket with the rear turn signal light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 71: Installing Rear Turn Signal Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL REAR SIDE MARKER LIGHT BULB a. Install the rear side marker light bulb to the rear side marker light socket. b. Turn the rear side marker light socket with the rear side marker light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 72: Installing Rear Side Marker Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL REAR COMBINATION LIGHT PACKING a. Install a new rear combination light packing.

Fig. 73: Identifying Rear Combination Light Packing

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR COMBINATION LIGHT ASSEMBLY a. Install the rear combination light assembly with the 4 nuts. Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf)

2. 3. 4. 5. 6. 7. 8. 9.

b. Engage the clamp. c. Connect each connector. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER . Refer to INSTALLATION Step 6 INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK . Refer to INSTALLATION - Step 4 INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to INSTALLATION Step 9 INSTALL REAR FLOOR FINISH PLATE . Refer to INSTALLATION - Step 10 INSTALL BAGGAGE HOLDER NET (w/ Partition Net) . Refer to INSTALLATION - Step 11 INSTALL SPARE WHEEL COVER ASSEMBLY . Refer to INSTALLATION - Step 12 INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to INSTALLATION - Step 13 INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION

REAR LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 74: Identifying Rear Light Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT REAR LIGHT ASSEMBLY LH

a. Disconnect the connector from the rear light assembly LH.

Fig. 75: Inspecting Rear Light Assembly LH Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Power switch on (READY) Below 1 and the V shift lever T18-2 (B)- not in R T18-1 (E) Power switch on (READY) 11 to 16 V and the shift lever in R TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Rear Light Assembly LH) If the result is not as specified, repair or replace the wire harness or connector. 2. INSPECT REAR LIGHT ASSEMBLY RH a. Disconnect the connector from the rear light assembly RH.

Fig. 76: Inspecting Rear Light Assembly RH Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition Power switch on (READY) Below 1

and the V shift lever not in R T17-2 (B)- Power T17-1 (E) switch on (READY) 11 to 16 V and the shift lever in R TEXT IN ILLUSTRATION Front view of wire harness *a connector (to Rear Light Assembly RH) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE LUGGAGE COMPARTMENT DOOR COVER . Refer to DISASSEMBLY - Step 1 2. REMOVE REAR LIGHT ASSEMBLY a. Disconnect the connector.

Fig. 77: Identifying Rear Light Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 nuts and rear light assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR LIGHT GASKET a. Remove the rear light gasket.

Fig. 78: Identifying Rear Light Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Be sure to remove all the traces of the old gasket from the body. Do not reuse the removed gasket. Be sure to install a new rear light gasket to prevent water ingress.

2. REMOVE BACK-UP LIGHT BULB a. Turn the back-up light socket with the back-up light bulb in the direction indicated by the arrow shown in the illustration and remove them as a unit.

Fig. 79: Removing Back-Up Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the back-up light bulb from the back-up light socket. REASSEMBLY REASSEMBLY

1. INSTALL BACK-UP LIGHT BULB a. Install the back-up light bulb to the back-up light socket. b. Turn the back-up light socket with the back-up light bulb in the direction indicated by the arrow shown in the illustration to install them as a unit.

Fig. 80: Installing Back-Up Light Bulb Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL REAR LIGHT GASKET a. Install a new rear light gasket.

Fig. 81: Identifying Rear Light Gasket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL REAR LIGHT ASSEMBLY a. Install the rear light assembly with the 3 nuts.

Fig. 82: Identifying Rear Light Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Nut (A) Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) Nut (B) Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) b. Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER . Refer to REASSEMBLY - Step 10

LICENSE PLATE LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 83: Identifying License Plate Light Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL

2. REMOVE LICENSE PLATE LIGHT ASSEMBLY a. Disconnect the connector.

Fig. 84: Locating License Plate Light Assembly Connector And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and remove the license plate light assembly. 3. REMOVE LICENSE PLATE LIGHT PACKING a. Remove the license plate light packing.

Fig. 85: Identifying License Plate Light Packing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not reuse the removed packing. Be sure to install a new license plate light packing to prevent water ingress.

INSPECTION INSPECTION

1. INSPECT LICENSE PLATE LIGHT ASSEMBLY a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 86: License Plate Light Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the license plate light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness *a connected (License Plate Light Assembly) If the result is not as specified, replace the bulb or license plate light socket and wire. INSTALLATION INSTALLATION

HINT: 

Use the same procedure for the RH and LH sides.



The procedure described below is for the LH side.

1. INSTALL LICENSE PLATE LIGHT PACKING a. Install a new license plate light packing. 2. INSTALL LICENSE PLATE LIGHT ASSEMBLY a. Engage the 2 claws to install the license plate light assembly. b. Connect the connector. 3. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION

HIGH MOUNTED STOP LIGHT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 87: Identifying High Mounted Stop Light Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CENTER STOP LIGHT SET a. Slide the center stop light set in the order and directions shown by the arrows in the illustration while pushing it towards the rear of the vehicle to disengage the 4 claws.

Fig. 88: Removing Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the center stop light set 180 degrees as shown by the arrow in the illustration.

Fig. 89: Turning Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: This makes it easier to disconnect the connector. c. Disconnect the connector and remove the center stop light set. INSPECTION INSPECTION

1. INSPECT CENTER STOP LIGHT SET a. Connect a positive (+) lead from the auxiliary battery to terminal 1 and a negative (-) lead to terminal 2.

Fig. 90: Identifying Center Stop Light Set Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the center stop light comes on. OK The light comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Center Stop Light Set) If the result is not as specified, replace the center stop light set. INSTALLATION INSTALLATION

1. INSTALL CENTER STOP LIGHT SET a. Connect the connector. b. Temporarily install the center stop light set.

c. Slide the center stop light set in the order and directions shown by the arrows in the illustration while pushing it towards the rear of the vehicle to engage the 4 claws.

Fig. 91: Installing Center Stop Light Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HEADLIGHT DIMMER SWITCH COMPONENTS ILLUSTRATION

Fig. 92: Identifying Headlight Dimmer Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY . Refer to REMOVAL - Step 3 3. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 93: Identifying Headlight Dimmer Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the 3 claws and remove the headlight dimmer switch assembly. INSPECTION INSPECTION

1. INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 94: Inspecting Headlight Dimmer Switch Assembly Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance LIGHT CONTROL SWITCH (W/ DRL OFF FUNCTION) Tester Switch Specified Connection Condition Condition 18 (T) - 15 Light 10 kohms (EL) or higher control 19 (H) - 15 switch off 10 kohms (EL) (DRL or higher 20 (A) - 15 OFF 10 kohms position) or higher (EL) Light control 20 (A) - 15 Below 1 switch in (EL) ohms AUTO position Light control 18 (T) - 15 Below 1 switch in (EL) ohms tail position 18 (T) - 15 Light (EL) control

Below 1 ohms

switch in 19 (H) - 15 Below 1 head (EL) ohms position LIGHT CONTROL SWITCH (W/O DRL OFF FUNCTION) Tester Switch Specified Connection Condition Condition 18 (T) - 15 10 kohms (EL) or higher Light 19 (H) - 15 10 kohms control (EL) or higher switch off 20 (A) - 15 10 kohms (EL) or higher Light control 20 (A) - 15 Below 1 switch in (EL) ohms AUTO position Light control 18 (T) - 15 Below 1 switch in (EL) ohms tail position 18 (T) - 15 Light Below 1 control (EL) ohms switch in 19 (H) - 15 head Below 1 (EL) position ohms DIMMER SWITCH Tester Switch Specified Connection Condition Condition Dimmer 14 (HU) - switch in Below 1 15 (EL) high ohms position 14 (HU) - Dimmer Below 1 switch in ohms 15 (EL) high 17 (HF) - flasher Below 1 15 (EL) position ohms TURN SIGNAL SWITCH Tester Switch Specified Connection Condition Condition

12 (TR) 15 (EL) 11 (TL) 15 (EL) 12 (TR) 15 (EL) 11 (TL) 15 (EL)

10 kohms or higher Neutral 10 kohms or higher Below 1 Right turn ohms Below 1 Left turn ohms

FRONT FOG LIGHT SWITCH*1 Tester Switch Specified Connection Condition Condition Front fog 8 (LFG) - 9 10 kohms light (BFG) or higher switch off Front fog 8 (LFG) - 9 Below 1 light (BFG) ohms switch on *1: w/ Front Fog Light TEXT IN ILLUSTRATION Component without harness connected *a (Headlight Dimmer Switch Assembly) If the result is not as specified, replace the headlight dimmer switch assembly. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY a. Engage the 3 claws to install the headlight dimmer switch assembly. b. Connect the connector. 2. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY . Refer to INSTALLATION - Step 1 3. INSTALL SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY Refer to INSTALLATION

HAZARD WARNING SWITCH COMPONENTS ILLUSTRATION

Fig. 95: Identifying Hazard Warning Switch Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 96: Identifying Hazard Warning Switch Replacement Components (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 97: Identifying Hazard Warning Switch Replacement Components (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 98: Identifying Hazard Warning Switch Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 99: Identifying Hazard Warning Switch Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to REMOVAL - Step 2 for Navigation Receiver Type: Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 6. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 8. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 9. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 11. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 12. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 13. REMOVE NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 11 14. REMOVE NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to REMOVAL - Step 12 15. REMOVE NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 13 16. REMOVE NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to REMOVAL - Step 14 17. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 15 18. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive

Parking Assist System) . Refer to REMOVAL - Step 16 19. REMOVE NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 10 20. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to REMOVAL - Step 11 21. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) . Refer to REMOVAL - Step 21 INSPECTION INSPECTION

1. INSPECT AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) a. Measure the resistance according to the value(s) in the table below.

Fig. 100: Inspecting Air Conditioning Control Assembly (Hazard Switch) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Hazard 10 kohms 4 (HAZ) - 6 switch off or higher (GND) Hazard Below 1

switch on ohms TEXT IN ILLUSTRATION Component without harness connected (Air *a Conditioning Control Assembly (Hazard Switch)) If the result is not as specified, replace the air conditioning control assembly. INSTALLATION INSTALLATION

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (HAZARD SWITCH) . Refer to INSTALLATION - Step 1 2. INSTALL NO. 1 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 8 3. INSTALL NO. 2 RADIO BRACKET (for Radio Receiver Type) . Refer to INSTALLATION - Step 9 4. INSTALL NO. 1 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 10 5. INSTALL NO. 2 RADIO BRACKET (for Radio and Display Type) . Refer to INSTALLATION Step 11 6. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 12 7. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 8. INSTALL NO. 1 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 5 9. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) . Refer to INSTALLATION - Step 6 10. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 11. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 12. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7

13. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 14. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 15. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 16. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 17. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION 18. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

19. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

20. INSTALL LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to INSTALLATION - Step 3 for Navigation Receiver Type: Refer to INSTALLATION - Step 3

HEADLIGHT LEVELING SWITCH COMPONENTS ILLUSTRATION

Fig. 101: Identifying Headlight Leveling Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 8 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 9 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 10 6. REMOVE HEADLIGHT LEVELING SWITCH

a. Disengage the 2 claws and remove the headlight leveling switch from the instrument cluster finish panel assembly.

Fig. 102: Identifying Headlight Leveling Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT HEADLIGHT LEVELING SWITCH a. Voltage Check 1. Connect a positive (+) lead from the auxiliary battery to terminal 1 (B) and a negative (-) lead to terminal 5 (E).

Fig. 103: Inspecting Headlight Leveling Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Condition Position Condition 10.44 to 0 11.16 V 9.16 to 1 9.88 V 7.88 to 2 8.60 V 2 (T) - 5 (E) 6.6 to 7.32 3 V 5.32 to 4 6.04 V 4.04 to 5 4.76 V HINT: Auxiliary battery voltage is 12 V.

TEXT IN ILLUSTRATION Component without harness *a connected (Headlight Leveling Switch) If the result is not as specified, replace the headlight leveling switch. b. LED Illumination Inspection

Fig. 104: Inspecting Headlight Leveling Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Apply auxiliary battery voltage to the headlight leveling switch and check that the switch illuminates. OK Tester Specified Connection Condition Auxiliary battery positive (+) -->

Terminal 3 (ILL+) Auxiliary battery Illuminates negative (-) --> Terminal 4 (ILL-) TEXT IN ILLUSTRATION Component without harness *a connected (Headlight Leveling Switch) If the result is not as specified, replace the headlight leveling switch. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT LEVELING SWITCH a. Engage the 2 claws to install the headlight leveling switch to the instrument cluster finish panel assembly. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 42 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 43 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 44 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43

STOP LIGHT SWITCH COMPONENTS ILLUSTRATION

Fig. 105: Identifying Stop Light Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STOP LIGHT SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 106: Locating Stop Light Switch Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the stop light switch assembly counterclockwise and remove it.

Fig. 107: Removing Stop Light Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT STOP LIGHT SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 108: Inspecting Stop Light Switch Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms Pushed or higher

1-2

Not pushed Pushed

3-4

Not pushed

Below 0.1 ohms Below 200 ohms 10 kohms or higher

TEXT IN ILLUSTRATION Component without harness *a connected (Stop Light Switch Assembly) *b Not Pushed *c Pushed If the result is not as specified, replace the stop light switch assembly. INSTALLATION INSTALLATION

1. INSTALL STOP LIGHT SWITCH ASSEMBLY a. Insert the stop light switch assembly until the threaded sleeve hits the pedal.

Fig. 109: Inserting Stop Light Switch Assembly Until Rod Hits Pedal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

b. Make a quarter turn clockwise to install the stop light switch assembly.

Fig. 110: Installing Stop Light Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less NOTE:

When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

c. Connect the connector. d. Check the protrusion of the plunger. PROTRUSION OF THE PLUNGER Area Measurement 1.5 to 2.5 mm a (0.0591 to 0.0984 in.) If the protrusion is not as specified, recheck switch installation and inspect brake pedal adjustment if necessary. Refer to ADJUSTMENT . NOTE:

Do not depress or support the brake pedal.

AUTOMATIC LIGHT CONTROL SENSOR

COMPONENTS ILLUSTRATION

Fig. 111: Identifying Automatic Light Control Sensor Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 112: Identifying Automatic Light Control Sensor Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 113: Identifying Automatic Light Control Sensor Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to REMOVAL - Step 2 for Navigation Receiver Type: Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 6. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 8. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 9. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to REMOVAL - Step 9 11. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to REMOVAL - Step 10 12. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to REMOVAL - Step 9 13. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to REMOVAL - Step 29 14. REMOVE AUTOMATIC LIGHT CONTROL SENSOR a. Disengage the 2 claws and remove the automatic light control sensor from the No. 1 speaker opening cover assembly.

Fig. 114: Identifying Solar Sensor Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR a. Disconnect the I61 automatic light control sensor connector.

Fig. 115: Inspecting I61 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure the voltage and resistance according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition Power Below 1 I61-6 switch off V (CLTB) Power I61-3 (CLTE) switch on 11 to 14 V (IG) Standard Resistance Tester Specified Condition Connection Condition I61-3 (CLTE) Below 1 Always Body ohms ground TEXT IN ILLUSTRATION Front

view of wire harness connector *a (to Automatic Light Control Sensor) If the result is not as specified, there may be a malfunction on the wire harness side. c. Reconnect the I61 automatic light control sensor connector.

Fig. 116: Inspecting I61 Automatic Light Control Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Connect an oscilloscope to the automatic light control sensor connector. TEXT IN ILLUSTRATION Component with harness connected *a (Automatic Light Control Sensor) e. Check the waveform.

Fig. 117: Identifying Waveform Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Tool Switch Specified Connection Setting Condition Condition I61-3 5 Power Correct (CLTE) - V/DIV., switch on waveform I61-5 5 (IG), light is as (CLTS) ms./DIV control shown switch in

AUTO position HINT: If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, the automatic light control sensor may have a malfunction. INSTALLATION INSTALLATION

1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR a. Engage the 2 claws to install the automatic light control sensor to the No. 1 speaker opening cover assembly. 2. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY . Refer to INSTALLATION - Step 23 3. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio Receiver Type) . Refer to INSTALLATION - Step 14 4. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type) . Refer to INSTALLATION - Step 15 5. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) . Refer to INSTALLATION - Step 7 6. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 7. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 9. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 10. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION 11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Radio and Display Type with Intuitive Parking Assist System) NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL (for Navigation Receiver Type) NOTE:

When disconnecting the cable, some systems need to be initialized after

the cable is reconnected. Refer to INITIALIZATION . 13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER for Radio and Display Type with Intuitive Parking Assist System: Refer to INSTALLATION - Step 3 for Navigation Receiver Type: Refer to INSTALLATION - Step 3

HEIGHT CONTROL SENSOR COMPONENTS ILLUSTRATION

Fig. 118: Identifying Height Control Sensor Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 119: Identifying Height Control Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Disconnect the connector.

Fig. 120: Locating Rear Height Control Sensor Sub-Assembly Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the nut and 2 bolts. c. Disengage the clamp and remove the rear height control sensor sub-assembly. NOTE:

Do not drop the rear height control sensor sub-assembly. If it is dropped, replace it with a new one.

INSPECTION INSPECTION

1. INSPECT REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Connect 3 dry cell batteries (1.5 V) in series. NOTE:

Do not use rechargeable batteries as they may not output a voltage of 1.5 V.

Fig. 121: Inspecting Rear Height Control Sensor Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the batteries to terminal 3 (SHB) and the negative (-) lead from the batteries to terminal 1 (SHG).

c. Measure the voltage between terminals 2 (SHRR) and 1 (SHG) while slowly moving the link up and down. Standard Voltage Tester Specified Condition Connection Condition 2 (SHRR) - +37.9° 3.77 V 1 (SHG) (High) 2 (SHRR) - 0° 2.25 V 1 (SHG) (Normal) 2 (SHRR) - -36.9° 0.77 V 1 (SHG) (Low) TEXT IN ILLUSTRATION Component without harness connected (Rear *a Height Control Sensor Subassembly) If the result is not as specified, replace the rear height control sensor sub-assembly. INSTALLATION INSTALLATION

1. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY a. Engage the clamp. b. Install the rear height control sensor sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) d. Connect the connector. 2. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 4. INITIALIZE HEIGHT CONTROL SENSOR SIGNAL Refer to INITIALIZATION 5. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT

HEADLIGHT LEVELING ECU COMPONENTS ILLUSTRATION

Fig. 122: Identifying Headlight Leveling ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to REMOVAL 2. REMOVE HEADLIGHT LEVELING ECU ASSEMBLY a. Disconnect the connector.

Fig. 123: Locating Headlight Leveling ECU Assembly Connector And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. TEXT IN ILLUSTRATION *1 Clamp *2 Guide c. Remove the bolt. d. Disengage the 2 guides and remove the headlight leveling ECU assembly. INSTALLATION INSTALLATION

1. INSTALL HEADLIGHT LEVELING ECU ASSEMBLY a. Engage the 2 guides. b. Install the headlight leveling ECU assembly with the bolt.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Engage the clamp. d. Connect the connector. 2. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION 3. INITIALIZE HEIGHT CONTROL SENSOR SIGNAL Refer to INITIALIZATION 4. ADJUST HEADLIGHT AIMING Refer to ADJUSTMENT

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT H-LP RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 124: H-LP Relay

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Voltage is not applied 10 kohms 3-5 between or higher terminals 1 and 2 Voltage is applied Below 1 3-5 between ohms terminals 1 and 2 If the result is not as specified, replace the H-LP relay.

2012-2017 ENGINE Lubrication System (Service Information) - Camry (2AR-FE)

OIL AND OIL FILTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Oil And Oil Filter Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REPLACEMENT REPLACEMENT

WARNING:







Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Wear protective clothing and gloves. Avoid contact with used oil. If contact occurs, wash your skin thoroughly with soap or waterless hand cleaner. Never use gasoline, thinners, or solvents to wash the skin. In order to protect the environment, dispose of used oil and used oil filters at designated disposal sites only.

1. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil pan drain plug and gasket, and drain the engine oil into a container. c. Clean the oil pan drain plug and install a new gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 2. REMOVE OIL FILTER CAP ASSEMBLY a. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Fig. 2: Connecting Hose To Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pipe *2 Hose b. Remove the oil filter drain plug from the oil filter cap.

Fig. 3: Locating Oil Filter Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the pipe to the oil filter cap.

Fig. 4: Identifying Oil Filter Cap Assembly Valve, Cap, O-Ring & Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Valve *2 Cap O*3 ring *4 Pipe NOTE:

HINT:

If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

Use a container to catch the draining oil. d. Check that the oil is drained from the oil filter. Then disconnect the pipe as shown in the illustration and remove the O-ring.

Fig. 5: Disconnecting Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, remove the oil filter cap.

Fig. 6: Identifying Oil Filter Cap And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil

Filter *1 Bracket Clip 

SST: 09228-06501

NOTE:

Do not remove the oil filter bracket clip.

f. Remove the oil filter element and O-ring from the oil filter cap.

Fig. 7: Identifying Oil Filter, Oil Filter Cap And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil *2 Filter Cap *3 O-ring NOTE:

Be sure to remove the O-ring by hand, without using any tools, to prevent damage to the O-ring groove.

3. INSTALL OIL FILTER CAP ASSEMBLY

a. Clean the inside of the oil filter cap, threads and O-ring groove. b. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

Fig. 8: Identifying Oil Filter Element, Oil Filter Cap And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil *2 Filter Cap *3 O-ring c. Set a new oil filter element into the oil filter cap. d. Remove any dirt or foreign matter from the installation surface of the engine. e. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. NOTE:

Make sure that the O-ring does not get caught between the parts.

f. Using SST, tighten the oil filter cap.

Fig. 9: Identifying Oil Filter Cap And SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No

*a Clearance 

SST: 09228-06501

Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE:

Make sure that the oil filter is installed securely as shown in the illustration.

g. Apply a small amount of engine oil to a new O-ring, and install it to the oil filter cap.

Fig. 10: Identifying Oil Filter Drain Plug "O" Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring NOTE:

Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

h. Install the oil filter drain plug. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) NOTE:

Be careful that the O-ring does not get caught between any

surrounding parts. 4. ADD ENGINE OIL a. Add new oil. Standard Oil Grade Oil Grade

Oil Viscosity

ILSAC multigrade 0W-20 engine oil Standard Capacity Item Drain and refill (with oil filter change) Drain and refill (without oil filter change)

Specified Condition 4.4 liters (4.6 US qts, 3.9 Imp. qts)

4.0 liters (4.2 US qts, 3.5 Imp. qts)

5.3 liters (5.6 US Dry fill qts, 4.7 Imp. qts) b. Install the oil filler cap. 5. INSPECT FOR OIL LEAK 6. INSPECT ENGINE OIL LEVEL . Refer to ON-VEHICLE INSPECTION - Step 1

OIL PRESSURE SWITCH COMPONENTS ILLUSTRATION

Fig. 11: Identifying Oil Pressure Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 12: Identifying Oil Pressure Switch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 24 mm deep socket wrench, remove the oil pressure switch. INSPECTION INSPECTION

1. INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the oil pressure switch connector. b. Start the engine. c. Measure the resistance according to the value(s) in the table below.

Fig. 13: Inspecting Engine Oil Pressure Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Engine Below 1 ohms 1 - Body stopped ground Engine 10 kohms idling or higher If the result is not as specified, replace the oil pressure switch assembly. INSTALLATION INSTALLATION

1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Apply adhesive to 2 or 3 threads of the oil pressure switch.

Fig. 14: Applying Adhesive To Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent. NOTE:

Do not let adhesive adhere to the oil hole.

b. Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Do not start the engine within 1 hour of installation.

c. Connect the connector. 2. INSPECT FOR OIL LEAK 3. INSPECT ENGINE OIL LEVEL . Refer to ON-VEHICLE INSPECTION - Step 1

OIL PUMP COMPONENTS

ILLUSTRATION

Fig. 15: Identifying Oil Pump Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 16: Identifying Oil Pump Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

Do not remove the oil pump or oil pump relief valve from the timing chain cover sub-assembly.

1. REMOVE ENGINE AND TRANSAXLE Refer to REMOVAL 2. REMOVE ENGINE WIRE a. Remove the engine wire. 3. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2 4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY a. Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.

Fig. 17: Locating Cylinder Head Cover And Gasket Bolts And Seal Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 gaskets from the camshaft bearing caps.

Fig. 18: Locating Camshaft Bearing Caps Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5. REMOVE CRANKSHAFT POSITION SENSOR . Refer to REMOVAL - Step 1 6. REMOVE CRANKSHAFT PULLEY . Refer to DISASSEMBLY - Step 16 7. REMOVE ENGINE MOUNTING BRACKET RH a. Remove the 5 bolts and engine mounting bracket RH.

Fig. 19: Locating Engine Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY . Refer to DISASSEMBLY - Step 13 9. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY a. Remove the 17 bolts and 2 nuts.

Fig. 20: Locating Timing Chain Cover Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

Fig. 21: Prying Between Timing Chain Cover And Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the contact surfaces of the cylinder head,

camshaft housing, cylinder block, stiffening crankcase or chain cover. HINT: Tape the screwdriver tip before use. c. Remove the 3 gaskets from the stiffening crankcase.

Fig. 22: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE TIMING CHAIN COVER OIL SEAL a. Using a screwdriver and wooden block, pry out the oil seal.

Fig. 23: Identifying Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wooden *1 Block NOTE:

Do not damage the surface of the oil seal press fit hole.

HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY a. Apply a light coat of engine oil to 3 new gaskets.

Fig. 24: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 gaskets to the stiffening crankcase. c. Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

Fig. 25: Locating Drive Rotor Spline & Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive *1 Rotor Spline Crankshaft *2 Timing Sprocket d. Apply seal packing in a line to the timing chain cover as shown in the following illustration.

Fig. 26: Applying Seal Packing Continuous Line To Timing Chain Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent. Apply Seal Packing as Follows Seal Packing Distance Diameter from (Round) Edge of

Seal

Cover Seal to Pacing Area Center Dimension of Seal (Flat) Packing 3.0 mm 2.5 mm Dashed (0.118 in.) (0.0984 Line in.) 3.0 mm 2.5 mm A - A (0.118 in.) (0.0984 in.) 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) 3.0 mm (0.118 B - B or more wide and in.) 3.0 mm (0.118 in.) or more thick 7.0 mm (0.276 in.) 13.0 mm (0.512 in.) 5.0 mm C - C or more (0.197 wide and in.) 3.0 mm (0.118 in.) or more thick 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) 3.0 mm D - D or more (0.118 wide and in.) 3.0 mm (0.118 in.) or more thick 3.0 mm 3.0 mm (0.118 in.) (0.118 E in.) NOTE:

Packing Application Length

-

-

28 mm (1.10 in.)

25 mm (0.984 in.)

26 mm (1.02 in.)

-







 

When the contact surfaces are wet, clean the surfaces with nonresidue solvent before applying seal packing. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. After applying seal packing to the timing chain cover, install the engine mounting bracket within 10 minutes. Do not apply oil for at least 4 hours after the installation. Do not start the engine for at least 4 hours after the installation.

e. Temporarily install the timing chain cover with the 17 bolts and 2 nuts.

Fig. 27: Identifying Timing Chain Cover Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt *a A Bolt *b B Bolt *c C *d Nut Bolt Length

Thread Diameter 30 mm 8 mm Bolt (1.18 (0.315 A in.) in.) 35 mm 10 mm Bolt (1.38 (0.394 B in.) in.) 45 mm 8 mm Bolt (1.77 (0.315 C in.) in.) Item Length

NOTE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

f. Tighten the 17 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

Fig. 28: Identifying Timing Chain Cover Bolts And Nuts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for bolt 1, 2, 3 and 4 Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) except bolt 1, 2, 3 and 4

Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 2. INSTALL ENGINE MOUNTING BRACKET RH a. Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

Fig. 29: Identifying Engine Mounting Bracket Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for bolt 1, 2 and 3 Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt 4 and 5 Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) NOTE:

3. 4. 5. 6. 7.

After applying seal packing to the timing chain cover, install the engine mounting bracket within 10 minutes.

INSTALL TIMING CHAIN COVER OIL SEAL . Refer to INSTALLATION - Step 1 INSTALL CRANKSHAFT PULLEY . Refer to REASSEMBLY - Step 44 INSTALL CRANKSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 INSTALL V-RIBBED BELT TENSIONER ASSEMBLY . Refer to REASSEMBLY - Step 48 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY a. Apply a light coat of engine oil to 3 new gaskets.

Fig. 30: Locating Camshaft Bearing Caps Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 gaskets to the camshaft bearing caps. c. Visually check the spark plug tube gasket.

Fig. 31: Identifying No Scratches Or Deformation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Specified Condition No Upper scratches or surface deformation No Outer scratches or lip deformation Inner No lip scratches Area

TEXT IN ILLUSTRATION Upper *a Surface Inner *b Lip Outer *c Lip HINT: If the result is not as specified, replace the spark plug tube gasket. d. Install a new gasket to the cylinder head cover. NOTE:

Remove any oil from the contact surface.

e. Apply seal packing as shown in the illustration.

Fig. 32: Cylinder Head Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.0 to 6.0 mm (0.118 to 0.236 in.) Application width A 5.0 mm (0.197 in.) TEXT IN ILLUSTRATION

Seal packing Timing *2 Chain Cover Camshaft *3 Housing *1

NOTE:

 

Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

f. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

Fig. 33: Identifying Cylinder Head Cover Bolts Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE:



Do not apply oil for at least 4 hours after the installation.

8. INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 9. INSTALL ENGINE WIRE a. Install the engine wire to the engine with transaxle. 10. INSTALL ENGINE AND TRANSAXLE Refer to INSTALLATION

2012-2017 ENGINE Lubrication System (Service Information) - Camry (2GR-FE)

OIL AND OIL FILTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Oil And Filter Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REPLACEMENT REPLACEMENT

WARNING:







Prolonged and repeated contact with engine oil will result in removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. Skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. In order to preserve the environment, used oil and used oil filters must be disposed of at designated disposal sites.

1. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil drain plug and drain the oil into a container. c. Clean the oil drain plug. d. Install the oil drain plug with a new gasket. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 2. REMOVE OIL FILTER CAP ASSEMBLY a. Connect the hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Fig. 2: Connecting Hose With An Inside Diameter Of 15 Mm (0.591 In.) To Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pipe *2 Hose b. Remove the oil filter drain plug from the oil filter cap.

Fig. 3: Removing Oil Filter Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the pipe with the hose into the oil filter cap.

Fig. 4: Identifying Cap, O-Ring And Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Cap O*2 ring *3 Pipe NOTE:

Be sure to insert the pipe with the O-ring installed on the oil filter cap.

HINT: Place the hose end into a container before draining oil from the hose.

d. Make sure that oil is completely drained, and remove the pipe and O-ring.

Fig. 5: Removing Pipe And O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Be sure to turn the pipe in the direction of the arrow to remove it. e. Using SST, remove the oil filter cap.

Fig. 6: Removing Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09228-06501 f. Remove the oil filter element and O-ring from the oil filter cap. 

Fig. 7: Identifying Oil Filter Elements, Oil Filter Cap And O-ring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil *2 Filter Cap *3 O-ring NOTE:

Do not use any tools to remove the O-ring in order to prevent the cap from being damaged. Be sure to remove it by hand.

3. INSTALL OIL FILTER CAP ASSEMBLY a. Clean the inside of the oil filter cap, threads and O-ring groove. b. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

Fig. 8: Identifying Oil Filter Elements, Oil Filter Cap And O-ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil

Filter Cap *3 O-ring *2

NOTE:

Make sure that the O-ring does not get twisted on the groove.

c. Install a new oil filter element to the oil filter cap. d. Remove all dirt and foreign matter from the installation surface and the inside of the cap on the engine side. e. Apply a light coat of engine oil to the O-ring again and install the oil filter cap. NOTE:

Make sure that the O-ring does not get caught between the parts.

f. Using SST, install the oil filter cap.

Fig. 9: Removing/Installing Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No *a Clearance 

SST: 09228-06501

Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

NOTE:

Make sure that there is no clearance between the parts after tightening the oil filter cap.

g. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

Fig. 10: Identifying O-ring Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring NOTE:

Remove all dirt and foreign matter from the installation surface.

h. Install the oil filter drain plug to the oil filter cap. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) NOTE:

Make sure that the O-ring does not get caught between the parts.

4. ADD ENGINE OIL a. Add clean engine oil and install the oil filler cap. Standard Oil Grade

Oil Grade

Oil Viscosity (SAE)

ILSAC multigrade engine oil Standard Capacity Item

Standard Condition

Drain and 6.1 liters refill (6.4 US with qts, 5.4 oil lmp. qts) filter change Drain and 5.7 liters refill (6.0 US without qts, 5.0 oil lmp. qts) filter change 6.8 liters (7.2 US Dry fill qts, 6.0 lmp. qts) 5. INSPECT FOR OIL LEAK

OIL PRESSURE SWITCH COMPONENTS ILLUSTRATION

0W20

Fig. 11: Identifying Oil Pressure Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the connector. b. Using a deep socket wrench, remove the oil pressure switch.

Fig. 12: Installing Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the oil pressure switch assembly connector. b. Start the engine. c. Measure the resistance according to the value(s) in the table below.

Fig. 13: Inspecting Engine Oil Pressure Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 - Switch 10 kohms Idling body or higher 1 - Switch Engine Below 1 body stopped ohms If the result is not as specified, replace the oil pressure switch assembly. d. Reconnect the oil pressure switch assembly connector. INSTALLATION INSTALLATION

1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Apply adhesive to 2 or 3 threads of the oil pressure switch.

Fig. 14: Applying Adhesive To Threads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent b. Using a deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Do not start the engine for at least 1 hour after installation.

c. Connect the connector. 2. INSPECT FOR OIL LEAK

OIL PUMP COMPONENTS ILLUSTRATION

Fig. 15: Identifying Oil Pump Replacement Components With Torque Specifications (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 16: Identifying Oil Pump Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 17: Identifying Oil Pump Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 18: Identifying Oil Pump Replacement Components With Torque Specifications (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 19: Identifying Oil Pump Replacement Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 20: Identifying Oil Pump Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 21: Identifying Oil Pump Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 22: Identifying Oil Pump Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

Refer to REMOVAL 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY . Refer to REMOVAL - Step 2 INSTALL ENGINE ON ENGINE STAND . Refer to REMOVAL - Step 78 REMOVE ENGINE HANGERS . Refer to REMOVAL - Step 1 REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE NO. 1 SURGE TANK STAY . Refer to REMOVAL - Step 3 REMOVE THROTTLE BODY BRACKET . Refer to REMOVAL - Step 4 REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 3 REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH . Refer to REMOVAL - Step 8 REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to REMOVAL - Step 9 REMOVE NO. 2 MANIFOLD STAY . Refer to REMOVAL - Step 11 REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to REMOVAL - Step 10 REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH . Refer to REMOVAL - Step 12 REMOVE V-RIBBED BELT TENSIONER ASSEMBLY . Refer to REMOVAL - Step 13 REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to DISASSEMBLY - Step 13 REMOVE NO. 2 TIMING GEAR COVER . Refer to REMOVAL - Step 14 REMOVE WATER PUMP PULLEY . Refer to REMOVAL - Step 15 REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE NO. 1 VACUUM SWITCHING VALVE . Refer to REMOVAL - Step 17 REMOVE CRANK POSITION SENSOR . Refer to REMOVAL - Step 2 REMOVE NO. 1 OIL PIPE . Refer to DISASSEMBLY - Step 8 REMOVE OIL PIPE . Refer to DISASSEMBLY - Step 9 REMOVE CRANKSHAFT PULLEY . Refer to REMOVAL - Step 6 REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH . Refer to DISASSEMBLY - Step 14 REMOVE WATER INLET HOUSING . Refer to REMOVAL - Step 10 REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 17 REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH . Refer to DISASSEMBLY - Step 18 REMOVE NO. 2 OIL PAN SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 19 REMOVE OIL STRAINER SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 20 REMOVE OIL PAN SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 21 REMOVE TIMING CHAIN COVER SUB-ASSEMBLY a. Remove the 23 bolts and 2 nuts shown in the illustration.

Fig. 23: Locating Timing Chain Cover Sub-Assembly Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut b. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

Fig. 24: Identifying Timing Chain Cover And Cylinder Head Or Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape NOTE:

Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use. c. Remove the gasket.

Fig. 25: Locating Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE TIMING CHAIN CASE OIL SEAL a. Using a screwdriver and wooden block, pry out the oil seal.

Fig. 26: Removing Timing Chain Case Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Wooden *2 Block HINT: Tape the screwdriver tip before use. DISASSEMBLY DISASSEMBLY

1. REMOVE OIL PUMP RELIEF VALVE a. Using a 27 mm socket wrench, remove the relief valve plug.

Fig. 27: Locating Oil Pump Relief Valve Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the relief valve spring and oil pump relief valve. 2. REMOVE OIL PUMP COVER a. Remove the 8 bolts, oil pump cover and oil pump rotor set.

Fig. 28: Locating Oil Pump Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT OIL PUMP RELIEF VALVE

a. Coat the relief valve with engine oil and check that it falls smoothly into the valve hole by its own weight.

Fig. 29: Inspecting Oil Pump Relief Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the valve does not fall smoothly, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT OIL PUMP ROTOR SET a. Install the rotors to the timing chain cover with the rotor marks facing up. Check that the rotors rotate smoothly.

Fig. 30: Identifying Oil Pump Rotor Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Mark b. Check the tip clearance.

Fig. 31: Measuring Clearance Between Drive Rotor And Driven Rotor Tips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a feeler gauge, measure the clearance between the drive and driven rotor tips as shown in the illustration. Tip Clearance Standard 0.060 to 0.160 mm (0.00236 to 0.00630 in.) Maximum 0.160 mm (0.00630 in.) If the tip clearance is greater than the maximum, replace the timing chain cover subassembly. c. Check the side clearance.

Fig. 32: Checking Side Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a feeler gauge and precision straightedge, measure the clearance between the rotors and precision straightedge as shown in the illustration. Side Clearance Standard 0.030 to 0.090 mm (0.00118 to 0.00354 in.) Maximum 0.090 mm (0.00354 in.) If the side clearance is greater than the maximum, replace the timing chain cover subassembly. d. Check the body clearance.

Fig. 33: Checking Body Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Using a feeler gauge, measure the clearance between the timing chain cover and driven rotor as shown in the illustration. Body Clearance Standard 0.250 to 0.325 mm (0.00984 to 0.0128 in.) Maximum 0.325 mm (0.0128 in.) If the body clearance is greater than the maximum, replace the timing chain cover subassembly. REASSEMBLY REASSEMBLY

1. INSTALL OIL PUMP COVER a. Coat the drive and driven rotors with engine oil and place them into the timing chain cover with the marks facing up (oil pump cover side). Check that the rotors rotate smoothly.

Fig. 34: Identifying Oil Pump Rotor Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Mark b. Install the oil pump cover with the 8 bolts.

Fig. 35: Locating Oil Pump Cover With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BOLT LENGTH Item Length 22 mm Bolt (0.866 A in.) 40 mm Bolt (1.58 B in.) Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 2. INSTALL OIL PUMP RELIEF VALVE a. Coat the oil pump relief valve with engine oil.

Fig. 36: Locating Oil Pump Relief Valve Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the relief valve and relief valve spring into the oil pump cover hole. c. Using a 27 mm socket wrench, install the plug. Torque: 49 N*m (500 kgf*cm, 37 ft.*lbf) INSTALLATION

INSTALLATION

1. INSTALL TIMING CHAIN CASE OIL SEAL a. Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge.

Fig. 37: Installing Timing Chain Case Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09223-22010 SST: 09506-35010

NOTE:

  

Keep the lip free from foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.

HINT: Tap in the oil seal so that it is positioned within 1.0 mm from the edge of the timing chain case. b. Apply a light coat of MP grease to the timing chain cover oil seal lip. 2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY a. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Fig. 38: Applying Seal Packing To Timing Chain Cover Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Seal Diameter: Seal *a 3.0 mm Packing or more Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 mm (0.118 in.) NOTE:





 

Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes. Do not start the engine for at least 2 hours after installing.

b. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Fig. 39: Identifying Timing Chain Cover Seal Packing Applying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Dashed Continuous line area line area (Seal (Seal packing: packing: Toyota Toyota Genuine Genuine *a Seal *b Seal Packing Packing Black, Black, Three Three Bond Bond 1207B or 1207B or equivalent) equivalent) Alternate

long and Diagonal short line area dashed (Seal line area packing: (Seal Toyota packing: Genuine Toyota *c Genuine *d Seal Packing Seal Black, Packing Three 1282B, Bond Three 1207B or Bond equivalent) 1282B or equivalent) Be sure to apply seal - packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent NOTE:







If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

SEAL PACKING APPLICATION CHART Application Seal Position Area Packing from Inside Diameter Seal Line 4.5 mm 1.0 to 2.0 Continuous or more mm (0.0394 Line Area (0.177 to 0.0787 in.) in.) Alternate 3.5 mm Long and 2.0 to 3.0 or more Short mm (0.0787 (0.138 Dashed to 0.118 in.) in.) Line Area

3.5 mm Dashed or more Line Area (0.138 in.) 6.0 mm Diagonal or more Line Area (0.236 in.)

3.0 to 4.0 mm (0.118 to 0.158 in.) 5.0 mm (0.197 in.)

c. Install a new gasket.

Fig. 40: Identifying Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Fig. 41: Aligning Oil Pump Drive Rotor Spline & Crankshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive *1 Rotor Spline *2 Crankshaft e. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Fig. 42: Locating Timing Chain Cover Nuts & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut BOLT LENGTH Item Length 40 mm Bolt (1.57 A in.) 55 mm Bolt (2.17 B in.) Bolt 25 mm

C

(0.984 in.)

NOTE:

Make sure that there is no oil on the threads of bolt B and C.

f. Fully tighten the bolts in this order: Area 1 and Area 2.

Fig. 43: Tightening Timing Chain Cover Nuts & Bolts Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Area *a 1 Area *b 2

Area 3 Area *d 4 *c

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) g. Fully tighten the bolts and nuts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts from top to bottom as shown in the illustration. h. Fully tighten the bolts in Area 4. Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts from bottom to top as shown in the illustration. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

INSTALL OIL PAN SUB-ASSEMBLY . Refer to REASSEMBLY - Step 37 INSTALL OIL STRAINER SUB-ASSEMBLY . Refer to REASSEMBLY - Step 38 INSTALL NO. 2 OIL PAN SUB-ASSEMBLY . Refer to REASSEMBLY - Step 39 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY . Refer to REASSEMBLY - Step 41 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH . Refer to REASSEMBLY - Step 42 INSTALL WATER INLET HOUSING . Refer to INSTALLATION - Step 3 INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH . Refer to REASSEMBLY - Step 35 INSTALL CRANKSHAFT PULLEY . Refer to INSTALLATION - Step 2 INSTALL NO. 1 OIL PIPE . Refer to REASSEMBLY - Step 48 INSTALL OIL PIPE . Refer to REASSEMBLY - Step 49 INSTALL CRANK POSITION SENSOR . Refer to INSTALLATION - Step 1 INSTALL NO. 1 VACUUM SWITCHING VALVE . Refer to INSTALLATION - Step 5 INSTALL WATER PUMP PULLEY . Refer to INSTALLATION - Step 6

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY . Refer to INSTALLATION - Step 7 INSTALL NO. 2 TIMING GEAR COVER . Refer to INSTALLATION - Step 8 INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to REASSEMBLY - Step 44 INSTALL V-RIBBED BELT TENSIONER ASSEMBLY . Refer to INSTALLATION - Step 9 INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 10 INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to INSTALLATION - Step 3 INSTALL NO. 2 MANIFOLD STAY . Refer to INSTALLATION - Step 2 INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to INSTALLATION - Step 13 INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH . Refer to INSTALLATION - Step 14 INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL THROTTLE BODY BRACKET . Refer to INSTALLATION - Step 19 INSTALL NO. 1 SURGE TANK STAY . Refer to INSTALLATION - Step 18 INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to INSTALLATION - Step 6 INSTALL ENGINE HANGERS . Refer to REMOVAL - Step 1 REMOVE ENGINE STAND INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY . Refer to INSTALLATION Step 2 INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to INSTALLATION

2012-2017 ENGINE Lubrication System (Service Information) (Hybrid)

OIL AND OIL FILTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Oil And Oil Filter Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REPLACEMENT REPLACEMENT

WARNING:







Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Wear protective clothing and gloves. Avoid contact with used oil. If contact occurs, wash your skin thoroughly with soap or waterless hand cleaner. Never use gasoline, thinners, or solvents to wash the skin. In order to protect the environment, dispose of used oil and used oil filters at designated disposal sites only.

1. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil pan drain plug and gasket, and drain the engine oil into a container. c. Clean the oil pan drain plug and install a new gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 2. REMOVE OIL FILTER CAP ASSEMBLY a. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Fig. 2: Connecting Hose To Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pipe *2 Hose b. Remove the oil filter drain plug from the oil filter cap.

Fig. 3: Identifying Oil Filter Drain Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the pipe to the oil filter cap.

Fig. 4: Identifying Oil Filter Cap Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Valve *2 Cap O*3 ring *4 Pipe NOTE:

HINT:

If the O-ring is removed with the oil filter drain plug, install the O-ring together with the pipe.

Use a container to catch the draining oil. d. Check that the oil is drained from the oil filter. Then disconnect the pipe as shown in the illustration and remove the O-ring.

Fig. 5: Disconnecting Oil Filter Cap Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, remove the oil filter cap.

Fig. 6: Removing The Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil Filter *1 Bracket Clip 

SST: 09228-06501

NOTE:

Do not remove the oil filter bracket clip.

f. Remove the oil filter element and O-ring from the oil filter cap.

Fig. 7: Identifying Oil Filter Element, O-Ring And Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil *2 Filter Cap *3 O-ring NOTE:

Be sure to remove the O-ring by hand, without using any tools, to prevent damage to the O-ring groove.

3. INSTALL OIL FILTER CAP ASSEMBLY a. Clean the inside of the oil filter cap, threads and O-ring groove. b. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

Fig. 8: Identifying Oil Filter Element, O-Ring And Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Oil *1 Filter Element Oil *2 Filter Cap *3 O-ring c. Set a new oil filter element into the oil filter cap. d. Remove any dirt or foreign matter from the installation surface of the engine. e. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. NOTE:

Make sure that the O-ring does not get caught between the parts.

f. Using SST, tighten the oil filter cap.

Fig. 9: Tightening The Oil Filter Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No

*a Clearance 

SST: 09228-06501

Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE:

Make sure that the oil filter is installed securely as shown in the illustration.

g. Apply a small amount of engine oil to a new O-ring, and install it to the oil filter cap.

Fig. 10: Identifying Oil Filter Cap O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION O*1 ring NOTE:

Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

h. Install the oil filter drain plug. Torque: 13 N*m (127 kgf*cm, 10 ft.*lbf) NOTE:

Be careful that the O-ring does not get caught between any

surrounding parts. 4. ADD ENGINE OIL a. Add new oil. Standard Oil Grade Oil Grade

Oil Viscosity

ILSAC multigrade 0W-20 engine oil Standard Oil Grade (Destination package for South Korea)

Oil Grade API grade SL "energyconserving", SM "energyconserving", SN "resourceconserving" or ILSAC multigrade engine oil API grade SL, SM or SN multigrade engine oil

Standard Capacity Item

Specified Condition

Drain and refill (with oil filter

4.4 liters (4.6 US qts, 3.9 Imp. qts)

Oil Viscosity (SAE) 

0W20



5W20



5W30



10W30



15W40



20W50

change) Drain and refill (without oil filter change)

4.0 liters (4.2 US qts, 3.5 Imp. qts)

5.3 liters (5.6 US Dry fill qts, 4.7 Imp. qts) b. Install the oil filler cap. 5. INSPECT FOR OIL LEAK 6. INSPECT ENGINE OIL LEVEL . Refer to ON-VEHICLE INSPECTION - Step 1

OIL PRESSURE SWITCH COMPONENTS ILLUSTRATION

Fig. 11: Identifying Oil Pressure Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the connector.

Fig. 12: Removing The Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 24 mm deep socket wrench, remove the oil pressure switch. INSPECTION INSPECTION

1. INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Disconnect the oil pressure switch connector. b. Start the engine. c. Measure the resistance according to the value(s) in the table below.

Fig. 13: Measuring The Resistance Of Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Engine Below 1 ohms 1 - Body stopped ground Engine 10 kohms idling or higher If the result is not as specified, replace the oil pressure switch assembly. INSTALLATION INSTALLATION

1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY a. Apply adhesive to 2 or 3 threads of the oil pressure switch.

Fig. 14: Applying Adhesive To Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Adhesive Adhesive TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent. NOTE:

Do not let adhesive adhere to the oil hole.

b. Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Do not start the engine within 1 hour of installation.

c. Connect the connector. 2. INSPECT FOR OIL LEAK 3. INSPECT ENGINE OIL LEVEL . Refer to ON-VEHICLE INSPECTION - Step 1

OIL PUMP COMPONENTS

ILLUSTRATION

Fig. 15: Identifying Oil Pump Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Identifying Oil Pump Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:

Do not remove the oil pump or oil pump relief valve from the timing chain cover sub-assembly.

1. REMOVE ENGINE AND TRANSAXLE Refer to REMOVAL 2. REMOVE ENGINE WIRE 3. REMOVE IGNITION COIL ASSEMBLY . Refer to REMOVAL - Step 2 4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY a. Remove the 16 bolts, 3 seal washers, cylinder head cover and cylinder head cover gasket.

Fig. 17: Locating Cylinder Head Cover And Gasket Bolts And Seal Washers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 gaskets from the camshaft bearing caps.

Fig. 18: Identifying Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE CRANKSHAFT POSITION SENSOR . Refer to REMOVAL - Step 1 6. REMOVE CRANKSHAFT PULLEY . Refer to DISASSEMBLY - Step 14 7. REMOVE ENGINE MOUNTING BRACKET RH a. Remove the 5 bolts and engine mounting bracket RH.

Fig. 19: Identifying Engine Mounting Bracket RH Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY a. Remove the 17 bolts and 2 nuts.

Fig. 20: Locating Timing Chain Cover Sub-Assembly Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

Fig. 21: Removing The Timing Chain Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*1

Protective Tape

NOTE:

Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase or chain cover.

HINT: Tape the screwdriver tip before use. c. Remove the 3 gaskets from the stiffening crankcase.

Fig. 22: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE TIMING CHAIN COVER OIL SEAL a. Using a screwdriver and wooden block, pry out the oil seal.

Fig. 23: Removing Timing Chain Cover Oil Seal Using Screwdriver & Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Wooden *2 Block NOTE:

Do not damage the surface of the oil seal press fit hole.

HINT: Tape the screwdriver tip before use. INSTALLATION INSTALLATION

1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY a. Apply a light coat of engine oil to 3 new gaskets.

Fig. 24: Locating Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 3 gaskets to the stiffening crankcase. c. Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

Fig. 25: Locating Drive Rotor Spline & Crankshaft Timing Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Drive *1 Rotor Spline Crankshaft *2 Timing Sprocket d. Apply seal packing in a line to the timing chain cover as shown in the following illustration.

Fig. 26: Applying Seal Packing Continuous Line To Timing Chain Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent. Apply Seal Packing as Follows Seal Packing Distance Diameter from (Round) Edge of

Seal

Cover Seal to Pacing Area Center Dimension of Seal (Flat) Packing 3.0 mm 2.5 mm Dashed (0.118 in.) (0.0984 Line in.) 3.0 mm 2.5 mm A - A (0.118 in.) (0.0984 in.) 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) 3.0 mm (0.118 B - B or more wide and in.) 3.0 mm (0.118 in.) or more thick 7.0 mm (0.276 in.) 13.0 mm (0.512 in.) 5.0 mm C - C or more (0.197 wide and in.) 3.0 mm (0.118 in.) or more thick 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) 3.0 mm D - D or more (0.118 wide and in.) 3.0 mm (0.118 in.) or more thick 3.0 mm 3.0 mm (0.118 in.) (0.118 E in.) NOTE:

Packing Application Length

-

-

28 mm (1.10 in.)

25 mm (0.984 in.)

26 mm (1.02 in.)

-







 

When the contact surfaces are wet, clean the surfaces with nonresidue solvent before applying seal packing. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. After applying seal packing to the timing chain cover, install the engine mounting bracket within 10 minutes. Do not apply oil for at least 2 hours after the installation. Do not start the engine for at least 2 hours after the installation.

e. Temporarily install the timing chain cover with the 17 bolts and 2 nuts.

Fig. 27: Locating Timing Chain Cover Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Nut - Bolt Length Thread Diameter 30 mm 8 mm Bolt (1.18 (0.315 A in.) in.) 35 mm 10 mm Bolt (1.38 (0.394 B in.) in.) 45 mm 8 mm Bolt (1.77 (0.315 C in.) in.) Item Length

NOTE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean

it before installation. f. Tighten the 17 bolts and 2 nuts in several steps, in the sequence shown in the illustration. for bolt A, C, and Nut Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt B Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 2. INSTALL ENGINE MOUNTING BRACKET RH a. Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

Fig. 28: Identifying Engine Mounting Bracket RH Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. for bolt 1, 2 and 3 Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt 4 and 5 Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

NOTE:

3. 4. 5. 6.

After applying seal packing to the timing chain cover, install the engine mounting bracket within 10 minutes.

INSTALL TIMING CHAIN COVER OIL SEAL . Refer to INSTALLATION - Step 1 INSTALL CRANKSHAFT PULLEY . Refer to REASSEMBLY - Step 45 INSTALL CRANKSHAFT POSITION SENSOR . Refer to INSTALLATION - Step 1 INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY a. Apply a light coat of engine oil to 2 new gaskets.

Fig. 29: Identifying Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 gaskets to the camshaft bearing caps. c. Visually check the spark plug tube gasket.

Fig. 30: Spark Plug Tube Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Specified Condition No Upper scratches or surface deformation No Outer scratches or lip deformation Inner No lip scratches Area

TEXT IN ILLUSTRATION Upper *1 Surface Inner *2 Lip Outer *3 Lip HINT:

If the result is not as specified, replace the spark plug tube gasket. d. Install a new cylinder head cover gasket to the cylinder head cover. NOTE:

Remove any oil from the contact surface.

e. Apply seal packing as shown in the illustration.

Fig. 31: Identifying Seal Packing Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter

3.0 to 6.0 mm (0.118 to 0.236 in.) TEXT IN ILLUSTRATION Timing *1 Chain Cover Camshaft *2 Housing Application width 5.0 *a mm (0.197 in.) Seal packing NOTE:

 

Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

f. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

Fig. 32: Aligning Cylinder Head Cover With Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Pin A Pin *b B Bolt *c A *a

g. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE:



Do not apply oil for at least 2 hours after the installation.

7. INSTALL IGNITION COIL ASSEMBLY . Refer to INSTALLATION - Step 2 8. INSTALL ENGINE WIRE 9. INSTALL ENGINE AND TRANSAXLE Refer to INSTALLATION

2012-2017 MAINTENANCE Maintenance - Camry (Hybrid)

OUTSIDE VEHICLE GENERAL MAINTENANCE GENERAL MAINTENANCE

These are maintenance and inspection items that are considered to be the owner's responsibility. The owner can do them or they can have them done at a service center. These items include those that should be checked on a daily basis, those that in most cases do not require special tools, and those that are considered to be reasonable for the owner to do. General maintenance items and procedures are as follows: 1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Following the maintenance schedule is mandatory.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES a. Check the tire inflation pressure with a gauge. Make adjustments if necessary. b. Check the surfaces of the tires for cuts, damage or excessive wear. 3. WHEEL NUTS a. Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION a. Check the maintenance schedule in the owner's manual supplement. 5. WINDSHIELD WIPER BLADES a. Check the blades for wear or cracks whenever they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS a. Check under the vehicle for leaking fuel, oil, water and other fluids. NOTE:

If you smell fuel or notice any leaks, locate the cause and correct it.

7. DOORS AND ENGINE HOOD

a. Check that all of the doors and the hood operate smoothly, and that all the latches lock securely. b. When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening.

INSIDE VEHICLE GENERAL MAINTENANCE GENERAL MAINTENANCE

These are maintenance and inspection items that are considered to be the owner's responsibility. The owner can do them or they can have them done at a service center. These items include those that should be checked on a daily basis, those that in most cases do not require special tools, and those that are considered to be reasonable for the owner to do. General maintenance items and procedures are as follows: 1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Maintain similar intervals between periodic maintenance unless noted.  Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS a. Check that the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink properly. Also, check if they have enough brightness. b. Check that the headlights are aimed properly. 3. WARNING LIGHTS AND BUZZERS a. Check that all the warning lights and buzzers are working. 4. HORNS a. Check if the horn is working correctly. 5. WINDSHIELD GLASS a. Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER a. Check that the washers are aimed properly. Also, check that the washer fluid hits the center of the operating range of each wiper on the windshield. b. Check if the wipers streak. Replace them if necessary. 7. WINDSHIELD DEFROSTER

8. 9. 10.

11.

a. When the air conditioning is on the defroster setting, check that air comes out of the defroster outlets. REAR VIEW MIRROR a. Check that the rear view mirror is securely mounted. SUN VISORS a. Check that the sun visors move freely and are securely mounted. STEERING WHEEL a. Check that the steering wheel has the proper amount of free play. Also check for steering difficulty and unusual noises. Refer to ON-VEHICLE INSPECTION - Step 1 . SEATS a. Check that the seat adjusters, seatback recliner and other seat controls operate smoothly. b. Check that all the latches lock securely in all positions. c. Check that the locks hold securely in all positions. d. Check that the headrests move up and down smoothly and that the locks hold securely in all latched positions. e. Check power seat function.

Fig. 1: Identifying Power Seat Functions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sliding

*1 Function Reclining *2 Function Lifter *3 Function Front *4 Vertical Function Lumbar Support *5 Adjustment Function

12.

13.

14.

15. 16.

17.

1. Operate the power seat switches and check that each seat function operates properly:  Sliding function  Reclining function  Lifter function*  Front vertical function*  Lumbar support adjustment function* *: for Driver SEAT BELTS a. Check that the seat belt components, such as the buckles, retractors and anchors, operate properly and smoothly. b. Check that the belt webbing is not cut, frayed, worn or damaged. ACCELERATOR PEDAL a. Check that the pedal operates smoothly. Check that the pedal does not have uneven resistance or stick in certain positions. BRAKE PEDAL a. Check that the brake pedal operates smoothly. b. Check that the pedal has the proper reserve distance and free play. Refer to ADJUSTMENT - Step 3. c. Start the engine and check the brake booster function. d. Start the engine and check the brake system indicator. BRAKES a. In a safe place, check that the vehicle does not pull or lead to the side when applying the brakes. PARKING BRAKE a. Check that the parking brake pedal has the proper amount of travel. Refer to ADJUSTMENT Step 1 . b. On a slight grade, check that the parking brake alone can hold the vehicle in place. HYBRID TRANSAXLE "PARK" MECHANISM a. Check the lock release button of the shift lever for proper and smooth operation.

b. Check the shift lever for proper and smooth operation. c. When the shift lever is in P and all brakes are released in an area that has a slight grade, check that the vehicle is stable. 18. FLOOR MATS a. Check that the correct floor mats are used, and that they are properly installed.

UNDER HOOD GENERAL MAINTENANCE GENERAL MAINTENANCE

1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Following the maintenance schedule is mandatory.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Maintain similar intervals between periodic maintenance unless noted.  Failing to check each maintenance item could lead to poor engine performance and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID a. Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL a. Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4. INVERTER COOLANT LEVEL a. Check that there is sufficient fluid in the tank. 5. RADIATOR AND HOSES a. Check that the front of the radiator is clean and not blocked by leaves, dirt and bugs. b. Check the radiator and hoses for:  Damage  Cracks  Kinks  Corrosion  Rot  Clogging  Leaks 6. BRAKE FLUID LEVEL a. Check that the brake fluid level is near the upper level line on the see-through reservoirs. 7. ENGINE OIL LEVEL

a. Check that the engine oil level is between the full level and low level marks on the dipstick with the engine turned off. 8. HYBRID TRANSAXLE FLUID LEVEL a. Check the level of the hybrid transaxle fluid. Refer to ADJUSTMENT - Step 3 . 9. EXHAUST SYSTEM a. Visually inspect for severe corrosion, cracks, holes or loose supports. HINT: If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, inspect and repair the exhaust system.

ENGINE GENERAL MAINTENANCE GENERAL MAINTENANCE

HINT: Perform these procedures after the engine has cooled down. 1. REPLACE ENGINE OIL AND OIL FILTER a. Check the engine oil and oil filter. Refer to REPLACEMENT . 2. REPLACE ENGINE COOLANT a. Check the engine coolant. Refer to REPLACEMENT . 3. INSPECT SPARK PLUGS a. Check the spark plugs. Refer to ON-VEHICLE INSPECTION . 4. INSPECT AUXILIARY BATTERY a. Check the auxiliary battery. Refer to ON-VEHICLE INSPECTION . 5. INSPECT AIR CLEANER FILTER ELEMENT a. Remove the air filter. b. Check that the air cleaner is not excessively dirty.

Fig. 2: Cleaning Air Cleaner Filter Element Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the air cleaner is excessively dirty, replace the air cleaner filter element.

6. 7. 8.

9.

c. If cleaning the air cleaner filter element, blow compressed air as shown in the illustration to clean it. d. Reinstall the air filter. e. When an excessive amount of dirt is present, replace the air filter. INSPECT EXHAUST PIPES AND MOUNTINGS a. Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. INSPECT FUEL TANK CAP GASKET a. Check the fuel tank gasket. Refer to INSPECTION . INSPECT FUEL LINES, CONNECTIONS, FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS a. Visually check the fuel lines and hoses for cracks, leaks, loose connections, or deformation. b. Check for tank band looseness or deformation. INSPECT CHARCOAL CANISTER a. Check the charcoal canister. Refer to INSPECTION .

BRAKE GENERAL MAINTENANCE GENERAL MAINTENANCE

1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection.

Fig. 3: Inspecting Brake Line Pipes And Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3.

4. 5.

a. Using a mirror, check the entire circumference and length of the brake lines and hoses for:  Damage  Wear  Deformation  Cracks  Kinks  Corrosion  Leaks  Twists b. Check all the clamps for tightness and check the connections for leakage. c. Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system. d. Check that the lines are installed properly and pass through the center of the grommets. INSPECT BRAKE PEDAL a. Check the brake pedal. Refer to ADJUSTMENT . INSPECT PARKING BRAKE a. Check the parking brake shoe clearance and parking brake pedal travel. Refer to ADJUSTMENT . b. Check the parking brake cables to ensure that they are not deformed or binding. INSPECT BRAKE LININGS AND DRUMS a. Check the parking brake linings and drums. INSPECT FRONT BRAKE

a. Check the front brake pads and discs. Refer to INSPECTION . 6. INSPECT REAR BRAKE a. Check the rear brake pads and discs. Refer to INSPECTION . 7. INSPECT OR CHANGE BRAKE FLUID a. Inspect or change the brake fluid. Refer to ON-VEHICLE INSPECTION . Fluid SAE J1703 or FMVSS No. 116 DOT3

CHASSIS GENERAL MAINTENANCE GENERAL MAINTENANCE

1. INSPECT STEERING LINKAGE AND GEAR HOUSING a. Check the steering wheel free play. Refer to ON-VEHICLE INSPECTION . b. Check the steering linkage for looseness or damage. 1. Check that the tie rod ends do not have any play. 2. Check that the dust seals and boots are not damaged. 3. Check that the boot clamps are not loose. 4. Check that the steering gear housing is not damaged. 2. INSPECT BALL JOINTS AND DUST COVERS a. Inspect the ball joints for excessive looseness. 1. Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires. 2. Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. 3. Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels. 4. Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play 0 mm (0 in.) If there is any play, replace the ball joint. b. Check the dust cover for damage. 3. INSPECT DRIVE SHAFT BOOTS a. Check the drive shaft boots for loose clamps, cracks, grease leaks, kinks or damage. 4. INSPECT HV TRANSAXLE

a. Visually check the transaxle for fluid leakage. If oil fluid is leaking, find the cause and repair it. 5. INSPECT FRONT AND REAR SUSPENSION a. Check the front and rear suspension. Suspension See Procedure Type Front Refer to Suspension ADJUSTMENT Rear Refer to Suspension ADJUSTMENT

BODY GENERAL MAINTENANCE GENERAL MAINTENANCE

1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY a. If necessary, tighten the bolts and nuts on the chassis parts listed below.  Front axle and suspension  Drivetrain  Rear axle and suspension  Brake system  Engine mounts  Other chassis parts b. If necessary, tighten the bolts and nuts on the body parts listed below.  Seat belt system  Seats  Doors and hood  Body mounts  Fuel tank  Exhaust system  Other body parts 2. REPLACE AIR CONDITIONING FILTER a. Remove the air conditioning filter. Refer to DISASSEMBLY - Step 7 . b. Visually inspect the surface of the air conditioning filter. c. If the air conditioning filter is contaminated with foreign matter, replace it. 3. ROAD TEST a. Check the engine and chassis for abnormal noises. b. Check that the vehicle does not wander or pull to one side.

c. Check that the brakes work properly and do not drag. d. Bed-in the parking brake shoes to the drums. 4. BODY INSPECTION a. Check the body exterior for dents, scratches and rust. b. Check the underbody for rust and damage. If necessary, replace the damaged part or repair the damaged area. 5. FINAL INSPECTION a. Check the operation of the body parts. 1. Hood  Auxiliary catch operates properly.  Hood locks securely when closed. 2. Front and rear doors  Door locks operate properly.  Doors close properly. 3. Luggage compartment door  Luggage compartment door opens and closes properly. 4. Seats  Seats adjust easily and lock securely in any position.  Front seatbacks lock securely in any position.  Fold-down rear seatbacks lock securely. 5. Be sure to deliver a clean car. Make sure to check the following:  Steering wheel  Shift lever knob  All switches and knobs  Door handles  Seats

REMINDER INDICATOR RESET PROCEDURES Toyota - 1980-14

ENGINE OIL CHANGE REMINDER LIGHT NOTE:

To determine the appropriate reset procedure, refer to ENGINE OIL CHANGE REMINDER LIGHT RESET INDEX. Only vehicles listed in this index have an Engine Oil Change Reminder Light reset.

ENGINE OIL CHANGE REMINDER LIGHT RESET INDEX Model & Year Reset Procedure 4Runner 2003-09 Engine Oil Change Reminder Light Reset - Procedure 3 2010-14 Engine Oil Change Reminder Light Reset - Procedure 1 Avalon 2005-14 Engine Oil Change Reminder Light Reset - Procedure 1 Camry 2004-06 Engine Oil Change Reminder Light Reset - Procedure 3 2007-14 Engine Oil Change Reminder Light Reset - Procedure 2 Camry Hybrid 2007-11 Engine Oil Change Reminder Light Reset - Procedure 8 2012-2017-14 Engine Oil Change Reminder Light Reset - Procedure 2 Camry Solara 2004-06 Engine Oil Change Reminder Light Reset - Procedure 3 2007-08 Engine Oil Change Reminder Light Reset - Procedure 4 Corolla 2005-08 Engine Oil Change Reminder Light Reset - Procedure 3 2009-14 Engine Oil Change Reminder Light Reset - Procedure 4 FJ Cruiser 2007-14 Engine Oil Change Reminder Light Reset - Procedure 3 Highlander 2004-07 Engine Oil Change Reminder Light Reset - Procedure 3 2008-13 Engine Oil Change Reminder Light Reset - Procedure 2 2014 Engine Oil Change Reminder Light Reset - Procedure 12 Highlander Hybrid 2006-07 Engine Oil Change Reminder Light Reset - Procedure 5 2008-13 Engine Oil Change Reminder Light Reset - Procedure 2 2014 Engine Oil Change Reminder Light Reset - Procedure 12 Land Cruiser 2003-07 Engine Oil Change Reminder Light Reset - Procedure 6 2008-11 Engine Oil Change Reminder Light Reset - Procedure 4

2013-14 Matrix 2005-08 2009-13 Previa 1991-97 Prius (All Models Except C) 2004-09 2010-14 Prius C 2012-2017-14 RAV4 2004-05 2006-14 Sequoia 2005-07 2008-14 Sienna 2004-10 2011-14 Tacoma 2005-11 2012-14 Tundra 2005-06 2007-14 Venza 2009-10 2011-14 Yaris 2007-14

Engine Oil Change Reminder Light Reset - Procedure 10 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 4 Engine Oil Change Reminder Light Reset - Procedure 7 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 9 Engine Oil Change Reminder Light Reset - Procedure 11 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 4 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 2 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 2 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 10 Engine Oil Change Reminder Light Reset - Procedure 3 Engine Oil Change Reminder Light Reset - Procedure 2 Engine Oil Change Reminder Light Reset - Procedure 4 Engine Oil Change Reminder Light Reset - Procedure 10 Engine Oil Change Reminder Light Reset - Procedure 4

ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 1 NOTE:

For all models, before starting reset procedure, switch the display to Trip Meter A while the engine is running.

With Smart Key System

CAUTION: To avoid engine from starting, DO NOT depress brake pedal when selecting modes.

NOTE:

On vehicles with smart key system, make sure smart key is in the vehicle. Pressing the "ENGINE START STOP" switch changes the ignition switch mode as follows:   

First Time - ACC mode (accessories on). Second Time - ON mode (power on and all accessories on). Third Time - Power OFF mode (indicator light is off).

1. Place smart key system in power OFF mode with odometer display showing. 2. Place smart key system in ON mode while holding down trip meter RESET button (stem). 3. Hold trip meter RESET button (stem) down for at least 5 seconds. Odometer should indicate "000000" and MAINT reminder light goes out. Without Smart Key System

1. Turn ignition switch to OFF position with odometer display showing. 2. Turn ignition switch to ON position while holding down trip meter RESET button (stem). 3. Hold trip meter RESET button (stem) down for at least 5 seconds. Odometer should indicate "000000" and MAINT reminder light goes out. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 2 NOTE:

For all models, before starting reset procedure, switch the display to Trip Meter A while ignition is ON.

To reset MAINT reminder indicator after engine oil change: 1. Set the "ENGINE START STOP" switch or ignition switch OFF with odometer showing TRIP A. 2. While pressing the trip meter reset button (stem), set the "ENGINE START STOP" switch or ignition switch ON. 3.  Without multi-information display: Continue to press and hold the button (stem) until the trip meter displays "000000".  With multi-information display: Continue to press and hold the button (stem) until "COMPLETE" (on some models, "RESETTING MAINTENANCE DATA") appears on the multiinformation display. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 3 To reset MAINT reminder indicator after engine oil change: 1. With ignition or POWER switch ON, press the ODO / TRIP switch until odometer displays "ODO". 2. Turn ignition or POWER switch to OFF position with odometer display showing. 3. Turn ignition POWER switch to ON position while holding down trip meter RESET button.

4. Hold trip meter RESET button down for at least 5 seconds. Odometer should indicate "000000", and MAINT reminder light goes out. NOTE:

On some models, before the light goes off, light will illuminate for 3 seconds, flash for 2 seconds and illuminate for 1 second.

5. If system fails to reset, light will remain flashing. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 4 To reset MAINT reminder indicator after engine oil change: 1. With the ignition switch (or Power switch) ON, ensure the odometer is showing TRIP A. Turn ignition (or Power) switch OFF. 2. Set the ignition switch (or Power switch) to ON position (DO NOT start engine) while holding down trip meter RESET (DISP on some models) button. 3. Hold trip meter RESET button down for at least 5 seconds until odometer indicates 000000. 4. When 000000 disappears and the indicator light turns off, the reset is complete. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 5 To reset MAINT reminder indicator after engine oil change: 1. Turn ignition key to LOCK position with odometer display showing. 2. Turn ignition key to ON position while holding down on trip meter reset knob. A message MAINT REQD RESET MODE will appear on display. 3. Hold trip meter knob for at least 5 seconds. A message COMPLETE will appear and beep will be heard. 4. If system fails to reset, repeat reset procedure. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 6 To reset MAINT reminder indicator after engine oil change: 1. Turn ignition switch to OFF position with odometer display showing. 2. Turn ignition switch to ON position while holding down ODO/TRIP reset button on instrument cluster. 3. Hold down reset button until MAINT REQD light goes off. Before MAINT REQD light goes off, it will illuminate for 3 seconds, flash for 2 seconds, illuminate again for one second. 4. If system fails to reset, MAINT REQD light will remain flashing. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 7 After changing oil and filter, reset warning light mileage counter. NOTE:

Reset mileage counter after oil and filter change even if light has not come on.

1. Remove plug from instrument panel faceplate below speedometer. 2. Insert a small punch or rod through plug hole and depress knob. See Fig. 1.

Fig. 1: Identifying Engine Oil Change Indicator Light Reset Button (Previa) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 8 To reset MAINT reminder indicator after engine oil change: 1. Turn off the hybrid system with odometer showing TRIP A. 2. While holding down the trip meter reset knob, turn the POWER switch to ON mode. A message "MAINT REQD RESET MODE" will appear on the display. 3. Hold down the knob for at least 5 seconds. When "MAINT REQD RESET MODE COMPLETE" disappears and the master caution indicator light turns off, the reset is complete. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 9 To reset MAINT reminder indicator after engine oil change: 1. Switch the odometer display to TRIP A with the POWER switch ON.

2. Turn the POWER switch OFF. 3. Turn the POWER switch ON with the km/h MPH button (upper left on center console) held down. 4. Keep pressing the km/h MPH button until the odometer indicates 000000 and the multi-information display indicates that the reset is complete. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 10 To reset MAINT reminder indicator after engine oil change: 1. Switch the odometer display to TRIP A while the engine is running. 2. Set the "ENGINE START STOP" (or ignition) switch to OFF. 3. While pressing the trip meter reset button, set the "ENGINE START STOP" (or ignition) switch to ON mode (DO NOT start the engine). Continue to press and hold the button until the odometer displays 000000, or the multi-information display indicates that the reset is complete. NOTE:

For Tacoma models, there is a significant difference between the reset procedure in the owner's manual (used above) and the instructions given in the Toyota service information. The owner's manual is considered to be more reliable for this type procedure, but in the event that the service information is correct, it is this: a. Turn the ignition switch to ON. b. Set the ODO/TRIP indication to ODO. c. While pressing the reset switch, turn the ignition switch OFF and ON again. d. Press the reset switch for more than 5 seconds.

NOTE:

If the system fails to reset, the warning light will continue flashing.

ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 11 To reset MAINT reminder indicator after engine oil change: 1. With the Engine switch (or Power switch) ON, ensure the odometer is displayed. Turn Engine (or Power) switch OFF. 2. Turn the Engine (or Power) switch to the ON position. The multi-information display's initial screen will be displayed for a few seconds. While the initial screen is being displayed, press the TRIP button on the steering wheel 3 times, holding the button down on the third press. 3. Continue to press and hold the button until the trip meter displays 000000. ENGINE OIL CHANGE REMINDER LIGHT RESET - PROCEDURE 12 Using Trip Meter (Monochrome Multi-information Display)

1. 2. 3. 4.

Turn ignition ON. Press the ODO/TRIP switch knob until the TRIP A meter appears. Turn the ignition switch OFF. Turn the ignition switch to ON while pressing and holding the ODO/TRIP switch knob. Hold the ODO/TRIP switch knob until TRIP A meter shows "000000" and the multi-information display shows that the reset is complete.

Using Multi-information Display (Color Display)

1. Turn the ignition switch to ON. 2. Using the steering pad switch assembly, display the SETTING display on the multi-information display. 3. Select MAINTENANCE SYSTEM from the setting display and perform initialization according to the multi-information display. 4. "Initialization Completed" will be displayed on the multi-information display when the reset procedure has finished.

OXYGEN SENSOR WARNING LIGHT NOTE:

To determine the appropriate reset procedure, refer to OXYGEN SENSOR WARNING LIGHT RESET INDEX. Only vehicles listed in this index have an Oxygen Sensor Warning Light reset.

OXYGEN SENSOR WARNING LIGHT RESET INDEX Model & Year Reset Procedure Corolla 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Corona 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Cressida 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Land Cruiser 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Pickup 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Supra 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 Tercel 1980-81 Oxygen Sensor Warning Light Reset - Procedure 1 OXYGEN SENSOR WARNING LIGHT RESET - PROCEDURE 1 1. At 30,000 mile intervals, a mileage counter activates warning light in dash to indicate oxygen sensor must be replaced. After replacing sensor, reset mileage counter.

2. To reset mileage counter, move switch to opposite position. On 1980 Celica Supra, cancel switch (Black) is located on bracket above brake pedal. On Cressida, switch is behind small trim panel next to steering column. On all other models, cancel switch (White) is on top of left kick panel. See Fig. 2.

Fig. 2: Resetting Oxygen Sensor Warning Light Counter (1980-81 Models) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TIMING BELT REMINDER LIGHT NOTE:

To determine the appropriate reset procedure, refer to TIMING BELT REMINDER LIGHT RESET INDEX. Only vehicles listed in this index have a Timing Belt Reminder Light reset.

TIMING BELT REMINDER LIGHT RESET INDEX Model & Year Reset Procedure Pickup (Diesel) 1981-87 Timing Belt Reminder Light Reset - Procedure 1 TIMING BELT REMINDER LIGHT RESET - PROCEDURE 1 TIMING BELT light will come on every 100,000 miles to indicate engine timing belt should be replaced. After belt is replaced, remove rubber grommet from speedometer bezel and reset speedometer counter by pressing reset switch. See Fig. 3.

Fig. 3: Resetting Speedometer Counter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TIRE PRESSURE MONITOR SYSTEM (TPMS) NOTE:

To determine the appropriate reset procedure, refer to TPMS RESET INDEX. Only vehicles listed in this index have a TPMS reset.

TPMS RESET INDEX Model & Year 4Runner 2004-07 2008-14 Avalon 2007 2008-14 Camry 2007 2008-12 2013-14

Reset Procedure TPMS Reset - Procedure 15 TPMS Reset - Procedure 16 TPMS Reset - Procedure 13 TPMS Reset - Procedure 17 TPMS Reset - Procedure 1 TPMS Reset - Procedure 17 TPMS Reset - Procedure 16

Camry Solara 2004-06 2007 2008 Corolla 2005-07 2008-14 FJ Cruiser 2007-11 2012-14 Highlander 2004-07 2008-14 Highlander Hybrid 2008-13 2014 Land Cruiser 2005-07 2008-14 Matrix 2005-07 2008-13 Prius (All Models) 2006-07 2008-14 RAV4 2004-05 2006-07 2008-12 2013-14 Sequoia 2005 to Aug.2007 Sept.2007 to 2014 Sienna 1998-06 2007 2008-14 Tacoma 2006-07 2008-14 Tundra 2005-07

TPMS Reset - Procedure 2 TPMS Reset - Procedure 1 TPMS Reset - Procedure 17 TPMS Reset - Procedure 4 TPMS Reset - Procedure 17 TPMS Reset - Procedure 5 TPMS Reset - Procedure 17 TPMS Reset - Procedure 6 TPMS Reset - Procedure 17 TPMS Reset - Procedure 16 TPMS Reset - Procedure 17 TPMS Reset - Procedure 7 TPMS Reset - Procedure 17 TPMS Reset - Procedure 8 TPMS Reset - Procedure 17 TPMS Reset - Procedure 9 TPMS Reset - Procedure 17 TPMS Reset - Procedure 10 TPMS Reset - Procedure 11 TPMS Reset - Procedure 16 TPMS Reset - Procedure 17 TPMS Reset - Procedure 7 TPMS Reset - Procedure 17 TPMS Reset - Procedure 12 TPMS Reset - Procedure 13 TPMS Reset - Procedure 17 TPMS Reset - Procedure 14 TPMS Reset - Procedure 17

TPMS Reset - Procedure 15 TPMS Reset - Procedure 17

2008-14 Venza 2009-14 Yaris 2008-11 2012-14

TPMS Reset - Procedure 16 TPMS Reset - Procedure 16 TPMS Reset - Procedure 17

TPMS RESET - PROCEDURE 1 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced. Set tire pressure within the specified range before initializing. When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. See Tire Pressure Sensor Registration.

Initializing Tire Pressure Monitor System

CAUTION: Set tire pressure within the specified range before initializing. DO NOT push the reset switch without adjusting tire inflation pressure of all 4 tires. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed. NOTE:

When initializing the system, the present tire condition is stored as a standard.

NOTE:

Perform the tire pressure adjustment after the vehicle has sufficiently cooled down. If it hasn't sufficiently cooled, increase the air pressure in the tires approximately 3-4psi (20-30kPa)

NOTE:

The initialization mode can be terminated by making a short circuit between terminals No. 4 and 13 of the DLC3 connector (located under left side of instrument panel).

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per minute. The initialization process is completed when the signals from the 4 tires have been received. The initialization process is canceled if the ignition switch is turned to OFF position prior to the completion of

initialization. To restart initialization, the tire pressure warning reset switch must be pressed again. 1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With the vehicle parked in a safe place, connect the intelligent tester to the DLC3 and turn ignition switch to the ON position. 3. Turn the intelligent tester ON and navigate to the "TIREPRESS" option using the on-screen prompts. 4. Within 30 seconds of turning the ignition ON, press and hold the tire pressure warning reset switch (located at left side of glove compartment opening) until the tire pressure warning light blinks 3 times at one-second intervals. See Fig. 4.

Fig. 4: Tire Pressure Warning Reset Switch - Blinking Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Wait 2 - 3 minutes, with the ignition ON, for the initialization process to complete. If the initialization has not been completed successfully, Diagnostic Trouble Code (DTC) C2177/77 is set in the tire pressure monitor ECU about 20 minutes after driving starts. 6. Confirm that initialization is complete by verifying that the correct tire pressure values are displayed on the intelligent tester. NOTE:

In winter, tire pressure may decrease due to low ambient temperatures about 1.45 psi (10 kPa) for every 18°F (10°C) drop in ambient temperature.

Therefore, the tire pressure warning is more likely to operate if the tire pressures are not adjusted appropriately. If the daily temperature variation is large, pressurize the tires so that they are in the specified range under cold conditions. With this adjustment, unnecessary warnings are less likely. Tire Pressure Sensor Registration

NOTE:

When a tire, wheel, tire pressure monitor valve sub-assembly and/or tire pressure monitor ECU are replaced, the transmitter ID needs to be registered in the tire pressure monitor ECU. To perform this procedure, a Toyota hand-held tester must be used.

Register Transmitter ID 1. Set the pressure of all tires (including spare tire) to the pressure specified on the tire and loading information label. 2. Connect the hand-held tester to DLC3. See Fig. 5. 3. Turn the ignition switch to the ON position. 4. Select REGISTER from the UTILITY menu. See Fig. 6. 5. Enter the transmitter ID(s) using the hand-held tester and transmit it to the tire pressure monitor ECU. 6. Set ID transmission condition to "ID Registration is complete". NOTE:

If steps 4-6 are not completed within 5 minutes, the mode will return to the normal operation mode.

Fig. 5: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Registering Transmitter ID

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Confirmation Of Transmitter ID Registration 1. Set the pressure of all tires (including spare tire) to the pressure specified on the tire and loading information label. 2. Connect the hand-held tester to DLC3. 3. Turn ignition switch to ON position. 4. Select the "TIRE PRESS" by following the prompts on the hand-held tester. 5. Confirm accurately registered tire pressures for all tires. If all values are displayed correctly, registration was completed successfully. NOTE:

It may take 2-3 minutes to update the tire pressure data. If ID registration has not occurred, DTC 2171/71 will be recorded in the ECU after 51 minutes or more.

TPMS RESET - PROCEDURE 2 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or when tire pressure warning light blinks twice every second. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function.

NOTE:

If the negative battery terminal is disconnected, initialize the following systems after the terminal is reconnected: power window and sliding roof. Refer to owner's manual or appropriate manufacturer service information. CAUTION: DO NOT push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With vehicle stopped and parking brake applied, turn ignition switch to ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position and perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See

appropriate manufacturer service information. 4. Drive the vehicle at 19 mph (30 km/h) or more to complete the initialization of the skid control ECU (it takes 0.5-1 hour). Vehicle should be driven under the following conditions:  The vehicle speed is between 31-62 mph (50-100 km/h).  The roads are dry, smooth and straight.  The number of passengers is 1 or 2 (including driver). NOTE:

If the tire pressure warning light blinks at 0.25 second intervals while the vehicle is being driven, the initialization may have failed. If so, turn ignition switch to OFF position and perform the initialization procedure again starting at step 1.

5. After initialization is completed, the skid control ECU monitors the tire pressure by using the wheel speed sensors. 6. To verify the system has been initialized, check the length of time the tire pressure warning light is on after turning the ignition switch to the ON position. Light will stay on for 3 seconds if system is initialized, or 4 seconds if system is not initialized. TPMS RESET - PROCEDURE 3 NOTE:

Initialization is required when changing tire size, rotating tire on vehicle with different front and rear tire inflation pressures.

1. 2. 3. 4.

Park vehicle in a safe place and turn ignition key to LOCK position. Adjust the pressure of all installed tires to specified cold tire inflation pressure level. Turn ignition to ON position. Push and hold tire pressure warning reset switch (located below left side of dash) until the tire pressure warning light blinks slowly 3 times. 5. Leave system for a few minutes with ignition switch in ON position, and then turn ignition key to LOCK position. If the tire warning reset switch is pushed while vehicle is moving, initialization will not take place. If reset switch is accidentally pushed, and initialization takes place, adjust tire inflation pressure to the specified level and initialize the system again. If tire pressure warning light does not blink slowly 3 times when you push and hold the reset switch, initialization has failed and tire pressure warning system may not work properly. In this case, initialize the system again. If initialization cannot be performed, have the system checked at an authorized dealer. TPMS RESET - PROCEDURE 4 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or when tire pressure warning light blinks once every 3 seconds. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function. CAUTION: DO NOT push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With vehicle stopped and parking brake applied, turn ignition switch to ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. See Fig. 7. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position and perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See appropriate manufacturer service information.

4. Drive the vehicle at 19 mph (30 km/h) or more to complete the initialization of the skid control ECU (it takes more than one hour). See Fig. 8. Vehicle should be driven under the following conditions:  The vehicle speed is between 31-62 mph (50-100 km/h).  The roads are dry, smooth and straight.  The number of passengers is 1 or 2 (including driver). NOTE:

If the tire pressure warning light repeats a cycle of ON (0.5 second) and OFF (2.5 seconds) while the vehicle is being driven, initialization may have failed. If so, turn ignition switch to OFF position and perform the initialization procedure again starting at step 1.

5. After initialization is completed, the skid control ECU monitors the tire pressure by using the wheel speed sensors. 6. To verify the system has been initialized, check the length of time the tire pressure warning light is on after turning the ignition switch to the ON position. Light will stay on for 3 seconds if system is initialized, or 4 seconds if system is not initialized.

Fig. 7: Locating TPM System Reset Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 8: Initializing TPM System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 5 NOTE:

Reset is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

It is necessary to register the transmitter ID in the tire pressure warning ECU when replacing the tire pressure warning valve, transmitter and/or tire pressure warning ECU. The transmitter ID is written on the tire pressure warning valve and transmitter. You will not be able to read the ID numbers after installing the tire pressure warning valve and transmitter on the tire and wheel. Take a note of the 7 digit number (transmitter ID) before starting registration.

When the tire pressure warning light does not go off, or when it comes on during driving, check tire pressure

(including spare tire) and adjust as necessary. The warning light should go out within a few minutes. Register Transmitter ID 1. Set the pressure of all tires (including spare tire) to the pressure specified on the tire and loading information label. 2. Turn ignition switch OFF. 3. Connect a Techstream to the DLC3. 4. Turn ignition switch ON. 5. Turn Techstream ON. 6. Enter the following menus: Chassis / Tire Pressure Monitor / Utility / ID Registration. 7. Follow the procedures displayed on the screen. 8. Confirm the ID numbers for all tires (including the spare tire) are displayed on the screen. NOTE:











It may take up to 2 or 3 minutes to update the tire pressure data. If the values are not displayed after a few minutes, see the appropriate manufacturer service information. If the IDs have not been registered, DTC C2171/71 is set in the tire pressure warning ECU after 3 minutes or more. If normal pressure values are displayed, the IDs have been registered correctly. If the tire pressure values are not displayed after a few minutes, the IDs may be incorrect or the system may have a malfunction. After all IDs are registered, DTC C2126/26 (Transmitter ID not Received in Main Mode) is set in the tire pressure warning ECU and the tire pressure warning light blinks for 1 minute and then stays on. When the tire pressure warning ECU successfully receives radio waves from all the transmitters whose IDs are stored in the ECU, DTC C2126/26 is deleted and the tire pressure warning light goes off.

Confirmation Of Transmitter ID Registration 1. Set the pressure of all tires (including spare tire) to the pressure specified on the tire and loading information label. 2. Connect a Techstream to the DLC3. 3. Turn ignition switch ON. 4. Turn Techstream ON. 5. Enter the following menus: Chassis / Tire Pressure Monitor / Data List. 6. Observe the "ID Tire Inflation Pressure" values. 7. Confirm the ID numbers for all tires (including the spare tire) are displayed on the screen. If all values are displayed correctly, registration was completed successfully.

TPMS RESET - PROCEDURE 6 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or when tire pressure warning light blinks twice every second. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function.

NOTE:

If the negative battery terminal is disconnected, initialize the following system after the terminal is reconnected: Moon Roof. Refer to owner's manual or appropriate manufacturer service information. CAUTION: DO NOT push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With vehicle stopped and parking brake applied, turn ignition switch to ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position and perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See appropriate manufacturer service information.

4. Drive the vehicle at 19 MPH (30 KM/H) or more to complete the initialization of the skid control ECU (it takes more than one hour.) Vehicle should be driven under the following conditions:  The vehicle speed is between 31-62 MPH (50-100 KM/H).  The roads are dry, smooth and straight.  The number of passengers is 1 or 2 (including driver). NOTE:

If the tire pressure warning light blinks at 0.25-second intervals while the vehicle is being driven, the initialization may have failed. If so, turn ignition switch to OFF position and perform the initialization procedure again starting at step 1.

5. After initialization is completed, the skid control ECU monitors the tire pressure by using the wheel speed sensors. 6. To verify the system has been initialized, check the length of time the tire pressure warning light is on

after turning the ignition switch to the ON position. Light will stay on for 3 seconds if system is initialized, or 4 seconds if system is not initialized. TPMS RESET - PROCEDURE 7 NOTE:

For Sequoia, this procedure applies to vehicles from 2005 up to August 2007. For Sequoia models from September 2007, see TPMS RESET - PROCEDURE 17.

NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are rotated; tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced. Set tire pressure within the specified range before initializing. If tire pressure sensor and/or tire pressure monitor ECU were replaced, ensure that tire pressure sensor IDs are registered prior to initialization. Refer to owner's manual or appropriate manufacturer service information. CAUTION: DO NOT push the reset switch without adjusting tire inflation pressure of all 5 tires (including the spare). Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

NOTE:

When initializing the system, the present tire condition is stored as a standard.

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per minute. The initialization process is completed when the signals from the 5 tires have been received. The initialization process is canceled if the ignition switch is turned to OFF position during initialization. To initialize again, the tire pressure warning reset switch must be pressed again. For this reason, once the tire pressure warning reset switch has been pressed, turning ignition switch to OFF position is not recommended for a minimum of 20 minutes. 1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. With the vehicle stopped and parking brake applied, turn the ignition switch to the ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. See Fig. 9. NOTE:

Do not turn the ignition switch to OFF position during initialization (the initialization process takes about 20 minutes). Initialization will be complete if signals are received from all the wheels including the spare.

Initialization will be canceled if the ignition switch is turned to OFF position during initialization. 4. Confirm that initialization is complete using the intelligent tester. Check that the pressure for each tire is displayed in INIT THRESHOLD 1 to 5.

Fig. 9: Locating TPM System Reset Switch (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 8 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or if warning light blinks once every 3 seconds. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function. CAUTION: DO NOT push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With vehicle stopped and parking brake applied, turn ignition switch to ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. See Fig. 10. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position and perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See appropriate manufacturer service information.

4. Drive the vehicle at 19 mph (30 km/h) or more to complete the initialization of the skid control ECU (it takes more than one hour). Vehicle should be driven under the following conditions:  The vehicle speed is between 31-62 mph (50-100 km/h).  The roads are dry, smooth and straight.  The number of passengers is 1 or 2 (including driver). NOTE:

If the tire pressure warning light repeats a cycle of ON (0.5 second) and OFF (2.5 seconds) while the vehicle is being driven, initialization may have failed. If so, turn ignition switch to OFF position and perform the initialization procedure again starting at step 1.

5. After initialization is completed, the skid control ECU monitors the tire pressure by using the wheel speed sensors. 6. To verify the system has been initialized, check the length of time the tire pressure warning light is on after turning the ignition switch to the ON position. Light will stay on for 3 seconds if system is initialized, or 4 seconds if system is not initialized.

Fig. 10: Locating TPM System Reset Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 9 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced; or when a new vehicle is delivered. Set tire pressure within the specified range before initializing. When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. See Tire Pressure Sensor Registration.

Initializing Tire Pressure Monitor System

CAUTION: Set tire pressure within the specified range before initializing. DO NOT push the reset switch without adjusting tire inflation pressure of all 4 tires. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

NOTE:

The initialization mode can be terminated by making a short circuit between terminals No. 4 and 13 of the DLC3 connector (located under left side of instrument panel).

NOTE:

When initializing the system, the present tire condition is stored as a standard.

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per minute. The initialization process is completed when the signals from the 4 tires have been received. The initialization process is canceled if the ignition switch is turned to OFF position during initialization. To initialize again, the tire pressure warning reset switch must be pressed again. For this reason, once the tire pressure warning reset switch has been pressed, turning ignition switch to OFF position is not recommended for a minimum of 20 minutes. 1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With the vehicle parked in a safe place and hybrid system turned off, turn the POWER switch to the IGON position. 3. Press and hold the tire pressure warning reset switch (located under steering wheel) until the tire pressure warning light blinks 3 times at one-second intervals. 4. After 2-3 minutes, the initialization process should be completed. If the initialization has not been completed successfully, Diagnostic Trouble Code (DTC) C2177/77 is set in the tire pressure monitor ECU about 20 minutes after driving starts. 5. Confirm that initialization is complete using the intelligent tester. This may be done by checking for the test DTCS (C2181/81 to C2191/91) to be indicated, or by ensuring that tire pressure values can be displayed on the tester (it can take 2-3 minutes to display tire pressure data). NOTE:

If outside temperatures are very low, tire pressures may be lower than expected. Leave ignition on for about 20 minute after confirmation that initialization has been completed, and increase the tire inflation pressure by 3-4 psi (20-30 kPa).

Tire Pressure Sensor Registration

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. To perform this procedure, a Toyota intelligent tester (with CAN VIM) must be used. It is not necessary to register the sensor IDs when only tire rotation is performed.

NOTE:

Before beginning registration process on vehicles where tire pressure sensors have not been replaced, retrieve sensor transmitter IDs using intelligent tester or by reading the ID on the tire pressure sensor. If sensor is being replaced with a new one, make a note of the 7-digit number (transmitter ID) before installation, as it cannot be seen after sensor is installed. See Fig. 12.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. Connect the intelligent tester (with CAN VIM) to DLC3. See Fig. 11.

Fig. 11: Connecting Intelligent Tester (With CAN VIM) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. 4. 5. 6. 7.

Turn the ignition switch to ON position. Read and record the transmitter IDs (ID1 to ID4) by using the DATA LIST. See Fig. 12 and Fig. 13 . Select the "REGIST TIRE" mode. Select the "MAIN" registration mode. Input the transmitter IDs (ID1 to ID4) using the intelligent tester and transmit it to the tire pressure monitor ECU. 8. Set ID transmission condition to "SUCCEEDED". NOTE:

The previously registered IDs will be deleted from the memory when the registration is completed.

NOTE:

If steps 4-8 are not completed within 5 minutes, the mode will return to the normal operation mode.

9. When intelligent tester confirms that ID registration has successfully been completed, turn ignition switch to OFF position. 10. Turn ignition switch to ON position. Select the "SIGNAL CHECK" mode on the intelligent tester.

11. Confirm that the transmitter IDs and the tire pressure data is displayed for all 4 tires on the intelligent tester. NOTE:

It may take up to one minute to update the tire pressure data.

NOTE:

If the IDs have not been registered, DTC C2171/71 is set in the tire pressure monitor ECU after about 60 minutes.

Fig. 12: Registering Transmitter ID Using Intelligent Tester (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 13: Registering Transmitter ID Using Intelligent Tester (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 10

NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or when tire pressure warning light blinks twice every second. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function. CAUTION: Do not push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With vehicle stopped and parking brake applied, turn ignition switch to ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position. Perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See appropriate manufacturer service information.

4. Drive the vehicle at 19 mph (30 km/h) or more to complete the initialization of the ABS/skid control ECU (it takes more than one hour). Vehicle should be driven under the following conditions:  The vehicle speed is between 31-62 mph (50-100 km/h).  The roads are dry, smooth and straight.  The number of passengers is 1 or 2 (including driver). NOTE:

If the tire pressure warning light blinks at 0.25 second intervals while the vehicle is being driven, the initialization may have failed. If so, turn ignition switch to OFF position. Perform the initialization procedure again starting at step 1.

5. After initialization is completed, the ABS/skid control ECU monitors the tire pressure by using the wheel speed sensors. 6. To verify the system has been initialized, check the length of time the tire pressure warning light is on after turning the ignition switch to the ON position. Light will stay on for 3 seconds if system is initialized, or 4 seconds if system is not initialized. TPMS RESET - PROCEDURE 11 NOTE:

Reset is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU. See Tire Pressure Sensor Registration.

Tire Pressure Monitor Warning Light

NOTE:

The tire pressure warning light may turn on due to natural causes such as natural air leaks or tire pressure changes caused by temperature. In this case, adjusting the tire pressure will turn off the warning light.

NOTE:

If warning light turned on due to very low outside temperatures (such as in winter) causing decreases in tire pressure, adjust pressure to a higher pressure suitable to cold conditions. Tire pressure decreases by about 1.45 psi (10 kPa) for every 50°F (10°C) drop in ambient temperature.

When the tire pressure warning light does not go off, or when it comes on during driving, check tire pressure (including spare tire) and adjust as necessary. The warning light should turn off within a few minutes. If the warning light is still on even though the tire pressure is correctly adjusted, the tire could be punctured. Repair as necessary. If the warning light turns on within several hours after adjusting the tire pressure, the tire may have a slow air leak. Repair as necessary. If the warning light stays on or blinks, there is a malfunction in the TPM system. See appropriate manufacturer service information. Under the following conditions, the system may not function properly: 

     

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The areas, facilities or devices that use similar radio wave frequencies are located in the vicinity of the vehicle. A radio device of similar frequency is used near the vehicle. A lot of snow or ice is stuck to the vehicle, especially around the wheels or wheel housings. Tires and wheels are installed that are not equipped with a tire pressure sensor. Snow tires or tire chains are used. The battery of the sensor has been depleted. Wheels other than manufacturer factory wheels are used. If any other wheels than the specified ones are used, the system may not function properly because the radio waves are differently transmitted from the tire pressure sensor. Radio waves from the air pressure sensor installed on the spare tire cannot be received. If this problem has occurred, rotate spare tire 90 degrees and recheck system. Depending on the tire type, the system may not function properly even though the specified wheels are used. Using a different type of tire in combination with genuine tires. If system was initialized with tire pressures which are not the specified values.

Tire Pressure Sensor Registration

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the

sensor ID must be memorized by the tire pressure monitor ECU. To perform this procedure, a Toyota intelligent tester (with CAN VIM) must be used. It is not necessary to register the sensor IDs when only tire rotation is performed. NOTE:

Before beginning registration process on vehicles where tire pressure sensors have not been replaced, retrieve sensor transmitter IDs using intelligent tester or by reading the ID on the tire pressure sensor. If sensor is being replaced with a new one, make a note of the 7-digit number (transmitter ID) before installation, as it cannot be seen after sensor is installed.

1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. Connect the intelligent tester (with CAN VIM) to DLC3. See Fig. 11. 3. Turn the ignition switch to ON position. 4. Read and record the transmitter IDs (ID1 to ID5) by using the DATA LIST. See Fig. 14 and Fig. 15 . 5. Select the "REGIST TIRE" mode. 6. Select the "MAIN" registration mode. 7. Input the transmitter IDs (ID1 to ID5) using the intelligent tester and transmit it to the tire pressure monitor ECU. 8. Set ID transmission condition to "COMPLETE". NOTE:

The previously registered IDs will be deleted from the memory when the registration is completed.

NOTE:

If steps 4-8 are not completed within 5 minutes, the mode will return to the normal operation mode.

9. When intelligent tester confirms that ID registration has successfully been completed, turn ignition switch to OFF position. 10. Turn ignition switch to ON position. Select the "SIGNAL CHECK" mode on the intelligent tester. 11. Confirm that the transmitter IDs and the tire pressure data is displayed for all 5 tires on the intelligent tester. NOTE:

It may take up to one minute to update the tire pressure data.

NOTE:

If the IDs have not been registered, DTC C2171/71 is set in the tire pressure monitor ECU after about 60 minutes.

Fig. 14: Registering Transmitter ID Using Intelligent Tester (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 15: Registering Transmitter ID Using Intelligent Tester (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 12

NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

This system requires initializing after changing tires or wheels, after rotating the tires, or when tire pressure warning light blinks twice every second. Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, tire pressure warning system will not function. See appropriate manufacturer service information.

NOTE:

If the negative battery terminal is disconnected, initialize the following systems after the terminal is reconnected: power window, power sliding door, power back door and moon roof. Refer to owner's manual or appropriate manufacturer service information. CAUTION: Do not push the reset switch without adjusting tire inflation pressure. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed.

1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With the vehicle stopped and parking brake applied, turn the ignition switch to the ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning light blinks 3 times at one-second intervals (continue pressing the switch for about 3-4 seconds). See Fig. 16. NOTE:

If the tire pressure warning light does not blink, turn ignition switch to OFF position and perform the initialization procedure again starting at step 2. If light still does not blink, there is a problem in the TPM system. See appropriate manufacturer service information.

4. On 2004-06 models, drive the vehicle at 19 MPH (30 KM/H) or more to initialize the skid control ECU. This may take 30-60 minutes.

Fig. 16: Locating TPM System Reset Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 13 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced; or when a new vehicle is delivered. Set tire pressure within the specified range before initializing. When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. See Tire Pressure Sensor Registration.

Initializing Tire Pressure Monitor System

CAUTION: Set tire pressure within the specified range before initializing. DO NOT

push the reset switch without adjusting tire inflation pressure of all 4 tires. Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed. NOTE:

When initializing the system, the present tire condition is stored as a standard.

NOTE:

Perform the tire pressure adjustment after the vehicle has sufficiently cooled down. If it hasn't sufficiently cooled, increase the air pressure in the tires approximately 3-4psi (20-30kPa)

NOTE:

The initialization mode can be terminated by making a short circuit between terminals No. 4 and 13 of the DLC3 connector (located under left side of instrument panel).

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per minute. The initialization process is completed when the signals from the 4 tires have been received. The initialization process is canceled if the ignition switch is turned to OFF position prior to the completion of initialization. To restart initialization, the tire pressure warning reset switch must be pressed again. 1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. With the vehicle parked in a safe place, connect the intelligent tester to the DLC3 and turn POWER switch to the ON position. 3. Turn the intelligent tester ON and navigate to the "TIREPRESS" option using the on-screen prompts. 4. Within 30 seconds of turning the ignition ON, press and hold the tire pressure warning reset switch (located to the left of the steering wheel) until the tire pressure warning light blinks 3 times at one-second intervals. 5. Wait 5 - 6 minutes, with the ignition ON, for the initialization process to complete. If the initialization has not been completed successfully, Diagnostic Trouble Code (DTC) C2177/77 is set in the tire pressure monitor ECU about 20 minutes after driving starts. 6. Confirm that initialization is complete by verifying that the correct tire pressure values are displayed on the intelligent tester. NOTE:

In winter, tire pressure may decrease due to low ambient temperatures (about 1.45 psi (10 kPa) for every 18°F (10°C) drop in ambient temperature). Therefore, the tire pressure warning is more likely to operate if the tire pressures are not adjusted appropriately. If the daily temperature variation is large, pressurize the tires so that they are in the specified range under cold conditions. With this adjustment, unnecessary warnings are less likely.

Tire Pressure Sensor Registration

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. To perform this procedure, a Toyota intelligent tester (with CAN VIM) must be used. It is not necessary to register the sensor ID(s) when only tire rotation is performed.

NOTE:

Before beginning registration process on vehicles where tire pressure sensors have not been replaced, retrieve sensor transmitter ID(s) using intelligent tester or by reading the ID on the tire pressure sensor. If sensor is being replaced with a new one, make a note of the 8-digit number (transmitter ID) before installation, as it cannot be seen after sensor is installed.

1. 2. 3. 4. 5.

Set the tire pressure of all wheels to pressure specified on the tire and loading information label. Connect the intelligent tester (with CAN VIM) to DLC3. See Fig. 11. Turn the ignition switch to ON position. Select the "REGIST TIRE" mode (UTILITY - REGIST TIRE). Input the transmitter ID(s) (ID1 to ID4), using the intelligent tester, and transmit them to the tire pressure warning ECU. See Fig. 17 and Fig. 18 . 6. Set the ID transmission condition to "ID REGISTRATION COMPLETE". NOTE:

Any previously registered ID(s) will be deleted from the memory when the registration is completed.

NOTE:

If steps 4-6 are not completed within 5 minutes, the mode will return to the normal operation mode.

7. Turn ignition switch to OFF position. 8. Turn ignition switch to ON position. Select the "TIRE PRESS" mode on the intelligent tester. 9. Confirm that the tire pressure data is displayed for all 4 tires on the intelligent tester. This will confirm that the registration has been completed successfully. NOTE:

It may take 5 - 6 minutes to update the tire pressure data.

NOTE:

If the ID(s) have not been registered, DTC C2171/71 is set in the tire pressure monitor ECU after about 3 minutes.

Fig. 17: Registering Transmitter ID Using Intelligent Tester (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Registering Transmitter ID Using Intelligent Tester (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TPMS RESET - PROCEDURE 14 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced; or when a new vehicle is delivered. Set tire pressure within the specified range before initializing. If tire pressure sensor and/or tire pressure monitor ECU were replaced, ensure that tire pressure sensor IDs are registered prior to initialization. See Tire Pressure Sensor Registration.

Initializing Tire Pressure Monitor System

CAUTION: Set tire pressure within the specified range before initializing. DO NOT push the reset switch without adjusting tire inflation pressure of all 5 tires (including the spare tire). Otherwise, the low tire pressure warning light may not come on even if the tire pressure is low, or it may come on when the tire inflation pressure is actually normal. If you push the reset switch while the vehicle is moving, initialization is not performed. NOTE:

The initialization mode can be terminated by making a short circuit between terminals No. 4 and 13 of the DLC3 connector (located under left side of instrument panel).

NOTE:

When initializing the system, the present tire condition is stored as a standard.

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per minute. The initialization process is completed when the signals from the 5 tires have been received. The initialization process is canceled if the ignition switch is turned to OFF position during initialization. To initialize again, the tire pressure warning reset switch must be pressed again. For this reason, once the tire pressure warning reset switch has been pressed, turning ignition switch to OFF position is not recommended for a minimum of 20 minutes. 1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. With the vehicle stopped and parking brake applied, turn the ignition switch to the ON position. 3. Press and hold the tire pressure warning reset switch (located under steering wheel) until the tire pressure warning light blinks 3 times at one-second intervals. 4. After 2-3 minutes, the initialization process should be completed. If the initialization has not been completed successfully, Diagnostic Trouble Code (DTC) C2177/77 is set in the tire pressure monitor ECU about 20 minutes after driving starts. 5. Confirm that initialization is complete using the intelligent tester. This may be done by checking for the

test DTCS (C2181/81 to C2191/91) to be indicated, or by ensuring that tire pressure values can be displayed on the tester (it can take 2-3 minutes to display tire pressure data). NOTE:

If outside temperatures are very low (such as in winter), which can cause decreases in tire pressure, leave ignition on for about 20 minutes after confirmation that initialization has been completed, and increase the tire inflation pressure by 3-4 psi (20-30 kPa).

Tire Pressure Sensor Registration

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. To perform this procedure, a Toyota intelligent tester must be used. It is not necessary to register the sensor IDs when only tire rotation is performed.

NOTE:

If transmitter IDs cannot be registered, the tire pressure monitor ECU is probably in initialization mode. Initialization mode can be terminated by making a short circuit between terminals No. 4 and 13 of the DLC3 connector (located under left side of instrument panel).

NOTE:

Before beginning registration process on vehicles where tire pressure sensors have not been replaced, retrieve sensor transmitter IDs using intelligent tester or by reading the ID on the tire pressure sensor. If sensor is being replaced with a new one, make a note of the 7-digit number (transmitter ID) before installation, as it cannot be seen after sensor is installed.

NOTE:

When system is in initialization mode after the reset switch has been operated, the registration is disabled until the initialization process is canceled or completed.

1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. Connect the intelligent tester to DLC3. See Fig. 19.

Fig. 19: Connecting Intelligent Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Turn the ignition switch to the ON position. 4. Read and record the transmitter IDs (ID1 to ID5) by using the DATA LIST. See Fig. 14. 5. Input the transmitter IDs (ID1 to ID5) using the intelligent tester and transmit it to the tire pressure monitor ECU. See Fig. 15. 6. Select the "REGIST TIRE" mode. 7. Select the "MAIN" registration mode. 8. Set ID transmission condition to "COMPLETE". NOTE:

The previously registered IDs will be deleted from the memory when the registration is completed.

NOTE:

If steps 4-8 are not completed within 5 minutes, the mode will return to the normal operation mode.

9. When intelligent tester confirms that ID registration has successfully been completed, turn ignition switch to OFF position. 10. Turn ignition switch to ON position. Select the "SIGNAL CHECK" mode on the intelligent tester. 11. Confirm that the transmitter IDs and the tire pressure data is displayed for all 5 tires on the intelligent tester. NOTE:

It may take up to one minute to update the tire pressure data.

NOTE:

If the IDs have not been registered, DTC C2171/71 is set in the tire pressure monitor ECU after about 30 minutes.

TPMS RESET - PROCEDURE 15 NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

The system will need to be initialized when tires are rotated; tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced. Set tire pressure within the specified range before initializing. See Initializing Tire Pressure Monitor System. When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU prior to system initialization. See Tire Pressure Sensor Registration.

Tire Pressure Monitor Warning Light

NOTE:

The tire pressure warning light may turn on due to natural causes such as natural air leaks or tire pressure changes caused by temperature. In this case, adjusting the tire pressure will turn off the warning light.

When the tire pressure warning light does not go off, or when it comes on during driving, check tire pressure (including spare tire) and adjust as necessary. The warning light should turn off after a few minutes. If the warning light is still on even though the tire pressure is correctly adjusted, the tire could be punctured. Repair as necessary. If the warning light is still on or blinks, there is a malfunction in the TPM system. See appropriate manufacturer service information. Under the following conditions, the system may not function properly: 

     



The areas, facilities or devices that use similar radio wave frequencies are located in the vicinity of the vehicle. A radio device of similar frequency is used in or near the vehicle. A lot of snow or ice is stuck to the vehicle, especially the wheels and around the wheel houses. The battery of the sensor has been depleted. A tire without tire pressure monitor valve sub-assembly is used. Tire chains are used. If any other wheels than the specified ones are used, the system may not function properly because the radio waves are differently transmitted from the tire pressure sensor. Depending on the tire type, the system may not function properly even though the specified wheels are used.

Initializing Tire Pressure Monitor System

NOTE:

The system will need to be initialized when tires are rotated; tires are replaced with tires of different pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced; or when a new vehicle is delivered. Set tire pressure within the specified range before initializing.

NOTE:

When initializing the system, the present tire condition is stored as a standard.

During initialization, the tire pressure monitor valve sub-assembly measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure monitor ECU at a frequency of one per 3 minutes. The initialization process is completed when the signals from the 5 tires have been received. 1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. With the vehicle stopped and parking brake applied, turn the ignition switch to the ON position. 3. Press and hold the tire pressure warning reset switch until the tire pressure warning lamp blinks 3 times at one-second intervals. 4. Confirm that initialization is complete using the hand-held tester. First select "DATA LIST" on the handheld tester, then verify that the "TIREPRESS" values are displayed. It may take 5 to 6 minutes for the "TIREPRESS" values to display on the hand-held tester screen NOTE:

The initialization process takes 5 to 6 minutes to be completed. The initialization process can be terminated by connecting terminals 4 (TC) and 13 (CG) of the DLC3.

Tire Pressure Sensor Registration

NOTE:

If the tire pressure sensor and/or tire pressure monitor ECU are replaced, the transmitter ID needs to be registered in the tire pressure monitor ECU prior to system initialization. To perform this procedure, the Toyota hand-held tester must be used.

Register Transmitter ID 1. Set the tire pressure of all wheels (including spare tire) to pressure specified on the tire and loading information label. 2. Connect the hand-held tester to DLC3. 3. Turn ignition switch to ON position. 4. Select the "REGIST TIRE" mode. See Fig. 14 and Fig. 20 . 5. Input the transmitter IDs (ID1 to ID5) using the hand-held tester and transmit it to the tire pressure monitor ECU. 6. Set the ID transmission condition to "SUCCEEDED". NOTE:

If steps 4-6 are not completed within 5 minutes, the mode will return to the normal operation mode.

Confirmation Of Transmitter ID Registration 1. 2. 3. 4. 5.

Set the tire pressure of all wheels (including spare tire) to the specified value. Connect the hand-held tester to DLC3. Turn ignition switch to ON position. Select "DATA LIST" mode on the hand-held tester. Confirm the "TIREPRESS" values are displayed on the hand-held tester screen.

Fig. 20: Registering Transmitter ID Using Hand-Held Tester Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TPMS RESET - PROCEDURE 16 NOTE:

Reset is NOT required if re-inflating tires to the currently specified tire pressure.

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU. See Tire

Pressure Sensor Registration. NOTE:

If the negative battery terminal is disconnected, initialize the following system after the terminal is reconnected: Power Window Control System. Refer to owner's manual or appropriate manufacturer service information.

Tire Pressure Monitor Warning Light

When the tire pressure warning light does not go off, or when it comes on during driving, check tire pressure and adjust as necessary. The warning light should turn off within a few minutes. If the warning light is still on even though the tire pressure is correctly adjusted, the tire could be punctured. Repair as necessary. If the warning light turns on within several hours after adjusting the tire pressure, the tire may have a slow air leak. If the warning light is still on or blinks, there is a malfunction in the TPM system. See appropriate manufacturer service information. NOTE:

The tire pressure warning light may turn on due to natural causes such as natural air leaks or tire pressure changes caused by temperature. In this case, adjusting the tire pressure will turn off the warning light. Under the following conditions, the system may not function properly: 

 



  





Facilities or devices that use similar radio wave frequencies are located in the vicinity of the vehicle. A radio device of similar frequency is used near the vehicle. A lot of snow or ice is stuck to the vehicle, especially around the wheels or wheel housings. Tires and wheels are installed that are not equipped with a tire pressure sensor. Snow tires or tire chains are used. The battery of the sensor has been depleted. Wheels other than manufacturer factory wheels are used. If any other wheels than the specified ones are used, the system may not function properly because the radio waves are differently transmitted from the tire pressure sensor. Depending on the tire type, the system may not function properly even though the specified wheels are used. Using a different type of tire in combination with genuine tires.

Tire Pressure Sensor Registration

NOTE:

When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor ID must be memorized by the tire pressure monitor ECU. To perform this procedure, a Toyota Techstream must be used. It is not necessary to register the sensor ID(s) when only tire rotation is performed.

NOTE:

Before beginning registration process on vehicles where tire pressure sensors have not been replaced, retrieve sensor transmitter ID(s) using intelligent tester or by reading the ID on the tire pressure sensor. If sensor is being replaced with a new one, make a note of the transmitter ID before installation, as it cannot be seen after sensor is installed. See Fig. 21.

Fig. 21: Locating Tire Pressure Monitor Valve Sub-Assembly Transmitter ID Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Set the tire pressure of all wheels to pressure specified on the tire and loading information label. 2. Connect the intelligent tester to DLC3. See Fig. 11.

3. Turn the Tachstream scan tool on and the ignition switch to ON position. 4. Enter the following menus: Chassis / Tire Pressure Monitor / Utility / ID Registration. 5. Perform the procedure displayed on the scan tool. NOTE:

Tire pressure sensor IDs that were previously registered will be deleted from the memory when registration is completed.

6. Confirm the tire pressure sensor's IDs are registered: 7. Enter the following menus: Chassis / Tire Pressure Monitor / Data List. 8. Confirm the tire pressure values are displayed for all 4 tires. NOTE:

It may take up to 2 or 3 minutes to update the tire pressure data. If tire pressure values do not display after 2 or 3 minutes, troubleshoot DTCs C2121/21 to C2124/24 (on some models, up to C2125/25).

NOTE:

If the ID(s) have not been registered, DTC C2171/71 is set in the tire pressure monitor ECU after 3 minutes or more.

TPMS RESET - PROCEDURE 17 NOTE:

For Sequoia, this procedure applies to vehicles from September 2007 and later. For Sequoia models from 2005 up to August 2007, see TPMS RESET PROCEDURE 7.

NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

The system will need to be initialized when tires are rotated; tires are inflated to a specification different from currently logged pressures; tire pressure sensor and/or tire pressure monitor ECU are replaced. See Initialization. When a tire pressure sensor and/or tire pressure monitor ECU are replaced, the sensor IDs must be memorized by the tire pressure monitor ECU prior to system initialization. See Registration. Registration

NOTE:

1. 2. 3. 4.

The transmitter ID is written on the tire pressure warning valve and transmitter. It will be unable to be read after installing the tire pressure warning valve and transmitter on the tire and wheel. Therefore, take a note of the transmitter ID before installing the tire pressure warning valve and transmitter.

Set the air pressure of all wheels to the specified value Turn the ignition switch off. Connect Techstream to the DLC3. Turn the ignition switch on (IG) and the Techstream on.

5. Enter the menu items in this order: Chassis / Tire Pressure Monitor / Utility / ID Registration 6. Perform the transmitter ID registration. 7. Input the transmitter IDs (ID1 to ID5) using the Techstream and transmit them to the tire pressure warning ECU. 8. The "ID Registration is complete" is displayed on the Techstream display. 9. Confirm transmitter ID registration. a. Enter the menu items in this order: Chassis / Tire Pressure Monitor / Data List b. Read the "ID Tire Inflation Pressure" values. c. Confirm that the data of tire pressure of all tires are displayed on the screen. NOTE:











It may take up to about 2 or 3 minutes to update the tire pressure data. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2124/24 (on models with full-sized spare, up to C2125/25). If the IDs have not been registered, DTC C2171/71 is set in the tire pressure warning ECU after 3 minutes or more. If normal pressure values are displayed, the IDs have been registered correctly. If the tire pressure values are not displayed after a few minutes, the IDs may be incorrect or the system may have a malfunction. After all IDs are registered, DTC C2126/26 (Transmitter ID not Received in Main Mode) is set in the tire pressure warning ECU and the tire pressure warning light blinks for 1 minute and then comes on. When the tire pressure warning ECU successfully receives radio waves from all the transmitters whose IDs are stored in the ECU, DTC C2126/26 is deleted and the tire pressure warning light goes off.

Initialization

NOTE:

Initialization is NOT required if re-inflating tires to the currently specified tire pressure.

The purpose of Initialization is to tell the TPMS ECU what the inflation pressures should be for the current set of tires. Perform Initialization if the specification changes. Also perform initialization in the following cases: 





After replacement of the tire pressure warning ECU. Perform initialization after the transmitter ID registration is completed. After replacement of the tire pressure warning valve and transmitter. Perform initialization after the transmitter ID registration is completed. After rotating the tires on vehicles whose front and rear tire inflation pressure standard values are different.

1. Turn the ignition switch to ON. 2. Press and hold the tire pressure warning reset switch for 3 seconds or more so that the tire pressure warning light blinks 3 times. 3. Turn the ignition switch to OFF. 4. Connect Techstream to the DLC3. 5. Turn the ignition switch to ON and turn the tester on. 6. Enter the following menus: Chassis / Tire Pressure Monitor / Data List. 7. Check that the initialization has been completed. 8. Confirm that the tire pressure data of all tires are displayed on the tester screen. NOTE:

 



The initialization is normally completed within 2 to 3 minutes. If the initialization has not been completed successfully, DTC C2177/77 is set after a vehicle speed of 8 km/h (5 mph) or more continues for 20 minutes or more. The initialization can be terminated by connecting terminals 13 (TC) and 4 (CG) of the DLC3 connector.

Fig. 22: Identifying Tire Pressure Warning Reset Switch (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2012-2017 MAINTENANCE Maintenance - Camry (Except Hybrid)

OUTSIDE VEHICLE GENERAL MAINTENANCE GENERAL MAINTENANCE

These are maintenance and inspection items that are considered to be the owner's responsibility. The owner can do them or they can have them done at a service center. These items include those that should be checked on a daily basis, those that in most cases do not require special tools, and those that are considered to be reasonable for the owner to do. General maintenance items and procedures are as follows: 1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Following the maintenance schedule is mandatory.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES a. Check the tire inflation pressure with a gauge. Make adjustments if necessary. b. Check the surfaces of the tires for cuts, damage or excessive wear. 3. WHEEL NUTS a. Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION a. Check the maintenance schedule in the owner's manual supplement. 5. WINDSHIELD WIPER BLADES a. Check the blades for wear or cracks whenever they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS a. Check under the vehicle for leaking fuel, oil, water and other fluids. NOTE:

If you smell fuel or notice any leaks, locate the cause and correct it.

7. DOORS AND ENGINE HOOD

a. Check that all of the doors and the hood operate smoothly, and that all the latches lock securely. b. When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening.

INSIDE VEHICLE GENERAL MAINTENANCE GENERAL MAINTENANCE

These are maintenance and inspection items that are considered to be the owner's responsibility. The owner can do them or they can have them done at a service center. These items include those that should be checked on a daily basis, those that in most cases do not require special tools, and those that are considered to be reasonable for the owner to do. General maintenance items and procedures are as follows: 1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Maintain similar intervals between periodic maintenance unless noted.  Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS a. Check that the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink properly. Also, check if they have enough brightness. b. Check that the headlights are aimed properly. 3. WARNING LIGHTS AND BUZZERS a. Check that all the warning lights and buzzers are working. 4. HORNS a. Check if the horn is working correctly. 5. WINDSHIELD GLASS a. Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER a. Check that the washers are aimed properly. Also, check that the washer fluid hits the center of the operating range of each wiper on the windshield. b. Check if the wipers streak. Replace them if necessary. 7. WINDSHIELD DEFROSTER

8. 9. 10.

11.

a. When the air conditioning is on the defroster setting, check that air comes out of the defroster outlets. REAR VIEW MIRROR a. Check that the rear view mirror is securely mounted. SUN VISORS a. Check that the sun visors move freely and are securely mounted. STEERING WHEEL a. Check that the steering wheel has the proper amount of free play. Also check for steering difficulty and unusual noises. Refer to ON-VEHICLE INSPECTION - Step 1 . SEATS a. Check that the seat adjusters, seatback recliner and other seat controls operate smoothly. b. Check that all the latches lock securely in all positions. c. Check that the locks hold securely in all positions. d. Check that the headrests move up and down smoothly and that the locks hold securely in all latched positions. e. Check power seat function.

Fig. 1: Identifying Power Seat Functions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Sliding

*1 Function Reclining *2 Function Lifter *3 Function Front *4 Vertical Function Lumbar Support *5 Adjustment Function

12.

13.

14.

15. 16.

17.

1. Operate the power seat switches and check that each seat function operates properly:  Sliding function  Reclining function  Lifter function*  Front vertical function*  Lumbar support adjustment function* *: for Driver SEAT BELTS a. Check that the seat belt components, such as the buckles, retractors and anchors, operate properly and smoothly. b. Check that the belt webbing is not cut, frayed, worn or damaged. ACCELERATOR PEDAL a. Check that the pedal operates smoothly. Check that the pedal does not have uneven resistance or stick in certain positions. BRAKE PEDAL a. Check that the brake pedal operates smoothly. b. Check that the pedal has the proper reserve distance and free play. Refer to ADJUSTMENT - Step 2. c. Start the engine and check the brake booster function. d. Start the engine and check the brake system indicator. BRAKES a. In a safe place, check that the vehicle does not pull or lead to the side when applying the brakes. PARKING BRAKE a. Check that the parking brake pedal has the proper amount of travel. Refer to ADJUSTMENT . b. On a slight grade, check that the parking brake alone can hold the vehicle in place. AUTOMATIC TRANSAXLE "PARK" MECHANISM a. Check the lock release button of the shift lever for proper and smooth operation.

b. Check the shift lever for proper and smooth operation. c. When the shift lever is in P and all brakes are released in an area that has a slight grade, check that the vehicle is stable. 18. FLOOR MATS a. Check that the correct floor mats are used, and that they are properly installed.

UNDER HOOD GENERAL MAINTENANCE GENERAL MAINTENANCE

1. GENERAL NOTES  Maintenance requirements vary depending on the country.  Check the maintenance schedule in the owner's manual supplement.  Following the maintenance schedule is mandatory.  Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first.  Maintain similar intervals between periodic maintenance unless noted.  Failing to check each maintenance item could lead to poor engine performance and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID a. Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL a. Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4. RADIATOR AND HOSES a. Check that the front of the radiator is clean and not blocked by leaves, dirt and bugs. b. Check the radiator and hoses for:  Damage  Cracks  Kinks  Corrosion  Rot  Clogging  Leaks 5. BATTERY ELECTROLYTE LEVEL a. Check that the electrolyte level of all the battery cells is between the upper and lower level lines on the case. HINT:

If the electrolyte level is difficult to see, lightly shake the vehicle. 6. BRAKE FLUID LEVEL a. Check that the brake fluid level is near the upper level line on the see-through reservoirs. 7. ENGINE DRIVE BELT a. Check the drive belt for fraying, cracks, wear or oil. 8. ENGINE OIL LEVEL a. Check that the engine oil level is between the full level and low level marks on the dipstick with the engine turned off. 9. EXHAUST SYSTEM a. Visually inspect for severe corrosion, cracks, holes or loose supports. HINT: If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, inspect and repair the exhaust system.

ENGINE GENERAL MAINTENANCE GENERAL MAINTENANCE

HINT: Perform these procedures after the engine has cooled down. 1. INSPECT DRIVE BELT a. Check the drive belt. See procedures Refer to ON2ARVEHICLE FE INSPECTION Refer to ON2GRVEHICLE FE INSPECTION Type

2. REPLACE ENGINE OIL AND OIL FILTER a. Check the engine oil and oil filter. Type See procedures 2AR- Refer to

FE REPLACEMENT 2GR- Refer to FE REPLACEMENT 3. REPLACE ENGINE COOLANT a. Check the engine coolant. Type See procedures 2AR- Refer to FE REPLACEMENT 2GR- Refer to FE REPLACEMENT 4. INSPECT SPARK PLUGS a. Check the spark plugs. See procedures Refer to ON2ARVEHICLE FE INSPECTION Refer to ON2GRVEHICLE FE INSPECTION Type

5. INSPECT BATTERY a. Check the battery. See procedures Refer to ON2ARVEHICLE FE INSPECTION Refer to ON2GRVEHICLE FE INSPECTION Type

6. INSPECT AIR CLEANER FILTER ELEMENT a. Remove the air filter. b. Check that the air cleaner is not excessively dirty.

Fig. 2: Cleaning Air Cleaner Filter Element Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the air cleaner is excessively dirty, replace the air cleaner filter element. c. If cleaning the air cleaner filter element, blow compressed air as shown in the illustration to clean it. d. Reinstall the air filter. e. When an excessive amount of dirt is present, replace the air filter. 7. INSPECT EXHAUST PIPES AND MOUNTINGS a. Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 8. INSPECT FUEL TANK CAP ASSEMBLY a. Check the fuel tank cap gasket. See procedures 2AR- Refer to FE INSPECTION 2GR- Refer to FE INSPECTION Type

9. INSPECT FUEL LINES, CONNECTIONS, FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS a. Visually check the fuel lines and hoses for cracks, leaks, loose connections, or deformation. b. Check for tank band looseness or deformation. 10. INSPECT CHARCOAL CANISTER a. Check the charcoal canister. See procedures 2AR- Refer to FE INSPECTION Type

2GR- Refer to FE INSPECTION

BRAKE GENERAL MAINTENANCE GENERAL MAINTENANCE

1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection.

Fig. 3: Inspecting Brake Line Pipes And Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a mirror, check the entire circumference and length of the brake lines and hoses for:  Damage  Wear  Deformation  Cracks  Kinks  Corrosion

Leaks  Twists b. Check all the clamps for tightness and check the connections for leakage. c. Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system. d. Check that the lines are installed properly and pass through the center of the grommets. INSPECT BRAKE PEDAL a. Check the brake pedal. Refer to ADJUSTMENT . INSPECT PARKING BRAKE a. Check the parking brake shoe clearance and parking brake pedal travel. Refer to ADJUSTMENT . b. Check the parking brake cables to ensure that they are not deformed or binding. INSPECT BRAKE LININGS AND DRUMS a. Check the parking brake linings and drums. INSPECT FRONT BRAKE a. Check the front brake pads and discs. Refer to INSPECTION . INSPECT REAR BRAKE a. Check the rear brake pads and discs. Refer to INSPECTION . INSPECT OR CHANGE BRAKE FLUID a. Inspect or change the brake fluid. Refer to ON-VEHICLE INSPECTION . 

2. 3.

4. 5. 6. 7.

Fluid SAE J1703 or FMVSS No. 116 DOT3

CHASSIS GENERAL MAINTENANCE GENERAL MAINTENANCE

1. INSPECT STEERING LINKAGE AND GEAR HOUSING a. Check the steering wheel free play. Refer to ON-VEHICLE INSPECTION - Step 1 . b. Check the steering linkage for looseness or damage. 1. Check that the tie rod ends do not have any play. 2. Check that the dust seals and boots are not damaged. 3. Check that the boot clamps are not loose. 4. Check that the steering gear housing is not damaged. 2. INSPECT BALL JOINTS AND DUST COVERS a. Inspect the ball joints for excessive looseness. 1. Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires.

2. Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. 3. Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels. 4. Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play 0 mm (0 in.) If there is any play, replace the ball joint. b. Check the dust cover for damage. 3. INSPECT DRIVE SHAFT BOOTS a. Check the drive shaft boots for loose clamps, cracks, grease leaks, kinks or damage. 4. INSPECT AUTOMATIC TRANSAXLE a. Visually check the transaxle for fluid leaks. If fluid is leaking, find the cause and repair it. 5. INSPECT FRONT AND REAR SUSPENSION a. Check the front and rear suspension. Suspension See Procedure Type Front Refer to Suspension ADJUSTMENT Rear Refer to Suspension ADJUSTMENT

BODY GENERAL MAINTENANCE GENERAL MAINTENANCE

1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY a. If necessary, tighten the bolts and nuts on the chassis parts listed below.  Front axle and suspension  Drivetrain  Rear axle and suspension  Brake system  Engine mounts  Other chassis parts b. If necessary, tighten the bolts and nuts on the body parts listed below.  Seat belt system

Seats  Doors and hood  Body mounts  Fuel tank  Exhaust system  Other body parts 2. REPLACE AIR CONDITIONING FILTER a. Remove the air conditioning filter. Refer to DISASSEMBLY - Step 7 . b. Visually inspect the surface of the air conditioning filter. c. If the air conditioning filter is contaminated with foreign matter, replace it. 3. ROAD TEST a. Check the engine and chassis for abnormal noises. b. Check that the vehicle does not wander or pull to one side. c. Check that the brakes work properly and do not drag. d. Bed-in the parking brake shoes to the drums. 4. BODY INSPECTION a. Check the body exterior for dents, scratches and rust. b. Check the underbody for rust and damage. 

If necessary, replace the damaged part or repair the damaged area. 5. FINAL INSPECTION a. Check the operation of the body parts. 1. Hood  Auxiliary catch operates properly.  Hood locks securely when closed. 2. Front and rear doors  Door locks operate properly.  Doors close properly. 3. Luggage compartment door  Luggage compartment door opens and closes properly. 4. Seats  Seats adjust easily and lock securely in any position.  Front seatbacks lock securely in any position.  Fold-down rear seatbacks lock securely. 5. Be sure to deliver a clean car. Make sure to check the following:  Steering wheel  Shift lever knob

  

All switches and knobs Door handles Seats

2012-2017 ACCESSORIES & EQUIPMENT Meter / Gauge / Display (Service Information) (Hybrid)

COMBINATION METER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Combination Meter Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Combination Meter Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 5. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 6. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 8 7. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 9 8. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 10 9. REMOVE COMBINATION METER ASSEMBLY a. Remove the 4 screws.

Fig. 3: Identifying Combination Meter Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Disengage the wire harness clamp.

Fig. 4: Identifying Combination Meter Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 2 connectors to remove the combination meter assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE COMBINATION METER GLASS a. Disengage the 8 claws and remove the combination meter glass.

Fig. 5: Identifying Combination Meter Glass Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL COMBINATION METER GLASS a. Engage the 8 claws to install the combination meter glass.

Fig. 6: Identifying Combination Meter Glass Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL COMBINATION METER ASSEMBLY a. Connect the 2 connectors. b. Engage the wire harness clamp. c. Install the combination meter assembly with the 4 screws. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 42 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 43

4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 44 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43 7. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

CLOCK COMPONENTS ILLUSTRATION

Fig. 7: Identifying Clock Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22

2. REMOVE CLOCK ASSEMBLY a. Remove the 2 screws and clock assembly with instrument cluster finish panel cover from the No. 1 center instrument cluster finish panel.

Fig. 8: Identifying Clock Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws and remove the clock assembly.

Fig. 9: Identifying Clock Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE CLOCK LENS a. Disengage the 5 claws and remove the clock lens.

Fig. 10: Identifying Clock Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL CLOCK LENS a. Engage the 5 claws to install the clock lens.

Fig. 11: Identifying Clock Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CLOCK ASSEMBLY a. Engage the 4 claws to install the clock assembly. b. Install the clock assembly with instrument cluster finish panel cover to the No. 1 center instrument cluster finish panel with the 2 screws. 2. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30

2012-2017 ACCESSORIES & EQUIPMENT Meter / Gauge / Display (Service Information) - Camry (Except Hybrid)

COMBINATION METER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Combination Meter Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 4. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 5. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 7 6. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 8 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 9 8. REMOVE COMBINATION METER ASSEMBLY a. Remove the 4 screws.

Fig. 2: Identifying Combination Meter Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the wire harness clamp.

Fig. 3: Identifying Combination Meter Assembly Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 2 connectors to remove the combination meter assembly. DISASSEMBLY DISASSEMBLY

1. REMOVE COMBINATION METER GLASS a. Disengage the 8 claws and remove the combination meter glass.

Fig. 4: Identifying Combination Meter Glass Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL COMBINATION METER GLASS a. Engage the 8 claws to install the combination meter glass.

Fig. 5: Identifying Combination Meter Glass Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL COMBINATION METER ASSEMBLY a. Connect the 2 connectors. b. Engage the wire harness clamp. c. Install the combination meter assembly with the 4 screws. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 44 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 45

4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 46 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

CLOCK COMPONENTS ILLUSTRATION

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

Fig. 6: Identifying Clock Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23

2. REMOVE CLOCK ASSEMBLY a. Remove the 2 screws and clock assembly with instrument cluster finish panel cover from the No. 1 center instrument cluster finish panel.

Fig. 7: Identifying Clock Assembly Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws and remove the clock assembly.

Fig. 8: Identifying Clock Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE CLOCK LENS a. Disengage the 5 claws and remove the clock lens.

Fig. 9: Identifying Clock Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL CLOCK LENS a. Engage the 5 claws to install the clock lens.

Fig. 10: Identifying Clock Lens Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CLOCK ASSEMBLY a. Engage the 4 claws to install the clock assembly. b. Install the clock assembly with instrument cluster finish panel cover to the No. 1 center instrument cluster finish panel with the 2 screws. 2. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30

2012-2017 ACCESSORIES & EQUIPMENT Mirror (Exterior) (Service Information) - Camry (Hybrid)

OUTER REAR VIEW MIRROR COMPONENTS ILLUSTRATION

Fig. 1: Identifying Outer Rear View Mirror Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Outer Rear View Mirror Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 5 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 6 4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 7 5. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 8 6. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 10 8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 12 9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY a. Disconnect the connector.

Fig. 3: Identifying Outer Rear View Mirror Assembly Connector, Bolts And Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts. c. Disengage the claw and remove the outer rear view mirror assembly. DISASSEMBLY DISASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1

2. 3. 4. 5.

REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 REMOVE OUTER MIRROR COVER (w/o Retract Mirror) See step 3 REMOVE OUTER MIRROR COVER (w/ Retract Mirror) See step 4 REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY (w/ Retract Mirror) . Refer to REMOVAL Step 3

INSPECTION INSPECTION

1. INSPECT OUTER REAR VIEW MIRROR ASSEMBLY RH a. Check the operation of the mirror surface (w/ Daytime Running Light). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 4: Identifying Mirror Surface Connector Terminal Identification RH (W/Daytime

Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -> Terminal 3 Turns (MV) upward Auxiliary battery negative (-) -> Terminal 4 (M+) Auxiliary battery positive (+) -> Terminal 4 (M+) Turns Auxiliary downward battery negative (-) -> Terminal 3 (MV) Auxiliary battery positive (+) -> Terminal 1 (MH) Turns left Auxiliary battery negative (-) -> Terminal 4 (M+) Auxiliary battery positive (+) -> Terminal 4 Turns right (M+) Auxiliary battery negative (-) --

> Terminal 1 (MH) TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. b. Check the operation of the mirror surface (w/o Daytime Running Light). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 5: Identifying Mirror Surface Connector Terminal Identification RH (W/O Daytime Running Lights) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -- Turns > Terminal 6 upward (MV) Auxiliary

battery negative (-) -> Terminal 5 (M+) Auxiliary battery positive (+) -> Terminal 5 (M+) Auxiliary battery negative (-) -> Terminal 6 (MV) Auxiliary battery positive (+) -> Terminal 4 (MH) Auxiliary battery negative (-) -> Terminal 5 (M+) Auxiliary battery positive (+) -> Terminal 5 (M+) Auxiliary battery negative (-) -> Terminal 4 (MH)

Turns downward

Turns left

Turns right

TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH.

c. Check the operation of the retractable mirror (w/o Daytime Running Light). NOTE:





Disconnect and reconnect the auxiliary battery between each mirror position check. The mirror position cannot be changed manually when the auxiliary battery is connected. To change the mirror position manually, the auxiliary battery must be disconnected first.

1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 6: Identifying Retractable Mirror Connector Terminal Identification RH (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. For each position: Disconnect the auxiliary battery, set the mirror position by hand, connect

the auxiliary battery, and check the retractable mirror's movement. OK Tester Specified Condition Connection Condition Auxiliary battery positive (+) Moves --> Terminal 3 from (A) Forward (MR) to position retracted Auxiliary (A) position battery (E) negative (-) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 Forward Does not (MF) position move Auxiliary (A) battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) Position --> between Moves Terminal 3 forward from (B) (MR) position to Auxiliary (A) and retracted battery driving position negative (-) position (E) --> (C) Terminal 9 (MF) Auxiliary battery positive (+) Position --> between Terminal 9 forward

Moves from (B)

(MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9 (MF)

position (A) and driving position (C)

to forward position (A)

Driving position (C)

Moves from (C) to retracted position (E)

Driving position (C)

Does not move

Position between driving position (C) and retracted position (E)

Moves from (D) to retracted position (E)

Auxiliary battery positive (+) Position --> between

Moves

Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR)

driving position (C) and retracted position (E)

from (D) to driving position (C)

Retracted Does not position move (E)

Moves Retracted from (E) position to driving (E) position (C)

TEXT IN ILLUSTRATION (A) *1 Forward Position *2 (B) (C) *3 Driving position *4 (D) (E) *5 Retracted Position Component

without harness connected (Outer *a Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. d. Check the operation of the mirror heater (w/ Mirror Heater and Daytime Running Light). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 7: Identifying Mirror Heater Connector Terminal Identification RH (W/Mirror Heater And Daytime Running Light)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 5 (-) F) ohms TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. 2. Connect the cable from the positive (+) terminal to terminal 2 and the negative auxiliary battery (-) terminal to terminal 5, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly RH. e. Check the operation of the mirror heater (w/ Mirror Heater and w/o Daytime Running Light). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 8: Identifying Mirror Heater Assembly Connector Terminal Identification RH (W/Mirror Heater And W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 8 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative auxiliary battery (-) terminal to terminal 8, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly RH. 2. INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH a. Check the operation of the mirror surface (w/ Daytime Running Light). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 9: Identifying Mirror Surface Connector Terminal Identification LH (W/Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Auxiliary battery positive (+) -- Turns > Terminal 3 upward (MV) Auxiliary

battery negative (-) -> Terminal 4 (M+) Auxiliary battery positive (+) -> Terminal 4 (M+) Auxiliary battery negative (-) -> Terminal 3 (MV) Auxiliary battery positive (+) -> Terminal 1 (MH) Auxiliary battery negative (-) -> Terminal 4 (M+) Auxiliary battery positive (+) -> Terminal 4 (M+) Auxiliary battery negative (-) -> Terminal 1 (MH)

Turns downward

Turns left

Turns right

TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH.

b. Check the operation of the mirror surface (w/o Daytime Running Light). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 10: Identifying Mirror Surface Connector Terminal Identification LH (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply auxiliary battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Auxiliary battery

positive (+) -> Terminal 6 (MV) Auxiliary battery negative (-) -> Terminal 5 (M+) Auxiliary battery positive (+) -> Terminal 5 (M+) Auxiliary battery negative (-) -> Terminal 6 (MV) Auxiliary battery positive (+) -> Terminal 4 (MH) Auxiliary battery negative (-) -> Terminal 5 (M+) Auxiliary battery positive (+) -> Terminal 5 (M+) Auxiliary battery negative (-) -> Terminal 4 (MH)

Turns upward

Turns downward

Turns left

Turns right

TEXT IN ILLUSTRATION Component without harness *a connected (Outer Rear View Mirror

Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. c. Check the operation of the retractable mirror (w/o Daytime Running Light). NOTE:





Disconnect and reconnect the auxiliary battery between each mirror position check. The mirror position cannot be changed manually when the auxiliary battery is connected. To change the mirror position manually, the auxiliary battery must be disconnected first.

1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 11: Identifying Retractable Mirror Connector Terminal Identification LH (W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. For each position: Disconnect the auxiliary battery, set the mirror position by hand, connect the auxiliary battery, and check the retractable mirror's movement. OK Tester Specified Condition Connection Condition Auxiliary battery positive (+) --> Moves Terminal 3 from (A) Forward (MR) to position Auxiliary retracted (A) battery position negative (-) (E) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 Forward Does not (MF) position move Auxiliary (A) battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) Position --> between Moves Terminal 3 forward from (B) (MR) position to Auxiliary (A) and retracted battery position driving negative (-) position (E) --> (C) Terminal 9 (MF)

Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9

Position between forward position (A) and driving position (C)

Moves from (B) to forward position (A)

Driving position (C)

Moves from (C) to retracted position (E)

Driving position (C)

Does not move

Position between driving position (C) and retracted position (E)

Moves from (D) to retracted position (E)

(MF) Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR) Auxiliary battery positive (+) --> Terminal 3 (MR) Auxiliary battery negative (-) --> Terminal 9 (MF) Auxiliary battery positive (+) --> Terminal 9 (MF) Auxiliary battery negative (-) --> Terminal 3 (MR)

Position between driving position (C) and retracted position (E)

Moves from (D) to driving position (C)

Retracted Does not position move (E)

Moves Retracted from (E) position to driving (E) position (C)

TEXT IN ILLUSTRATION (A) *1 Forward Position *2 (B) (C) *3 Driving position *4 (D)

(E) *5 Retracted Position Component without harness connected *a (Outer Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. d. Check the operation of the mirror heater (w/ Mirror Heater and Daytime Running Light). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 12: Identifying Mirror Heater Connector Terminal Identification LH (W/Mirror Heater And Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 5 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative auxiliary battery (-) terminal to terminal 5, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly LH. e. Check the operation of the mirror heater (w/ Mirror Heater and w/o Daytime Running Light). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 13: Identifying Mirror Heater Connector Terminal Identification LH (W/Mirror Heater And W/O Daytime Running Light) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 8 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative auxiliary battery (-) terminal to terminal 8, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly LH. REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY (w/ Retract Mirror) . Refer to INSTALLATION - Step 1 2. INSTALL OUTER MIRROR COVER (w/o Retract Mirror) See step 1 3. INSTALL OUTER MIRROR COVER (w/ Retract Mirror) See step 2 4. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 5. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY a. Engage the claw to temporarily install the outer rear view mirror assembly. b. Install the outer rear view mirror assembly with the 3 bolts. Torque: 11 N*m (107 kgf*cm, 8 ft.*lbf)

2. 3. 4. 5. 6. 7. 8. 9.

c. Connect the connector. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 37 INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 39 INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 41 INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 42 INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 43 INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 44 INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 45

OUTER REAR VIEW MIRROR GLASS COMPONENTS ILLUSTRATION

Fig. 14: Identifying Outer Rear View Mirror Glass Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) a. Apply protective tape to the areas shown in the illustration.

Fig. 15: Removing Outer Rear View Mirror Using Protective Tape (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Push the lower part of the mirror surface and tilt it. c. Using a moulding remover, disengage the 2 claws at the upper part of the outer rear view mirror as shown in the illustration.

Fig. 16: Identifying Moulding Remover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Moulding *1 Remover d. Disengage the 2 guides and remove the outer rear view mirror as shown in the illustration.

Fig. 17: Removing Outer Rear View Mirror Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. w/ Mirror Heater: 1. Disconnect the 2 connectors and remove the outer rear view mirror.

Fig. 18: Identifying Outer Rear View Mirror Connectors

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Mirror Heater and Blind Spot Monitor System: 1. Disconnect the 2 mirror heater connectors. 2. Disengage the 2 claws. 3. Using a screwdriver, release the tabs of the blind spot monitor indicator connector to disconnect the connector and remove the outer rear view mirror.

Fig. 19: Identifying Mirror Heater Connector And Blind Spot Monitor Indicator Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mirror *1 Heater Connector Blind Spot *2 Monitor Indicator Connector NOTE:





Do not bend the tabs excessively to prevent them from being damaged. If the tabs are damaged, replace the outer rear view mirror

with a new one. 2. REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) a. Apply protective tape to the areas shown in the illustration.

Fig. 20: Identifying Protective Tape (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Push the upper part of the mirror surface and tilt it. c. Using a moulding remover, disengage the 2 claws at the lower part of the outer rear view mirror as shown in the illustration.

Fig. 21: Identifying Moulding Remover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Moulding *1 Remover d. Disengage the 2 guides as shown in the illustration.

Fig. 22: Identifying Lower Part Of Outer Rear View Mirror Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the 2 connectors and remove the outer rear view mirror.

Fig. 23: Identifying Outer Rear View Mirror Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT OUTER REAR VIEW MIRROR RH a. Check the outer mirror heater operation (w/ Blind Spot Monitor System).

Fig. 24: Measuring Resistance Of Outer Mirror Heater (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition

1-2

25°C (77° 7.6 to 11.4 F) ohms

If the result is not as specified, replace the outer rear view mirror RH. b. Check the outer mirror heater operation (w/o Blind Spot Monitor System).

Fig. 25: Measuring Resistance Of Outer Mirror Heater (W/O Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition

1-2

25°C (77° 7.6 to 11.4 F) ohms

If the result is not as specified, replace the outer rear view mirror RH. c. Check the outer rear view mirror indicator RH operation (w/ Blind Spot Monitor System).

Fig. 26: Identifying Outer Rear View Mirror Component Without Harness Connected RH (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the auxiliary battery to terminal 1 (+) and a negative (-) lead to terminal 2 (-). 2. Check that the outer rear view mirror indicator comes on. OK

Outer rear view mirror indicator comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Outer rear view mirror RH) If the result is not as specified, replace the outer rear view mirror RH. 2. INSPECT OUTER REAR VIEW MIRROR LH a. Check the outer mirror heater operation (w/ Blind Spot Monitor System).

Fig. 27: Measuring Outer Mirror Heater Resistance (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (77° 7.6 to 11.4 1-2 F) ohms If the result is not as specified, replace the outer rear view mirror LH. b. Check the outer mirror heater operation (w/o Blind Spot Monitor System).

Fig. 28: Measuring Outer Mirror Heater Resistance (W/O Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (77° 7.6 to 11.4 1-2 F) ohms If the result is not as specified, replace the outer rear view mirror LH. c. Check the outer rear view mirror indicator LH operation.

Fig. 29: Identifying Outer Rear View Mirror Component With Harness Connected LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the auxiliary battery to terminal 1 (+) and a negative (-) lead to terminal 2 (-). 2. Check that the outer rear view mirror indicator comes on. OK Outer rear view mirror indicator comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Outer rear view mirror LH) If the result is not as specified, replace the outer rear view mirror LH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) a. w/ Mirror Heater: 1. Connect the 2 connectors. b. w/ Mirror Heater and Blind Spot Monitor System: 1. Connect the 3 connectors. 2. Engage the 2 claws. c. Engage the 2 guides on the lower part of the outer mirror to the outer rear view mirror.

Fig. 30: Identifying Lower Part Of Outer Rear View Mirror Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the 2 claws on the upper part of the outer mirror to the outer rear view mirror.

Fig. 31: Identifying Upper Part Of Outer Rear View Mirror Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) a. Connect the 2 connectors. b. Engage the 2 guides on the upper part of the outer mirror to the outer rear view mirror.

Fig. 32: Identifying Upper Part Of Outer Rear View Mirror Guides (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 2 claws on the lower part of the outer mirror to the outer rear view mirror.

Fig. 33: Identifying Lower Part Of Outer Rear View Mirror Claws (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OUTER REAR VIEW MIRROR COVER COMPONENTS ILLUSTRATION

Fig. 34: Identifying Outer Rear View Mirror Cover Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 2. REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 3. REMOVE OUTER MIRROR COVER (w/o Retract Mirror) a. Disengage the 8 claws and remove the outer mirror cover.

Fig. 35: Identifying Outer Mirror Cover Claws (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE OUTER MIRROR COVER (w/ Retract Mirror) a. Remove the 3 screws.

Fig. 36: Identifying Outer Mirror Cover Screws (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp.

Fig. 37: Identifying Outer Mirror Cover Clamp (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the 2 connectors and remove the mirror actuator. d. Disengage the 7 claws and remove the outer mirror cover.

Fig. 38: Identifying Outer Mirror Cover Claws (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER MIRROR COVER (w/o Retract Mirror)

a. Engage the 8 claws to install the outer mirror cover. 2. INSTALL OUTER MIRROR COVER (w/ Retract Mirror) a. Engage the 7 claws to install the outer mirror cover. b. Connect the 2 connectors. c. Engage the clamp. d. Install the mirror actuator with the 3 screws. Torque: 1.1 N*m (11 kgf*cm, 10 in.*lbf) 3. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 4. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2

OUTER MIRROR SWITCH COMPONENTS ILLUSTRATION

Fig. 39: Identifying Outer Mirror Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 6 2. REMOVE OUTER MIRROR SWITCH ASSEMBLY a. Disengage the 4 claws and remove the outer mirror switch assembly.

Fig. 40: Identifying Outer Mirror Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT OUTER MIRROR SWITCH ASSEMBLY a. w/o Retract mirror 1. Check the mirror select switch and mirror surface adjust switch. 2. Turn the mirror select switch to the L position.

Fig. 41: Identifying Mirror Select Switch And Mirror Surface Adjust Switch (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Mirror *1 select switch Mirror surface *2 adjust switch Component without harness connected *a (Outer Mirror Switch Assembly) Standard Resistance (for left side) Tester Switch Specified Connection Condition Condition Below 1 4 (MLV) - UP ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 4 (MLV) - DOWN Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher Below 1 5 (MLH) - LEFT ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 5 (MLH) - RIGHT Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher 4. Turn the mirror select switch to the R position. 5. Measure the resistance according to the value(s) in the table below. Standard Resistance (for right side) Tester Switch Specified Connection Condition Condition

3 (MRV) 8 (B) 6 (M+) - 7 (E) 3 (MRV) 7 (E) 6 (M+) - 8 (B) 2 (MRH) 8 (B) 6 (M+) - 7 (E) 2 (MRH) 7 (E) 6 (M+) - 8 (B)

UP OFF DOWN OFF LEFT OFF RIGHT OFF

Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher

If the result is not as specified, replace the outer mirror switch assembly. b. w/ Retract mirror 1. Check the mirror select switch and mirror surface adjust switch. 2. Turn the mirror select switch to the L position.

Fig. 42: Identifying Mirror Select Switch And Mirror Surface Adjust Switch (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Mirror *1 select switch Mirror surface *2 adjust switch Component without harness connected *a (Outer Mirror Switch Assembly) Standard Resistance (for left side) Tester Switch Specified Connection Condition Condition Below 1 4 (MLV) - UP ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 4 (MLV) - DOWN Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher Below 1 5 (MLH) - LEFT ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 5 (MLH) - RIGHT Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher 4. Turn the mirror select switch to the R position. 5. Measure the resistance according to the value(s) in the table below. Standard Resistance (for right side) Tester Switch Specified Connection Condition Condition

3 (MRV) 8 (B) 6 (M+) - 7 (E) 3 (MRV) 7 (E) 6 (M+) - 8 (B) 2 (MRH) 8 (B) 6 (M+) - 7 (E) 2 (MRH) 7 (E) 6 (M+) - 8 (B)

UP OFF DOWN OFF LEFT OFF RIGHT OFF

Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher

If the result is not as specified, replace the outer mirror switch assembly. c. Check the mirror retract switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 43: Identifying Retract Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mirror

retract switch Component without harness connected *a (Outer Mirror Switch Assembly)

*1

Standard Resistance Tester Switch Specified Connection Condition Condition 10 (MF) - 7 Mirror Below 1 retract (E) ohms switch 9 (MR) - 8 retract Below 1 (B) position ohms 10 (MF) - 8 Mirror retract (B) switch 9 (MR) - 7 return (E) position

Below 1 ohms Below 1 ohms

If the result is not as specified, replace the outer mirror switch assembly. INSTALLATION INSTALLATION

1. INSTALL OUTER MIRROR SWITCH ASSEMBLY a. Engage the 4 claws and install the outer mirror switch assembly. 2. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 42

2012-2017 ACCESSORIES & EQUIPMENT Mirror (Exterior) (Service Information) - Camry (Except Hybrid)

OUTER REAR VIEW MIRROR COMPONENTS ILLUSTRATION

Fig. 1: Identifying Outer Rear View Mirror Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Outer Rear View Mirror Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 4 3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 5 4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 6 5. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 7 6. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 9 8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to DISASSEMBLY - Step 11 9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY a. Disconnect the connector.

Fig. 3: Identifying Outer Rear View Mirror Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts. c. Disengage the claw and remove the outer rear view mirror assembly. DISASSEMBLY DISASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1

2. 3. 4. 5.

REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 REMOVE OUTER MIRROR COVER (w/o Retract Mirror) See step 3 REMOVE OUTER MIRROR COVER (w/ Retract Mirror) See step 4 REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY (w/ Retract Mirror) . Refer to REMOVAL Step 3

INSPECTION INSPECTION

1. INSPECT OUTER REAR VIEW MIRROR ASSEMBLY RH a. Check the operation of the mirror surface (w/ Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 4: Identifying Mirror Surface (W/Daytime Running Light Control) RH

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal 3 Turns (MV) Battery upward negative (-) -> Terminal 4 (M+) Battery positive (+) -> Terminal 4 (M+) Turns downward Battery negative (-) -> Terminal 3 (MV) Battery positive (+) -> Terminal 1 (MH) Turns left Battery negative (-) -> Terminal 4 (M+) Battery positive (+) -> Terminal 4 (M+) Turns Battery right negative (-) -> Terminal 1 (MH) TEXT IN ILLUSTRATION Component without *a harness connected (Outer

Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. b. Check the operation of the mirror surface (w/o Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 5: Identifying Mirror Surface (W/O Daytime Running Light Control) RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage and check the operation of the mirror. OK

Measurement Specified Condition Condition Battery positive (+) -> Terminal 6 (MV) Turns Battery upward negative (-) -> Terminal 5 (M+) Battery positive (+) -> Terminal 5 Turns (M+) downward Battery negative (-) -> Terminal 6 (MV) Battery positive (+) -> Terminal 4 (MH) Turns left Battery negative (-) -> Terminal 5 (M+) Battery positive (+) -> Terminal 5 (M+) Turns Battery right negative (-) -> Terminal 4 (MH) TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH.

c. Check the operation of the retractable mirror (w/o Daytime Running Light Control). NOTE:





Disconnect and reconnect the battery between each mirror position check. The mirror position cannot be changed manually when the battery is connected. To change the mirror position manually, the battery must be disconnected first.

1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 6: Identifying Retractable Mirror (W/O Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. For each position: Disconnect the battery, set the mirror position by hand, connect the battery, and check the retractable mirror's movement.

OK Tester Specified Condition Connection Condition Battery positive (+) --> Moves Terminal 3 from (A) Forward (MR) to position Battery retracted (A) negative (-) position --> (E) Terminal 9 (MF) Battery positive (+) --> Terminal 9 Forward (MF) Does not position Battery move (A) negative (-) --> Terminal 3 (MR) Battery positive (+) Position between Moves --> Terminal 3 forward from (B) position to (MR) (A) and retracted Battery position negative (-) driving position (E) --> Terminal 9 (C) (MF) Battery positive (+) Position --> between Moves Terminal 9 forward from (B) (MF) position to forward Battery (A) and position negative (-) driving (A) --> position Terminal 3 (C) (MR) Battery positive (+) -->

Moves

Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR) Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR) Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF)

Driving position (C)

from (C) to retracted position (E)

Driving position (C)

Does not move

Position between driving position (C) and retracted position (E)

Moves from (D) to retracted position (E)

Position between driving position (C) and retracted position (E)

Moves from (D) to driving position (C)

Retracted Does not position move (E)

Battery positive (+) --> Moves Terminal 9 Retracted from (E) (MF) position to driving Battery position (E) negative (-) (C) --> Terminal 3 (MR) TEXT IN ILLUSTRATION (A) *1 Forward Position *2 (B) (C) *3 Driving position *4 (D) (E) *5 Retracted Position Component without harness connected *a (Outer Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. d. Check the operation of the mirror heater (w/ Mirror Heater and Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 7: Identifying Mirror Heater (W/Mirror Heater And Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 5 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. 2. Connect the cable from the positive (+) terminal to terminal 2 and the negative battery (-) terminal to terminal 5, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly RH. e. Check the operation of the mirror heater (w/ Mirror Heater and w/o Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly RH connector.

Fig. 8: Identifying Mirror Heater (W/Mirror Heater And W/O Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 8 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly RH) If the result is not as specified, replace the outer rear view mirror assembly RH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative battery (-) terminal to terminal 8, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly RH. 2. INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH a. Check the operation of the mirror surface (w/ Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 9: Applying Voltage To Mirror Surface (W/Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal 3 Turns (MV) upward Battery negative (-) -> Terminal 4

(M+) Battery positive (+) -> Terminal 4 (M+) Battery negative (-) -> Terminal 3 (MV) Battery positive (+) -> Terminal 1 (MH) Battery negative (-) -> Terminal 4 (M+) Battery positive (+) -> Terminal 4 (M+) Battery negative (-) -> Terminal 1 (MH)

Turns downward

Turns left

Turns right

TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. b. Check the operation of the mirror surface (w/o Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 10: Identifying Mirror Surface Connector Terminal Identification LH (W/O Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery voltage and check the operation of the mirror. OK Measurement Specified Condition Condition Battery positive (+) -> Terminal 6 Turns upward (MV) Battery negative (-) --

> Terminal 5 (M+) Battery positive (+) -> Terminal 5 (M+) Battery negative (-) -> Terminal 6 (MV) Battery positive (+) -> Terminal 4 (MH) Battery negative (-) -> Terminal 5 (M+) Battery positive (+) -> Terminal 5 (M+) Battery negative (-) -> Terminal 4 (MH)

Turns downward

Turns left

Turns right

TEXT IN ILLUSTRATION Component without harness connected *a (Outer Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. c. Check the operation of the retractable mirror (w/o Daytime Running Light Control). NOTE:





Disconnect and reconnect the battery between each mirror position check. The mirror position cannot be changed manually when the battery is connected. To change the mirror position manually,

the battery must be disconnected first. 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 11: Identifying Retractable Mirror Connector Terminal Identification LH (W/O Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. For each position: Disconnect the battery, set the mirror position by hand, connect the battery, and check the retractable mirror's movement. OK Tester Specified Condition Connection Condition

Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR) Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR)

Forward position (A)

Moves from (A) to retracted position (E)

Forward position (A)

Does not move

Position between forward position (A) and driving position (C)

Moves from (B) to retracted position (E)

Position between forward position (A) and driving position (C)

Moves from (B) to forward position (A)

Battery positive (+) Driving --> Terminal 3 position (C) (MR) Battery negative (-)

Moves from (C) to retracted position

--> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR) Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF) Battery positive (+) --> Terminal 9 (MF) Battery negative (-) --> Terminal 3 (MR) Battery positive (+) --> Terminal 3 (MR) Battery negative (-) --> Terminal 9 (MF)

(E)

Driving position (C)

Does not move

Position between driving position (C) and retracted position (E)

Moves from (D) to retracted position (E)

Position between driving position (C) and retracted position (E)

Moves from (D) to driving position (C)

Retracted Does not position move (E)

Battery positive (+) --> Moves Terminal 9 Retracted from (E)

(MF) position Battery (E) negative (-) --> Terminal 3 (MR)

to driving position (C)

TEXT IN ILLUSTRATION (A) *1 Forward Position *2 (B) (C) *3 Driving position *4 (D) (E) *5 Retracted Position Component without harness connected *a (Outer Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. d. Check the operation of the mirror heater (w/ Mirror Heater and Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 12: Identifying Mirror Heater Connector Terminal Identification LH (W/Mirror Heater And Daytime Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 5 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative battery (-) terminal to terminal 5, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly LH. e. Check the operation of the mirror heater (w/ Mirror Heater and w/o Daytime Running Light Control). 1. Disconnect the outer rear view mirror assembly LH connector.

Fig. 13: Identifying Mirror Heater Connector Terminal Identification LH (W/Mirror Heater And W/O Daytime Running Light Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (75° 7.6 to 11.4 2 (+) - 8 (-) F) ohms TEXT IN ILLUSTRATION Component

without harness connected (Outer *a Rear View Mirror Assembly LH) If the result is not as specified, replace the outer rear view mirror assembly LH. 3. Connect the cable from the positive (+) terminal to terminal 2 and the negative battery (-) terminal to terminal 8, then check that the mirror becomes warm. HINT: It takes a short time for the mirror to become warm. OK Mirror becomes warm. If the result is not as specified, replace the outer rear view mirror assembly LH. REASSEMBLY REASSEMBLY

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY (w/ Retract Mirror) . Refer to INSTALLATION - Step 1 2. INSTALL OUTER MIRROR COVER (w/o Retract Mirror) See step 1 3. INSTALL OUTER MIRROR COVER (w/ Retract Mirror) See step 2 4. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 5. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY a. Engage the claw to temporarily install the outer rear view mirror assembly. b. Install the outer rear view mirror assembly with the 3 bolts. Torque: 11 N*m (107 kgf*cm, 8 ft.*lbf)

2. 3. 4. 5. 6. 7. 8. 9.

c. Connect the connector. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP . Refer to REASSEMBLY - Step 38 INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 40 INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 42 INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 43 INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 44 INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 45 INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 46

OUTER REAR VIEW MIRROR GLASS COMPONENTS ILLUSTRATION

Fig. 14: Identifying Outer Rear View Mirror Glass Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) a. Apply protective tape to the areas shown in the illustration.

Fig. 15: Identifying Outer Rear View Mirror Protective Tape (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Push the lower part of the mirror surface and tilt it. c. Using a moulding remover, disengage the 2 claws at the upper part of the outer rear view mirror as shown in the illustration.

Fig. 16: Identifying Moulding Remover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Moulding *1 Remover d. Disengage the 2 guides and remove the outer rear view mirror as shown in the illustration.

Fig. 17: Removing Outer Rear View Mirror Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. w/ Mirror Heater: 1. Disconnect the 2 connectors and remove the outer rear view mirror.

Fig. 18: Identifying Outer Rear View Mirror Connectors (W/Mirror Heater)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. w/ Mirror Heater and Blind Spot Monitor System: 1. Disconnect the 2 mirror heater connectors. 2. Disengage the 2 claws. 3. Using a screwdriver, release the tabs of the blind spot monitor indicator connector to disconnect the connector and remove the outer rear view mirror.

Fig. 19: Identifying Blind Spot Monitor Indicator Connectors (W/Mirror Heater And Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mirror *1 Heater Connector Blind Spot *2 Monitor Indicator Connector NOTE:





Do not bend the tabs excessively to prevent them from being damaged. If the tabs are damaged, replace the outer rear view mirror

with a new one. 2. REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) a. Apply protective tape to the areas shown in the illustration.

Fig. 20: Identifying Protective Tape (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Push the upper part of the mirror surface and tilt it. c. Using a moulding remover, disengage the 2 claws at the lower part of the outer rear view mirror as shown in the illustration.

Fig. 21: Identifying Moulding Remover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Moulding *1 Remover d. Disengage the 2 guides as shown in the illustration.

Fig. 22: Identifying Outer Rear View Mirror Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the 2 connectors and remove the outer rear view mirror.

Fig. 23: Identifying Outer Rear View Mirror Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT OUTER REAR VIEW MIRROR RH a. Check the outer mirror heater operation (w/ Blind Spot Monitor System).

Fig. 24: Measuring Resistance Of Outer Mirror Heater (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition

1-2

25°C (77° 7.6 to 11.4 F) ohms

If the result is not as specified, replace the outer rear view mirror RH. b. Check the outer mirror heater operation (w/o Blind Spot Monitor System).

Fig. 25: Identifying Mirror Heater Operation (W/O Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition

1-2

25°C (77° 7.6 to 11.4 F) ohms

If the result is not as specified, replace the outer rear view mirror RH. c. Check the outer rear view mirror indicator RH operation (w/ Blind Spot Monitor System).

Fig. 26: Identifying Outer Rear View Mirror Indicator Operation RH (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the battery to terminal 1 (+) and a negative (-) lead to terminal 2 (-). 2. Check that the outer rear view mirror indicator comes on. OK

Outer rear view mirror indicator comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Outer rear view mirror RH) If the result is not as specified, replace the outer rear view mirror RH. 2. INSPECT OUTER REAR VIEW MIRROR LH a. Check the outer mirror heater operation (w/ Blind Spot Monitor System).

Fig. 27: Measuring Outer Mirror Heater Resistance (W/Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (77° 7.6 to 11.4 1-2 F) ohms If the result is not as specified, replace the outer rear view mirror LH. b. Check the outer mirror heater operation (w/o Blind Spot Monitor System).

Fig. 28: Identifying Outer Mirror Heater Operation (W/O Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance according the value(s) in the table below. Standard Resistance Tester Specified Condition Connection Condition 25°C (77° 7.6 to 11.4 1-2 F) ohms If the result is not as specified, replace the outer rear view mirror LH. c. Check the outer rear view mirror indicator LH operation.

Fig. 29: Identifying Outer Rear View Mirror Component LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect a positive (+) lead from the battery to terminal 1 (+) and a negative (-) lead to terminal 2 (-). 2. Check that the outer rear view mirror indicator comes on. OK Outer rear view mirror indicator comes on. TEXT IN ILLUSTRATION Component without harness *a connected (Outer rear view mirror LH) If the result is not as specified, replace the outer rear view mirror LH. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) a. w/ Mirror Heater: 1. Connect the 2 connectors. b. w/ Mirror Heater and Blind Spot Monitor System: 1. Connect the 3 connectors. 2. Engage the 2 claws. c. Engage the 2 guides on the lower part of the outer mirror to the outer rear view mirror.

Fig. 30: Identifying Outer Rear View Mirror Guides (W/Mirror Heater And Blind Spot Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Engage the 2 claws on the upper part of the outer mirror to the outer rear view mirror.

Fig. 31: Identifying Outer Rear View Mirror Claws (W/Mirror Heater And Blind Spot

Monitor System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) a. Connect the 2 connectors. b. Engage the 2 guides on the upper part of the outer mirror to the outer rear view mirror.

Fig. 32: Identifying Outer Rear View Mirror Guides (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 2 claws on the lower part of the outer mirror to the outer rear view mirror.

Fig. 33: Identifying Outer Rear View Mirror Claws (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OUTER REAR VIEW MIRROR COVER COMPONENTS ILLUSTRATION

Fig. 34: Identifying Outer Rear View Mirror Cover Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. REMOVE OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 2. REMOVE OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2 3. REMOVE OUTER MIRROR COVER (w/o Retract Mirror) a. Disengage the 8 claws and remove the outer mirror cover.

Fig. 35: Identifying Outer Mirror Cover Claws (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE OUTER MIRROR COVER (w/ Retract Mirror) a. Remove the 3 screws.

Fig. 36: Identifying Outer Mirror Cover (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp.

Fig. 37: Identifying Outer Mirror Cover Clamp (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disconnect the 2 connectors and remove the mirror actuator. d. Disengage the 7 claws and remove the outer mirror cover.

Fig. 38: Identifying Outer Mirror Cover Claws And Connectors (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:  

Use the same procedure for both the RH and LH sides. The procedure described below is for the LH side.

1. INSTALL OUTER MIRROR COVER (w/o Retract Mirror)

a. Engage the 8 claws to install the outer mirror cover. 2. INSTALL OUTER MIRROR COVER (w/ Retract Mirror) a. Engage the 7 claws to install the outer mirror cover. b. Connect the 2 connectors. c. Engage the clamp. d. Install the mirror actuator with the 3 screws. Torque: 1.1 N*m (11 kgf*cm, 10 in.*lbf) 3. INSTALL OUTER REAR VIEW MIRROR (w/o Retract Mirror) See step 1 4. INSTALL OUTER REAR VIEW MIRROR (w/ Retract Mirror) See step 2

OUTER MIRROR SWITCH COMPONENTS ILLUSTRATION

Fig. 39: Identifying Outer Mirror Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL . Refer to DISASSEMBLY - Step 5 2. REMOVE OUTER MIRROR SWITCH ASSEMBLY a. Disengage the 4 claws and remove the outer mirror switch assembly.

Fig. 40: Identifying Outer Mirror Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT OUTER MIRROR SWITCH ASSEMBLY a. w/o Retract mirror 1. Check the mirror select switch and mirror surface adjust switch. 2. Turn the mirror select switch to the L position.

Fig. 41: Identifying Mirror Select Switch And Mirror Surface Adjust Switch (W/O Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Mirror *1 select switch Mirror surface *2 adjust switch Component without harness connected *a (Outer Mirror Switch Assembly) Standard Resistance (for left side) Tester Switch Specified Connection Condition Condition Below 1 4 (MLV) - UP ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 4 (MLV) - DOWN Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher Below 1 5 (MLH) - LEFT ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 5 (MLH) - RIGHT Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher 4. Turn the mirror select switch to the R position. 5. Measure the resistance according to the value(s) in the table below. Standard Resistance (for right side) Tester Switch Specified Connection Condition Condition

3 (MRV) 8 (B) 6 (M+) - 7 (E) 3 (MRV) 7 (E) 6 (M+) - 8 (B) 2 (MRH) 8 (B) 6 (M+) - 7 (E) 2 (MRH) 7 (E) 6 (M+) - 8 (B)

UP OFF DOWN OFF LEFT OFF RIGHT OFF

Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher

If the result is not as specified, replace the outer mirror switch assembly. b. w/ Retract mirror 1. Check the mirror select switch and mirror surface adjust switch. 2. Turn the mirror select switch to the L position.

Fig. 42: Identifying Mirror Select Switch And Mirror Surface Adjust Switch (W/Retract Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Mirror *1 select switch Mirror surface *2 adjust switch Component without harness connected *a (Outer Mirror Switch Assembly) Standard Resistance (for left side) Tester Switch Specified Connection Condition Condition Below 1 4 (MLV) - UP ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 4 (MLV) - DOWN Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher Below 1 5 (MLH) - LEFT ohms 8 (B) 6 (M+) - 7 10 kohms OFF (E) or higher 5 (MLH) - RIGHT Below 1 ohms 7 (E) 6 (M+) - 8 10 kohms OFF (B) or higher 4. Turn the mirror select switch to the R position. 5. Measure the resistance according to the value(s) in the table below. Standard Resistance (for right side) Tester Switch Specified Connection Condition Condition

3 (MRV) 8 (B) 6 (M+) - 7 (E) 3 (MRV) 7 (E) 6 (M+) - 8 (B) 2 (MRH) 8 (B) 6 (M+) - 7 (E) 2 (MRH) 7 (E) 6 (M+) - 8 (B)

UP OFF DOWN OFF LEFT OFF RIGHT OFF

Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher Below 1 ohms 10 kohms or higher

If the result is not as specified, replace the outer mirror switch assembly. c. Check the mirror retract switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 43: Identifying Retract Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Mirror

retract switch Component without harness connected *a (Outer Mirror Switch Assembly)

*1

Standard Resistance Tester Switch Specified Connection Condition Condition 10 (MF) - 7 Mirror Below 1 retract (E) ohms switch 9 (MR) - 8 retract Below 1 (B) position ohms 10 (MF) - 8 Mirror retract (B) switch 9 (MR) - 7 return (E) position

Below 1 ohms Below 1 ohms

If the result is not as specified, replace the outer mirror switch assembly. INSTALLATION INSTALLATION

1. INSTALL OUTER MIRROR SWITCH ASSEMBLY a. Engage the 4 claws and install the outer mirror switch assembly. 2. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL . Refer to REASSEMBLY - Step 43

2012-2017 ACCESSORIES & EQUIPMENT Mirrors (Interior) (Service Information) (Hybrid)

INNER REAR VIEW MIRROR PRECAUTION PRECAUTION

1. PRECAUTION FOR DISCONNECTING CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable from the negative (-) auxiliary battery terminal, initialize the following system after the cable is reconnected. System See Procedure Name Parking Assist Refer to Monitor INITIALIZATION System

COMPONENTS ILLUSTRATION

Fig. 1: Identifying Inner Rear View Mirror Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Identifying Inner Rear View Mirror System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CALIBRATION CALIBRATION

1. SELECT COMPASS DISPLAY MODE a. The AUTO switch allows selection of the compass display.

Fig. 3: Identifying Compass Display And AUTO Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *1 Display AUTO *2 Switch 2. SET ZONE a. The compass indicates the direction that the vehicle is heading by detecting the direction and strength of the earth's magnetic field (magnetic north). However, there is a difference between magnetic north and actual north depending on the location of the vehicle. To compensate for this difference, it is necessary to set the zone in which the vehicle will be used (refer to Compass Zone Map). The zone setting can be changed using the AUTO switch of the inner mirror. 3. PERFORM CALIBRATION a. Because each vehicle has its own magnetic field, calibration should be performed. The calibration function is used to compensate for the residual magnetism of the vehicle. 4. WHEN COMPASS IS MAGNETIZED

a. The compass or vehicle may become magnetized while the vehicle is being shipped. As a result, it is necessary to perform calibration for the compass before the vehicle is delivered to the customer. If calibration cannot be performed successfully (calibration cannot be completed in spite of driving around several times), it may be caused by excessive magnetization of the vehicle. Demagnetize the vehicle using a demagnetizer and perform calibration again. 5. SET COMPASS

Fig. 4: Compass Calibration Flow Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. ZONE SETTING MODE a. When the compass is in normal mode, pressing the AUTO switch for 6 seconds will activate zone setting mode. A number from 1 to 15 will be displayed on the compass display. HINT: If the initial zone setting has not been changed, 8 will be displayed. b. The displayed number increases by 1 every time the AUTO switch is pressed. Referring to the compass zone map, check the number for the area where the vehicle will be used and set the zone number.

c. Do not touch the AUTO switch for several seconds after setting the zone. Check that the compass display shows a direction (N, NE, E, SE, S, SW, W or NW). 7. CALIBRATION MODE a. When the compass is in normal mode, pressing the AUTO switch for 12 seconds will activate calibration mode. b. Drive the vehicle in a circle at a speed of 8 km/h (5 mph) or less.

Fig. 5: Identifying Calibration Mode Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. After driving around in a circle 1 to 3 times, the direction (N, NE, E, SE, S, SW, W or NW) will be displayed on the compass display. This indicates that calibration has finished.

HINT: After calibration is performed, it is not necessary to repeat the calibration procedure unless the magnetic field of the vehicle changes drastically. If the magnetic field changes drastically, the compass display will indicate "C".

Fig. 6: Identifying Compass Zone Map (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *a Zone -Map

Fig. 7: Identifying Compass Zone Map (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *a Zone -Map PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: 

Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed.

Replace parts as necessary. AUTOMATIC GLARE-RESISTANT EC MIRROR Symptom Suspected Area ECU-IG1 No. 2 fuse Auto glare-resistant EC Inner rear view mirror mirror does not operate Wire harness or connector

See Refer to INSPECTION -

REMOVAL REMOVAL

1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) a. Using a T20 "TORX" socket wrench, remove the screw.

Fig. 8: Identifying Inner Rear View Mirror Assembly Screw (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration to remove it.

Fig. 9: Sliding Inner Rear View Mirror Assembly (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) a. Disengage the 2 claws and slide the inner rear view mirror stay holder cover in the direction indicated by the arrow shown in the illustration.

Fig. 10: Identifying Inner Rear View Mirror Stay Holder Cover Claws (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 6 claws and remove the inner rear view mirror stay holder cover.

Fig. 11: Identifying Inner Rear View Mirror Stay Holder Cover Claws (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) a. Disconnect the connector.

Fig. 12: Identifying Inner Rear View Mirror Assembly Connector (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T20 "TORX" socket wrench, remove the screw and inner rear view mirror assembly. INSPECTION INSPECTION

1. INSPECT INNER REAR VIEW MIRROR ASSEMBLY a. Inspect the operation of the electrochromic inner mirror.

Fig. 13: Inspecting Operation Of Electrochromic Inner Mirror Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Black Forward *1 *2 Colored Sensor Tape *3 Bright *4 Dark Auxiliary *5 - Battery Component without harness connected *a - (Inner Rear View Mirror Assembly) 1. Connect a positive (+) lead from the auxiliary battery to terminal 4 and a negative (-) lead to terminal 1. 2. Press the AUTO switch. 3. Attach black colored tape to the forward sensor to prevent it from sensing. 4. Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. Standard Mirror surface changes from bright to dark.

If the result is not as specified, replace the inner rear view mirror assembly. INSTALLATION INSTALLATION

1. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) a. Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration.

Fig. 14: Sliding Inner Rear View Mirror Assembly (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T20 "TORX" socket wrench, install the inner rear view mirror assembly with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 2. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) a. Using a T20 "TORX" socket wrench, install the inner rear view mirror assembly with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) b. Connect the connector. 3. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) a. Engage the 6 claws and temporarily install the inner rear view mirror stay holder cover. b. Slide the inner rear view mirror stay holder cover in the direction indicated by arrow shown in the

illustration and engage the 2 claws to install the cover.

Fig. 15: Sliding Inner Rear View Mirror Stay Holder Cover (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2012-2017 ACCESSORIES & EQUIPMENT Mirrors (Interior) (Service Information) - Camry (Except Hybrid)

INNER REAR VIEW MIRROR PRECAUTION PRECAUTION

1. PRECAUTION FOR DISCONNECTING CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected.

System See Procedure Name Parking Assist Refer to Monitor INITIALIZATION System 2. IGNITION SWITCH EXPRESSIONS a. The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this service information. Ignition Engine Expression Switch Switch (Position) (Condition) Ignition LOCK Off Switch off Ignition Switch ACC On (ACC) ACC Ignition ON On (IG) Switch ON Engine START Start Start COMPONENTS ILLUSTRATION

Fig. 1: Identifying Inner Rear View Mirror Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM DIAGRAM SYSTEM DIAGRAM

Fig. 2: Identifying Inner Rear View Mirror System Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CALIBRATION CALIBRATION

1. SELECT COMPASS DISPLAY MODE a. The AUTO switch allows selection of the compass display.

Fig. 3: Identifying Compass Display And AUTO Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *1 Display AUTO *2 Switch 2. SET ZONE a. The compass indicates the direction that the vehicle is heading by detecting the direction and strength of the earth's magnetic field (magnetic north). However, there is a difference between magnetic north and actual north depending on the location of the vehicle. To compensate for this difference, it is necessary to set the zone in which the vehicle will be used (refer to Compass Zone Map in Fig. 6). The zone setting can be changed using the AUTO switch of the inner mirror. 3. PERFORM CALIBRATION a. Because each vehicle has its own magnetic field, calibration should be performed. The calibration function is used to compensate for the residual magnetism of the vehicle. 4. WHEN COMPASS IS MAGNETIZED

a. The compass or vehicle may become magnetized while the vehicle is being shipped. As a result, it is necessary to perform calibration for the compass before the vehicle is delivered to the customer. If calibration cannot be performed successfully (calibration cannot be completed in spite of driving around several times), it may be caused by excessive magnetization of the vehicle. Demagnetize the vehicle using a demagnetizer and perform calibration again. 5. SET COMPASS

Fig. 4: Set Compass Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. ZONE SETTING MODE a. When the compass is in normal mode, pressing the AUTO switch for 6 seconds will activate zone setting mode. A number from 1 to 15 will be displayed on the compass display. HINT: If the initial zone setting has not been changed, 8 will be displayed. b. The displayed number increases by 1 every time the AUTO switch is pressed. Referring to the compass zone map, check the number for the area where the vehicle will be used and set the zone number.

c. Do not touch the AUTO switch for several seconds after setting the zone. Check that the compass display shows a direction (N, NE, E, SE, S, SW, W or NW). 7. CALIBRATION MODE a. When the compass is in normal mode, pressing the AUTO switch for 12 seconds will activate calibration mode. b. Drive the vehicle in a circle at a speed of 8 km/h (5 mph) or less.

Fig. 5: Identifying Calibration Mode Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. After driving around in a circle 1 to 3 times, the direction (N, NE, E, SE, S, SW, W or NW) will be displayed on the compass display. This indicates that calibration has finished.

HINT: After calibration is performed, it is not necessary to repeat the calibration procedure unless the magnetic field of the vehicle changes drastically. If the magnetic field changes drastically, the compass display will indicate "C".

Fig. 6: Identifying Compass Zone Map (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *a Zone -Map

Fig. 7: Identifying Compass Zone Map (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Compass *a Zone -Map PROBLEM SYMPTOMS TABLE PROBLEM SYMPTOMS TABLE

HINT: 

Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed.

Replace parts as necessary. AUTOMATIC GLARE-RESISTANT EC MIRROR Symptom Suspected Area ECU-IG1 No. 2 fuse Auto glare-resistant EC Inner rear view mirror mirror does not operate Wire harness or connector

See Refer to INSPECTION -

REMOVAL REMOVAL

1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) a. Using a T20 "TORX" socket wrench, remove the screw.

Fig. 8: Identifying Inner Rear View Mirror Assembly Screw (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration to remove it.

Fig. 9: Sliding Inner Rear View Mirror Assembly (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) a. Disengage the 2 claws and slide the inner rear view mirror stay holder cover in the direction indicated by the arrow shown in the illustration.

Fig. 10: Identifying Inner Rear View Mirror Stay Holder Cover Claws (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 6 claws and remove the inner rear view mirror stay holder cover.

Fig. 11: Identifying Inner Rear View Mirror Stay Holder Cover Claws (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) a. Disconnect the connector.

Fig. 12: Identifying Inner Rear View Mirror Assembly Connector (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T20 "TORX" socket wrench, remove the screw and inner rear view mirror assembly. INSPECTION INSPECTION

1. INSPECT INNER REAR VIEW MIRROR ASSEMBLY a. Inspect the operation of the electrochromic inner mirror.

Fig. 13: Inspecting Operation Of Electrochromic Inner Mirror Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Black Forward *1 *2 Colored Sensor Tape *3 Bright *4 Dark *5 Battery - Component without harness connected *a - (Inner Rear View Mirror Assembly) 1. Connect a positive (+) lead from the battery to terminal 4 and a negative (-) lead to terminal 1. 2. Press the AUTO switch. 3. Attach black colored tape to the forward sensor to prevent it from sensing. 4. Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. Standard Mirror surface changes from bright to dark.

If the result is not as specified, replace the inner rear view mirror assembly. INSTALLATION INSTALLATION

1. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) a. Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration.

Fig. 14: Sliding Inner Rear View Mirror Assembly (W/O EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a T20 "TORX" socket wrench, install the inner rear view mirror assembly with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 2. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) a. Using a T20 "TORX" socket wrench, install the inner rear view mirror assembly with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) b. Connect the connector. 3. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) a. Engage the 6 claws and temporarily install the inner rear view mirror stay holder cover. b. Slide the inner rear view mirror stay holder cover in the direction indicated by arrow shown in the

illustration and engage the 2 claws to install the cover.

Fig. 15: Sliding Inner Rear View Mirror Stay Holder Cover (W/EC Mirror) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2012-2017 ACCESSORIES & EQUIPMENT Navigation System (Service Information) (Hybrid)

NAVIGATION RECEIVER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Navigation Receiver Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Navigation Receiver Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Navigation Receiver Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:





After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . A Hard Disk Drive (HDD) is built into the navigation receiver assembly to store map and other data, and is used for the navigation system. Therefore, care must be taken for the following points when



handling the navigation receiver assembly. When removing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 9. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY a. Apply protective tape to the areas shown in the illustration.

Fig. 4: Protective Tape Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 5: Identifying Navigation Receiver Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the navigation receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 6: Identifying Navigation Receiver Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the navigation receiver assembly with air conditioning control assembly. 10. REMOVE NO. 1 RADIO RECEIVER BRACKET a. Remove the 5 screws and No. 1 radio receiver bracket.

Fig. 7: Locating No. 1 Radio Receiver Bracket Fasteners (For Radio And Display Type With Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE NO. 2 RADIO RECEIVER BRACKET a. Remove the 5 screws and No. 2 radio receiver bracket.

Fig. 8: Locating No. 2 Radio Receiver Bracket Fasteners (For Radio And Display Type With Intuitive Parking Assist System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 21 13. REMOVE HARD DISK DRIVE See step 13 14. REMOVE NAVIGATION COMPUTER SUB-ASSEMBLY INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12.

When installing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

INSTALL NAVIGATION COMPUTER SUB-ASSEMBLY INSTALL HARD DISK DRIVE See step 2 INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL NO. 1 RADIO RECEIVER BRACKET a. Install the No. 1 radio receiver bracket with the 5 screws. INSTALL NO. 2 RADIO RECEIVER BRACKET a. Install the No. 2 radio receiver bracket with the 5 screws. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the navigation receiver assembly with air conditioning control assembly. c. Install the navigation receiver assembly with air conditioning control assembly with the 4 bolts. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

13. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

14. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 15. INSPECT HARD DISK DRIVE Refer to OPERATION CHECK 16. REPLACED OPERATION (w/ Parking Assist Monitor System) Refer to CALIBRATION

NAVIGATION ECU COMPONENTS ILLUSTRATION

Fig. 9: Identifying Navigation ECU Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Identifying Navigation ECU Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 4. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 5. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23

6. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 10 7. REMOVE NO. 1 RADIO BRACKET . Refer to REMOVAL - Step 13 8. REMOVE NO. 2 RADIO BRACKET . Refer to REMOVAL - Step 14 9. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 21 10. REMOVE EXTENSION MODULE a. Disconnect the 3 connectors to remove the navigation wire.

Fig. 11: Identifying Extension Module Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector to remove the extension module.

Fig. 12: Identifying Extension Module And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL EXTENSION MODULE a. Connect the connector to install the extension module. b. Connect the 3 connectors to install the navigation wire. 2. INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 3. INSTALL NO. 1 RADIO BRACKET . Refer to INSTALLATION - Step 10 4. INSTALL NO. 2 RADIO BRACKET . Refer to INSTALLATION - Step 11 5. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 15 6. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 7. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 9. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 10. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

HARD DISK DRIVE COMPONENTS ILLUSTRATION

Fig. 13: Identifying Hard Disk Drive Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Identifying Hard Disk Drive Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 15: Identifying Hard Disk Drive Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

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





After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . for Navigation Receiver Type: A Hard Disk Drive (HDD) is built into the navigation receiver assembly to store map and other data, and is used for the navigation system. Therefore, care must be taken for the following points when handling the navigation receiver assembly. for Radio and Display Type with Intuitive Parking Assist System: A Hard Disk Drive (HDD) is built into the navigation receiver assembly to store multi-media data, and is used for the audio and visual system. Therefore, care must be taken for the following points when handling the navigation receiver assembly. When removing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 5. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 7. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 22 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 23 9. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) See step 9 10. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 10 11. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) See step 11

12. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 16 13. REMOVE HARD DISK DRIVE a. Remove the 2 screws.

Fig. 16: Identifying Hard Disk Drive Cover Screws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the cover. c. Pull out the hard disk drive from the navigation receiver assembly or radio and display receiver assembly in the direction shown by the arrow in the illustration to remove it.

Fig. 17: Pulling Out The Hard Disk Drive From The Navigation Receiver Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

When installing the hard disk drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. INSTALL HARD DISK DRIVE a. Insert the hard disk drive in the direction shown by the arrow in the illustration to install it.

Fig. 18: Inserting The Hard Disk Drive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6.

7. 8. 9. 10. 11.

b. Engage the 2 guides to temporarily install the cover. c. Install the cover with the 2 screws. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) See step 6 INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) See step 7 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 15 INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 14. INSPECT HARD DISK DRIVE for Navigation Receiver Type: Refer to OPERATION CHECK for Radio and Display Type with Intuitive Parking Assist System: Refer to OPERATION CHECK

NAVIGATION ANTENNA COMPONENTS ILLUSTRATION

Fig. 19: Identifying Navigation Antenna Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Refer to REMOVAL 2. 3. 4. 5. 6. 7.

REMOVE NO. 1 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 3 REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 4 REMOVE NO. 3 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 5 REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 6 REMOVE DEFROSTER NOZZLE ASSEMBLY . Refer to DISASSEMBLY - Step 8 REMOVE NAVIGATION ANTENNA ASSEMBLY a. Remove the 2 screws.

Fig. 20: Identifying Navigation Antenna Screws And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clamps and remove the navigation antenna assembly. INSTALLATION INSTALLATION

1. INSTALL NAVIGATION ANTENNA ASSEMBLY a. Engage the 2 clamps. b. Install the navigation antenna assembly with the 2 screws. 2. INSTALL DEFROSTER NOZZLE ASSEMBLY . Refer to REASSEMBLY - Step 4 3. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 6 4. INSTALL NO. 3 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 7

5. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 8 6. INSTALL NO. 1 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 9 7. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION

2012-2017 ACCESSORIES & EQUIPMENT Navigation System (Service Information) - Camry (Except Hybrid)

NAVIGATION RECEIVER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Navigation Receiver Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 2: Identifying Navigation Receiver Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION NOTE:





After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . A Hard Disk Drive (HDD) is built into the navigation receiver



assembly to store map and other data, and is used for the navigation system. Therefore, care must be taken when handling the navigation receiver assembly. When removing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 4. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 6. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 7. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 8. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY a. Apply protective tape to the area shown in the illustration.

Fig. 3: Identifying Protective Tape Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape b. Remove the 4 bolts.

Fig. 4: Identifying Navigation Receiver Assembly With Air Conditioning Control Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the navigation receiver assembly with air conditioning control assembly toward the rear of the vehicle and disengage the 8 clips.

Fig. 5: Identifying Navigation Receiver Assembly With Air Conditioning Control Assembly Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect each connector and remove the navigation receiver assembly with air conditioning control assembly. 9. REMOVE NO. 1 RADIO RECEIVER BRACKET a. Remove the 5 screws and No. 1 radio receiver bracket.

Fig. 6: Locating No. 1 Radio Receiver Bracket Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE NO. 2 RADIO RECEIVER BRACKET a. Remove the 5 screws and No. 2 radio receiver bracket.

Fig. 7: Locating No. 2 Radio Receiver Bracket Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE HARD DISK DRIVE See step 12 12. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 20 13. REMOVE NAVIGATION COMPUTER SUB-ASSEMBLY INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

2. 3. 4. 5.

When installing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

INSTALL NAVIGATION COMPUTER SUB-ASSEMBLY INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL HARD DISK DRIVE See step 2 INSTALL NO. 1 RADIO RECEIVER BRACKET a. Install the No. 1 radio receiver bracket with the 5 screws. 6. INSTALL NO. 2 RADIO RECEIVER BRACKET a. Install the No. 2 radio receiver bracket with the 5 screws. 7. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY

8. 9. 10. 11. 12.

a. Connect each connector. b. Engage the 8 clips to the vehicle body to temporarily install the navigation receiver assembly with air conditioning control assembly. c. Install the navigation receiver assembly with air conditioning control assembly with the 4 bolts. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

14. INSPECT HARD DISK DRIVE Refer to OPERATION CHECK 15. REPLACED OPERATION (w/ Parking Assist Monitor System) Refer to CALIBRATION

NAVIGATION ECU COMPONENTS ILLUSTRATION

Fig. 8: Identifying Navigation ECU Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 9: Identifying Navigation ECU Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY

Refer to REMOVAL 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 4. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 5. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 6. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 9 7. REMOVE NO. 1 RADIO BRACKET . Refer to REMOVAL - Step 12 8. REMOVE NO. 2 RADIO BRACKET . Refer to REMOVAL - Step 13 9. REMOVE AIR CONDITIONING CONTROL ASSEMBLY . Refer to REMOVAL - Step 20 10. REMOVE EXTENSION MODULE a. Disconnect the 3 connectors to remove the navigation wire.

Fig. 10: Identifying Navigation Wire Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector to remove the extension module.

Fig. 11: Identifying Extension Module Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL EXTENSION MODULE a. Connect the connector to install the extension module. b. Connect the 3 connectors to install the navigation wire. 2. INSTALL AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 1 3. INSTALL NO. 1 RADIO BRACKET . Refer to INSTALLATION - Step 10 4. INSTALL NO. 2 RADIO BRACKET . Refer to INSTALLATION - Step 11 5. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY . Refer to INSTALLATION - Step 15 6. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 7. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 9. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 10. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

HARD DISK DRIVE COMPONENTS ILLUSTRATION

Fig. 12: Identifying Hard Disk Drive Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 13: Identifying Hard Disk Drive Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:









After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . for Navigation Receiver Type: A Hard Disk Drive (HDD) is built into the navigation receiver assembly to store map and other data, and is used for the navigation system. Therefore, care must be taken for the following points when handling the navigation receiver assembly. for Radio and Display Type with Intuitive Parking Assist System: A Hard Disk Drive (HDD) is built into the radio and display receiver assembly to store multi-media data, and is used for the audio and visual system. Therefore, care must be taken for the following points when handling the radio and display receiver assembly. When removing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 4. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 6. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 23 7. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 24 8. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) See step 8 9. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) . Refer to REMOVAL - Step 9 10. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) See step 10 11. REMOVE NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive

Parking Assist System) . Refer to REMOVAL - Step 15 12. REMOVE HARD DISK DRIVE a. Remove the 2 screws.

Fig. 14: Identifying Hard Disk Drive Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the cover. c. Pull out the hard disk drive from the navigation receiver assembly or radio and display receiver assembly in the direction shown by the arrow in the illustration to remove it.

Fig. 15: Removing Hard Disk Drive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. PRECAUTION NOTE:

When installing the hard disc drive, eliminate static electricity by touching the vehicle body to prevent components from being damaged.

2. INSTALL HARD DISK DRIVE a. Insert the hard disk drive in the direction shown by the arrow in the illustration to install it.

Fig. 16: Installing Hard Disk Drive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6.

7. 8. 9. 10. 11.

b. Engage the 2 guides to temporarily install the cover. c. Install the cover with the 2 screws. INSTALL NO. 2 RADIO RECEIVER BRACKET (for Navigation Receiver Type) See step 6 INSTALL NO. 2 RADIO RECEIVER BRACKET (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 13 INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Navigation Receiver Type) See step 7 INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (for Radio and Display Type with Intuitive Parking Assist System) . Refer to INSTALLATION - Step 15 INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 29 INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 30 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSPECT HARD DISK DRIVE Refer to OPERATION CHECK

NAVIGATION ANTENNA COMPONENTS ILLUSTRATION

Fig. 17: Identifying Navigation Antenna Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

Refer to REMOVAL 2. 3. 4. 5. 6. 7.

REMOVE NO. 1 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 3 REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 4 REMOVE NO. 3 HEATER TO REGISTER DUCT . Refer to DISASSEMBLY - Step 5 REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to DISASSEMBLY - Step 6 REMOVE DEFROSTER NOZZLE ASSEMBLY . Refer to DISASSEMBLY - Step 8 REMOVE NAVIGATION ANTENNA ASSEMBLY a. Remove the 2 screws.

Fig. 18: Identifying Navigation Antenna Assembly Screws And Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 clamps and remove the navigation antenna assembly. INSTALLATION INSTALLATION

1. INSTALL NAVIGATION ANTENNA ASSEMBLY a. Engage the 2 clamps. b. Install the navigation antenna assembly with the 2 screws. 2. INSTALL DEFROSTER NOZZLE ASSEMBLY . Refer to REASSEMBLY - Step 4 3. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 6 4. INSTALL NO. 3 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 7

5. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT . Refer to REASSEMBLY - Step 8 6. INSTALL NO. 1 HEATER TO REGISTER DUCT . Refer to REASSEMBLY - Step 9 7. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Refer to INSTALLATION

2012-2017 ACCESSORIES & EQUIPMENT Network Gateway ECU (Service Information) (Except Hybrid) - Camry

NETWORK GATEWAY ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Network Gateway ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

NOTE:





When disassembling the network gateway ECU, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

2. REMOVE ECU INTEGRATION BOX RH Refer to REMOVAL . 3. REMOVE NETWORK GATEWAY ECU a. Disengage the 2 claws and remove the network gateway ECU.

Fig. 2: Identifying Network Gateway ECU Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NETWORK GATEWAY ECU a. Install the network gateway ECU. 2. INSTALL ECU INTEGRATION BOX RH Refer to INSTALLATION . 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

2012-2017 ELECTRICAL OEM Connector List - Camry Hybrid

CONNECTOR LIST NOTE:

For any illustration containing an asterisk *, refer to ADDITIONAL INFORMATION at the end of this article.

LOW PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A1)

Fig. 1: Low Pitched Horn Assembly Connector End View (A1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY) CONNECTOR END VIEW (A2)

Fig. 2: Engine Hood Courtesy Switch (Hood Lock Assembly) Connector End View (A2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) CONNECTOR END VIEW (A3)

Fig. 3: Ambient Temperature Sensor (Thermistor Assembly) Connector End View (A3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HIGH PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A4)

Fig. 4: High Pitched Horn Assembly Connector End View (A4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 ULTRASONIC SENSOR LH CONNECTOR END VIEW (A5)

Fig. 5: Front No. 1 Ultrasonic Sensor LH Connector End View (A5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FOG LIGHT ASSEMBLY LH CONNECTOR END VIEW (A6)

Fig. 6: Fog Light Assembly LH Connector End View (A6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU CONNECTOR END VIEW (A10)

Fig. 7: Cooling Fan ECU Connector End View (A10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VEHICLE APPROACHING SPEAKER ASSEMBLY CONNECTOR END VIEW (A11)

Fig. 8: Vehicle Approaching Speaker Assembly Connector End View (A11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT AIRBAG SENSOR LH CONNECTOR END VIEW (A12)

Fig. 9: Front Airbag Sensor LH Connector End View (A12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (A13)

Fig. 10: Inverter With Converter Assembly Connector End View (A13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (A14)

Fig. 11: Inverter With Converter Assembly Connector End View (A14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WIRELESS DOOR LOCK BUZZER CONNECTOR END VIEW (A15)

Fig. 12: Wireless Door Lock Buzzer Connector End View (A15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SPEED SENSOR LH CONNECTOR END VIEW (A16)

Fig. 13: Front Speed Sensor LH Connector End View (A16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A17)

Fig. 14: Headlight Assembly LH Connector End View (A17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A20)

Fig. 15: Headlight Assembly LH Connector End View (A20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A24)

Fig. 16: Headlight Assembly LH Connector End View (A24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECM CONNECTOR END VIEW (A25)

Fig. 17: ECM Connector End View (A25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SKID CONTROL ECU WITH ACTUATOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY) CONNECTOR END VIEW (A28)

Fig. 18: Skid Control ECU With Actuator (Brake Booster With Master Cylinder Assembly) Connector End View (A28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER MOTOR ASSEMBLY CONNECTOR END VIEW (A29)

Fig. 19: Windshield Wiper Motor Assembly Connector End View (A29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE FLUID LEVEL WARNING SWITCH (BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY) CONNECTOR END VIEW (A30)

Fig. 20: Brake Fluid Level Warning Switch (Brake Master Cylinder Reservoir Assembly) Connector End View (A30) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STOP LIGHT SWITCH ASSEMBLY CONNECTOR END VIEW (A33)

Fig. 21: Stop Light Switch Assembly Connector End View (A33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT LEVELING ECU ASSEMBLY CONNECTOR END VIEW (A34)

Fig. 22: Headlight Leveling ECU Assembly Connector End View (A34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ACCELERATOR PEDAL SENSOR ASSEMBLY CONNECTOR END VIEW (A36)

Fig. 23: Accelerator Pedal Sensor Assembly Connector End View (A36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER MANAGEMENT CONTROL ECU CONNECTOR END VIEW (A38)

Fig. 24: Power Management Control ECU Connector End View (A38) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER MANAGEMENT CONTROL ECU CONNECTOR END VIEW (A39)

Fig. 25: Power Management Control ECU Connector End View (A39) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE PEDAL STROKE SENSOR ASSEMBLY CONNECTOR END VIEW (A41)

Fig. 26: Brake Pedal Stroke Sensor Assembly Connector End View (A41) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARKING BRAKE SWITCH ASSEMBLY CONNECTOR END VIEW (A42)

Fig. 27: Parking Brake Switch Assembly Connector End View (A42) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE BOOSTER PUMP ASSEMBLY CONNECTOR END VIEW (A46)

Fig. 28: Brake Booster Pump Assembly Connector End View (A46) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE BOOSTER PUMP ASSEMBLY CONNECTOR END VIEW (A47)

Fig. 29: Brake Booster Pump Assembly Connector End View (A47) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WATER PUMP ASSEMBLY CONNECTOR END VIEW (A50)

Fig. 30: Inverter Water Pump Assembly Connector End View (A50) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SPEED SENSOR RH CONNECTOR END VIEW (A53)

Fig. 31: Front Speed Sensor RH Connector End View (A53) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY CONNECTOR END VIEW (A54)

Fig. 32: Windshield Washer Motor And Pump Assembly Connector End View (A54) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C PRESSURE SENSOR (A/C TUBE&ACCESSORY ASSEMBLY) CONNECTOR END VIEW (A55)

Fig. 33: A/C Pressure Sensor (A/C Tube&Accessory Assembly) Connector End View (A55) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 ULTRASONIC SENSOR RH CONNECTOR END VIEW (A56)

Fig. 34: Front No. 1 Ultrasonic Sensor RH Connector End View (A56) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FOG LIGHT ASSEMBLY RH CONNECTOR END VIEW (A57)

Fig. 35: Fog Light Assembly RH Connector End View (A57) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT AIRBAG SENSOR RH CONNECTOR END VIEW (A58)

Fig. 36: Front Airbag Sensor RH Connector End View (A58) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A60)

Fig. 37: Headlight Assembly RH Connector End View (A60) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A63)

Fig. 38: Headlight Assembly RH Connector End View (A63) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A66)

Fig. 39: Headlight Assembly RH Connector End View (A66) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A71)

Fig. 40: Junction Connector End View (A71) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A72)

Fig. 41: Junction Connector End View (A72) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A73)

Fig. 42: Junction Connector End View (A73) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A74)

Fig. 43: Headlight Assembly LH Connector End View (A74) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A75)

Fig. 44: Headlight Assembly LH Connector End View (A75) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A76)

Fig. 45: Headlight Assembly RH Connector End View (A76)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A77)

Fig. 46: Headlight Assembly RH Connector End View (A77) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A78)

Fig. 47: Headlight Assembly RH Connector End View (A78) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A79)

Fig. 48: Headlight Assembly LH Connector End View (A79) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LEVEL WARNING SWITCH ASSEMBLY CONNECTOR END VIEW (A80)

Fig. 49: Level Warning Switch Assembly Connector End View (A80) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SUPER LOW PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A81)

Fig. 50: Super Low Pitched Horn Assembly Connector End View (A81) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (C1)

Fig. 51: Inverter With Converter Assembly Connector End View (C1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (E1)

Fig. 52: Inverter with Converter Assembly Connector End View (E1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT LEVER POSITION SENSOR CONNECTOR END VIEW (E11)

Fig. 53: Shift Lever Position Sensor Connector End View (E11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE TRANSAXLE ASSEMBLY CONNECTOR END VIEW (E12)

Fig. 54: Hybrid Vehicle Transaxle Assembly Connector End View (E12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE TRANSAXLE ASSEMBLY CONNECTOR END VIEW (E13)

Fig. 55: Hybrid Vehicle Transaxle Assembly Connector End View (E13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INTAKE MASS AIR FLOW METER SUB-ASSEMBLY CONNECTOR END VIEW (E14)

Fig. 56: Intake Mass Air Flow Meter Sub-Assembly Connector End View (E14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE TRANSAXLE ASSEMBLY CONNECTOR END VIEW (E15)

Fig. 57: Hybrid Vehicle Transaxle Assembly Connector End View (E15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE BODY ASSEMBLY WITH MOTOR CONNECTOR END VIEW (E16)

Fig. 58: Throttle Body Assembly With Motor Connector End View (E16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) CONNECTOR END VIEW (E19)

Fig. 59: Air Fuel Ratio Sensor (Bank 1 Sensor 1) Connector End View (E19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OXYGEN SENSOR (BANK 1 SENSOR 2) CONNECTOR END VIEW (E21)

Fig. 60: Oxygen Sensor (Bank 1 Sensor 2) Connector End View (E21) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EGR VALVE ASSEMBLY CONNECTOR END VIEW (E24)

Fig. 61: EGR Valve Assembly Connector End View (E24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. E.F.I. VACUUM SENSOR ASSEMBLY CONNECTOR END VIEW (E25)

Fig. 62: E.F.I. Vacuum Sensor Assembly Connector End View (E25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECM CONNECTOR END VIEW (E28)

Fig. 63: ECM Connector End View (E28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 1 CONNECTOR END VIEW (E29)

Fig. 64: Fuel Injector Assembly No. 1 Connector End View (E29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 2 CONNECTOR END VIEW (E34)

Fig. 65: Fuel Injector Assembly No. 2 Connector End View (E34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 1 CONNECTOR END VIEW (E37)

Fig. 66: Ignition Coil Assembly No. 1 Connector End View (E37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 3 CONNECTOR END VIEW (E38)

Fig. 67: Ignition Coil Assembly No. 3 Connector End View (E38) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 2 CONNECTOR END VIEW (E40)

Fig. 68: Ignition Coil Assembly No. 2 Connector End View (E40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 4 CONNECTOR END VIEW (E43)

Fig. 69: Ignition Coil Assembly No. 4 Connector End View (E43) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. E.F.I. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR END VIEW (E47)

Fig. 70: E.F.I. Engine Coolant Temperature Sensor Connector End View (E47) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PURGE VSV CONNECTOR END VIEW (E49)

Fig. 71: Purge VSV Connector End View (E49) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (CAMSHAFT POSITION SENSOR) CONNECTOR END VIEW (E55)

Fig. 72: VVT Sensor (Camshaft Position Sensor) Connector End View (E55) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (INTAKE SIDE) CONNECTOR END VIEW (E63)

Fig. 73: Camshaft Timing Oil Control Valve Assembly (Intake Side) Connector End View (E63) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE OIL PRESSURE SWITCH ASSEMBLY CONNECTOR END VIEW (E64)

Fig. 74: Engine Oil Pressure Switch Assembly Connector End View (E64) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPRESSOR WITH MOTOR ASSEMBLY CONNECTOR END VIEW (E65)

Fig. 75: Compressor With Motor Assembly Connector End View (E65) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE WATER PUMP ASSEMBLY CONNECTOR END VIEW (E66)

Fig. 76: Engine Water Pump Assembly Connector End View (E66) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRANK POSITION SENSOR CONNECTOR END VIEW (E72)

Fig. 77: Crank Position Sensor Connector End View (E72) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPRESSOR WITH MOTOR ASSEMBLY CONNECTOR END VIEW (G1)

Fig. 78: Compressor With Motor Assembly Connector End View (G1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (G2)

Fig. 79: Inverter with Converter Assembly Connector End View (G2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 3 CONNECTOR END VIEW (H1)

Fig. 80: Fuel Injector Assembly No. 3 Connector End View (H1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 4 CONNECTOR END VIEW (H2)

Fig. 81: Fuel Injector Assembly No. 4 Connector End View (H2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (I1)

Fig. 82: Front No. 2 Speaker Assembly LH Connector End View (I1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (I2)

Fig. 83: Front No. 2 Speaker Assembly LH Connector End View (I2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER MANAGEMENT CONTROL ECU CONNECTOR END VIEW (I3)

Fig. 84: Power Management Control ECU Connector End View (I3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER MANAGEMENT CONTROL ECU CONNECTOR END VIEW (I4)

Fig. 85: Power Management Control ECU Connector End View (I4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY CONNECTOR END VIEW (I5)

Fig. 86: Back Sonar or Clearance Sonar Switch Assembly Connector End View (I5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLIND SPOT MONITOR MAIN SWITCH (WARNING CANCELING SWITCH ASSEMBLY) CONNECTOR END VIEW (I10)

Fig. 87: Blind Spot Monitor Main Switch (Warning Canceling Switch Assembly) Connector End View (I10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MAIN BODY ECU CONNECTOR END VIEW (I12)

Fig. 88: Main Body ECU Connector End View (I12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MAIN BODY ECU CONNECTOR END VIEW (I13)

Fig. 89: Main Body ECU Connector End View (I13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMBINATION METER ASSEMBLY CONNECTOR END VIEW (I17)

Fig. 90: Combination Meter Assembly Connector End View (I17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMBINATION METER ASSEMBLY CONNECTOR END VIEW (I18)

Fig. 91: Combination Meter Assembly Connector End View (I18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEERING LOCK ACTUATOR ASSEMBLY CONNECTOR END VIEW (I24)

Fig. 92: Steering Lock Actuator Assembly Connector End View (I24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT DIMMER SWITCH ASSEMBLY CONNECTOR END VIEW (I25)

Fig. 93: Headlight Dimmer Switch Assembly Connector End View (I25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (I27)

Fig. 94: Spiral Cable Sub-Assembly Connector End View (I27) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (I28)

Fig. 95: Spiral Cable Sub-Assembly Connector End View (I28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEERING SENSOR CONNECTOR END VIEW (I29)

Fig. 96: Steering Sensor Connector End View (I29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER SWITCH ASSEMBLY CONNECTOR END VIEW (I31)

Fig. 97: Windshield Wiper Switch Assembly Connector End View (I31) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER SWITCH ASSEMBLY CONNECTOR END VIEW (I32)

Fig. 98: Windshield Wiper Switch Assembly Connector End View (I32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DATA LINK CONNECTOR 3 CONNECTOR END VIEW (I39)

Fig. 99: Data Link Connector 3 Connector End View (I39) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY CONNECTOR END VIEW (I40)

Fig. 100: Lower No. 1 Instrument Panel Airbag Assembly Connector End View (I40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. QUICK HEATER ASSEMBLY CONNECTOR END VIEW (I41)

Fig. 101: Quick Heater Assembly Connector End View (I41) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT LOCK CONTROL ECU (LOWER SHIFT LEVER ASSEMBLY) CONNECTOR END VIEW (I42)

Fig. 102: Shift Lock Control ECU (Lower Shift Lever Assembly) Connector End View (I42) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER OUTLET SOCKET ASSEMBLY CONNECTOR END VIEW (I45)

Fig. 103: Rear Power Outlet Socket Assembly Connector End View (I45) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (I46)

Fig. 104: No. 1 Indoor Electrical Key Antenna Assembly Connector End View (I46) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (I47)

Fig. 105: Airbag Sensor Assembly Connector End View (I47) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PATTERN SELECT SWITCH ASSEMBLY CONNECTOR END VIEW (I48)

Fig. 106: Pattern Select Switch Assembly Connector End View (I48) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECO SWITCH ASSEMBLY CONNECTOR END VIEW (I49)

Fig. 107: ECO Switch Assembly Connector End View (I49) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER SWITCH LH CONNECTOR END VIEW (I52)

Fig. 108: Seat Heater Switch LH Connector End View (I52) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER SWITCH RH CONNECTOR END VIEW (I53)

Fig. 109: Seat Heater Switch RH Connector End View (I53) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 CLEARANCE WARNING BUZZER CONNECTOR END VIEW (I54)

Fig. 110: No. 1 Clearance Warning Buzzer Connector End View (I54) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER OUTLET SOCKET ASSEMBLY CONNECTOR END VIEW (I55)

Fig. 111: Front Power Outlet Socket Assembly Connector End View (I55)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C CONTROL ASSEMBLY CONNECTOR END VIEW (I56)

Fig. 112: A/C Control Assembly Connector End View (I56) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLER (ROOM TEMPERATURE SENSOR) THERMISTOR CONNECTOR END VIEW (I57)

Fig. 113: Cooler (Room Temperature Sensor) Thermistor Connector End View (I57) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER SWITCH CONNECTOR END VIEW (I58)

Fig. 114: Power Switch Connector End View (I58) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLOCK ASSEMBLY CONNECTOR END VIEW (I59)

Fig. 115: Clock Assembly Connector End View (I59) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 3 SPEAKER ASSEMBLY CONNECTOR END VIEW (I60)

Fig. 116: Front No. 3 Speaker Assembly Connector End View (I60) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AUTOMATIC LIGHT CONTROL SENSOR CONNECTOR END VIEW (I61)

Fig. 117: Automatic Light Control Sensor Connector End View (I61) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT POSITION INDICATOR (INDICATOR LIGHT WIRE SUB-ASSEMBLY) CONNECTOR END VIEW (I62)

Fig. 118: Shift Position Indicator (Indicator Light Wire Sub-Assembly) Connector End View (I62)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I64)

Fig. 119: Multi-Media Module Receiver Sub-Assembly Connector End View (I64) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I65)

Fig. 120: Multi-Media Module Receiver Sub-Assembly Connector End View (I65) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I66)

Fig. 121: Multi-Media Module Receiver Sub-Assembly Connector End View (I66) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I67)

Fig. 122: Multi-Media Module Receiver Sub-Assembly Connector End View (I67) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEREO COMPONENT AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I68)

Fig. 123: Stereo Component Amplifier Assembly Connector End View (I68) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEREO COMPONENT AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I69)

Fig. 124: Stereo Component Amplifier Assembly Connector End View (I69) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VEHICLE APPROACHING SPEAKER CONTROLLER CONNECTOR END VIEW (I71)

Fig. 125: Vehicle Approaching Speaker Controller Connector End View (I71) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIODE (FRONT COURTESY LIGHT) CONNECTOR END VIEW (I75)

Fig. 126: Diode (Front Courtesy Light) Connector End View (I75) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLOWER MOTOR SUB-ASSEMBLY WITH FAN CONNECTOR END VIEW (I76)

Fig. 127: Blower Motor Sub-Assembly with Fan Connector End View (I76) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I77)

Fig. 128: A/C Amplifier Assembly Connector End View (I77)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLEARANCE WARNING ECU ASSEMBLY CONNECTOR END VIEW (I82)

Fig. 129: Clearance Warning ECU Assembly Connector End View (I82) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (I83)

Fig. 130: Front No. 2 Speaker Assembly RH Connector End View (I83) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (I84)

Fig. 131: Front No. 2 Speaker Assembly RH Connector End View (I84) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (I86)

Fig. 132: Certification ECU Connector End View (I86) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (I87)

Fig. 133: Certification ECU Connector End View (I87) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OPTION CONNECTOR (REMOTE ENGINE STARTER) CONNECTOR END VIEW (I89)

Fig. 134: Option Connector (Remote Engine Starter) Connector End View (I89) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I92)

Fig. 135: Junction Connector End View (I92) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I93)

Fig. 136: Junction Connector End View (I93) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I94)

Fig. 137: Junction Connector End View (I94) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I95)

Fig. 138: Junction Connector End View (I95) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I96)

Fig. 139: Junction Connector End View (I96) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I97)

Fig. 140: Junction Connector End View (I97) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I100)

Fig. 141: Junction Connector End View (I100) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

JUNCTION CONNECTOR END VIEW (I101)

Fig. 142: Junction Connector End View (I101) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I102)

Fig. 143: Junction Connector End View (I102) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I103)

Fig. 144: Junction Connector End View (I103) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I104)

Fig. 145: Junction Connector End View (I104) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I106)

Fig. 146: Junction Connector End View (I106) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I107)

Fig. 147: Junction Connector End View (I107) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I109)

Fig. 148: Junction Connector End View (I109) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I110)

Fig. 149: Junction Connector End View (I110) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I111)

Fig. 150: Junction Connector End View (I111) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I124)

Fig. 151: Junction Connector End View (I124) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I125)

Fig. 152: Junction Connector End View (I125) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I126)

Fig. 153: Junction Connector End View (I126) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I128)

Fig. 154: Junction Connector End View (I128) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VSC OFF SWITCH CONNECTOR END VIEW (I130)

Fig. 155: VSC Off Switch Connector End View (I130) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT LEVELING SWITCH CONNECTOR END VIEW (I131)

Fig. 156: Headlight Leveling Switch Connector End View (I131) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I134)

Fig. 157: Radio & Display Receiver Assembly Connector End View (I134) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (I135)

Fig. 158: DCM (Telematics Transceiver) Connector End View (I135) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BACK-UP BATTERY (MAYDAY BATTERY) CONNECTOR END VIEW (I136)

Fig. 159: Back-Up Battery (Mayday Battery) Connector End View (I136) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TIRE PRESSURE WARNING RESET SWITCH CONNECTOR END VIEW (I137)

Fig. 160: Tire Pressure Warning Reset Switch Connector End View (I137) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLOVE BOX LIGHT ASSEMBLY CONNECTOR END VIEW (I138)

Fig. 161: Glove Box Light Assembly Connector End View (I138) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY CONNECTOR END VIEW (I140)

Fig. 162: Lower No. 2 Instrument Panel Airbag Assembly Connector End View (I140) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 STEREO JACK ADAPTER ASSEMBLY CONNECTOR END VIEW (I146)

Fig. 163: No. 1 Stereo Jack Adapter Assembly Connector End View (I146) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I147)

Fig. 164: Multi-Media Module Receiver Sub-Assembly Connector End View (I147) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I148)

Fig. 165: Radio Receiver Assembly Connector End View (I148) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I149)

Fig. 166: Radio Receiver Assembly Connector End View (I149) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I150)

Fig. 167: Radio Receiver Assembly Connector End View (I150) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I151)

Fig. 168: Radio Receiver Assembly Connector End View (I151)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I152)

Fig. 169: Radio & Display Receiver Assembly Connector End View (I152) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I153)

Fig. 170: Radio & Display Receiver Assembly Connector End View (I153) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I154)

Fig. 171: Radio & Display Receiver Assembly Connector End View (I154) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I155)

Fig. 172: Radio & Display Receiver Assembly Connector End View (I155) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I156)

Fig. 173: Radio & Display Receiver Assembly Connector End View (I156) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EXTENSION MODULE CONNECTOR END VIEW (I157)

Fig. 174: Extension Module Connector End View (I157) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. YAW RATE SENSOR CONNECTOR END VIEW (I158)

Fig. 175: Yaw Rate Sensor Connector End View (I158) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I159)

Fig. 176: Junction Connector End View (I159) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR LOCK ASSEMBLY WITH MOTOR RH CONNECTOR END VIEW (J1)

Fig. 177: Front Door Lock Assembly with Motor RH Connector End View (J1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT COURTESY LIGHT ASSEMBLY RH CONNECTOR END VIEW (J2)

Fig. 178: Front Courtesy Light Assembly RH Connector End View (J2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT NO. 1 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (J5)

Fig. 179: Front No. 1 Speaker Assembly RH Connector End View (J5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY RH CONNECTOR END VIEW (J7)

Fig. 180: Outer Rear View Mirror Assembly RH Connector End View (J7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR SIDE AIRBAG SENSOR RH CONNECTOR END VIEW (J10)

Fig. 181: Door Side Airbag Sensor RH Connector End View (J10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR SWITCH ASSEMBLY RH CONNECTOR END VIEW (J11)

Fig. 182: Front Power Window Regulator Switch Assembly RH Connector End View (J11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR CONTROL SWITCH ASSEMBLY CONNECTOR END VIEW (J12)

Fig. 183: Door Control Switch Assembly Connector End View (J12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY RH CONNECTOR END VIEW (J13)

Fig. 184: Outer Rear View Mirror Assembly RH Connector End View (J13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH CONNECTOR END VIEW (J14)

Fig. 185: Front Power Window Regulator Motor Assembly RH Connector End View (J14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT DOOR LOCK ASSEMBLY WITH MOTOR LH CONNECTOR END VIEW (K1)

Fig. 186: Front Door Lock Assembly with Motor LH Connector End View (K1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT COURTESY LIGHT ASSEMBLY LH CONNECTOR END VIEW (K2)

Fig. 187: Front Courtesy Light Assembly LH Connector End View (K2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (K5)

Fig. 188: Front No. 1 Speaker Assembly LH Connector End View (K5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER MIRROR SWITCH ASSEMBLY CONNECTOR END VIEW (K6)

Fig. 189: Outer Mirror Switch Assembly Connector End View (K6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY LH CONNECTOR END VIEW (K7)

Fig. 190: Outer Rear View Mirror Assembly LH Connector End View (K7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH CONNECTOR END VIEW (K9)

Fig. 191: Front Power Window Regulator Motor Assembly LH Connector End View (K9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR SIDE AIRBAG SENSOR LH CONNECTOR END VIEW (K10)

Fig. 192: Door Side Airbag Sensor LH Connector End View (K10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY CONNECTOR END VIEW (K11)

Fig. 193: Power Window Regulator Master Switch Assembly Connector End View (K11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY LH CONNECTOR END VIEW (K12)

Fig. 194: Outer Rear View Mirror Assembly LH Connector End View (K12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR LOCK ASSEMBLY WITH MOTOR RH CONNECTOR END VIEW (L1)

Fig. 195: Rear Door Lock Assembly with Motor RH Connector End View (L1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY RH CONNECTOR END VIEW (L5)

Fig. 196: Rear Power Window Regulator Motor Assembly RH Connector End View (L5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY RH CONNECTOR END VIEW (L6)

Fig. 197: Rear Power Window Regulator Switch Assembly RH Connector End View (L6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR LOCK ASSEMBLY WITH MOTOR LH CONNECTOR END VIEW (M1)

Fig. 198: Rear Door Lock Assembly With Motor LH Connector End View (M1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH CONNECTOR END VIEW (M5)

Fig. 199: Rear Power Window Regulator Motor Assembly LH Connector End View (M5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY LH CONNECTOR END VIEW (M6)

Fig. 200: Rear Power Window Regulator Switch Assembly LH Connector End View (M6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (N5)

Fig. 201: Airbag Sensor Assembly Connector End View (N5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY LH CONNECTOR END VIEW (N7)

Fig. 202: Front Door Courtesy Light Switch Assembly LH Connector End View (N7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SIDE AIRBAG SENSOR ASSEMBLY LH CONNECTOR END VIEW (N8)

Fig. 203: Side Airbag Sensor Assembly LH Connector End View (N8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT OUTER BELT ASSEMBLY LH CONNECTOR END VIEW (N9)

Fig. 204: Front Seat Outer Belt Assembly LH Connector End View (N9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (N10)

Fig. 205: No. 2 Indoor Electrical Key Antenna Assembly Connector End View (N10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL SUCTION TUBE ASSEMBLY WITH PUMP&GAGE CONNECTOR END VIEW (N11)

Fig. 206: Fuel Suction Tube Assembly With Pump&Gage Connector End View (N11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY LH CONNECTOR END VIEW (N15)

Fig. 207: Rear Door Courtesy Light Switch Assembly LH Connector End View (N15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BATTERY VOLTAGE SENSOR CONNECTOR END VIEW (N18)

Fig. 208: Battery Voltage Sensor Connector End View (N18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY CONNECTOR END VIEW (N23)

Fig. 209: No. 1 Luggage Compartment Light Assembly Connector End View (N23) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO SETTING CONDENSER (CENTER STOP LIGHT) CONNECTOR END VIEW (N26)

Fig. 210: Radio Setting Condenser (Center Stop Light) Connector End View (N26) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CURTAIN SHIELD AIRBAG ASSEMBLY LH CONNECTOR END VIEW (N27)

Fig. 211: Curtain Shield Airbag Assembly LH Connector End View (N27) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO SETTING CONDENSER (REAR WINDOW DEFOGGER) CONNECTOR END VIEW (N28)

Fig. 212: Radio Setting Condenser (Rear Window Defogger) Connector End View (N28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR WINDOW DEFOGGER (BACK WINDOW GLASS) CONNECTOR END VIEW (N29)

Fig. 213: Rear Window Defogger (Back Window Glass) Connector End View (N29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY LH CONNECTOR END VIEW (N32)

Fig. 214: Front Seat Inner Belt Assembly LH Connector End View (N32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 SIDE AIRBAG SENSOR ASSEMBLY LH CONNECTOR END VIEW (N33)

Fig. 215: No. 2 Side Airbag Sensor Assembly LH Connector End View (N33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CANISTER PUMP MODULE CONNECTOR END VIEW (N34)

Fig. 216: Canister Pump Module Connector End View (N34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (N36)

Fig. 217: No. 3 Indoor Electrical Key Antenna Assembly Connector End View (N36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CENTER STOP LIGHT SET CONNECTOR END VIEW (N37)

Fig. 218: Center Stop Light Set Connector End View (N37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (N38)

Fig. 219: Airbag Sensor Assembly Connector End View (N38) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (O2)

Fig. 220: Certification ECU Connector End View (O2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (O7)

Fig. 221: Airbag Sensor Assembly Connector End View (O7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR END VIEW (O9)

Fig. 222: Hybrid Battery Junction Block Assembly Connector End View (O9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY RH CONNECTOR END VIEW (O10)

Fig. 223: Front Door Courtesy Light Switch Assembly RH Connector End View (O10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SIDE AIRBAG SENSOR ASSEMBLY RH CONNECTOR END VIEW (O11)

Fig. 224: Side Airbag Sensor Assembly RH Connector End View (O11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT OUTER BELT ASSEMBLY RH CONNECTOR END VIEW (O12)

Fig. 225: Front Seat Outer Belt Assembly RH Connector End View (O12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY RH CONNECTOR END VIEW (O16)

Fig. 226: Rear Door Courtesy Light Switch Assembly RH Connector End View (O16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (O17)

Fig. 227: Rear Height Control Sensor Sub-Assembly Connector End View (O17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEAKER ASSEMBLY RH CONNECTOR END VIEW (O18)

Fig. 228: Rear Speaker Assembly RH Connector End View (O18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (O19)

Fig. 229: Rear No. 2 Speaker Assembly RH Connector End View (O19)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (O20)

Fig. 230: Rear No. 2 Speaker Assembly LH Connector End View (O20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEAKER ASSEMBLY LH CONNECTOR END VIEW (O21)

Fig. 231: Rear Speaker Assembly LH Connector End View (O21) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WOOFER SPEAKER (REAR SPEAKER ASSEMBLY) CONNECTOR END VIEW (O22)

Fig. 232: Woofer Speaker (Rear Speaker Assembly) Connector End View (O22) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CURTAIN SHIELD AIRBAG ASSEMBLY RH CONNECTOR END VIEW (O23)

Fig. 233: Curtain Shield Airbag Assembly RH Connector End View (O23) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR CONTROL RECEIVER CONNECTOR END VIEW (O25)

Fig. 234: Door Control Receiver Connector End View (O25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BATTERY THERMOMETER SENSOR (THERMISTOR ASSEMBLY) CONNECTOR END VIEW (O26)

Fig. 235: Battery Thermometer Sensor (Thermistor Assembly) Connector End View (O26) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SECURITY HORN ASSEMBLY CONNECTOR END VIEW (O27)

Fig. 236: Security Horn Assembly Connector End View (O27) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

BLIND SPOT MONITOR SENSOR RH CONNECTOR END VIEW (O28)

Fig. 237: Blind Spot Monitor Sensor RH Connector End View (O28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUSIBLE LINK BLOCK ASSEMBLY CONNECTOR END VIEW (O29)

Fig. 238: Fusible Link Block Assembly Connector End View (O29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (O30)

Fig. 239: Junction Connector End View (O30) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 SIDE AIRBAG SENSOR ASSEMBLY RH CONNECTOR END VIEW (O32)

Fig. 240: No. 2 Side Airbag Sensor Assembly RH Connector End View (O32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TIRE PRESSURE WARNING ECU AND RECEIVER (DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY) CONNECTOR END VIEW (O33)

Fig. 241: Tire Pressure Warning ECU And Receiver (Door Control And Tire Pressure Monitoring System Receiver Assembly) Connector End View (O33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ROOF ANTENNA ASSEMBLY CONNECTOR END VIEW (O34)

Fig. 242: Roof Antenna Assembly Connector End View (O34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 3 ANTENNA CORD SUB-ASSEMBLY CONNECTOR END VIEW (O35)

Fig. 243: No. 3 Antenna Cord Sub-Assembly Connector End View (O35) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (O36)

Fig. 244: DCM (Telematics Transceiver) Connector End View (O36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (O37)

Fig. 245: DCM (Telematics Transceiver) Connector End View (O37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR CONTROL RECEIVER CONNECTOR END VIEW (O38)

Fig. 246: Door Control Receiver Connector End View (O38) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (O39)

Fig. 247: Airbag Sensor Assembly Connector End View (O39) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR WINDOW DEFOGGER (BACK WINDOW GLASS) CONNECTOR END VIEW (P1)

Fig. 248: Rear Window Defogger (Back Window Glass) Connector End View (P1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (Q1)

Fig. 249: Inverter with Converter Assembly Connector End View (Q1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR END VIEW (Q2)

Fig. 250: Hybrid Battery Junction Block Assembly Connector End View (Q2)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR END VIEW (Q3)

Fig. 251: Hybrid Battery Junction Block Assembly Connector End View (Q3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HUMIDITY SENSOR (A/C THERMISTOR ASSEMBLY) CONNECTOR END VIEW (S3)

Fig. 252: Humidity Sensor (A/C Thermistor Assembly) Connector End View (S3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SLIDING ROOF CONTROL ECU (SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY) CONNECTOR END VIEW (S4)

Fig. 253: Sliding Roof Control ECU (Sliding Roof Drive Gear Sub-Assembly) Connector End View (S4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VANITY LIGHT ASSEMBLY LH CONNECTOR END VIEW (S5)

Fig. 254: Vanity Light Assembly LH Connector End View (S5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VISOR ASSEMBLY LH CONNECTOR END VIEW (S6)

Fig. 255: Visor Assembly LH Connector End View (S6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VANITY LIGHT ASSEMBLY RH CONNECTOR END VIEW (S8)

Fig. 256: Vanity Light Assembly RH Connector End View (S8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VISOR ASSEMBLY RH CONNECTOR END VIEW (S9)

Fig. 257: Visor Assembly RH Connector End View (S9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INNER REAR VIEW MIRROR ASSEMBLY CONNECTOR END VIEW (S11)

Fig. 258: Inner Rear View Mirror Assembly Connector End View (S11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ROOF CONSOLE BOX ASSEMBLY CONNECTOR END VIEW (S12)

Fig. 259: Roof Console Box Assembly Connector End View (S12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 ROOM LIGHT ASSEMBLY CONNECTOR END VIEW (S13)

Fig. 260: No. 1 Room Light Assembly Connector End View (S13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPOT LIGHT ASSEMBLY LH CONNECTOR END VIEW (S14)

Fig. 261: Spot Light Assembly LH Connector End View (S14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPOT LIGHT ASSEMBLY RH CONNECTOR END VIEW (S15)

Fig. 262: Spot Light Assembly RH Connector End View (S15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OPTION CONNECTOR (AUTOMATIC GLARE-RESISTANT EC MIRROR) CONNECTOR END VIEW (S16)

Fig. 263: Option Connector (Automatic Glare-Resistant EC Mirror) Connector End View (S16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LICENSE PLATE LIGHT ASSEMBLY RH CONNECTOR END VIEW (T2)

Fig. 264: License Plate Light Assembly RH Connector End View (T2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY CONNECTOR END VIEW (T3)

Fig. 265: Luggage Compartment Door Lock Assembly Connector End View (T3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LUGGAGE DOOR OPENING SWITCH ASSEMBLY CONNECTOR END VIEW (T4)

Fig. 266: Luggage Door Opening Switch Assembly Connector End View (T4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LICENSE PLATE LIGHT ASSEMBLY LH CONNECTOR END VIEW (T5)

Fig. 267: License Plate Light Assembly LH Connector End View (T5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR TELEVISION CAMERA ASSEMBLY CONNECTOR END VIEW (T6)

Fig. 268: Rear Television Camera Assembly Connector End View (T6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T8)

Fig. 269: Rear Combination Light Assembly LH Connector End View (T8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T9)

Fig. 270: Rear Combination Light Assembly LH Connector End View (T9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLIND SPOT MONITOR SENSOR LH CONNECTOR END VIEW (T10)

Fig. 271: Blind Spot Monitor Sensor LH Connector End View (T10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR ELECTRICAL KEY ANTENNA CONNECTOR END VIEW (T11)

Fig. 272: Rear Electrical Key Antenna Connector End View (T11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T12)

Fig. 273: Rear Combination Light Assembly RH Connector End View (T12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T13)

Fig. 274: Rear Combination Light Assembly RH Connector End View (T13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR ELECTRICAL KEY ANTENNA CONNECTOR END VIEW (T14)

Fig. 275: Rear Electrical Key Antenna Connector End View (T14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (T15)

Fig. 276: Junction Connector End View (T15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION TERMINAL CONNECTOR END VIEW (T16)

Fig. 277: Junction Terminal Connector End View (T16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR LIGHT ASSEMBLY RH CONNECTOR END VIEW (T17)

Fig. 278: Rear Light Assembly RH Connector End View (T17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR LIGHT ASSEMBLY LH CONNECTOR END VIEW (T18)

Fig. 279: Rear Light Assembly LH Connector End View (T18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T19)

Fig. 280: Rear Combination Light Assembly LH Connector End View (T19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T20)

Fig. 281: Rear Combination Light Assembly RH Connector End View (T20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR LH CONNECTOR END VIEW (U1)

Fig. 282: Rear No. 1 Ultrasonic Sensor LH Connector End View (U1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR CENTER LH CONNECTOR END VIEW (U2)

Fig. 283: Rear No. 1 Ultrasonic Sensor Center LH Connector End View (U2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR CENTER RH CONNECTOR END VIEW (U3)

Fig. 284: Rear No. 1 Ultrasonic Sensor Center RH Connector End View (U3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR RH CONNECTOR END VIEW (U4)

Fig. 285: Rear No. 1 Ultrasonic Sensor RH Connector End View (U4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH CONNECTOR END VIEW (V1)

Fig. 286: Front Door Outside Handle Assembly RH Connector End View (V1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH CONNECTOR END VIEW (W1)

Fig. 287: Front Door Outside Handle Assembly LH Connector End View (W1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. KNOCK CONTROL SENSOR (BANK 1) CONNECTOR END VIEW (Y1)

Fig. 288: Knock Control Sensor (Bank 1) Connector End View (Y1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WITHOUT DOOR CONNECTOR END VIEW (B1)

Fig. 289: Instrument Panel Passenger Airbag Assembly without Door Connector End View (b1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WITHOUT DOOR CONNECTOR END VIEW (B2)

Fig. 290: Instrument Panel Passenger Airbag Assembly without Door Connector End View (b2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LIGHT CUT RELAY CONNECTOR END VIEW (C1)

Fig. 291: Light Cut Relay Connector End View (c1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OCCUPANT DETECTION ECU CONNECTOR END VIEW (D8)

Fig. 292: Occupant Detection ECU Connector End View (d8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY RH CONNECTOR END VIEW (D9)

Fig. 293: Front Seat Inner Belt Assembly RH Connector End View (d9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT OUT WEIGHT DETECTOR SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (D10)

Fig. 294: Front Out Weight Detector Sensor Sub-Assembly Connector End View (d10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OCCUPANT DETECTION ECU CONNECTOR END VIEW (D11)

Fig. 295: Occupant Detection ECU Connector End View (d11)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT IN WEIGHT DETECTOR SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (D12)

Fig. 296: Front In Weight Detector Sensor Sub-Assembly Connector End View (d12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY RH CONNECTOR END VIEW (D13)

Fig. 297: Front Seat Inner Belt Assembly RH Connector End View (d13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT CUSHION HEATER ASSEMBLY RH CONNECTOR END VIEW (D14)

Fig. 298: Front Seat Cushion Heater Assembly RH Connector End View (d14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SLIDE POSITION MOTOR RH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER RH) CONNECTOR END VIEW (D15)

Fig. 299: Front Power Seat Slide Position Motor RH (Front Seat Frame Assembly with Adjuster RH) Connector End View (d15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH RH CONNECTOR END VIEW (D16)

Fig. 300: Front Power Seat Switch RH Connector End View (d16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR RH (FRONT SEAT BACK FRAME SUBASSEMBLY RH) CONNECTOR END VIEW (D17)

Fig. 301: Front Power Seat Reclining Position Motor RH (Front Seat Back Frame Sub-Assembly RH) Connector End View (d17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LUMBAR SWITCH LH CONNECTOR END VIEW (E5)

Fig. 302: Front Power Seat Lumbar Switch LH Connector End View (e5)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LIFT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E8)

Fig. 303: Front Power Seat Lift Position Motor LH (Front Seat Frame Assembly with Adjuster LH) Connector End View (e8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT TILT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E9)

Fig. 304: Front Power Seat Tilt Position Motor LH (Front Seat Frame Assembly with Adjuster LH) Connector End View (e9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT CUSHION HEATER ASSEMBLY LH CONNECTOR END VIEW (E10)

Fig. 305: Front Seat Cushion Heater Assembly LH Connector End View (e10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SLIDE POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E11)

Fig. 306: Front Power Seat Slide Position Motor LH (Front Seat Frame Assembly with Adjuster LH) Connector End View (e11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH LH CONNECTOR END VIEW (E12)

Fig. 307: Front Power Seat Switch LH Connector End View (e12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR LH (FRONT SEAT BACK FRAME SUBASSEMBLY LH) CONNECTOR END VIEW (E13)

Fig. 308: Front Power Seat Reclining Position Motor LH (Front Seat Back Frame Sub-Assembly LH) Connector End View (e13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LUMBAR SUPPORT MOTOR LH (LUMBAR SUPPORT ADJUSTER ASSEMBLY LH) CONNECTOR END VIEW (E14)

Fig. 309: Front Power Seat Lumbar Support Motor LH (Lumbar Support Adjuster Assembly LH) Connector End View (e14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEED SENSOR RH CONNECTOR END VIEW (H1)

Fig. 310: Rear Speed Sensor RH Connector End View (h1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEED SENSOR LH CONNECTOR END VIEW (I1)

Fig. 311: Rear Speed Sensor LH Connector End View (i1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING ECU ASSEMBLY CONNECTOR END VIEW (J2)

Fig. 312: Power Steering ECU Assembly Connector End View (j2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING ECU ASSEMBLY CONNECTOR END VIEW (J3)

Fig. 313: Power Steering ECU Assembly Connector End View (j3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLASS BREAKAGE SENSOR ECU ASSEMBLY CONNECTOR END VIEW (K1)

Fig. 314: Glass Breakage Sensor ECU Assembly Connector End View (k1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLASS BREAKAGE SENSOR MICROPHONE CONNECTOR END VIEW (K2)

Fig. 315: Glass Breakage Sensor Microphone Connector End View (k2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EXTENSION MODULE CONNECTOR END VIEW (M1)

Fig. 316: Extension Module Connector End View (m1)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (M2)

Fig. 317: Radio & Display Receiver Assembly Connector End View (m2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (M3)

Fig. 318: Radio & Display Receiver Assembly Connector End View (m3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (N1)

Fig. 319: Inverter with Converter Assembly Connector End View (n1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE TRANSAXLE ASSEMBLY CONNECTOR END VIEW (N2)

Fig. 320: Hybrid Vehicle Transaxle Assembly Connector End View (n2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INVERTER WITH CONVERTER ASSEMBLY CONNECTOR END VIEW (O1)

Fig. 321: Inverter with Converter Assembly Connector End View (o1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE TRANSAXLE ASSEMBLY CONNECTOR END VIEW (O2)

Fig. 322: Hybrid Vehicle Transaxle Assembly Connector End View (o2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR END VIEW (Q1)

Fig. 323: Hybrid Battery Junction Block Assembly Connector End View (q1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

BATTERY VOLTAGE SENSOR, HV SUPPLY BATTERY ASSEMBLY CONNECTOR END VIEW (Q2)

Fig. 324: Battery Voltage Sensor, HV Supply Battery Assembly Connector End View (q2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BATTERY COOLING BLOWER ASSEMBLY CONNECTOR END VIEW (R1)

Fig. 325: Battery Cooling Blower Assembly Connector End View (r1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INTERLOCK SWITCH (SERVICE PLUG GRIP) CONNECTOR END VIEW (R2)

Fig. 326: Interlock Switch (Service Plug Grip) Connector End View (r2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C AMPLIFIER ASSEMBLY, A/C UNIT (A/C HARNESS ASSEMBLY) CONNECTOR END VIEW (Z1)

Fig. 327: A/C Amplifier Assembly, A/C Unit (A/C Harness Assembly) Connector End View (z1)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRUISE CONTROL MAIN SWITCH, SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (Z2)

Fig. 328: Cruise Control Main Switch, Spiral Cable Sub-Assembly Connector End View (z2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, STEERING PAD SWITCH ASSEMBLY CONNECTOR END VIEW (Z3)

Fig. 329: Spiral Cable Sub-Assembly, Steering Pad Switch Assembly Connector End View (z3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, DRIVER SIDE SQUIB CIRCUIT, (HORN BUTTON ASSEMBLY) CONNECTOR END VIEW (Z4)

Fig. 330: Spiral Cable Sub-Assembly, Driver Side Squib Circuit, (Horn Button Assembly) Connector End View (z4)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, DRIVER SIDE SQUIB CIRCUIT (HORN BUTTON ASSEMBLY) CONNECTOR END VIEW (Z5)

Fig. 331: Spiral Cable Sub-Assembly, Driver Side Squib Circuit (Horn Button Assembly) Connector End View (z5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BATTERY VOLTAGE SENSOR, HV SUPPLY BATTERY ASSEMBLY CONNECTOR END VIEW (Z7)

Fig. 332: Battery Voltage Sensor, HV Supply Battery Assembly Connector End View (z7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BATTERY VOLTAGE SENSOR, HV SUPPLY BATTERY ASSEMBLY CONNECTOR END VIEW (Z8)

Fig. 333: Battery Voltage Sensor, HV Supply Battery Assembly Connector End View (z8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR END VIEW (Z9)

Fig. 334: Hybrid Battery Junction Block Assembly Connector End View (z9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT AIRBAG ASSEMBLY LH CONNECTOR END VIEW (Z10)

Fig. 335: Front Seat Airbag Assembly LH Connector End View (z10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT AIRBAG ASSEMBLY RH CONNECTOR END VIEW (Z11)

Fig. 336: Front Seat Airbag Assembly RH Connector End View (z11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SEAT AIRBAG ASSEMBLY LH CONNECTOR END VIEW (Z12)

Fig. 337: Rear Seat Airbag Assembly LH Connector End View (z12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SEAT AIRBAG ASSEMBLY RH CONNECTOR END VIEW (Z13)

Fig. 338: Rear Seat Airbag Assembly RH Connector End View (z13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU, COOLING FAN MOTOR CONNECTOR END VIEW (Z14)

Fig. 339: Cooling Fan ECU, Cooling Fan Motor Connector End View (z14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU, NO. 2 COOLING FAN MOTOR CONNECTOR END VIEW (Z15)

Fig. 340: Cooling Fan ECU, No. 2 Cooling Fan Motor Connector End View (z15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AA1)

Fig. 341: Connector End View (AA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AN1)

Fig. 342: Connector End View (AN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AN2)

Fig. 343: Connector End View (AN2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AN3)

Fig. 344: Connector End View (AN3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EA1)

Fig. 345: Connector End View (EA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EA2)

Fig. 346: Connector End View (EA2)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EA3)

Fig. 347: Connector End View (EA3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EH1)

Fig. 348: Connector End View (EH1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EY2)

Fig. 349: Connector End View (EY2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IA2)

Fig. 350: Connector End View (IA2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA3)

Fig. 351: Connector End View (IA3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA4)

Fig. 352: Connector End View (IA4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IA5)

Fig. 353: Connector End View (IA5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA6)

Fig. 354: Connector End View (IA6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA8)

Fig. 355: Connector End View (IA8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA9)

Fig. 356: Connector End View (IA9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (II2)

Fig. 357: Connector End View (II2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IN1)

Fig. 358: Connector End View (IN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IO1)

Fig. 359: Connector End View (IO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IO2)

Fig. 360: Connector End View (IO2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IO3)

Fig. 361: Connector End View (IO3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IS1)

Fig. 362: Connector End View (IS1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IS2)

Fig. 363: Connector End View (IS2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IB2)

Fig. 364: Connector End View (Ib2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IC1)

Fig. 365: Connector End View (Ic1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IJ1)

Fig. 366: Connector End View (Ij1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IJ2)

Fig. 367: Connector End View (Ij2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IK1)

Fig. 368: Connector End View (Ik1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (JI1)

Fig. 369: Connector End View (JI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (JI2)

Fig. 370: Connector End View (JI2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (JO1)

Fig. 371: Connector End View (JO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (KI1)

Fig. 372: Connector End View (KI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (KI2)

Fig. 373: Connector End View (KI2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (KN1)

Fig. 374: Connector End View (KN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (LO1)

Fig. 375: Connector End View (LO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (MN1)

Fig. 376: Connector End View (MN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NI1)

Fig. 377: Connector End View (NI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NE1)

Fig. 378: Connector End View (Ne1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NR1)

Fig. 379: Connector End View (Nr1)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NZ1)

Fig. 380: Connector End View (Nz1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NZ2)

Fig. 381: Connector End View (Nz2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OA1)

Fig. 382: Connector End View (OA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (OD1)

Fig. 383: Connector End View (Od1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OD2)

Fig. 384: Connector End View (Od2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OZ1)

Fig. 385: Connector End View (Oz1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (OZ2)

Fig. 386: Connector End View (Oz2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (QA1)

Fig. 387: Connector End View (QA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (QO1)

Fig. 388: Connector End View (QO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (TN1)

Fig. 389: Connector End View (TN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (TN2)

Fig. 390: Connector End View (TN2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (TO1)

Fig. 391: Connector End View (TO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (UO1)

Fig. 392: Connector End View (UO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (VJ1)

Fig. 393: Connector End View (VJ1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (WK1)

Fig. 394: Connector End View (WK1)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (DD1)

Fig. 395: Connector End View (dd1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EE1)

Fig. 396: Connector End View (ee1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (HO1)

Fig. 397: Connector End View (hO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IN1)

Fig. 398: Connector End View (iN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ADDITIONAL INFORMATION *1: Front Side Marker *2: Front Turn Signal and Parking Light *3: Low Halogen Type

2012-2017 ELECTRICAL OEM Connector List - Camry

CONNECTOR LIST NOTE:

For any illustration containing an asterisk *, refer to ADDITIONAL INFORMATION at the end of this article.

LOW PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A1)

Fig. 1: Low Pitched Horn Assembly Connector End View (A1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY) CONNECTOR END VIEW (A2)

Fig. 2: Engine Hood Courtesy Switch (Hood Lock Assembly) Connector End View (A2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AMBIENT TEMPERATURE SENSOR (THERMISTOR ASSEMBLY) CONNECTOR END VIEW (A3)

Fig. 3: Ambient Temperature Sensor (Thermistor Assembly) Connector End View (A3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HIGH PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A4)

Fig. 4: High Pitched Horn Assembly Connector End View (A4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 ULTRASONIC SENSOR LH CONNECTOR END VIEW (A5)

Fig. 5: Front No. 1 Ultrasonic Sensor LH Connector End View (A5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FOG LIGHT ASSEMBLY LH CONNECTOR END VIEW (A6)

Fig. 6: Fog Light Assembly LH Connector End View (A6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN MOTOR CONNECTOR END VIEW (A7)

Fig. 7: Cooling Fan Motor Connector End View (A7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NO. 2 COOLING FAN MOTOR CONNECTOR END VIEW (A8)

Fig. 8: No. 2 Cooling Fan Motor Connector End View (A8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VSV (AIR INTAKE CONTROL) CONNECTOR END VIEW (A9)

Fig. 9: VSV (Air Intake Control) Connector End View (A9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU CONNECTOR END VIEW (A10)

Fig. 10: Cooling Fan ECU Connector End View (A10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT AIRBAG SENSOR LH CONNECTOR END VIEW (A12)

Fig. 11: Front Airbag Sensor LH Connector End View (A12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WIRELESS DOOR LOCK BUZZER CONNECTOR END VIEW (A15)

Fig. 12: Wireless Door Lock Buzzer Connector End View (A15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SPEED SENSOR LH CONNECTOR END VIEW (A16)

Fig. 13: Front Speed Sensor LH Connector End View (A16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A17)

Fig. 14: Headlight Assembly LH Connector End View (A17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A20)

Fig. 15: Headlight Assembly LH Connector End View (A20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A24)

Fig. 16: Headlight Assembly LH Connector End View (A24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECM CONNECTOR END VIEW (A25)

Fig. 17: ECM Connector End View (A25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER MOTOR ASSEMBLY CONNECTOR END VIEW (A29)

Fig. 18: Windshield Wiper Motor Assembly Connector End View (A29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE FLUID LEVEL WARNING SWITCH (BRAKE MASTER CYLINDER RESERVOIR SUBASSEMBLY) CONNECTOR END VIEW (A30)

Fig. 19: Brake Fluid Level Warning Switch (Brake Master Cylinder Reservoir Sub-Assembly) Connector End View (A30) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STOP LIGHT SWITCH ASSEMBLY CONNECTOR END VIEW (A33)

Fig. 20: Stop Light Switch Assembly Connector End View (A33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT LEVELING ECU ASSEMBLY CONNECTOR END VIEW (A34)

Fig. 21: Headlight Leveling ECU Assembly Connector End View (A34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ACCELERATOR PEDAL SENSOR ASSEMBLY CONNECTOR END VIEW (A36)

Fig. 22: Accelerator Pedal Sensor Assembly Connector End View (A36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE PEDAL LOAD SENSING SWITCH (BRAKE PEDAL SUPPORT ASSEMBLY) CONNECTOR END VIEW (A40)

Fig. 23: Brake Pedal Load Sensing Switch (Brake Pedal Support Assembly) Connector End View (A40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARKING BRAKE SWITCH ASSEMBLY CONNECTOR END VIEW (A42)

Fig. 24: Parking Brake Switch Assembly Connector End View (A42) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (A43)

Fig. 25: Certification ECU Connector End View (A43) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SECURITY HORN ASSEMBLY CONNECTOR END VIEW (A44)

Fig. 26: Security Horn Assembly Connector End View (A44) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE ACTUATOR ASSEMBLY CONNECTOR END VIEW (A49)

Fig. 27: Brake Actuator Assembly Connector End View (A49) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SPEED SENSOR RH CONNECTOR END VIEW (A53)

Fig. 28: Front Speed Sensor RH Connector End View (A53) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY CONNECTOR END VIEW (A54)

Fig. 29: Windshield Washer Motor And Pump Assembly Connector End View (A54) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C PRESSURE SENSOR (A/C TUBE&ACCESSORY ASSEMBLY) CONNECTOR END VIEW (A55)

Fig. 30: A/C Pressure Sensor (A/C Tube&Accessory Assembly) Connector End View (A55) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 ULTRASONIC SENSOR RH CONNECTOR END VIEW (A56)

Fig. 31: Front No. 1 Ultrasonic Sensor RH Connector End View (A56) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FOG LIGHT ASSEMBLY RH CONNECTOR END VIEW (A57)

Fig. 32: Fog Light Assembly RH Connector End View (A57) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT AIRBAG SENSOR RH CONNECTOR END VIEW (A58)

Fig. 33: Front Airbag Sensor RH Connector End View (A58)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A60)

Fig. 34: Headlight Assembly RH Connector End View (A60) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A63)

Fig. 35: Headlight Assembly RH Connector End View (A63) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A66)

Fig. 36: Headlight Assembly RH Connector End View (A66) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A70)

Fig. 37: Junction Connector End View (A70) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A71)

Fig. 38: Junction Connector End View (A71) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (A73)

Fig. 39: Junction Connector End View (A73) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A74)

Fig. 40: Headlight Assembly LH Connector End View (A74) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A75)

Fig. 41: Headlight Assembly LH Connector End View (A75) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A76)

Fig. 42: Headlight Assembly RH Connector End View (A76) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A77)

Fig. 43: Headlight Assembly RH Connector End View (A77) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY RH CONNECTOR END VIEW (A78)

Fig. 44: Headlight Assembly RH Connector End View (A78) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT ASSEMBLY LH CONNECTOR END VIEW (A79)

Fig. 45: Headlight Assembly LH Connector End View (A79) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LEVEL WARNING SWITCH ASSEMBLY CONNECTOR END VIEW (A80)

Fig. 46: Level Warning Switch Assembly Connector End View (A80) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SUPER LOW PITCHED HORN ASSEMBLY CONNECTOR END VIEW (A84)

Fig. 47: Super Low Pitched Horn Assembly Connector End View (A84) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL POSITION SWITCH ASSEMBLY CONNECTOR END VIEW (E4)

Fig. 48: Park/Neutral Position Switch Assembly Connector End View (E4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRANSMISSION CONTROL ECU ASSEMBLY CONNECTOR END VIEW (E7)

Fig. 49: Transmission Control ECU Assembly Connector End View (E7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID (TRANSMISSION WIRE) CONNECTOR END VIEW (E8)

Fig. 50: Electronically Controlled Transmission Solenoid (Transmission Wire) Connector End View (E8)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STARTER ASSEMBLY CONNECTOR END VIEW (E9)

Fig. 51: Starter Assembly Connector End View (E9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VSV (ACM) CONNECTOR END VIEW (E10)

Fig. 52: VSV (ACM) Connector End View (E10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INTAKE MASS AIR FLOW METER SUB-ASSEMBLY CONNECTOR END VIEW (E14)

Fig. 53: Intake Mass Air Flow Meter Sub-Assembly Connector End View (E14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE BODY ASSEMBLY WITH MOTOR CONNECTOR END VIEW (E16)

Fig. 54: Throttle Body Assembly with Motor Connector End View (E16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) CONNECTOR END VIEW (E19)

Fig. 55: Air Fuel Ratio Sensor (Bank 1 Sensor 1) Connector End View (E19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OXYGEN SENSOR (BANK 2 SENSOR 2) CONNECTOR END VIEW (E20)

Fig. 56: Oxygen Sensor (Bank 2 Sensor 2) Connector End View (E20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OXYGEN SENSOR (BANK 1 SENSOR 2) CONNECTOR END VIEW (E21)

Fig. 57: Oxygen Sensor (Bank 1 Sensor 2) Connector End View (E21) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OXYGEN SENSOR (BANK 1 SENSOR 2) CONNECTOR END VIEW (E22)

Fig. 58: Oxygen Sensor (Bank 1 Sensor 2) Connector End View (E22) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECM CONNECTOR END VIEW (E26)

Fig. 59: ECM Connector End View (E26) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 1 CONNECTOR END VIEW (E29)

Fig. 60: Fuel Injector Assembly No. 1 Connector End View (E29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 1 CONNECTOR END VIEW (E30)

Fig. 61: Fuel Injector Assembly No. 1 Connector End View (E30) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 3 CONNECTOR END VIEW (E31)

Fig. 62: Fuel Injector Assembly No. 3 Connector End View (E31) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 3 CONNECTOR END VIEW (E32)

Fig. 63: Fuel Injector Assembly No. 3 Connector End View (E32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 5 CONNECTOR END VIEW (E33)

Fig. 64: Fuel Injector Assembly No. 5 Connector End View (E33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 2 CONNECTOR END VIEW (E34)

Fig. 65: Fuel Injector Assembly No. 2 Connector End View (E34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 4 CONNECTOR END VIEW (E35)

Fig. 66: Fuel Injector Assembly No. 4 Connector End View (E35) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL INJECTOR ASSEMBLY NO. 6 CONNECTOR END VIEW (E36)

Fig. 67: Fuel Injector Assembly No. 6 Connector End View (E36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 1 CONNECTOR END VIEW (E37)

Fig. 68: Ignition Coil Assembly No. 1 Connector End View (E37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 3 CONNECTOR END VIEW (E38)

Fig. 69: Ignition Coil Assembly No. 3 Connector End View (E38) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 5 CONNECTOR END VIEW (E39)

Fig. 70: Ignition Coil Assembly No. 5 Connector End View (E39) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 2 CONNECTOR END VIEW (E40)

Fig. 71: Ignition Coil Assembly No. 2 Connector End View (E40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 2 CONNECTOR END VIEW (E41)

Fig. 72: Ignition Coil Assembly No. 2 Connector End View (E41) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 4 CONNECTOR END VIEW (E42)

Fig. 73: Ignition Coil Assembly No. 4 Connector End View (E42) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 4 CONNECTOR END VIEW (E43)

Fig. 74: Ignition Coil Assembly No. 4 Connector End View (E43) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL ASSEMBLY NO. 6 CONNECTOR END VIEW (E44)

Fig. 75: Ignition Coil Assembly No. 6 Connector End View (E44) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VSV (ACIS) CONNECTOR END VIEW (E45)

Fig. 76: VSV (ACIS) Connector End View (E45) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VSV (ACIS) CONNECTOR END VIEW (E46)

Fig. 77: VSV (ACIS) Connector End View (E46) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. E.F.I. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR END VIEW (E47)

Fig. 78: E.F.I. Engine Coolant Temperature Sensor Connector End View (E47) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) CONNECTOR END VIEW (E48)

Fig. 79: Air Fuel Ratio Sensor (Bank 2 Sensor 1) Connector End View (E48) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PURGE VSV CONNECTOR END VIEW (E49)

Fig. 80: Purge VSV Connector End View (E49) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PURGE VSV CONNECTOR END VIEW (E50)

Fig. 81: Purge VSV Connector End View (E50) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (BANK 1 EXHAUST SIDE) CONNECTOR END VIEW (E52)

Fig. 82: VVT Sensor (Bank 1 Exhaust Side) Connector End View (E52) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (BANK 1 EXHAUST SIDE) CONNECTOR END VIEW (E53)

Fig. 83: VVT Sensor (Bank 1 Exhaust Side) Connector End View (E53) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (BANK 1 INTAKE SIDE) CONNECTOR END VIEW (E54)

Fig. 84: VVT Sensor (Bank 1 Intake Side) Connector End View (E54) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VVT SENSOR (BANK 1 INTAKE SIDE) CONNECTOR END VIEW (E55)

Fig. 85: VVT Sensor (Bank 1 Intake Side) Connector End View (E55) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (EXHAUST SIDE) CONNECTOR END VIEW (E56)

Fig. 86: Camshaft Timing Oil Control Valve Assembly (Exhaust Side) Connector End View (E56) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1 EXHAUST SIDE) CONNECTOR END VIEW (E57)

Fig. 87: Camshaft Timing Oil Control Valve Assembly (Bank 1 Exhaust Side) Connector End View (E57) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1 INTAKE SIDE) CONNECTOR END VIEW (E58)

Fig. 88: Camshaft Timing Oil Control Valve Assembly (Bank 1 Intake Side) Connector End View (E58)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (BANK 2 EXHAUST SIDE) CONNECTOR END VIEW (E59)

Fig. 89: VVT Sensor (Bank 2 Exhaust Side) Connector End View (E59) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VVT SENSOR (BANK 2 INTAKE SIDE) CONNECTOR END VIEW (E60)

Fig. 90: VVT Sensor (Bank 2 Intake Side) Connector End View (E60) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2 EXHAUST SIDE) CONNECTOR END VIEW (E61)

Fig. 91: Camshaft Timing Oil Control Valve Assembly (Bank 2 Exhaust Side) Connector End View (E61) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2 INTAKE SIDE) CONNECTOR END VIEW (E62)

Fig. 92: Camshaft Timing Oil Control Valve Assembly (Bank 2 Intake Side) Connector End View (E62) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (INTAKE SIDE) CONNECTOR END VIEW (E63)

Fig. 93: Camshaft Timing Oil Control Valve Assembly (Intake Side) Connector End View (E63) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE OIL PRESSURE SWITCH ASSEMBLY CONNECTOR END VIEW (E64)

Fig. 94: Engine Oil Pressure Switch Assembly Connector End View (E64) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GENERATOR ASSEMBLY CONNECTOR END VIEW (E67)

Fig. 95: Generator Assembly Connector End View (E67) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GENERATOR ASSEMBLY CONNECTOR END VIEW (E68)

Fig. 96: Generator Assembly Connector End View (E68) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GENERATOR ASSEMBLY CONNECTOR END VIEW (E70)

Fig. 97: Generator Assembly Connector End View (E70) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRANK POSITION SENSOR CONNECTOR END VIEW (E72)

Fig. 98: Crank Position Sensor Connector End View (E72) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPRESSOR ASSEMBLY WITH PULLEY CONNECTOR END VIEW (E73)

Fig. 99: Compressor Assembly with Pulley Connector End View (E73) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPRESSOR ASSEMBLY WITH PULLEY CONNECTOR END VIEW (E74)

Fig. 100: Compressor Assembly with Pulley Connector End View (E74) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPRESSOR ASSEMBLY WITH PULLEY CONNECTOR END VIEW (E75)

Fig. 101: Compressor Assembly with Pulley Connector End View (E75) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (E76)

Fig. 102: Junction Connector End View (E76) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STARTER ASSEMBLY CONNECTOR END VIEW (F2)

Fig. 103: Starter Assembly Connector End View (F2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (I1)

Fig. 104: Front No. 2 Speaker Assembly LH Connector End View (I1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (I2)

Fig. 105: Front No. 2 Speaker Assembly LH Connector End View (I2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY CONNECTOR END VIEW (I5)

Fig. 106: Back Sonar or Clearance Sonar Switch Assembly Connector End View (I5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLIND SPOT MONITOR MAIN SWITCH (WARNING CANCELING SWITCH ASSEMBLY) CONNECTOR END VIEW (I10)

Fig. 107: Blind Spot Monitor Main Switch (Warning Canceling Switch Assembly) Connector End View (I10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MAIN BODY ECU CONNECTOR END VIEW (I12)

Fig. 108: Main Body ECU Connector End View (I12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MAIN BODY ECU CONNECTOR END VIEW (I13)

Fig. 109: Main Body ECU Connector End View (I13)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMBINATION METER ASSEMBLY CONNECTOR END VIEW (I17)

Fig. 110: Combination Meter Assembly Connector End View (I17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMBINATION METER ASSEMBLY CONNECTOR END VIEW (I18)

Fig. 111: Combination Meter Assembly Connector End View (I18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRANSPONDER KEY ECU ASSEMBLY CONNECTOR END VIEW (I19)

Fig. 112: Transponder Key ECU Assembly Connector End View (I19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEERING LOCK ACTUATOR ASSEMBLY CONNECTOR END VIEW (I24)

Fig. 113: Steering Lock Actuator Assembly Connector End View (I24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT DIMMER SWITCH ASSEMBLY CONNECTOR END VIEW (I25)

Fig. 114: Headlight Dimmer Switch Assembly Connector End View (I25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (I27)

Fig. 115: Spiral Cable Sub-Assembly Connector End View (I27) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (I28)

Fig. 116: Spiral Cable Sub-Assembly Connector End View (I28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEERING SENSOR CONNECTOR END VIEW (I29)

Fig. 117: Steering Sensor Connector End View (I29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER SWITCH ASSEMBLY CONNECTOR END VIEW (I31)

Fig. 118: Windshield Wiper Switch Assembly Connector End View (I31) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WINDSHIELD WIPER SWITCH ASSEMBLY CONNECTOR END VIEW (I32)

Fig. 119: Windshield Wiper Switch Assembly Connector End View (I32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. UN-LOCK WARNING SWITCH ASSEMBLY CONNECTOR END VIEW (I33)

Fig. 120: Un-Lock Warning Switch Assembly Connector End View (I33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRANSPONDER KEY AMPLIFIER CONNECTOR END VIEW (I34)

Fig. 121: Transponder Key Amplifier Connector End View (I34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. KEY INTER LOCK SOLENOID CONNECTOR END VIEW (I35)

Fig. 122: Key Inter Lock Solenoid Connector End View (I35) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IGNITION OR STARTER SWITCH ASSEMBLY CONNECTOR END VIEW (I36)

Fig. 123: Ignition or Starter Switch Assembly Connector End View (I36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DATA LINK CONNECTOR 3 CONNECTOR END VIEW (I39)

Fig. 124: Data Link Connector 3 Connector End View (I39) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY CONNECTOR END VIEW (I40)

Fig. 125: Lower No. 1 Instrument Panel Airbag Assembly Connector End View (I40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT LOCK CONTROL ECU (LOWER SHIFT LEVER ASSEMBLY) CONNECTOR END VIEW

(I42)

Fig. 126: Shift Lock Control ECU (Lower Shift Lever Assembly) Connector End View (I42) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT LOCK CONTROL ECU (LOWER SHIFT LEVER ASSEMBLY) CONNECTOR END VIEW (I43)

Fig. 127: Shift Lock Control ECU (Lower Shift Lever Assembly) Connector End View (I43) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRANSMISSION CONTROL SWITCH (LOWER SHIFT LEVER ASSEMBLY) CONNECTOR END VIEW (I44)

Fig. 128: Transmission Control Switch (Lower Shift Lever Assembly) Connector End View (I44) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER OUTLET SOCKET ASSEMBLY CONNECTOR END VIEW (I45)

Fig. 129: Rear Power Outlet Socket Assembly Connector End View (I45) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (I46)

Fig. 130: No. 1 Indoor Electrical Key Antenna Assembly Connector End View (I46) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (I47)

Fig. 131: Airbag Sensor Assembly Connector End View (I47) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER SWITCH LH CONNECTOR END VIEW (I52)

Fig. 132: Seat Heater Switch LH Connector End View (I52) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER SWITCH RH CONNECTOR END VIEW (I53)

Fig. 133: Seat Heater Switch RH Connector End View (I53) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 CLEARANCE WARNING BUZZER CONNECTOR END VIEW (I54)

Fig. 134: No. 1 Clearance Warning Buzzer Connector End View (I54) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER OUTLET SOCKET ASSEMBLY CONNECTOR END VIEW (I55)

Fig. 135: Front Power Outlet Socket Assembly Connector End View (I55)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C CONTROL ASSEMBLY CONNECTOR END VIEW (I56)

Fig. 136: A/C Control Assembly Connector End View (I56) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLER (ROOM TEMPERATURE SENSOR) THERMISTOR CONNECTOR END VIEW (I57)

Fig. 137: Cooler (Room Temperature Sensor) Thermistor Connector End View (I57) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE SWITCH CONNECTOR END VIEW (I58)

Fig. 138: Engine Switch Connector End View (I58) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLOCK ASSEMBLY CONNECTOR END VIEW (I59)

Fig. 139: Clock Assembly Connector End View (I59) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 3 SPEAKER ASSEMBLY CONNECTOR END VIEW (I60)

Fig. 140: Front No. 3 Speaker Assembly Connector End View (I60) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AUTOMATIC LIGHT CONTROL SENSOR CONNECTOR END VIEW (I61)

Fig. 141: Automatic Light Control Sensor Connector End View (I61) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT POSITION INDICATOR (INDICATOR LIGHT WIRE SUB-ASSEMBLY) CONNECTOR END VIEW (I62)

Fig. 142: Shift Position Indicator (Indicator Light Wire Sub-Assembly) Connector End View (I62)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I64)

Fig. 143: Multi-Media Module Receiver Sub-Assembly Connector End View (I64) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I65)

Fig. 144: Multi-Media Module Receiver Sub-Assembly Connector End View (I65) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I66)

Fig. 145: Multi-Media Module Receiver Sub-Assembly Connector End View (I66) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I67)

Fig. 146: Multi-Media Module Receiver Sub-Assembly Connector End View (I67) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEREO COMPONENT AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I68)

Fig. 147: Stereo Component Amplifier Assembly Connector End View (I68) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STEREO COMPONENT AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I69)

Fig. 148: Stereo Component Amplifier Assembly Connector End View (I69) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLOVE BOX LIGHT ASSEMBLY CONNECTOR END VIEW (I74)

Fig. 149: Glove Box Light Assembly Connector End View (I74) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIODE (FRONT COURTESY LIGHT) CONNECTOR END VIEW (I75)

Fig. 150: Diode (Front Courtesy Light) Connector End View (I75) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLOWER MOTOR SUB-ASSEMBLY WITH FAN CONNECTOR END VIEW (I76)

Fig. 151: Blower Motor Sub-Assembly with Fan Connector End View (I76) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C AMPLIFIER ASSEMBLY CONNECTOR END VIEW (I77)

Fig. 152: A/C Amplifier Assembly Connector End View (I77) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (I78)

Fig. 153: Certification ECU Connector End View (I78) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NETWORK GATEWAY ECU CONNECTOR END VIEW (I81)

Fig. 154: Network Gateway ECU Connector End View (I81) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLEARANCE WARNING ECU ASSEMBLY CONNECTOR END VIEW (I82)

Fig. 155: Clearance Warning ECU Assembly Connector End View (I82) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (I83)

Fig. 156: Front No. 2 Speaker Assembly RH Connector End View (I83) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (I84)

Fig. 157: Front No. 2 Speaker Assembly RH Connector End View (I84) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I92)

Fig. 158: Junction Connector End View (I92) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I93)

Fig. 159: Junction Connector End View (I93)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I94)

Fig. 160: Junction Connector End View (I94) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I95)

Fig. 161: Junction Connector End View (I95) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I96)

Fig. 162: Junction Connector End View (I96) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I97)

Fig. 163: Junction Connector End View (I97) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I100)

Fig. 164: Junction Connector End View (I100) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I101)

Fig. 165: Junction Connector End View (I101) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I102)

Fig. 166: Junction Connector End View (I102) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

JUNCTION CONNECTOR END VIEW (I103)

Fig. 167: Junction Connector End View (I103) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I104)

Fig. 168: Junction Connector End View (I104) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I105)

Fig. 169: Junction Connector End View (I105) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I106)

Fig. 170: Junction Connector End View (I106) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I107)

Fig. 171: Junction Connector End View (I107) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I108)

Fig. 172: Junction Connector End View (I108) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I111)

Fig. 173: Junction Connector End View (I111) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I124)

Fig. 174: Junction Connector End View (I124) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I125)

Fig. 175: Junction Connector End View (I125) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I126)

Fig. 176: Junction Connector End View (I126) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

JUNCTION CONNECTOR END VIEW (I128)

Fig. 177: Junction Connector End View (I128) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VSC OFF SWITCH CONNECTOR END VIEW (I130)

Fig. 178: VSC Off Switch Connector End View (I130) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HEADLIGHT LEVELING SWITCH CONNECTOR END VIEW (I131)

Fig. 179: Headlight Leveling Switch Connector End View (I131) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AUTOMATIC LIGHT CONTROL SENSOR CONNECTOR END VIEW (I132)

Fig. 180: Automatic Light Control Sensor Connector End View (I132) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO & DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I134)

Fig. 181: Radio & Display Receiver Assembly Connector End View (I134) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (I135)

Fig. 182: DCM (Telematics Transceiver) Connector End View (I135) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BACK-UP BATTERY (MAYDAY BATTERY) CONNECTOR END VIEW (I136)

Fig. 183: Back-Up Battery (Mayday Battery) Connector End View (I136) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TIRE PRESSURE WARNING RESET SWITCH CONNECTOR END VIEW (I137)

Fig. 184: Tire Pressure Warning Reset Switch Connector End View (I137) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY CONNECTOR END VIEW (I140)

Fig. 185: Lower No. 2 Instrument Panel Airbag Assembly Connector End View (I140) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOTE ENGINE STARTER CONNECTOR END VIEW (I141)

Fig. 186: Remote Engine Starter Connector End View (I141) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CHECK CONNECTOR (REMOTE ENGINE STARTER) CONNECTOR END VIEW (I143)

Fig. 187: Check Connector (Remote Engine Starter) Connector End View (I143) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CHECK CONNECTOR (REMOTE ENGINE STARTER) CONNECTOR END VIEW (I144)

Fig. 188: Check Connector (Remote Engine Starter) Connector End View (I144) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 STEREO JACK ADAPTER ASSEMBLY CONNECTOR END VIEW (I146)

Fig. 189: No. 1 Stereo Jack Adapter Assembly Connector End View (I146) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MULTI-MEDIA MODULE RECEIVER SUB-ASSEMBLY CONNECTOR END VIEW (I147)

Fig. 190: Multi-Media Module Receiver Sub-Assembly Connector End View (I147) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I148)

Fig. 191: Radio Receiver Assembly Connector End View (I148) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I149)

Fig. 192: Radio Receiver Assembly Connector End View (I149) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I150)

Fig. 193: Radio Receiver Assembly Connector End View (I150)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO RECEIVER ASSEMBLY CONNECTOR END VIEW (I151)

Fig. 194: Radio Receiver Assembly Connector End View (I151) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I152)

Fig. 195: Radio&Display Receiver Assembly Connector End View (I152) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I153)

Fig. 196: Radio&Display Receiver Assembly Connector End View (I153) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I154)

Fig. 197: Radio&Display Receiver Assembly Connector End View (I154) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I155)

Fig. 198: Radio&Display Receiver Assembly Connector End View (I155) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (I156)

Fig. 199: Radio&Display Receiver Assembly Connector End View (I156) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. YAW RATE SENSOR CONNECTOR END VIEW (I172)

Fig. 200: Yaw Rate Sensor Connector End View (I172) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (I173)

Fig. 201: Junction Connector End View (I173) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EXTENSION MODULE CONNECTOR END VIEW (I175)

Fig. 202: Extension Module Connector End View (I175) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR LOCK ASSEMBLY WITH MOTOR RH CONNECTOR END VIEW (J1)

Fig. 203: Front Door Lock Assembly with Motor RH Connector End View (J1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT COURTESY LIGHT ASSEMBLY RH CONNECTOR END VIEW (J2)

Fig. 204: Front Courtesy Light Assembly RH Connector End View (J2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT NO. 1 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (J5)

Fig. 205: Front No. 1 Speaker Assembly RH Connector End View (J5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY RH CONNECTOR END VIEW (J7)

Fig. 206: Outer Rear View Mirror Assembly RH Connector End View (J7)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR SIDE AIRBAG SENSOR RH CONNECTOR END VIEW (J10)

Fig. 207: Door Side Airbag Sensor RH Connector End View (J10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR SWITCH ASSEMBLY RH CONNECTOR END VIEW (J11)

Fig. 208: Front Power Window Regulator Switch Assembly RH Connector End View (J11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR CONTROL SWITCH ASSEMBLY CONNECTOR END VIEW (J12)

Fig. 209: Door Control Switch Assembly Connector End View (J12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY RH CONNECTOR END VIEW (J13)

Fig. 210: Outer Rear View Mirror Assembly RH Connector End View (J13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH CONNECTOR END VIEW (J14)

Fig. 211: Front Power Window Regulator Motor Assembly RH Connector End View (J14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR LOCK ASSEMBLY WITH MOTOR LH CONNECTOR END VIEW (K1)

Fig. 212: Front Door Lock Assembly With Motor LH Connector End View (K1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT COURTESY LIGHT ASSEMBLY LH CONNECTOR END VIEW (K2)

Fig. 213: Front Courtesy Light Assembly LH Connector End View (K2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT NO. 1 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (K5)

Fig. 214: Front No. 1 Speaker Assembly LH Connector End View (K5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER MIRROR SWITCH ASSEMBLY CONNECTOR END VIEW (K6)

Fig. 215: Outer Mirror Switch Assembly Connector End View (K6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY LH CONNECTOR END VIEW (K7)

Fig. 216: Outer Rear View Mirror Assembly LH Connector End View (K7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH CONNECTOR END VIEW (K9)

Fig. 217: Front Power Window Regulator Motor Assembly LH Connector End View (K9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR SIDE AIRBAG SENSOR LH CONNECTOR END VIEW (K10)

Fig. 218: Door Side Airbag Sensor LH Connector End View (K10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY CONNECTOR END VIEW (K11)

Fig. 219: Power Window Regulator Master Switch Assembly Connector End View (K11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTER REAR VIEW MIRROR ASSEMBLY LH CONNECTOR END VIEW (K12)

Fig. 220: Outer Rear View Mirror Assembly LH Connector End View (K12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR LOCK ASSEMBLY WITH MOTOR RH CONNECTOR END VIEW (L1)

Fig. 221: Rear Door Lock Assembly with Motor RH Connector End View (L1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY RH CONNECTOR END VIEW (L5)

Fig. 222: Rear Power Window Regulator Motor Assembly RH Connector End View (L5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY RH CONNECTOR END VIEW (L6)

Fig. 223: Rear Power Window Regulator Switch Assembly RH Connector End View (L6)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR LOCK ASSEMBLY WITH MOTOR LH CONNECTOR END VIEW (M1)

Fig. 224: Rear Door Lock Assembly With Motor LH Connector End View (M1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH CONNECTOR END VIEW (M5)

Fig. 225: Rear Power Window Regulator Motor Assembly LH Connector End View (M5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY LH CONNECTOR END VIEW (M6)

Fig. 226: Rear Power Window Regulator Switch Assembly LH Connector End View (M6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (N5)

Fig. 227: Airbag Sensor Assembly Connector End View (N5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY LH CONNECTOR END VIEW (N7)

Fig. 228: Front Door Courtesy Light Switch Assembly LH Connector End View (N7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SIDE AIRBAG SENSOR ASSEMBLY LH CONNECTOR END VIEW (N8)

Fig. 229: Side Airbag Sensor Assembly LH Connector End View (N8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT OUTER BELT ASSEMBLY LH CONNECTOR END VIEW (N9)

Fig. 230: Front Seat Outer Belt Assembly LH Connector End View (N9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (N10)

Fig. 231: No. 2 Indoor Electrical Key Antenna Assembly Connector End View (N10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL SUCTION TUBE ASSEMBLY WITH PUMP&GAGE CONNECTOR END VIEW (N11)

Fig. 232: Fuel Suction Tube Assembly With Pump&Gage Connector End View (N11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY LH CONNECTOR END VIEW (N15)

Fig. 233: Rear Door Courtesy Light Switch Assembly LH Connector End View (N15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY CONNECTOR END VIEW (N23)

Fig. 234: No. 1 Luggage Compartment Light Assembly Connector End View (N23) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO SETTING CONDENSER (CENTER STOP LIGHT) CONNECTOR END VIEW (N26)

Fig. 235: Radio Setting Condenser (Center Stop Light) Connector End View (N26) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CURTAIN SHIELD AIRBAG ASSEMBLY LH CONNECTOR END VIEW (N27)

Fig. 236: Curtain Shield Airbag Assembly LH Connector End View (N27) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO SETTING CONDENSER (REAR WINDOW DEFOGGER) CONNECTOR END VIEW (N28)

Fig. 237: Radio Setting Condenser (Rear Window Defogger) Connector End View (N28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR WINDOW DEFOGGER (BACK WINDOW GLASS) CONNECTOR END VIEW (N29)

Fig. 238: Rear Window Defogger (Back Window Glass) Connector End View (N29) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL PUMP CONTROL ECU ASSEMBLY CONNECTOR END VIEW (N30)

Fig. 239: Fuel Pump Control ECU Assembly Connector End View (N30) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY LH CONNECTOR END VIEW (N32)

Fig. 240: Front Seat Inner Belt Assembly LH Connector End View (N32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 SIDE AIRBAG SENSOR ASSEMBLY LH CONNECTOR END VIEW (N33)

Fig. 241: No. 2 Side Airbag Sensor Assembly LH Connector End View (N33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CANISTER PUMP MODULE CONNECTOR END VIEW (N35)

Fig. 242: Canister Pump Module Connector End View (N35) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY CONNECTOR END VIEW (N36)

Fig. 243: No. 3 Indoor Electrical Key Antenna Assembly Connector End View (N36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CENTER STOP LIGHT SET CONNECTOR END VIEW (N37)

Fig. 244: Center Stop Light Set Connector End View (N37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (N40)

Fig. 245: Airbag Sensor Assembly Connector End View (N40) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CERTIFICATION ECU CONNECTOR END VIEW (O1)

Fig. 246: Certification ECU Connector End View (O1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (O7)

Fig. 247: Airbag Sensor Assembly Connector End View (O7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY RH CONNECTOR END VIEW (O10)

Fig. 248: Front Door Courtesy Light Switch Assembly RH Connector End View (O10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SIDE AIRBAG SENSOR ASSEMBLY RH CONNECTOR END VIEW (O11)

Fig. 249: Side Airbag Sensor Assembly RH Connector End View (O11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT OUTER BELT ASSEMBLY RH CONNECTOR END VIEW (O12)

Fig. 250: Front Seat Outer Belt Assembly RH Connector End View (O12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY RH CONNECTOR END VIEW (O16)

Fig. 251: Rear Door Courtesy Light Switch Assembly RH Connector End View (O16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (O17)

Fig. 252: Rear Height Control Sensor Sub-Assembly Connector End View (O17)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEAKER ASSEMBLY RH CONNECTOR END VIEW (O18)

Fig. 253: Rear Speaker Assembly RH Connector End View (O18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 2 SPEAKER ASSEMBLY RH CONNECTOR END VIEW (O19)

Fig. 254: Rear No. 2 Speaker Assembly RH Connector End View (O19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 2 SPEAKER ASSEMBLY LH CONNECTOR END VIEW (O20)

Fig. 255: Rear No. 2 Speaker Assembly LH Connector End View (O20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEAKER ASSEMBLY LH CONNECTOR END VIEW (O21)

Fig. 256: Rear Speaker Assembly LH Connector End View (O21) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WOOFER SPEAKER (REAR SPEAKER ASSEMBLY) CONNECTOR END VIEW (O22)

Fig. 257: Woofer Speaker (Rear Speaker Assembly) Connector End View (O22) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CURTAIN SHIELD AIRBAG ASSEMBLY RH CONNECTOR END VIEW (O23)

Fig. 258: Curtain Shield Airbag Assembly RH Connector End View (O23) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DOOR CONTROL RECEIVER CONNECTOR END VIEW (O24)

Fig. 259: Door Control Receiver Connector End View (O24) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TIRE PRESSURE WARNING ECU AND RECEIVER (DOOR CONTROL AND TIRE PRESSURE MONITORING SYSTEM RECEIVER ASSEMBLY) CONNECTOR END VIEW (O25)

Fig. 260: Tire Pressure Warning ECU And Receiver (Door Control And Tire Pressure Monitoring System Receiver Assembly) Connector End View (O25) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLIND SPOT MONITOR SENSOR RH CONNECTOR END VIEW (O28)

Fig. 261: Blind Spot Monitor Sensor RH Connector End View (O28) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (O30)

Fig. 262: Junction Connector End View (O30)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 2 SIDE AIRBAG SENSOR ASSEMBLY RH CONNECTOR END VIEW (O32)

Fig. 263: No. 2 Side Airbag Sensor Assembly RH Connector End View (O32) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TIRE PRESSURE WARNING ECU AND RECEIVER CONNECTOR END VIEW (O33)

Fig. 264: Tire Pressure Warning ECU And Receiver Connector End View (O33) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ROOF ANTENNA ASSEMBLY CONNECTOR END VIEW (O34)

Fig. 265: Roof Antenna Assembly Connector End View (O34) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 3 ANTENNA CORD SUB-ASSEMBLY CONNECTOR END VIEW (O35)

Fig. 266: No. 3 Antenna Cord Sub-Assembly Connector End View (O35) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (O36)

Fig. 267: DCM (Telematics Transceiver) Connector End View (O36) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DCM (TELEMATICS TRANSCEIVER) CONNECTOR END VIEW (O37)

Fig. 268: DCM (Telematics Transceiver) Connector End View (O37) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRBAG SENSOR ASSEMBLY CONNECTOR END VIEW (O42)

Fig. 269: Airbag Sensor Assembly Connector End View (O42)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR WINDOW DEFOGGER (BACK WINDOW GLASS) CONNECTOR END VIEW (P1)

Fig. 270: Rear Window Defogger (Back Window Glass) Connector End View (P1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SLIDING ROOF CONTROL ECU (SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY) CONNECTOR END VIEW (S4)

Fig. 271: Sliding Roof Control ECU (Sliding Roof Drive Gear Sub-Assembly) Connector End View (S4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VANITY LIGHT ASSEMBLY LH CONNECTOR END VIEW (S5)

Fig. 272: Vanity Light Assembly LH Connector End View (S5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VISOR ASSEMBLY LH CONNECTOR END VIEW (S6)

Fig. 273: Visor Assembly LH Connector End View (S6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VANITY LIGHT ASSEMBLY RH CONNECTOR END VIEW (S8)

Fig. 274: Vanity Light Assembly RH Connector End View (S8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VISOR ASSEMBLY RH CONNECTOR END VIEW (S9)

Fig. 275: Visor Assembly RH Connector End View (S9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INNER REAR VIEW MIRROR ASSEMBLY CONNECTOR END VIEW (S11)

Fig. 276: Inner Rear View Mirror Assembly Connector End View (S11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ROOF CONSOLE BOX ASSEMBLY CONNECTOR END VIEW (S12)

Fig. 277: Roof Console Box Assembly Connector End View (S12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO. 1 ROOM LIGHT ASSEMBLY CONNECTOR END VIEW (S13)

Fig. 278: No. 1 Room Light Assembly Connector End View (S13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPOT LIGHT ASSEMBLY LH CONNECTOR END VIEW (S14)

Fig. 279: Spot Light Assembly LH Connector End View (S14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPOT LIGHT ASSEMBLY RH CONNECTOR END VIEW (S15)

Fig. 280: Spot Light Assembly RH Connector End View (S15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OPTION CONNECTOR (AUTOMATIC GLARE-RESISTANT EC MIRROR) CONNECTOR END VIEW (S16)

Fig. 281: Option Connector (Automatic Glare-Resistant EC Mirror) Connector End View (S16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LICENSE PLATE LIGHT ASSEMBLY RH CONNECTOR END VIEW (T2)

Fig. 282: License Plate Light Assembly RH Connector End View (T2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY CONNECTOR END VIEW (T3)

Fig. 283: Luggage Compartment Door Lock Assembly Connector End View (T3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LUGGAGE DOOR OPENING SWITCH ASSEMBLY CONNECTOR END VIEW (T4)

Fig. 284: Luggage Door Opening Switch Assembly Connector End View (T4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LICENSE PLATE LIGHT ASSEMBLY LH CONNECTOR END VIEW (T5)

Fig. 285: License Plate Light Assembly LH Connector End View (T5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR TELEVISION CAMERA ASSEMBLY CONNECTOR END VIEW (T6)

Fig. 286: Rear Television Camera Assembly Connector End View (T6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T8)

Fig. 287: Rear Combination Light Assembly LH Connector End View (T8)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T9)

Fig. 288: Rear Combination Light Assembly LH Connector End View (T9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BLIND SPOT MONITOR SENSOR LH CONNECTOR END VIEW (T10)

Fig. 289: Blind Spot Monitor Sensor LH Connector End View (T10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR ELECTRICAL KEY ANTENNA CONNECTOR END VIEW (T11)

Fig. 290: Rear Electrical Key Antenna Connector End View (T11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T12)

Fig. 291: Rear Combination Light Assembly RH Connector End View (T12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T13)

Fig. 292: Rear Combination Light Assembly RH Connector End View (T13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR ELECTRICAL KEY ANTENNA CONNECTOR END VIEW (T14)

Fig. 293: Rear Electrical Key Antenna Connector End View (T14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (T15)

Fig. 294: Junction Connector End View (T15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION TERMINAL CONNECTOR END VIEW (T16)

Fig. 295: Junction Terminal Connector End View (T16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR LIGHT ASSEMBLY RH CONNECTOR END VIEW (T17)

Fig. 296: Rear Light Assembly RH Connector End View (T17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR LIGHT ASSEMBLY LH CONNECTOR END VIEW (T18)

Fig. 297: Rear Light Assembly LH Connector End View (T18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR COMBINATION LIGHT ASSEMBLY LH CONNECTOR END VIEW (T19)

Fig. 298: Rear Combination Light Assembly LH Connector End View (T19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR COMBINATION LIGHT ASSEMBLY RH CONNECTOR END VIEW (T20)

Fig. 299: Rear Combination Light Assembly RH Connector End View (T20) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR LH CONNECTOR END VIEW (U1)

Fig. 300: Rear No. 1 Ultrasonic Sensor LH Connector End View (U1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR CENTER LH CONNECTOR END VIEW (U2)

Fig. 301: Rear No. 1 Ultrasonic Sensor Center LH Connector End View (U2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR NO. 1 ULTRASONIC SENSOR CENTER RH CONNECTOR END VIEW (U3)

Fig. 302: Rear No. 1 Ultrasonic Sensor Center RH Connector End View (U3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR NO. 1 ULTRASONIC SENSOR RH CONNECTOR END VIEW (U4)

Fig. 303: Rear No. 1 Ultrasonic Sensor RH Connector End View (U4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH CONNECTOR END VIEW (V1)

Fig. 304: Front Door Outside Handle Assembly RH Connector End View (V1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH CONNECTOR END VIEW (W1)

Fig. 305: Front Door Outside Handle Assembly LH Connector End View (W1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. KNOCK CONTROL SENSOR (BANK 1) CONNECTOR END VIEW (Y1)

Fig. 306: Knock Control Sensor (Bank 1) Connector End View (Y1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. KNOCK CONTROL SENSOR (BANK 2) CONNECTOR END VIEW (Y2)

Fig. 307: Knock Control Sensor (Bank 2) Connector End View (Y2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INTAKE AIR CONTROL VALVE ACTUATOR CONNECTOR END VIEW (Y4)

Fig. 308: Intake Air Control Valve Actuator Connector End View (Y4)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WITHOUT DOOR CONNECTOR END VIEW (B1)

Fig. 309: Instrument Panel Passenger Airbag Assembly Without Door Connector End View (b1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WITHOUT DOOR CONNECTOR END VIEW (B2)

Fig. 310: Instrument Panel Passenger Airbag Assembly Without Door Connector End View (b2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LIGHT CUT RELAY CONNECTOR END VIEW (C1)

Fig. 311: Light Cut Relay Connector End View (c1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT POWER SEAT SLIDE POSITION MOTOR RH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER RH) CONNECTOR END VIEW (D1)

Fig. 312: Front Power Seat Slide Position Motor RH (Front Seat Frame Assembly With Adjuster RH) Connector End View (d1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH RH CONNECTOR END VIEW (D4)

Fig. 313: Front Power Seat Switch RH Connector End View (d4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER CONTROL SUB-ASSEMBLY RH CONNECTOR END VIEW (D6)

Fig. 314: Seat Heater Control Sub-Assembly RH Connector End View (d6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (D7)

Fig. 315: Junction Connector End View (d7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OCCUPANT DETECTION ECU CONNECTOR END VIEW (D8)

Fig. 316: Occupant Detection ECU Connector End View (d8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY RH CONNECTOR END VIEW (D9)

Fig. 317: Front Seat Inner Belt Assembly RH Connector End View (d9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT OUT WEIGHT DETECTOR SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (D10)

Fig. 318: Front Out Weight Detector Sensor Sub-Assembly Connector End View (d10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OCCUPANT DETECTION ECU CONNECTOR END VIEW (D11)

Fig. 319: Occupant Detection ECU Connector End View (d11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT IN WEIGHT DETECTOR SENSOR SUB-ASSEMBLY CONNECTOR END VIEW (D12)

Fig. 320: Front In Weight Detector Sensor Sub-Assembly Connector End View (d12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY RH CONNECTOR END VIEW (D13)

Fig. 321: Front Seat Inner Belt Assembly RH Connector End View (d13)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT CUSHION HEATER ASSEMBLY RH CONNECTOR END VIEW (D14)

Fig. 322: Front Seat Cushion Heater Assembly RH Connector End View (d14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SLIDE POSITION MOTOR RH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER RH) CONNECTOR END VIEW (D15)

Fig. 323: Front Power Seat Slide Position Motor RH (Front Seat Frame Assembly With Adjuster RH) Connector End View (d15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH RH CONNECTOR END VIEW (D16)

Fig. 324: Front Power Seat Switch RH Connector End View (d16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR RH (FRONT SEAT BACK FRAME SUBASSEMBLY RH) CONNECTOR END VIEW (D17)

Fig. 325: Front Power Seat Reclining Position Motor RH (Front Seat Back Frame Sub-Assembly RH) Connector End View (d17) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OCCUPANT DETECTION ECU CONNECTOR END VIEW (D18)

Fig. 326: Occupant Detection ECU Connector End View (d18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT INNER BELT ASSEMBLY RH CONNECTOR END VIEW (D19)

Fig. 327: Front Seat Inner Belt Assembly RH Connector End View (d19) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SLIDE POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E1)

Fig. 328: Front Power Seat Slide Position Motor LH (Front Seat Frame Assembly With Adjuster LH) Connector End View (e1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT TILT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E2)

Fig. 329: Front Power Seat Tilt Position Motor LH (Front Seat Frame Assembly with Adjuster LH) Connector End View (e2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LIFT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E3)

Fig. 330: Front Power Seat Lift Position Motor LH (Front Seat Frame Assembly With Adjuster LH) Connector End View (e3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH LH CONNECTOR END VIEW (E4)

Fig. 331: Front Power Seat Switch LH Connector End View (e4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LUMBAR SWITCH CONNECTOR END VIEW (E5)

Fig. 332: Front Power Seat Lumbar Switch Connector End View (e5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SEAT HEATER CONTROL SUB-ASSEMBLY LH CONNECTOR END VIEW (E6)

Fig. 333: Seat Heater Control Sub-Assembly LH Connector End View (e6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. JUNCTION CONNECTOR END VIEW (E7)

Fig. 334: Junction Connector End View (e7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LIFT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E8)

Fig. 335: Front Power Seat Lift Position Motor LH (Front Seat Frame Assembly With Adjuster LH) Connector End View (e8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT TILT POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E9)

Fig. 336: Front Power Seat Tilt Position Motor LH (Front Seat Frame Assembly With Adjuster LH) Connector End View (e9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT CUSHION HEATER ASSEMBLY LH CONNECTOR END VIEW (E10)

Fig. 337: Front Seat Cushion Heater Assembly LH Connector End View (e10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SLIDE POSITION MOTOR LH (FRONT SEAT FRAME ASSEMBLY WITH ADJUSTER LH) CONNECTOR END VIEW (E11)

Fig. 338: Front Power Seat Slide Position Motor LH (Front Seat Frame Assembly With Adjuster LH) Connector End View (e11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT SWITCH LH CONNECTOR END VIEW (E12)

Fig. 339: Front Power Seat Switch LH Connector End View (e12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR LH (FRONT SEAT BACK FRAME SUBASSEMBLY LH) CONNECTOR END VIEW (E13)

Fig. 340: Front Power Seat Reclining Position Motor LH (Front Seat Back Frame Sub-Assembly LH) Connector End View (e13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LUMBAR SUPPORT MOTOR LH (LUMBAR SUPPORT ADJUSTER ASSEMBLY LH) CONNECTOR END VIEW (E14)

Fig. 341: Front Power Seat Lumbar Support Motor LH (Lumbar Support Adjuster Assembly LH) Connector End View (e14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR RH (FRONT SEAT BACK FRAME SUBASSEMBLY RH) CONNECTOR END VIEW (F1)

Fig. 342: Front Power Seat Reclining Position Motor RH (Front Seat Back Frame Sub-Assembly RH) Connector End View (f1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT RECLINING POSITION MOTOR LH (FRONT SEAT BACK FRAME SUBASSEMBLY LH) CONNECTOR END VIEW (G1)

Fig. 343: Front Power Seat Reclining Position Motor LH (Front Seat Back Frame Sub-Assembly LH) Connector End View (g1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT POWER SEAT LUMBAR SUPPORT MOTOR LH (LUMBAR SUPPORT ADJUSTER ASSEMBLY LH) CONNECTOR END VIEW (G2)

Fig. 344: Front Power Seat Lumbar Support Motor LH (Lumbar Support Adjuster Assembly LH) Connector End View (g2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEED SENSOR RH CONNECTOR END VIEW (H1)

Fig. 345: Rear Speed Sensor RH Connector End View (h1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SPEED SENSOR LH CONNECTOR END VIEW (I1)

Fig. 346: Rear Speed Sensor LH Connector End View (i1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING ECU ASSEMBLY CONNECTOR END VIEW (J1)

Fig. 347: Power Steering ECU Assembly Connector End View (j1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING ECU ASSEMBLY CONNECTOR END VIEW (J2)

Fig. 348: Power Steering ECU Assembly Connector End View (j2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING ECU ASSEMBLY CONNECTOR END VIEW (J3)

Fig. 349: Power Steering ECU Assembly Connector End View (j3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLASS BREAKAGE SENSOR ECU ASSEMBLY CONNECTOR END VIEW (K1)

Fig. 350: Glass Breakage Sensor ECU Assembly Connector End View (k1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GLASS BREAKAGE SENSOR MICROPHONE CONNECTOR END VIEW (K2)

Fig. 351: Glass Breakage Sensor Microphone Connector End View (k2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EXTENSION MODULE CONNECTOR END VIEW (M1)

Fig. 352: Extension Module Connector End View (m1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (M2)

Fig. 353: Radio&Display Receiver Assembly Connector End View (m2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RADIO&DISPLAY RECEIVER ASSEMBLY CONNECTOR END VIEW (M3)

Fig. 354: Radio&Display Receiver Assembly Connector End View (m3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C AMPLIFIER ASSEMBLY, A/C UNIT (A/C HARNESS ASSEMBLY) CONNECTOR END VIEW (Z1)

Fig. 355: A/C Amplifier Assembly, A/C Unit (A/C Harness Assembly) Connector End View (z1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRUISE CONTROL MAIN SWITCH, SPIRAL CABLE SUB-ASSEMBLY CONNECTOR END VIEW (Z2)

Fig. 356: Cruise Control Main Switch, Spiral Cable Sub-Assembly Connector End View (z2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, STEERING PAD SWITCH ASSEMBLY CONNECTOR END VIEW (Z3)

Fig. 357: Spiral Cable Sub-Assembly, Steering Pad Switch Assembly Connector End View (z3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, DRIVER SIDE SQUIB CIRCUIT (HORN BUTTON ASSEMBLY) CONNECTOR END VIEW (Z4)

Fig. 358: Spiral Cable Sub-Assembly, Driver Side Squib Circuit (Horn Button Assembly) Connector End View (z4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SPIRAL CABLE SUB-ASSEMBLY, DRIVER SIDE SQUIB CIRCUIT (HORN BUTTON ASSEMBLY) CONNECTOR END VIEW (Z5)

Fig. 359: Spiral Cable Sub-Assembly, Driver Side Squib Circuit (Horn Button Assembly) Connector End View (z5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT AIRBAG ASSEMBLY LH CONNECTOR END VIEW (Z10)

Fig. 360: Front Seat Airbag Assembly LH Connector End View (z10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT SEAT AIRBAG ASSEMBLY RH CONNECTOR END VIEW (Z11)

Fig. 361: Front Seat Airbag Assembly RH Connector End View (z11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SEAT AIRBAG ASSEMBLY LH CONNECTOR END VIEW (Z12)

Fig. 362: Rear Seat Airbag Assembly LH Connector End View (z12) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR SEAT AIRBAG ASSEMBLY RH CONNECTOR END VIEW (Z13)

Fig. 363: Rear Seat Airbag Assembly RH Connector End View (z13) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU, COOLING FAN MOTOR CONNECTOR END VIEW (Z14)

Fig. 364: Cooling Fan ECU, Cooling Fan Motor Connector End View (z14) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING FAN ECU, NO. 2 COOLING FAN MOTOR CONNECTOR END VIEW (Z15)

Fig. 365: Cooling Fan ECU, No. 2 Cooling Fan Motor Connector End View (z15) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRIC POWER STEERING COLUMN SUB-ASSEMBLY CONNECTOR END VIEW (Z16)

Fig. 366: Electric Power Steering Column Sub-Assembly Connector End View (z16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING MOTOR ASSEMBLY CONNECTOR END VIEW (Z18)

Fig. 367: Power Steering Motor Assembly Connector End View (z18) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AN1)

Fig. 368: Connector End View (AN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (AN2)

Fig. 369: Connector End View (AN2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EA1)

Fig. 370: Connector End View (EA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EA2)

Fig. 371: Connector End View (EA2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EY1)

Fig. 372: Connector End View (EY1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EY3)

Fig. 373: Connector End View (EY3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA2)

Fig. 374: Connector End View (IA2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA3)

Fig. 375: Connector End View (IA3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA4)

Fig. 376: Connector End View (IA4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA5)

Fig. 377: Connector End View (IA5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA6)

Fig. 378: Connector End View (IA6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA7)

Fig. 379: Connector End View (IA7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IA8)

Fig. 380: Connector End View (IA8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (II2)

Fig. 381: Connector End View (II2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IN1)

Fig. 382: Connector End View (IN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IO1)

Fig. 383: Connector End View (IO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IO2)

Fig. 384: Connector End View (IO2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IO3)

Fig. 385: Connector End View (IO3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IS1)

Fig. 386: Connector End View (IS1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IS2)

Fig. 387: Connector End View (IS2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IB2)

Fig. 388: Connector End View (Ib2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IC1)

Fig. 389: Connector End View (Ic1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IJ1)

Fig. 390: Connector End View (Ij1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IJ2)

Fig. 391: Connector End View (Ij2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (IK1)

Fig. 392: Connector End View (Ik1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (JI1)

Fig. 393: Connector End View (JI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (JI2)

Fig. 394: Connector End View (JI2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (JO1)

Fig. 395: Connector End View (JO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (KI1)

Fig. 396: Connector End View (KI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (KI2)

Fig. 397: Connector End View (KI2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (KN1)

Fig. 398: Connector End View (KN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (LO1)

Fig. 399: Connector End View (LO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (MN1)

Fig. 400: Connector End View (MN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NI1)

Fig. 401: Connector End View (NI1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NE1)

Fig. 402: Connector End View (Ne1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (NZ1)

Fig. 403: Connector End View (Nz1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (NZ2)

Fig. 404: Connector End View (Nz2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OA1)

Fig. 405: Connector End View (OA1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OD1)

Fig. 406: Connector End View (Od1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OD2)

Fig. 407: Connector End View (Od2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OZ1)

Fig. 408: Connector End View (Oz1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (OZ2)

Fig. 409: Connector End View (Oz2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONNECTOR END VIEW (TN1)

Fig. 410: Connector End View (TN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (TN2)

Fig. 411: Connector End View (TN2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (TO1)

Fig. 412: Connector End View (TO1)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (UO1)

Fig. 413: Connector End View (UO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (VJ1)

Fig. 414: Connector End View (VJ1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (WK1)

Fig. 415: Connector End View (WK1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (DD1)

Fig. 416: Connector End View (dd1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (EE1)

Fig. 417: Connector End View (ee1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (FD1)

Fig. 418: Connector End View (fd1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (GE1)

Fig. 419: Connector End View (ge1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (HO1)

Fig. 420: Connector End View (hO1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CONNECTOR END VIEW (IN1)

Fig. 421: Connector End View (iN1) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ADDITIONAL INFORMATION *1: Front Side Marker Light *2: Front Turn Signal and Parking Light *3: Headlight Leveling Motor *4: Low Halogen Type

2012-2017 ACCESSORIES & EQUIPMENT Park Assist & Monitoring System (Service Information) (Hybrid)

CLEARANCE WARNING ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Clearance Warning ECU Replacement Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Clearance Warning ECU Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Clearance Warning ECU Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 4 . 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 5 . 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 33 7. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 34 8. REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 9. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 35 10. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 11. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 37 12. REMOVE ECU INTEGRATION BOX RH a. Disconnect each connector. b. Remove the bolt, 2 nuts and ECU integration box RH.

Fig. 4: Locating ECU Integration Box RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE CLEARANCE WARNING ECU ASSEMBLY a. Disengage the 2 claws and remove the clearance warning ECU assembly.

Fig. 5: Locating Clearance Warning ECU Assembly And Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CLEARANCE WARNING ECU ASSEMBLY a. Engage the 2 claws to install the clearance warning ECU assembly. 2. INSTALL ECU INTEGRATION BOX RH a. Install the ECU integration box RH with the 2 nuts and bolt. Bolt Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Nut Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)

3. 4. 5. 6. 7. 8. 9.

b. Connect each connector. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37 INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 47 INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 44 .

10. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 45 . 11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 13. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

CLEARANCE WARNING BUZZER COMPONENTS ILLUSTRATION

Fig. 6: Identifying Clearance Warning Buzzer Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY

Refer to REMOVAL 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 4. REMOVE NO. 1 CLEARANCE WARNING BUZZER a. Disconnect the connector.

Fig. 7: Locating No. 1 Clearance Warning Buzzer Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp to remove the No. 1 clearance warning buzzer. INSTALLATION INSTALLATION

1. INSTALL NO. 1 CLEARANCE WARNING BUZZER a. Engage the clamp to install the No. 1 clearance warning buzzer. b. Connect the connector. 2. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 3. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 4. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

ULTRASONIC SENSOR (FOR FRONT SIDE) COMPONENTS ILLUSTRATION

Fig. 8: Identifying Ultrasonic Sensor (For Front Side) Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL

2. REMOVE NO. 1 ULTRASONIC SENSOR a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor.

Fig. 9: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION LH *A Side RH *B Side 3. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor retainer from the front bumper assembly.

Fig. 10: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side INSPECTION INSPECTION

1. INSPECT NO. 1 ULTRASONIC SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 11: No. 1 Ultrasonic Sensor Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (BI) - 5 10 kohms Always (EI) or higher 1 (BI) - 2 10 kohms Always (BO) or higher 3 (SI) - 4 Below 1 Always (SO) ohms 5 (EI) - 6 Below 1 Always (EO) ohms

TEXT IN ILLUSTRATION Component without harness *a connected: (No. 1 Ultrasonic Sensor) If the result is not as specified, replace the No. 1 ultrasonic sensor. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER a. Engage the 2 claws to install the No. 1 ultrasonic sensor retainer to the front bumper assembly.

Fig. 12: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A LH Side

RH Side *a Keyhole *b Snap

*B

NOTE:





Do not damage the front bumper with the protrusion when installing the retainer. Securely install the No. 1 ultrasonic sensor retainer so that there are no gaps between the retainer and surface of the front bumper.

HINT: When installing the retainer, align the keyhole and snap as shown in the illustration. 2. INSTALL NO. 1 ULTRASONIC SENSOR a. Engage the 2 claws to install the No. 1 ultrasonic sensor to the No. 1 ultrasonic sensor retainer.

Fig. 13: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Push the No. 1 ultrasonic sensor retainer from the outside of the bumper when there is a gap between the retainer and the bumper surface. In this case, do not push on the ultrasonic sensor.

3. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION

ULTRASONIC SENSOR (FOR REAR SIDE) COMPONENTS ILLUSTRATION

Fig. 14: Identifying Ultrasonic Sensor (For Rear Side) Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL 2. REMOVE ULTRASONIC SENSOR CLIP a. Disconnect the connector.

Fig. 15: Locating Ultrasonic Sensor Clip And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side b. Disengage the clamp. c. Disengage the 4 claws to remove the ultrasonic sensor clip.

Fig. 16: Identifying Ultrasonic Sensor Clip And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side 3. REMOVE NO. 1 ULTRASONIC SENSOR a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor.

Fig. 17: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side 4. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor retainer from the rear bumper assembly.

Fig. 18: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side INSPECTION INSPECTION

1. INSPECT NO. 1 ULTRASONIC SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 19: No. 1 Ultrasonic Sensor Connector End View Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (BI) - 5 10 kohms Always (EI) or higher 1 (BI) - 2 10 kohms Always (BO) or higher 3 (SI) - 4 Below 1 Always (SO) ohms 5 (EI) - 6 Below 1 Always (EO) ohms

TEXT IN ILLUSTRATION Component without harness *a connected: (No. 1 Ultrasonic Sensor) If the result is not as specified, replace the No. 1 ultrasonic sensor. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER a. Engage the 2 claws to install the No. 1 ultrasonic sensor retainer to the rear bumper assembly.

Fig. 20: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A LH Side

Other Side *a Keyhole *b Snap

*B

NOTE:





Do not damage the front bumper with the protrusion when installing the retainer. Securely install the No. 1 ultrasonic sensor retainer so that there are no gaps between the retainer and surface of the front bumper.

HINT: When installing the retainer, align the keyhole and snap as shown in the illustration. 2. INSTALL NO. 1 ULTRASONIC SENSOR a. Engage the 2 claws to install the No. 1 ultrasonic sensor to the No. 1 ultrasonic sensor retainer.

Fig. 21: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side NOTE:

Push the No. 1 ultrasonic sensor retainer from the outside of the bumper when there is a gap between the retainer and the bumper surface. In this case, do not push on the ultrasonic sensor.

3. INSTALL ULTRASONIC SENSOR CLIP a. Engage the 4 claws to install the ultrasonic sensor clip.

Fig. 22: Identifying Ultrasonic Sensor Clip And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side b. Engage the clamp.

Fig. 23: Locating Ultrasonic Sensor Clip And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side c. Connect the connector. 4. INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION

BLIND SPOT MONITOR SENSOR COMPONENTS ILLUSTRATION

Fig. 24: Identifying Blind Spot Monitor Sensor Replacement Components With Torque Specifications

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL 2. REMOVE BLIND SPOT MONITOR SENSOR a. for LH Side: 1. Disengage the 2 clamps.

Fig. 25: Locating LH Blind Spot Monitor Sensor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for RH Side: 1. Disengage the clamp.

Fig. 26: Locating RH Blind Spot Monitor Sensor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 3 nuts.

Fig. 27: Locating Blind Spot Monitor Sensor Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disconnect the connector to remove the blind spot monitor sensor.

Fig. 28: Identifying Blind Spot Monitor Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Replace the blind spot monitor sensor if it has been dropped or subjected to a severe impact.

3. REMOVE BLIND SPOT MONITOR COVER a. Remove the 2 nuts.

Fig. 29: Locating Blind Spot Monitor Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw to remove the blind spot monitor cover. INSTALLATION INSTALLATION

1. INSTALL BLIND SPOT MONITOR COVER a. Engage the claw. b. Install the blind spot monitor cover with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 2. INSTALL BLIND SPOT MONITOR SENSOR a. Connect the connector.

Fig. 30: Identifying RH & LH Blind Spot Monitor Sensor And Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A for RH Side:

*B for LH Side: Identification *1 Mark NOTE:







Replace the blind spot monitor sensor if it has been dropped or subjected to a severe impact. Confirm the identification marks on the blind spot monitor sensor before installing it. If the blind spot monitor sensors are not installed to the correct side, the blind spot monitor system will not operate.

b. Install the blind spot monitor sensor with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) c. for LH Side: 1. Engage the 2 clamps. d. for RH Side: 1. Engage the clamp. 3. INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION 4. PERFORM BLIND SPOT MONITOR BEAM AXIS INSPECTION a. Refer to operation check. Refer to OPERATION CHECK .  SST: 09870-60000 09870-60010  SST: 09870-60040 5. PERFORM DIAGNOSTIC SYSTEM CHECK Refer to DTC CHECK / CLEAR

TELEVISION CAMERA COMPONENTS ILLUSTRATION

Fig. 31: Identifying Television Camera Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL 2. REMOVE REAR TELEVISION CAMERA ASSEMBLY a. Disconnect the connector.

Fig. 32: Locating Rear Television Camera Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the rear television camera assembly.

Fig. 33: Identifying Rear Television Camera Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION INSTALLATION

1. INSTALL REAR TELEVISION CAMERA ASSEMBLY a. Engage the 2 claws to install the rear television camera assembly. b. Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION 3. ADJUST REAR TELEVISION CAMERA ASSEMBLY OPTICAL AXIS (w/ Parking Assist Monitor System) Refer to CALIBRATION

CLEARANCE SONAR MAIN SWITCH COMPONENTS ILLUSTRATION

Fig. 34: Identifying Clearance Sonar Main Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 8 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 9 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 10 6. REMOVE BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY

a. Disengage the 2 claws and remove the back sonar or clearance sonar switch assembly.

Fig. 35: Identifying Back Sonar Or Clearance Sonar Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 36: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (IG) & (ECU) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Clearance 9 (IG) - 6 sonar Below 1 (ECU) main ohms switch on Clearance 9 (IG) - 6 sonar 10 kohms (ECU) main or higher switch off TEXT IN ILLUSTRATION Component without harness connected *a (Back Sonar or Clearance Sonar Switch

Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. b. Check that the switch illuminates. 1. Apply auxiliary battery voltage to the back sonar or clearance sonar switch assembly and check that the switch illuminates.

Fig. 37: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (ILL+) & (ILL-) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Specified Connection Condition Auxiliary battery positive (+) --> Terminal 8 Illuminates (ILL+) Auxiliary battery negative (-) -->

Terminal 7 (ILL-) TEXT IN ILLUSTRATION Component without harness connected (Back *a Sonar or Clearance Sonar Switch Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. c. Check switch indicator operation. 1. Apply auxiliary battery voltage to the back sonar or clearance sonar switch assembly and check that the switch indicator illuminates.

Fig. 38: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (E) & (IG) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK

Tester Switch Specified Connection Condition Condition Auxiliary battery positive (+) --> Terminal 9 Clearance (IG) Indicator sonar Auxiliary main Illuminates battery switch on negative (-) --> Terminal 10 (E) TEXT IN ILLUSTRATION Component without harness connected (Back *a Sonar or Clearance Sonar Switch Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. INSTALLATION INSTALLATION

1. INSTALL BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY a. Engage the 2 claws to install the back sonar or clearance sonar switch assembly. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 42 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 43 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 44 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43

BLIND SPOT MONITOR MAIN SWITCH COMPONENTS ILLUSTRATION

Fig. 39: Identifying Blind Spot Monitor Main Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL -

Step 8 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 9 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 10 6. REMOVE BLIND SPOT MONITOR MAIN SWITCH ASSEMBLY (WARNING CANCELING SWITCH ASSEMBLY) a. Disengage the 2 claws to remove the blind spot monitor main switch assembly (warning canceling switch assembly).

Fig. 40: Identifying Back Sonar Or Clearance Sonar Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT BLIND SPOT MONITOR MAIN SWITCH (WARNING CANCELING SWITCH ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 41: Identifying Blind Spot Monitor Main Switch Connector Terminals (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Blind spot monitor 11 (B) - 8 main switch Below 1 (D) assembly ohms on (not protruding) Blind spot monitor 11 (B) - 8 main switch 10 kohms (D) assembly or higher off (protruding) TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor

Main Switch (Warning *a Canceling Switch Assembly)) If the result is not as specified, replace the blind spot monitor main switch (warning canceling switch assembly). b. Check that the switch illuminates. 1. Apply auxiliary battery voltage to the blind spot monitor main switch (warning canceling switch assembly) and check that the switch illuminates.

Fig. 42: Identifying Blind Spot Monitor Main Switch Connector Terminals (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Connection Auxiliary battery positive (+) --> Terminal

Specified Condition

10 (ILL+) Auxiliary battery negative (-) Illuminates --> Terminal 9 (ILL-) TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor *a Main Switch (Warning Canceling Switch Assembly)) If the result is not as specified, replace the blind spot monitor main switch (warning canceling switch assembly). c. Check that the switch indicator illuminates. 1. Apply auxiliary battery voltage to the blind spot monitor main switch assembly and check the operation of the switch, as shown in the table below.

Fig. 43: Identifying Blind Spot Monitor Main Switch Connector Terminals (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Connection

Switch Specified Condition Condition

Auxiliary battery positive (+) --> Terminal 11 (B) Auxiliary battery negative (-) --> Terminal 12 (E)

Blind spot monitor main Indicator switch Illuminates assembly on (not protruding)

TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor

Main Switch (Warning *a Canceling Switch Assembly)) If the result is not as specified, replace the blind spot monitor main switch (warning canceling switch assembly). INSTALLATION INSTALLATION

1. INSTALL BLIND SPOT MONITOR MAIN SWITCH ASSEMBLY (WARNING CANCELING SWITCH ASSEMBLY) a. Engage the 2 claws to install the blind spot monitor main switch assembly (warning canceling switch assembly). 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 42 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 43 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 44 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 43

2012-2017 ACCESSORIES & EQUIPMENT Park Assist & Monitoring System (Service Information) (Except Hybrid) - Camry

CLEARANCE WARNING ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Clearance Warning ECU Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Clearance Warning ECU Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 3 . 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 4 . 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 34 . 6. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 35 . 7. REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 14 . 8. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 36 . 9. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 8 . 10. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 38 . 11. REMOVE ECU INTEGRATION BOX RH a. Disconnect each connector. b. Remove the bolt, 2 nuts and ECU integration box RH.

Fig. 3: Locating ECU Integration Box RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE CLEARANCE WARNING ECU ASSEMBLY a. Disengage the 2 claws and remove the clearance warning ECU assembly.

Fig. 4: Locating Clearance Warning ECU Assembly And Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CLEARANCE WARNING ECU ASSEMBLY a. Engage the 2 claws to install the clearance warning ECU assembly. 2. INSTALL ECU INTEGRATION BOX RH a. Install the ECU integration box RH with the 2 nuts and bolt. Bolt Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Nut Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)

3. 4. 5. 6. 7. 8. 9.

b. Connect each connector. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 . INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 . INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 39 . INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 . INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 46 . INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 43 .

10. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 44 . 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

12. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

CLEARANCE WARNING BUZZER COMPONENTS ILLUSTRATION

Fig. 5: Identifying Clearance Warning Buzzer Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL .

2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 4. REMOVE NO. 1 CLEARANCE WARNING BUZZER a. Disconnect the connector.

Fig. 6: Locating No. 1 Clearance Warning Buzzer Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp to remove the No. 1 clearance warning buzzer. INSTALLATION INSTALLATION

1. INSTALL NO. 1 CLEARANCE WARNING BUZZER a. Engage the clamp to install the No. 1 clearance warning buzzer. b. Connect the connector. 2. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . 3. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . 4. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION .

ULTRASONIC SENSOR (FOR FRONT SIDE)

COMPONENTS ILLUSTRATION

Fig. 7: Identifying Ultrasonic Sensor (For Front Side) Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT BUMPER ASSEMBLY Refer to REMOVAL . 2. REMOVE NO. 1 ULTRASONIC SENSOR a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor.

Fig. 8: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side 3. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor retainer from the front bumper assembly.

Fig. 9: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side INSPECTION INSPECTION

1. INSPECT NO. 1 ULTRASONIC SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 10: Inspecting No. 1 Ultrasonic Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (BI) - 5 10 kohms Always (EI) or higher 1 (BI) - 2 10 kohms Always (BO) or higher 3 (SI) - 4 Below 1 Always (SO) ohms 5 (EI) - 6 Below 1 Always (EO) ohms

TEST IN ILLUSTRATION Component without harness *a connected: (No. 1 Ultrasonic Sensor) If the result is not as specified, replace the No. 1 ultrasonic sensor. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER a. Engage the 2 claws to install the No. 1 ultrasonic sensor retainer to the front bumper assembly.

Fig. 11: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A LH Side

RH Side *a Keyhole *b Snap

*B

NOTE:





Do not damage the front bumper with the protrusion when installing the retainer. Securely install the No. 1 ultrasonic sensor retainer so that there are no gaps between the retainer and surface of the front bumper.

HINT: When installing the retainer, align the keyhole and snap as shown in the illustration. 2. INSTALL NO. 1 ULTRASONIC SENSOR a. Engage the 2 claws to install the No. 1 ultrasonic sensor to the No. 1 ultrasonic sensor retainer.

Fig. 12: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side RH *B Side NOTE:

Push the No. 1 ultrasonic sensor retainer from the outside of the bumper when there is a gap between the retainer and the bumper surface. In this case, do not push on the ultrasonic sensor.

3. INSTALL FRONT BUMPER ASSEMBLY Refer to INSTALLATION .

ULTRASONIC SENSOR (FOR REAR SIDE) COMPONENTS ILLUSTRATION

Fig. 13: Identifying Ultrasonic Sensor (For Rear Side) Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL . 2. REMOVE ULTRASONIC SENSOR CLIP a. Disconnect the connector.

Fig. 14: Locating Ultrasonic Sensor Clip And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side b. Disengage the clamp. c. Disengage the 4 claws to remove the ultrasonic sensor clip.

Fig. 15: Identifying Ultrasonic Sensor Clip And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side 3. REMOVE NO. 1 ULTRASONIC SENSOR a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor.

Fig. 16: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side 4. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER a. Disengage the 2 claws to remove the No. 1 ultrasonic sensor retainer from the rear bumper assembly.

Fig. 17: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side INSPECTION INSPECTION

1. INSPECT NO. 1 ULTRASONIC SENSOR a. Measure the resistance according to the value(s) in the table below.

Fig. 18: Inspecting No. 1 Ultrasonic Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition 1 (BI) - 5 10 kohms Always (EI) or higher 1 (BI) - 2 10 kohms Always (BO) or higher 3 (SI) - 4 Below 1 Always (SO) ohms 5 (EI) - 6 Below 1 Always (EO) ohms

TEST IN ILLUSTRATION Component without harness *a connected: (No. 1 Ultrasonic Sensor) If the result is not as specified, replace the No. 1 ultrasonic sensor. INSTALLATION INSTALLATION

1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER a. Engage the 2 claws to install the No. 1 ultrasonic sensor retainer to the rear bumper assembly.

Fig. 19: Identifying No. 1 Ultrasonic Sensor Retainer And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A LH Side

Other Side *a Keyhole *b Snap

*B

NOTE:





Do not damage the front bumper with the protrusion when installing the retainer. Securely install the No. 1 ultrasonic sensor retainer so that there are no gaps between the retainer and surface of the front bumper.

HINT: When installing the retainer, align the keyhole and snap as shown in the illustration. 2. INSTALL NO. 1 ULTRASONIC SENSOR a. Engage the 2 claws to install the No. 1 ultrasonic sensor to the No. 1 ultrasonic sensor retainer.

Fig. 20: Identifying No. 1 Ultrasonic Sensor And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side NOTE:

Push the No. 1 ultrasonic sensor retainer from the outside of the bumper when there is a gap between the retainer and the bumper surface. In this case, do not push on the ultrasonic sensor.

3. INSTALL ULTRASONIC SENSOR CLIP a. Engage the 4 claws to install the ultrasonic sensor clip.

Fig. 21: Identifying Ultrasonic Sensor Clip And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side b. Engage the clamp.

Fig. 22: Locating Ultrasonic Sensor Clip And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH

*A Side Other *B Side c. Connect the connector. 4. INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION .

BLIND SPOT MONITOR SENSOR COMPONENTS ILLUSTRATION

Fig. 23: Identifying Blind Spot Monitor Sensor Replacement Components With Torque Specifications

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR BUMPER ASSEMBLY Refer to REMOVAL . 2. REMOVE BLIND SPOT MONITOR SENSOR a. for LH Side: 1. Disengage the 2 clamps.

Fig. 24: Locating LH Blind Spot Monitor Sensor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for RH Side: 1. Disengage the clamp.

Fig. 25: Locating RH Blind Spot Monitor Sensor Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 3 nuts.

Fig. 26: Locating Blind Spot Monitor Sensor Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disconnect the connector to remove the blind spot monitor sensor.

Fig. 27: Identifying Blind Spot Monitor Sensor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Replace the blind spot monitor sensor if it has been dropped or subjected to a severe impact.

3. REMOVE BLIND SPOT MONITOR COVER a. Remove the 2 nuts.

Fig. 28: Locating Blind Spot Monitor Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw to remove the blind spot monitor cover. INSTALLATION INSTALLATION

1. INSTALL BLIND SPOT MONITOR COVER a. Engage the claw. b. Install the blind spot monitor cover with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 2. INSTALL BLIND SPOT MONITOR SENSOR a. Connect the connector.

Fig. 29: Identifying RH & LH Blind Spot Monitor Sensor And Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *A for RH Side:

*B for LH Side: Identification *1 Mark NOTE:







Replace the blind spot monitor sensor if it has been dropped or subjected to a severe impact. Confirm the identification marks on the blind spot monitor sensor before installing it. If the blind spot monitor sensors are not installed to the correct side, the blind spot monitor system will not operate.

b. Install the blind spot monitor sensor with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) c. for LH Side: 1. Engage the 2 clamps. d. for RH Side: 1. Engage the clamp. 3. INSTALL REAR BUMPER ASSEMBLY Refer to INSTALLATION . 4. PERFORM BLIND SPOT MONITOR BEAM AXIS INSPECTION a. Refer to OPERATION CHECK .  SST: 09870-60000 09870-60010  SST: 09870-60040 5. PERFORM DIAGNOSTIC SYSTEM CHECK Refer to DTC CHECK / CLEAR .

TELEVISION CAMERA COMPONENTS ILLUSTRATION

Fig. 30: Identifying Television Camera Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to REMOVAL . 2. REMOVE REAR TELEVISION CAMERA ASSEMBLY a. Disconnect the connector.

Fig. 31: Locating Rear Television Camera Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the rear television camera assembly.

Fig. 32: Identifying Rear Television Camera Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION INSTALLATION

1. INSTALL REAR TELEVISION CAMERA ASSEMBLY a. Engage the 2 claws to install the rear television camera assembly. b. Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH SUB-ASSEMBLY Refer to INSTALLATION . 3. ADJUST REAR TELEVISION CAMERA ASSEMBLY OPTICAL AXIS (w/ Parking Assist Monitor System) Refer to CALIBRATION .

CLEARANCE SONAR MAIN SWITCH COMPONENTS ILLUSTRATION

Fig. 33: Identifying Clearance Sonar Main Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 . 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 7 . 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 8. 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 9.

6. REMOVE BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY a. Disengage the 2 claws and remove the back sonar or clearance sonar switch assembly.

Fig. 34: Identifying Back Sonar Or Clearance Sonar Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY a. Measure the resistance according to the value(s) in the table below.

Fig. 35: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (IG) & (ECU) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Clearance 9 (IG) - 6 sonar Below 1 (ECU) main ohms switch on Clearance 9 (IG) - 6 sonar 10 kohms (ECU) main or higher switch off TEXT IN ILLUSTRATION Component without harness connected *a (Back Sonar or Clearance Sonar Switch

Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. b. Check that the switch illuminates. 1. Apply battery voltage to the back sonar or clearance sonar switch assembly and check that the switch illuminates.

Fig. 36: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (ILL+) & (ILL-) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Specified Connection Condition Battery positive (+) --> Terminal 8 (ILL+) Illuminates Battery negative (-) --> Terminal 7 (ILL-)

TEXT IN ILLUSTRATION Component without harness connected (Back *a Sonar or Clearance Sonar Switch Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. c. Check switch indicator operation. 1. Apply battery voltage to the back sonar or clearance sonar switch assembly and check that the switch indicator illuminates.

Fig. 37: Inspecting Back Sonar Or Clearance Sonar Switch Assembly (E) & (IG) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Tester Switch Specified Connection Condition Condition

Battery positive (+) --> Terminal 9 (IG) Battery negative (-) --> Terminal 10 (E)

Clearance sonar Indicator main Illuminates switch on

TEXT IN ILLUSTRATION Component without harness connected (Back *a Sonar or Clearance Sonar Switch Assembly) If the result is not as specified, replace the back sonar or clearance sonar switch assembly. INSTALLATION INSTALLATION

1. INSTALL BACK SONAR OR CLEARANCE SONAR SWITCH ASSEMBLY a. Engage the 2 claws to install the back sonar or clearance sonar switch assembly. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 44 . 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 45 . 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 46 . 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 .

BLIND SPOT MONITOR MAIN SWITCH COMPONENTS

ILLUSTRATION

Fig. 38: Identifying Blind Spot Monitor Main Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 . 2. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 7 . 4. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 8. 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step

9. 6. REMOVE BLIND SPOT MONITOR MAIN SWITCH ASSEMBLY (WARNING CANCELING SWITCH ASSEMBLY) a. Disengage the 2 claws to remove the blind spot monitor main switch assembly (warning canceling switch assembly).

Fig. 39: Identifying Back Sonar Or Clearance Sonar Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT BLIND SPOT MONITOR MAIN SWITCH (WARNING CANCELING SWITCH ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 40: Inspecting MSW1 (B) & (D) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Switch Specified Connection Condition Condition Blind spot monitor 11 (B) - 8 main switch Below 1 (D) assembly ohms on (not protruding) Blind spot monitor 11 (B) - 8 main switch 10 kohms (D) assembly or higher off (protruding) TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor

Main Switch (Warning *a Canceling Switch Assembly)) If the result is not as specified, replace the blind spot monitor main switch (warning canceling switch assembly). b. Check that the switch illuminates. 1. Apply battery voltage to the blind spot monitor main switch (warning canceling switch assembly) and check that the switch illuminates.

Fig. 41: Inspecting MSW1 (ILL+) & (ILL-) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Connection

Specified Condition

Battery positive (+) Illuminates --> Terminal 10 (ILL+)

Battery negative (-) --> Terminal 9 (ILL-) TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor *a Main Switch (Warning Canceling Switch Assembly)) If the result is not as specified, replace the blind spot monitor main switch (warning canceling switch assembly). c. Check that the switch indicator. 1. Apply battery voltage to the blind spot monitor main switch assembly and check operation of the switch, as shown in the table below.

Fig. 42: Inspecting MSW1 (E) & (B) Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OK Connection

Switch Specified Condition Condition

Battery positive (+) --> Terminal 11 (B) Battery negative (-) --> Terminal 12 (E)

Blind spot monitor main Indicator switch Illuminates assembly on (not protruding)

TEXT IN ILLUSTRATION Component without harness connected (Blind Spot Monitor *a Main Switch (Warning Canceling Switch Assembly)) If the result is not as specified, replace the back sonar or blind spot monitor main switch (warning canceling switch assembly). INSTALLATION INSTALLATION

1. INSTALL BLIND SPOT MONITOR MAIN SWITCH ASSEMBLY (WARNING CANCELING SWITCH ASSEMBLY) a. Engage the 2 claws to install the blind spot monitor main switch assembly (warning canceling switch assembly). 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 44 . 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION -

Step 45 . 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 46 . 5. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 .

2012-2017 BRAKES Parking Brake (Service Information) (Hybrid)

PARKING BRAKE PEDAL COMPONENTS ILLUSTRATION

Fig. 1: Identifying Parking Brake Pedal Replacement Components (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Parking Brake Pedal Replacement Components (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing.  

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION

HINT: After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. HINT: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION . 4. REMOVE SHIFT LEVER SUPPORT Refer to REMOVAL 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 10 6. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Built-in Type Yaw Rate Sensor) . Refer to REMOVAL - Step 7 7. REMOVE YAW RATE SENSOR (for Separate Type Yaw Rate Sensor) . Refer to REMOVAL Step 4 8. REMOVE NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Separate Type Yaw Rate Sensor) . Refer to REMOVAL - Step 5 9. REMOVE YAW RATE SENSOR BRACKET (for Separate Type Yaw Rate Sensor) . Refer to REMOVAL - Step 6 10. REMOVE FLOOR CARPET BRACKET RH . Refer to REMOVAL - Step 29 11. REMOVE AIRBAG SENSOR ASSEMBLY . Refer to REMOVAL - Step 17

12. REMOVE POWER MANAGEMENT CONTROL ECU . Refer to REMOVAL - Step 2 13. LOOSEN ADJUSTING NUT a. Remove the lock nut and loosen the adjusting nut.

Fig. 6: Identifying Parking Brake Cable Lock Nut And Adjusting Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Lock Nut Adjusting *2 Nut 14. SEPARATE NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Separate the No. 4 parking brake cable assembly from the parking brake control pedal assembly as shown in the illustration.

Fig. 7: Separating No. 4 Parking Brake Cable Assembly From Control Pedal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 15. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY a. Turn back the floor carpet. b. Remove the clip from the No. 1 parking brake cable assembly.

Fig. 8: Identifying No. 1 Parking Brake Cable Assembly Clips, Bolt, Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and 2 nuts, and separate the No. 1 parking brake cable assembly. d. Disconnect the parking brake switch connector.

Fig. 9: Identifying Parking Brake Switch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the bolt, 2 nuts and parking brake control pedal assembly.

Fig. 10: Identifying Parking Brake Control Pedal Assembly Nuts And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY See step 2 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY See step 2 3. REMOVE PARKING PEDAL PAD a. Remove the parking pedal pad from the parking brake pedal assembly. REASSEMBLY REASSEMBLY

1. INSTALL PARKING PEDAL PAD a. Install the parking pedal pad to the parking brake pedal assembly. 2. INSTALL PARKING BRAKE SWITCH ASSEMBLY See step 1 3. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY See step 27 INSTALLATION INSTALLATION

1. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY a. Install the parking brake control pedal assembly with the bolt and 2 nuts.

Fig. 11: Identifying Parking Brake Control Pedal Assembly Nuts And Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Tighten the bolt and 2 nuts in the order shown in the illustration.

b. Connect the parking brake switch connector. c. Install the No. 1 parking brake cable assembly with the bolt and 2 nuts.

Fig. 12: Identifying No. 1 Parking Brake Cable Assembly Clips, Bolt, Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Nut Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) d. Install the clip to the No. 1 parking brake cable assembly. e. Install the floor carpet. f. Temporarily install the lock nut.

Fig. 13: Identifying Parking Brake Cable Lock Nut And Adjusting Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Lock Nut Adjusting *2 Nut HINT: After adjusting parking brake pedal travel, tighten the lock nut. 2. CONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Connect the No. 4 parking brake cable assembly to the parking brake control pedal assembly as shown in the illustration.

Fig. 14: Connecting No. 4 Parking Brake Cable Assembly From Control Pedal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. 4. 5. 6. 7. 8. 9. 10. 11.

INSTALL POWER MANAGEMENT CONTROL ECU . Refer to INSTALLATION - Step 1 INSTALL AIRBAG SENSOR ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FLOOR CARPET BRACKET RH . Refer to INSTALLATION - Step 14 INSTALL NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Built-in Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 1 INSTALL YAW RATE SENSOR BRACKET (for Separate Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 1 INSTALL NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Separate Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 2 INSTALL YAW RATE SENSOR (for Separate Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 3 INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL SHIFT LEVER SUPPORT Refer to INSTALLATION

12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 14. PERFORM DIAGNOSTIC SYSTEM CHECK  for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR  for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 15. INSPECT SRS WARNING LIGHT  for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM  for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM 16. ADJUST PARKING BRAKE PEDAL TRAVEL . Refer to ADJUSTMENT - Step 2 17. INSPECT BRAKE WARNING LIGHT . Refer to ADJUSTMENT - Step 3

PARKING BRAKE CABLE COMPONENTS ILLUSTRATION

Fig. 15: Identifying Parking Brake Cable Replacement Components With Torque Specifications (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Identifying Parking Brake Cable Replacement Components With Torque Specifications (2 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 17: Identifying Parking Brake Cable Replacement Components With Torque Specifications (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Identifying Parking Brake Cable Replacement Components With Torque Specifications (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 19: Identifying Parking Brake Cable Replacement Components With Torque Specifications (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 20: Identifying Parking Brake Cable Replacement Components With Torque Specifications (6 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 21: Identifying Parking Brake Cable Replacement Components With Torque Specifications (7 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: 



The following procedure is for the No. 1 parking brake cable assembly, No. 3 parking brake cable assembly and No. 4 parking brake cable assembly. Use the same procedure for the No. 3 parking brake cable assembly and No. 2 parking brake cable assembly.

1. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to REMOVAL 2. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY

a. Pull up the parking brake pedal claw.

Fig. 22: Pulling Up The Parking Brake Pedal Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the No. 1 parking brake cable assembly.

b. Remove the adjusting nut.

Fig. 23: Identifying Parking Brake Pedal Adjusting Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the clip from the No. 1 parking brake cable assembly.

Fig. 24: Removing The No. 1 Parking Brake Clip And Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6. 7. 8. 9.

d. Remove the No. 1 parking brake cable assembly from the parking brake pedal assembly. REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 19 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the rear door opening trim weatherstrip LH. REMOVE LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to REMOVAL - Step 8 DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 23 REMOVE REAR DOOR SCUFF PLATE RH . Refer to REMOVAL - Step 26 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side.

REMOVE LAP BELT OUTER ANCHOR COVER (for RH Side) . Refer to REMOVAL - Step 28 DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH . Refer to REMOVAL - Step 29 REMOVE CENTER PILLAR LOWER GARNISH RH . Refer to REMOVAL - Step 30 REMOVE FRONT SEAT ASSEMBLY LH  for Manual Seat: Refer to REMOVAL  for Power Seat: Refer to REMOVAL 14. REMOVE FRONT SEAT ASSEMBLY RH

10. 11. 12. 13.

HINT: Use the same procedure as for the LH side. 15. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to REMOVAL - Step 2 16. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to REMOVAL - Step 3 17. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 2 18. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 3 19. REMOVE FLOOR CARPET HOOK . Refer to REMOVAL - Step 23 20. REMOVE NO. 4 CROSS MEMBER FLOOR REINFORCEMENT SUB-ASSEMBLY a. Remove the screw.

Fig. 25: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 26: Identifying Fuel Lid Lock Open Lever Guide

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the floor carpet to a position where the No. 4 cross member floor reinforcement subassembly can be removed. d. Remove the 8 bolts and No. 4 cross member floor reinforcement sub-assembly.

Fig. 27: Identifying No. 4 Cross Member Floor Reinforcement Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Separate the No. 3 parking brake cable assembly from the parking brake equalizer.

Fig. 28: Identifying No. 2, 3, 4 Parking Brake Cables And Parking Brake Equalizer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Parking *1 Brake Equalizer No. 2 Parking *2 Brake Cable Assembly No. 3 Parking *3 Brake Cable Assembly No. 4 Parking *4 Brake Cable Assembly b. Separate the No. 2 parking brake cable assembly to remove the parking brake equalizer. c. Slide the parking brake equalizer and rubber boot.

Fig. 29: Identifying Parking Brake Equalizer, Rubber Boot And No. 4 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Boot Parking *2 Brake Equalizer No. 4 Parking *3 Brake Cable Assembly

d. Remove the No. 4 parking brake cable assembly from the parking brake equalizer. 22. REMOVE FRONT EXHAUST PIPE ASSEMBLY Refer to REMOVAL 23. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR a. Remove the 3 nuts and front No. 2 floor heat insulator.

Fig. 30: Identifying No. 2 Floor Heat Insulator Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE PARKING BRAKE SHOE LEVER Refer to DISASSEMBLY 25. REMOVE NO. 2 FLOOR UNDER COVER (for LH Side) . Refer to REMOVAL - Step 2 26. REMOVE NO. 1 FLOOR UNDER COVER (for RH Side) . Refer to REMOVAL - Step 3 27. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the clip from the No. 3 parking brake cable assembly.

Fig. 31: Removing No. 3 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and separate the No. 3 parking brake cable assembly.

Fig. 32: Identifying No. 3 Parking Brake Cable Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 4 bolts, nut and No. 3 parking brake cable assembly.

Fig. 33: Identifying No. 3 Parking Brake Cable Nut And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE NO. 2 PARKING BRAKE CABLE CLAMP a. Remove the No. 2 parking brake cable clamp. INSTALLATION INSTALLATION

1. INSTALL NO. 2 PARKING BRAKE CABLE CLAMP a. Install a new No. 2 parking brake cable clamp to the No. 3 parking brake cable assembly. 2. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 3 parking brake cable assembly with the 4 bolts and nut.

Fig. 34: Identifying No. 3 Parking Brake Cable Nut And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt (A) Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) and Nut Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) b. Install the No. 3 parking brake cable assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the clip to the No. 3 parking brake cable assembly. 3. INSTALL NO. 2 FLOOR UNDER COVER (for LH Side) . Refer to INSTALLATION - Step 10 4. INSTALL NO. 1 FLOOR UNDER COVER (for RH Side) . Refer to INSTALLATION - Step 11 5. INSTALL PARKING BRAKE SHOE LEVER See step 6 6. INSTALL FRONT NO. 2 FLOOR HEAT INSULATOR a. Install the front No. 2 floor heat insulator with the 3 nuts. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 7. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Refer to INSTALLATION - Step 1 8. INSTALL NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 4 parking brake cable assembly to the parking brake equalizer.

Fig. 35: Identifying Parking Brake Equalizer, Rubber Boot And No. 4 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 4 Parking *1 Brake Cable Assembly Rubber

*2 Boot Parking *3 Brake Equalizer b. Slide the parking brake equalizer and rubber boot as shown in the illustration. NOTE:

Make sure that the rubber boot is securely inserted into the groove of the No. 4 parking brake cable assembly.

c. Connect the No. 3 parking brake cable assembly to the parking brake equalizer.

Fig. 36: Identifying No. 2, 3, 4 Parking Brake Cables And Parking Brake Equalizer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Parking *1 Brake Equalizer No. 2 Parking *2 Brake Cable Assembly No. 3 Parking

Brake *3 Cable Assembly No. 4 Parking *4 Brake Cable Assembly d. Connect the No. 2 parking brake cable assembly to the parking brake equalizer. 9. INSTALL NO. 4 CROSS MEMBER FLOOR REINFORCEMENT SUB-ASSEMBLY a. Install the No. 4 cross member floor reinforcement sub-assembly with the 8 bolts. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) b. Install the floor carpet. c. Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 37: Identifying Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the screw. 10. INSTALL FLOOR CARPET HOOK . Refer to INSTALLATION - Step 16 11. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to INSTALLATION - Step 4

12. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to INSTALLATION Step 5 13. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to INSTALLATION - Step 4 14. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to INSTALLATION - Step 5 15. INSTALL FRONT SEAT ASSEMBLY LH  for Manual Seat: Refer to INSTALLATION  for Power Seat: Refer to INSTALLATION 16. INSTALL FRONT SEAT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 17. INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 23 18. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 19. INSTALL LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to INSTALLATION Step 7 20. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 21. INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 27 22. INSTALL CENTER PILLAR LOWER GARNISH RH . Refer to INSTALLATION - Step 30 23. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH . Refer to INSTALLATION - Step 31 24. INSTALL LAP BELT OUTER ANCHOR COVER (for RH Side) . Refer to INSTALLATION Step 32 25. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 26. INSTALL REAR DOOR SCUFF PLATE RH . Refer to INSTALLATION - Step 34 27. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY a. Pass the No. 1 parking brake cable assembly through the parking brake pedal assembly. b. Install the clip to the No. 1 parking brake cable assembly. c. Temporarily install the adjusting nut. d. Bend the parking brake pedal claw.

Fig. 38: Bending Parking Brake Pedal Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to INSTALLATION

PARKING BRAKE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 39: Identifying Parking Brake Assembly Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 40: Identifying Parking Brake Assembly Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 41: Identifying Parking Brake Assembly Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

NOTE:





When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC. While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch is turned on. Therefore, even if only brake pads are to be removed and installed, be sure to perform the Disable Brake Control procedure and disconnect the cable from the negative (-) terminal of the auxiliary battery before beginning work.

HINT:  

Use the same procedure for the RH side and LH side. The following procedure is for the LH side.

1. PRECAUTION NOTE:

2. 3. 4. 5. 6. 7.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal, Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

DISABLE BRAKE CONTROL . Refer to REMOVAL - Step 2 REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY . Refer to REPLACEMENT - Step 4 REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG REMOVE REAR DISC . Refer to REMOVAL - Step 16 REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Front Side) a. Remove the parking brake shoe return tension spring.

Fig. 42: Identifying Parking Brake Shoe Return Tension Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Rear Side) a. Remove the parking brake shoe return tension spring.

Fig. 43: Identifying Parking Brake Shoe Return Tension Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Front Side) a. Using SST, remove the parking brake shoe hold down compression spring.

Fig. 44: Removing Parking Brake Shoe Hold Down Compression Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 10. REMOVE PARKING BRAKE SHOE STRUT a. Pull the No. 1 parking brake shoe assembly towards the front of the vehicle by hand as shown in the illustration. 

Fig. 45: Pulling No. 1 Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the parking brake shoe strut.

Fig. 46: Identifying Parking Brake Shoe Strut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Rear Side) a. Using SST, remove the parking brake shoe hold down compression spring.

Fig. 47: Removing Parking Brake Shoe Hold Down Compression Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 12. SEPARATE PARKING BRAKE SHOE LEVER a. Expand the No. 1 and No. 2 parking brake shoe assemblies outward by hand and pull downward to separate them from the parking brake plate. 

Fig. 48: Separating Parking Brake Shoe Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Separate the parking brake shoe lever from the No. 2 parking brake shoe assembly. 13. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET

a. Remove the parking brake shoe adjusting screw set.

Fig. 49: Identifying Parking Brake Shoe Adjusting Screw Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY a. Remove the No. 1 parking brake shoe assembly.

Fig. 50: Identifying No. 1 Parking Brake Shoe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Lower Side) a. Remove the parking brake shoe return tension spring.

Fig. 51: Identifying Parking Brake Shoe Return Tension Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE PARKING BRAKE SHOE LEVER a. Using needle-nose pliers, remove the parking brake shoe lever from the No. 3 parking brake cable assembly as shown in the illustration.

Fig. 52: Removing Parking Brake Shoe Lever From The No. 3 Parking Brake Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE PARKING BRAKE SHOE HOLD DOWN SPRING PIN a. Remove the parking brake shoe hold down spring pin (for front side).

Fig. 53: Identifying Parking Brake Shoe Hold Down Spring Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the parking brake shoe hold down spring pin (for rear side).

Fig. 54: Identifying Parking Brake Shoe Hold Down Spring Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT BRAKE DISC INSIDE DIAMETER a. Using a brake drum gauge or an equivalent tool, measure the inside diameter of the disc.

Fig. 55: Measuring Inside Diameter Of Disc Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard inside diameter 173 mm (6.81 in.) Maximum inside diameter 174 mm (6.85 in.) If the inside diameter is more than the maximum, replace the rear disc. 2. INSPECT PARKING BRAKE SHOE LINING THICKNESS a. Using a ruler, measure the thickness of the parking brake shoe lining.

Fig. 56: Measuring Thickness Of Parking Brake Shoe Lining Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thickness 3.35 mm (0.131 in.) Minimum thickness 1.0 mm (0.0394 in.) If the lining thickness is less than the minimum, or if there is severe or uneven wear, replace the parking brake shoe assembly. NOTE:

Always replace both right and left parking brake shoes together.

3. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT a. Apply chalk to the inside surface of the disc, then slide the brake shoe against the disc to check the fit of the brake shoe lining to the disc.

Fig. 57: Applying Chalk To Inside Surface Of Disc Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the contact between the disc and the brake shoe lining is incorrect, repair it using a brake shoe grinder or replace the parking brake shoe assembly. NOTE:

 

Always replace both right and left parking brake shoes together. Wipe off the chalk after inspection.

REASSEMBLY REASSEMBLY

1. APPLY HIGH TEMPERATURE GREASE

a. Apply high temperature grease to the areas of the parking brake plate which make contact with the shoe as shown in the illustration.

Fig. 58: Identifying High Temperature Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease 2. INSTALL PARKING BRAKE SHOE HOLD DOWN SPRING PIN a. Install the 2 parking brake shoe hold down spring pins. 3. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Lower Side) a. Install the parking brake shoe return tension spring to the No. 2 parking brake shoe assembly. 4. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY a. Install the No. 1 parking brake shoe assembly to the parking brake shoe return tension spring. 5. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET a. Apply high temperature grease to the parking brake shoe adjusting screw set as shown in the illustration.

Fig. 59: Installing Parking Brake Shoe Adjusting Screw Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease b. Install the parking brake shoe adjusting screw set to the No. 1 parking brake shoe assembly and No. 2 parking brake shoe assembly. 6. INSTALL PARKING BRAKE SHOE LEVER a. Using needle-nose pliers, install the parking brake shoe lever to the No. 3 parking brake cable assembly.

Fig. 60: Installing Parking Brake Shoe Lever From The No. 3 Parking Brake Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply high temperature grease to the areas of the parking brake shoe lever which make contact with the No. 2 parking brake shoe assembly.

Fig. 61: Identifying High Temperature Grease Application Area

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease c. Install the parking brake shoe lever to the No. 2 parking brake shoe assembly.

Fig. 62: Installing Parking Brake Shoe Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Expand the No. 1 and No. 2 parking brake shoe assemblies outward by hand and fit them to the parking brake plate.

NOTE:

Make sure that the parking brake shoe lever does not separate from the No. 2 parking brake shoe assembly.

7. INSTALL PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Rear Side) a. Using SST, install the parking brake shoe hold down compression spring.

Fig. 63: Installing Parking Brake Shoe Hold Down Compression Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 8. INSTALL PARKING BRAKE SHOE STRUT a. Install the parking brake shoe strut. b. Install the No. 1 parking brake shoe assembly. 

Fig. 64: Installing No. 1 Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Front Side) a. Using SST, install the parking brake shoe hold down compression spring.

Fig. 65: Installing Parking Brake Shoe Hold Down Compression Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 10. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Rear Side) a. Apply a small amount of high temperature grease to the areas shown in the illustration. 

Fig. 66: Identifying High Temperature Grease Application Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease b. Install the parking brake shoe return tension spring. 11. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Front Side) a. Install the parking brake shoe return tension spring. 12. CHECK PARKING BRAKE INSTALLATION a. Check that each part is installed properly.

Fig. 67: Checking Parking Brake Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH RH *A *B Side Side Front of the - Vehicle NOTE:

There should be no oil or grease on the friction surfaces of the shoe linings or discs.

13. 14. 15. 16.

INSTALL REAR DISC . Refer to INSTALLATION - Step 1 INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG INSTALL REAR DISC BRAKE CALIPER ASSEMBLY . Refer to REPLACEMENT - Step 11 ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL . Refer to ADJUSTMENT - Step 2 17. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 18. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL a. Connect the cable to the negative (-) auxiliary battery terminal. Refer to INSTALLATION - Step

2. b. Connect the reservoir level switch connector. c. Clear the DTCs. Refer to DTC CHECK / CLEAR . 19. BED IN PARKING BRAKE SHOES TO DISCS a. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. b. Depress the parking brake pedal with 150 N (15 kgf, 33.7 lbf) of force. c. Drive the vehicle for about 400 m (0.25 mile) in this condition. d. Repeat this procedure 3 times. NOTE:

Set a 5-minute interval between each procedure to prevent the brake assembly from overheating.

PARKING BRAKE SWITCH COMPONENTS ILLUSTRATION

Fig. 68: Identifying Parking Brake Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to REMOVAL

2. REMOVE PARKING BRAKE SWITCH ASSEMBLY a. Remove the screw and parking brake switch assembly from the parking brake control pedal assembly.

Fig. 69: Identifying Parking Brake Switch Assembly And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT PARKING BRAKE SWITCH ASSEMBLY a. Measure the resistance between the connector terminal and the nut inside the parking brake switch assembly.

Fig. 70: Inspecting Parking Brake Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Terminal *2 Nut *a ON *b OFF STANDARD RESISTANCE Tester Switch Specified Connection Condition Condition On (When Terminal - shaft is Below 1 Nut ohms not pressed) Off Terminal - (When 10 kohms Nut shaft is or higher pressed) If the value is not as specified, replace the parking brake switch assembly. INSTALLATION INSTALLATION

1. INSTALL PARKING BRAKE SWITCH ASSEMBLY a. Install the parking brake switch assembly to the parking brake control pedal assembly with the screw.

Fig. 71: Identifying Parking Brake Switch Assembly And Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf) 2. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to INSTALLATION

2012-2017 BRAKES Parking Brake (Service Information) (Except Hybrid) - Camry

PARKING BRAKE PEDAL COMPONENTS ILLUSTRATION

Fig. 1: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Parking Brake Pedal Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Parking Brake Pedal Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE SHIFT LEVER SUPPORT  For U660E: Refer to REMOVAL .  For U760E: Refer to REMOVAL . 2. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to REMOVAL Step 9 . 3. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Built-in Type Yaw Rate Sensor) w/ Smart Key System: Refer to REMOVAL - Step 7 . 4. REMOVE YAW RATE SENSOR (for Separate Type Yaw Rate Sensor) . Refer to REMOVAL Step 4 . 5. REMOVE NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Separate Type Yaw Rate Sensor) w/ Smart Key System: Refer to REMOVAL - Step 5 . 6. REMOVE YAW RATE SENSOR BRACKET (for Separate Type Yaw Rate Sensor) . Refer to REMOVAL - Step 6 . 7. REMOVE FLOOR CARPET BRACKET RH . Refer to REMOVAL - Step 34 . 8. REMOVE AIRBAG SENSOR ASSEMBLY . Refer to REMOVAL - Step 17 . 9. LOOSEN ADJUSTING NUT a. Remove the lock nut and loosen the adjusting nut.

Fig. 5: Identifying Parking Brake Cable Lock Nut And Adjusting Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Lock Nut Adjusting *2 Nut 10. SEPARATE NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Separate the No. 4 parking brake cable assembly from the parking brake control pedal assembly as shown in the illustration.

Fig. 6: Separating No. 4 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold 11. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY a. Turn back the floor carpet. b. Remove the clip from the No. 1 parking brake cable assembly.

Fig. 7: Removing Parking Brake Control Pedal Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and 2 nuts, and separate the No. 1 parking brake cable assembly. d. Disconnect the parking brake switch connector.

Fig. 8: Locating Parking Brake Switch Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the bolt, 2 nuts and parking brake control pedal assembly.

Fig. 9: Locating Parking Brake Control Pedal Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY DISASSEMBLY

1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY . See step 2. 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY . See step 2. 3. REMOVE PARKING PEDAL PAD a. Remove the parking pedal pad from the parking brake pedal assembly. REASSEMBLY REASSEMBLY

1. INSTALL PARKING PEDAL PAD a. Install the parking pedal pad to the parking brake pedal assembly. 2. INSTALL PARKING BRAKE SWITCH ASSEMBLY . See step 1. 3. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY . See step 27. INSTALLATION INSTALLATION

1. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY a. Install the parking brake control pedal assembly with the bolt and 2 nuts.

Fig. 10: Identifying Parking Brake Control Pedal Assembly Fasteners With Tightening

Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE:

Tighten the bolt and 2 nuts in the order shown in the illustration.

b. Connect the parking brake switch connector. c. Install the No. 1 parking brake cable assembly with the bolt and 2 nuts.

Fig. 11: Installing Parking Brake Control Pedal Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Nut Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) d. Install the clip to the No. 1 parking brake cable assembly. e. Install the floor carpet. f. Temporarily install the lock nut.

Fig. 12: Identifying Parking Brake Cable Lock Nut And Adjusting Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Lock Nut Adjusting *2 Nut HINT: After adjusting parking brake pedal travel, tighten the lock nut. 2. CONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Connect the No. 4 parking brake cable assembly to the parking brake control pedal assembly as shown in the illustration.

Fig. 13: Connecting No. 4 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Turn *b Hold Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL AIRBAG SENSOR ASSEMBLY . Refer to INSTALLATION - Step 1 . 4. INSTALL FLOOR CARPET BRACKET RH . Refer to INSTALLATION - Step 14 . 5. INSTALL NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Built-in Type Yaw Rate Sensor) w/ Smart Key System: Refer to INSTALLATION - Step 1 . 6. INSTALL YAW RATE SENSOR BRACKET (for Separate Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 1 . 7. INSTALL NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (for Separate Type Yaw Rate Sensor) w/ Smart Key System: Refer to INSTALLATION - Step 2 . 8. INSTALL YAW RATE SENSOR (for Separate Type Yaw Rate Sensor) . Refer to INSTALLATION - Step 3 . 9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY . Refer to

INSTALLATION - Step 1 . 10. INSTALL SHIFT LEVER SUPPORT  For U660E. Refer to INSTALLATION .  For U760E. Refer to INSTALLATION . 11. ADJUST PARKING BRAKE PEDAL TRAVEL . Refer to ADJUSTMENT - Step 2 . 12. INSPECT BRAKE WARNING LIGHT . Refer to ADJUSTMENT - Step 3 .

PARKING BRAKE CABLE COMPONENTS ILLUSTRATION

Fig. 14: Identifying Parking Brake Cable Replacement Components (1 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 15: Identifying Parking Brake Cable Replacement Components With Torque Specifications (2 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 16: Identifying Parking Brake Cable Replacement Components With Torque Specifications (3 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 17: Identifying Parking Brake Cable Replacement Components (4 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 18: Identifying Parking Brake Cable Replacement Components With Torque Specifications (5 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 19: Identifying Parking Brake Cable Replacement Components With Torque Specifications (6 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 20: Identifying Parking Brake Cable Replacement Components With Torque Specifications (7 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 21: Identifying Parking Brake Cable Replacement Components With Torque Specifications (8 Of 8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT: 



The following procedure is for the No. 1 parking brake cable assembly and No. 3 parking brake cable assembly. Use the same procedure for the No. 3 parking brake cable assembly and No. 2 parking brake cable assembly.

1. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to REMOVAL. 2. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY a. Pull up the parking brake pedal claw.

Fig. 22: Removing No. 1 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the No. 1 parking brake cable assembly.

b. Remove the adjusting nut.

Fig. 23: Identifying No. 1 Parking Brake Cable Assembly Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the clip from the No. 1 parking brake cable assembly.

Fig. 24: Identifying No. 1 Parking Brake Cable Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6. 7. 8. 9.

d. Remove the No. 1 parking brake cable assembly from the parking brake pedal assembly. REMOVE REAR DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 18 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the rear door opening trim weatherstrip LH. REMOVE LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to REMOVAL - Step 7 . DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE CENTER PILLAR LOWER GARNISH LH . Refer to REMOVAL - Step 22 . REMOVE REAR DOOR SCUFF PLATE RH . Refer to REMOVAL - Step 25 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure as for the LH side.

REMOVE LAP BELT OUTER ANCHOR COVER (for RH Side) . Refer to REMOVAL - Step 27 . DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH . Refer to REMOVAL - Step 28 . REMOVE CENTER PILLAR LOWER GARNISH RH . Refer to REMOVAL - Step 29 . REMOVE FRONT SEAT ASSEMBLY LH  For TMMK Made Manual Seat: Refer to REMOVAL .  For TMMK Made Power Seat: Refer to REMOVAL .  For SIA Made Manual Seat: Refer to REMOVAL .  For SIA Made Power Seat: Refer to REMOVAL . 14. REMOVE FRONT SEAT ASSEMBLY RH

10. 11. 12. 13.

HINT: Use the same procedure as for the LH side. 15. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to REMOVAL - Step 2 . 16. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to REMOVAL - Step 3 . 17. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 2. 18. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to REMOVAL - Step 3 . 19. REMOVE FLOOR CARPET HOOK . Refer to REMOVAL - Step 28 . 20. REMOVE NO. 4 CROSS MEMBER FLOOR REINFORCEMENT SUB-ASSEMBLY a. Remove the screw.

Fig. 25: Identifying Fuel Lid Lock Open Lever Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 26: Disengaging Fuel Lid Lock Open Lever Guide

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the floor carpet to a position where the No. 4 cross member floor reinforcement subassembly can be removed. d. Remove the 8 bolts and No. 4 cross member floor reinforcement sub-assembly.

Fig. 27: Identifying No. 4 Cross Member Floor Reinforcement Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Separate the No. 3 parking brake cable assembly from the parking brake equalizer.

Fig. 28: Identifying Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Parking *1 Brake Equalizer No. 2 Parking *2 Brake Cable Assembly No. 3 Parking *3 Brake Cable Assembly No. 4 Parking *4 Brake Cable Assembly b. Separate the No. 2 parking brake cable assembly to remove the parking brake equalizer. c. Slide the parking brake equalizer and rubber boot.

Fig. 29: Removing Parking Brake Cable Assembly From Parking Brake Equalizer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rubber *1 Boot Parking *2 Brake Equalizer No. 4 Parking *3 Brake Cable Assembly d. Remove the No. 4 parking brake cable assembly from the parking brake equalizer.

22. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2AR-FE) Refer to REMOVAL . 23. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR (for 2AR-FE) a. Remove the 3 nuts and front No. 2 floor heat insulator.

Fig. 30: Locating Front No. 2 Floor Heat Insulator (For 2AR-FE) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE PARKING BRAKE SHOE LEVER Refer to DISASSEMBLY. 25. REMOVE NO. 2 FLOOR UNDER COVER (for LH Side) a. w/ Floor Under Cover: 1. Remove the 2 bolts and 2 clips.

Fig. 31: Identifying No. 2 Floor Under Cover (For LH Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) 2. Disengage the 3 nuts and remove the No. 2 floor under cover. 26. REMOVE NO. 1 FLOOR UNDER COVER (for RH Side) a. Remove the 2 bolts.

Fig. 32: Identifying No. 1 Floor Under Cover (For RH Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) b. Disengage the 3 nuts and 2 clips, and remove the No. 1 floor under cover. 27. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the clip from the No. 3 parking brake cable assembly.

Fig. 33: Removing No. 3 Parking Brake Cable Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and separate the No. 3 parking brake cable assembly.

Fig. 34: Locating No. 3 Parking Brake Cable Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 4 bolts, nut and No. 3 parking brake cable assembly.

Fig. 35: Locating No. 3 Parking Brake Cable Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE NO. 2 PARKING BRAKE CABLE CLAMP a. Remove the No. 2 parking brake cable clamp. INSTALLATION INSTALLATION

1. INSTALL NO. 2 PARKING BRAKE CABLE CLAMP a. Install a new No. 2 parking brake cable clamp to the No. 3 parking brake cable assembly. 2. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 3 parking brake cable assembly with the 4 bolts and nut.

Fig. 36: Locating No. 3 Parking Brake Cable Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Bolt (A) Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) and Nut Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) b. Install the No. 3 parking brake cable assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Install the clip to the No. 3 parking brake cable assembly. 3. INSTALL NO. 2 FLOOR UNDER COVER (for LH Side) a. w/ Floor Under Cover: 1. Install the No. 2 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 4. INSTALL NO. 1 FLOOR UNDER COVER (for RH Side)

a. Install the No. 1 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 5. INSTALL PARKING BRAKE SHOE LEVER See step 6. 6. INSTALL FRONT NO. 2 FLOOR HEAT INSULATOR (for 2AR-FE) a. Install the front No. 2 floor heat insulator with the 3 nuts. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2AR-FE) Refer to INSTALLATION - Step 2 . 8. INSTALL NO. 4 PARKING BRAKE CABLE ASSEMBLY a. Install the No. 4 parking brake cable assembly to the parking brake equalizer.

Fig. 37: Installing Parking Brake Cable Assembly To Parking Brake Equalizer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION No. 4 Parking *1 Brake Cable Assembly Rubber *2 Boot Parking *3 Brake Equalizer b. Slide the parking brake equalizer and rubber boot as shown in the illustration.

NOTE:

Make sure that the rubber boot is securely inserted into the groove of the No. 4 parking brake cable assembly.

c. Connect the No. 3 parking brake cable assembly to the parking brake equalizer.

Fig. 38: Identifying Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Parking *1 Brake Equalizer No. 2 Parking *2 Brake Cable Assembly No. 3 Parking *3 Brake Cable Assembly No. 4 Parking *4 Brake Cable Assembly

d. Connect the No. 2 parking brake cable assembly to the parking brake equalizer. 9. INSTALL NO. 4 CROSS MEMBER FLOOR REINFORCEMENT SUB-ASSEMBLY a. Install the No. 4 cross member floor reinforcement sub-assembly with the 8 bolts. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) b. Install the floor carpet. c. Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.

Fig. 39: Engaging Fuel Lid Lock Open Lever Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

10. 11. 12. 13. 14. 15.

d. Install the screw. INSTALL FLOOR CARPET HOOK . Refer to INSTALLATION - Step 16 . INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) . Refer to INSTALLATION - Step 4 . INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) . Refer to INSTALLATION Step 5 . INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) . Refer to INSTALLATION - Step 4 . INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers) . Refer to INSTALLATION - Step 5 . INSTALL FRONT SEAT ASSEMBLY LH  For TMMK Made Manual Seat: Refer to INSTALLATION .  For TMMK Made Power Seat: Refer to INSTALLATION .

For SIA Made Manual Seat: Refer to INSTALLATION .  For SIA Made Power Seat: Refer to INSTALLATION . 16. INSTALL FRONT SEAT ASSEMBLY RH 

HINT: Use the same procedure as for the LH side. 17. INSTALL CENTER PILLAR LOWER GARNISH LH . Refer to INSTALLATION - Step 22 . 18. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 6 . 19. INSTALL LAP BELT OUTER ANCHOR COVER (for LH Side) . Refer to INSTALLATION Step 7 . 20. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 21. INSTALL REAR DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 26 . 22. INSTALL CENTER PILLAR LOWER GARNISH RH . Refer to INSTALLATION - Step 29 . 23. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH . Refer to INSTALLATION - Step 30 . 24. INSTALL LAP BELT OUTER ANCHOR COVER (for RH Side) . Refer to INSTALLATION Step 31 . 25. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 26. INSTALL REAR DOOR SCUFF PLATE RH . Refer to INSTALLATION - Step 33 . 27. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY a. Pass the No. 1 parking brake cable assembly through the parking brake pedal assembly. b. Install the clip to the No. 1 parking brake cable assembly. c. Temporarily install the adjusting nut. d. Bend the parking brake pedal claw.

Fig. 40: Installing No. 1 Parking Brake Cable Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to INSTALLATION.

PARKING BRAKE ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 41: Identifying Parking Brake Assembly Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 42: Identifying Parking Brake Assembly Replacement Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 43: Identifying Parking Brake Assembly Replacement Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

HINT:  

1. 2. 3. 4. 5.

Use the same procedure for the RH side and LH side. The following procedure is for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY . Refer to REPLACEMENT - Step 2 . REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG REMOVE REAR DISC . Refer to REMOVAL - Step 14 . REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Front Side) a. Remove the parking brake shoe return tension spring.

Fig. 44: Identifying Parking Brake Shoe Return Tension Spring (For Front Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Rear Side) a. Remove the parking brake shoe return tension spring.

Fig. 45: Identifying Parking Brake Shoe Return Tension Spring (For Rear Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Front Side) a. Using SST, remove the parking brake shoe hold down compression spring.

Fig. 46: Remove/Install Parking Brake Shoe Hold Down Compression Spring (For Front Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 8. REMOVE PARKING BRAKE SHOE STRUT a. Pull the No. 1 parking brake shoe assembly towards the front of the vehicle by hand as shown in the illustration. 

Fig. 47: Removing No. 1 Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the parking brake shoe strut.

Fig. 48: Locating Parking Brake Shoe Strut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. REMOVE PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Rear Side) a. Using SST, remove the parking brake shoe hold down compression spring.

Fig. 49: Remove/Install Parking Brake Shoe Hold Down Compression Spring (For Rear Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 10. SEPARATE PARKING BRAKE SHOE LEVER a. Expand the No. 1 and No. 2 parking brake shoe assemblies outward by hand and pull downward to separate them from the parking brake plate. 

Fig. 50: Separating Parking Brake Shoe Assemblies Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Separate the parking brake shoe lever from the No. 2 parking brake shoe assembly. 11. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET

a. Remove the parking brake shoe adjusting screw set.

Fig. 51: Identifying Parking Brake Shoe Adjusting Screw Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY a. Remove the No. 1 parking brake shoe assembly.

Fig. 52: Identifying No. 1 Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (for Lower Side) a. Remove the parking brake shoe return tension spring.

Fig. 53: Identifying Parking Brake Shoe Return Tension Spring (For Lower Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE PARKING BRAKE SHOE LEVER a. Using needle-nose pliers, remove the parking brake shoe lever from the No. 3 parking brake cable assembly as shown in the illustration.

Fig. 54: Removing Parking Brake Shoe Lever From No. 3 Parking Brake Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE PARKING BRAKE SHOE HOLD DOWN SPRING PIN a. Remove the parking brake shoe hold down spring pin (for front side).

Fig. 55: Locating Parking Brake Shoe Hold Down Spring Pin (For Front Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the parking brake shoe hold down spring pin (for rear side).

Fig. 56: Locating Parking Brake Shoe Hold Down Spring Pin (For Rear Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION INSPECTION

1. INSPECT BRAKE DISC INSIDE DIAMETER a. Using a brake drum gauge or an equivalent tool, measure the inside diameter of the disc.

Fig. 57: Measuring Inside Diameter Of Disc Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard inside diameter 173 mm (6.81 in.) Maximum inside diameter 174 mm (6.85 in.) If the inside diameter is more than the maximum, replace the rear disc. 2. INSPECT PARKING BRAKE SHOE LINING THICKNESS a. Using a ruler, measure the thickness of the parking brake shoe lining.

Fig. 58: Measuring Thickness Of Parking Brake Shoe Lining Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thickness 3.35 mm (0.131 in.) Minimum thickness 1.0 mm (0.0394 in.) If the lining thickness is less than the minimum, or if there is severe or uneven wear, replace the parking brake shoe assembly. NOTE:

Always replace both right and left parking brake shoes together.

3. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT a. Apply chalk to the inside surface of the disc, then slide the brake shoe against the disc to check the fit of the brake shoe lining to the disc.

Fig. 59: Applying Chalk To Inside Surface Of Disc Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the contact between the disc and the brake shoe lining is incorrect, repair it using a brake shoe grinder or replace the parking brake shoe assembly. NOTE:

 

Always replace both right and left parking brake shoes together. Wipe off the chalk after inspection.

REASSEMBLY REASSEMBLY

1. APPLY HIGH TEMPERATURE GREASE

a. Apply high temperature grease to the areas of the parking brake plate which make contact with the shoe as shown in the illustration.

Fig. 60: Locating High Temperature Grease Applying Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease 2. INSTALL PARKING BRAKE SHOE HOLD DOWN SPRING PIN a. Install the 2 parking brake shoe hold down spring pins. 3. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Lower Side) a. Install the parking brake shoe return tension spring to the No. 2 parking brake shoe assembly. 4. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY a. Install the No. 1 parking brake shoe assembly to the parking brake shoe return tension spring. 5. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET a. Apply high temperature grease to the parking brake shoe adjusting screw set as shown in the illustration.

Fig. 61: Locating High Temperature Grease Applying Areas To Parking Brake Shoe Adjusting Screw Set Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease b. Install the parking brake shoe adjusting screw set to the No. 1 parking brake shoe assembly and No. 2 parking brake shoe assembly. 6. INSTALL PARKING BRAKE SHOE LEVER a. Using needle-nose pliers, install the parking brake shoe lever to the No. 3 parking brake cable assembly.

Fig. 62: Installing Parking Brake Shoe Lever To No. 3 Parking Brake Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply high temperature grease to the areas of the parking brake shoe lever which make contact with the No. 2 parking brake shoe assembly.

Fig. 63: Locating High Temperature Grease Applying Areas To Parking Brake Shoe Lever

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease c. Install the parking brake shoe lever to the No. 2 parking brake shoe assembly.

Fig. 64: Installing Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Expand the No. 1 and No. 2 parking brake shoe assemblies outward by hand and fit them to the parking brake plate.

NOTE:

Make sure that the parking brake shoe lever does not separate from the No. 2 parking brake shoe assembly.

7. INSTALL PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Rear Side) a. Using SST, install the parking brake shoe hold down compression spring.

Fig. 65: Remove/Install Parking Brake Shoe Hold Down Compression Spring (For Rear Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 8. INSTALL PARKING BRAKE SHOE STRUT a. Install the parking brake shoe strut. b. Install the No. 1 parking brake shoe assembly. 

Fig. 66: Installing No. 1 Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL PARKING BRAKE SHOE HOLD DOWN COMPRESSION SPRING (for Front Side) a. Using SST, install the parking brake shoe hold down compression spring.

Fig. 67: Remove/Install Parking Brake Shoe Hold Down Compression Spring (For Front

Side) Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09718-00011 10. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Rear Side) a. Apply a small amount of high temperature grease to the areas shown in the illustration. 

Fig. 68: Locating High Temperature Grease Applying Areas To Parking Brake Shoe Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION High Temperature Grease b. Install the parking brake shoe return tension spring. 11. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (for Front Side) a. Install the parking brake shoe return tension spring. 12. CHECK PARKING BRAKE INSTALLATION a. Check that each part is installed properly.

Fig. 69: Identifying Correct Parking Brake Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION LH RH *A *B Side Side Front of the - Vehicle NOTE:

There should be no oil or grease on the friction surfaces of the shoe linings or discs.

13. 14. 15. 16.

INSTALL REAR DISC . Refer to INSTALLATION - Step 1 . INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG INSTALL REAR DISC BRAKE CALIPER ASSEMBLY . Refer to REPLACEMENT - Step 9 . ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL . Refer to ADJUSTMENT - Step 2 . 17. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 18. BED IN PARKING BRAKE SHOES TO DISCS a. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road.

b. Depress the parking brake pedal with 150 N (15 kgf, 33.7 lbf) of force. c. Drive the vehicle for about 400 m (0.25 mile) in this condition. d. Repeat this procedure 3 times. NOTE:

Set a 5-minute interval between each procedure to prevent the brake assembly from overheating.

PARKING BRAKE SWITCH COMPONENTS ILLUSTRATION

Fig. 70: Identifying Parking Brake Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to REMOVAL. 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY a. Remove the screw and parking brake switch assembly from the parking brake control pedal assembly.

Fig. 71: Identifying Parking Brake Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT PARKING BRAKE SWITCH ASSEMBLY a. Measure the resistance between the connector terminal and the nut inside the parking brake switch assembly.

Fig. 72: Inspecting Parking Brake Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Terminal *2 Nut *a ON *b OFF STANDARD RESISTANCE Tester Switch Specified Connection Condition Condition On (When Terminal - shaft is Below 1 Nut ohms not pressed) Off Terminal - (When 10 kohms Nut shaft is or higher pressed) If the value is not as specified, replace the parking brake switch assembly. INSTALLATION INSTALLATION

1. INSTALL PARKING BRAKE SWITCH ASSEMBLY a. Install the parking brake switch assembly to the parking brake control pedal assembly with the screw.

Fig. 73: Identifying Parking Brake Switch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf) 2. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY Refer to INSTALLATION.

2012-2017 ELECTRICAL Power Distribution (Service Information) (Hybrid)

MAIN BODY ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Main Body ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE POWER MANAGEMENT CONTROL ECU

Refer to REMOVAL 2. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY a. Disconnect the 5 connectors.

Fig. 2: Identifying Instrument Panel Junction Block Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and 2 nuts, and disconnect the instrument panel junction block assembly.

Fig. 3: Identifying Instrument Panel Junction Block Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the claw and disconnect the connector as shown in the illustration.

Fig. 4: Identifying Instrument Panel Junction Block Connector Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the claw and release the connector lock as shown in the illustration.

Fig. 5: Releasing Instrument Panel Junction Block Assembly Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

e. Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly.

Fig. 6: Disconnecting Instrument Panel Junction Block Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) a. Press the claw of the junction block as shown in the illustration to release the lock.

Fig. 7: Identifying Junction Block Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Main Body ECU *1 (Multiplex Network Body ECU) Claw of *2 Junction Block Protective *3 Tape

b. With the junction block lock released, insert a screwdriver with its tip wrapped with protective tape horizontally between the main body ECU (multiplex network body ECU) and junction block. NOTE:

Use a screwdriver with a diameter of between 5.0 mm (0.197 in.) and 6.3 mm (0.248 in.) and a length of approximately 90 mm (3.54 in.).

c. Using the screwdriver, carefully raise the main body ECU (multiplex network body ECU) up to the position where the connector becomes disengaged.

Fig. 8: Identifying Main Body ECU (Multiplex Network Body ECU) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:





Do not insert the screwdriver opening between the junction block and the connector of the main body ECU (multiplex network body ECU). Do not twist the screwdriver to raise the main body ECU (multiplex network body ECU).

d. Raise the main body ECU (multiplex network body ECU) as shown by the arrow (1), and then pull it out as shown by the arrow (2) in the illustration.

Fig. 9: Identifying Main Body ECU (Multiplex Network Body ECU) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the ECU connector.

INSTALLATION INSTALLATION

1. INSTALL MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) NOTE:

 

Make sure that no foreign matter gets on the connecting surfaces. Do not touch the ECU connector.

a. Insert the main body ECU (multiplex network body ECU) up to the position where it contacts the housing sidewall of the guide as shown in the illustration.

Fig. 10: Identifying Housing Sidewall Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Housing *1 Sidewall *a 20° HINT: Make sure to keep the angle 20° or more as shown in the illustration. b. Slide the guide of the main body ECU (multiplex network body ECU) along the housing sidewall so that it contacts the junction block fuses as shown in the illustration.

Fig. 11: Identifying Housing Sidewall And Junction Block Fuse Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Housing *1 Sidewall Junction *2 Block Fuse c. While keeping the main body ECU (multiplex network body ECU) in contact with side A of the junction block (axis of rotation), rotate it downward as shown in the illustration.

Fig. 12: Identifying Side A Contact Portion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Side A *1 Contact Portion d. Press the push area until the claw engages to install the main body ECU (multiplex network body ECU).

Fig. 13: Identifying Push Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Push *1 Area NOTE:

 

Make sure to press only the push area. Confirm the engagement of the main body ECU (multiplex network body ECU) and junction block by listening for the lock sound.

HINT: If a lock sound cannot be heard, visually check the lock part engagement. The engagement can also

be confirmed if the main body ECU (multiplex network body ECU) and junction block are flush. 2. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY a. Engage the claw to connect the connector as shown in the illustration.

Fig. 14: Identifying Instrument Panel Junction Block Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to engage the connector securely.

b. Engage the claw to lock the connector lock as shown in the illustration.

Fig. 15: Identifying Claw To Lock Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the claw to connect the connector as shown in the illustration.

Fig. 16: Identifying Connector Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be sure to engage the connector securely.

d. Install the instrument panel junction block assembly with the bolt and 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) e. Connect each connector. NOTE:

Be sure to engage each connector securely.

3. INSTALL POWER MANAGEMENT CONTROL ECU Refer to INSTALLATION

POWER MANAGEMENT CONTROL ECU COMPONENTS ILLUSTRATION

Fig. 17: Identifying Power Management Control ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to REMOVAL 2. REMOVE POWER MANAGEMENT CONTROL ECU a. Disconnect the 4 connectors.

Fig. 18: Identifying Power Management Control ECU Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and power management control ECU.

Fig. 19: Identifying Power Management Control ECU Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL POWER MANAGEMENT CONTROL ECU a. Install the power management control ECU with the 2 nuts in the order shown in the illustration.

Fig. 20: Identifying Power Management Control ECU Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) b. Connect the 4 connectors. 2. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to INSTALLATION

INTEGRATION RELAY COMPONENTS ILLUSTRATION

Fig. 21: Identifying Integration Relay Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 22: Identifying Integration Relay Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (SIGNAL READING CHECK) NOTE:

Both present and history signal readings will be cleared if the engine room junction block assembly is removed. Make sure not to remove it before inspection.

HINT: The signal readings of the engine room junction block assembly can be checked by inspecting the voltage at the diagnosis terminal.

a. Signal reading check 1. Turn the power switch on (IG). 2. Connect the positive (+) terminal of a voltmeter to the engine room junction block assembly and the negative (-) terminal to the body ground.

Fig. 23: Identifying Engine Room Junction Block Assembly Voltmeter To Body Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component with *a harness connected (Engine Room

Junction Block Assembly) Diagnosis *b Terminal 3. Using the illustration below as a reference, determine whether any channels are malfunctioning based on the observed signal reading.

Fig. 24: Engine Room Junction Block Assembly Blinking Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 



Present signal reading and history signal reading will be displayed alternately after the power switch is turned on (IG). By measuring the duration of each header, the present signal reading and history signal reading can be recognized. A unit malfunction indicates an internal malfunction of the engine room junction block assembly. If a malfunction is detected for any channel from channel 0 to 9, an electrical load connected to the engine room junction block assembly may be malfunctioning or there may be a short in the engine room junction block assembly







circuit or in the wire harness. The present signal reading will be stored as a history signal reading when electrical loads are operated after a malfunctioning part returns to normal. Both present and history signal readings can be cleared by disconnecting the cable from the negative (-) auxiliary battery terminal. Regarding electrical loads connected to channels 0 to 9, refer to the table below: Connected Channel Electrical Load Back-up ch0 lights ch1 Mirror ch2 heater ch3 ch4 Rear fog ch5 lights Front fog ch6 lights Rear window ch7 defogger wire High beam ch8 headlight LH High beam ch9 headlight RH

2. INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (RESULTS OF SIGNAL READING CHECK) a. Results of signal reading check 1. Depending on the signal reading, perform troubleshooting according the table below. Output Signal Reading Normal

Repair Method Continue troubleshooting for each system. Replace the

The unit is engine room malfunctioning. junction block.

A malfunction in a channel (ch0 to ch9)

a. Check for a short in the wire harnesses between the engine room junction block assembly and each electrical load. b. Inspect each of the electrical loads. c. Replace the engine room junction block.

HINT: Make sure to clear the signal readings by disconnecting the cable from the negative (-) auxiliary battery terminal after replacement or repair of the malfunctioning part. 2. If no signal readings are output, perform troubleshooting according to the following troubleshooting procedure.

Fig. 25: Identifying Engine Room Junction Block Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Remove the engine room junction block assembly. Refer to REMOVAL.

b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Specified Condition Connection Condition 1F-15 Power (IGN) switch on 11 to 14 V Body (IG) ground TEXT IN ILLUSTRATION Component without engine room junction block assembly *a (Engine Room Relay Block and Junction Block Assembly) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE NO. 1 RELAY BLOCK COVER a. Disengage the 2 claws and remove the No. 1 relay block cover as shown in the illustration.

Fig. 26: Removing No. 1 Relay Block Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE ENGINE ROOM JUNCTION BLOCK ASSEMBLY a. Disengage the 2 claws as shown in the illustration.

Fig. 27: Identifying Engine Room Junction Block Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape -Pulled *a -Position b. Using pliers, pull up the engine room junction block assembly at the position indicated in the illustration and disconnect the 4 connectors from the engine room relay block assembly. NOTE:

When pulling a engine room junction block assembly, take care not to damage the engine room junction block assembly.

HINT: Tape the pliers tip before use. c. Disconnect the 2 connectors and remove the engine room junction block assembly.

Fig. 28: Identifying Engine Room Junction Block Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

INSTALLATION INSTALLATION

Do not drop or allow any impact on parts. Do not touch the connector.

1. INSTALL ENGINE ROOM JUNCTION BLOCK ASSEMBLY a. Connect the 2 connectors. b. Connect the 4 connectors to the engine room relay block assembly.

Fig. 29: Installing Engine Room Junction Block Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 2 claws to install the engine room junction block assembly. 2. INSTALL NO. 1 RELAY BLOCK COVER a. Engage the 2 claws to install the No. 1 relay block cover.

Fig. 30: Installing No. 1 Relay Block Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

2012-2017 ELECTRICAL Power Distribution (Service Information) - Camry (Except Hybrid)

MAIN BODY ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Main Body ECU Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY

Refer to REMOVAL 2. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY a. Disconnect the 5 connectors.

Fig. 2: Identifying Instrument Panel Junction Block Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and 2 nuts, and disconnect the instrument panel junction block assembly.

Fig. 3: Identifying Instrument Panel Junction Block Assembly Bolt And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the claw and disconnect the connector as shown in the illustration.

Fig. 4: Disconnecting Instrument Panel Junction Block Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the claw and release the connector lock as shown in the illustration.

Fig. 5: Releasing Instrument Panel Junction Block Assembly Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

e. Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly.

Fig. 6: Disconnecting Instrument Panel Junction Block Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) a. Press the claw of the junction block as shown in the illustration to release the lock.

Fig. 7: Identifying Junction Block Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Main Body ECU *1 (Multiplex Network Body ECU) Claw of *2 Junction Block Protective *3 Tape

b. With the junction block lock released, insert a screwdriver with its tip wrapped with protective tape horizontally between the main body ECU (multiplex network body ECU) and junction block. NOTE:

Use a screwdriver with a diameter of between 5.0 mm (0.197 in.) and 6.3 mm (0.248 in.) and a length of approximately 90 mm (3.54 in.).

c. Using the screwdriver, carefully raise the main body ECU (multiplex network body ECU) up to the position where the connector becomes disengaged.

Fig. 8: Identifying Main Body ECU (Multiplex Network Body ECU) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:

Do not insert the screwdriver opening between the junction block and the connector of the main body ECU (multiplex network body ECU). Do not twist the screwdriver to raise the main body ECU (multiplex network body ECU).

d. Raise the main body ECU (multiplex network body ECU) as shown by the arrow (1), and then pull it out as shown by the arrow (2) in the illustration.

Fig. 9: Identifying Main Body ECU (Multiplex Network Body ECU) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not touch the ECU connector.

INSTALLATION INSTALLATION

1. INSTALL MAIN BODY ECU (MULTIPLEX NETWORK BODY ECU) NOTE:

 

Make sure that no foreign matter gets on the connecting surfaces. Do not touch the ECU connector.

a. Insert the main body ECU (multiplex network body ECU) up to the position where it contacts the housing sidewall of the guide as shown in the illustration.

Fig. 10: Identifying Housing Sidewall Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Housing *1 Sidewall *a 20° HINT: Make sure to keep the angle 20° or more as shown in the illustration. b. Slide the guide of the main body ECU (multiplex network body ECU) along the housing sidewall so that it contacts the junction block fuses as shown in the illustration.

Fig. 11: Identifying Housing Sidewall And Junction Block Fuse Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Housing *1 Sidewall Junction *2 Block Fuse c. While keeping the main body ECU (multiplex network body ECU) in contact with side A of the junction block (axis of rotation), rotate it downward as shown in the illustration.

Fig. 12: Identifying Side A Contact Portion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Side A *1 Contact Portion d. Press the push area until the claw engages to install the main body ECU (multiplex network body ECU).

Fig. 13: Identifying Push Area Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Push *1 Area NOTE:

 

Make sure to press only the push area. Confirm the engagement of the main body ECU (multiplex network body ECU) and junction block by listening for the lock sound.

HINT: If a lock sound cannot be heard, visually check the lock part engagement. The engagement can also

be confirmed if the main body ECU (multiplex network body ECU) and junction block are flush. 2. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY a. Engage the claw to install the connector as shown in the illustration.

Fig. 14: Identifying Instrument Panel Junction Block Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be sure to engage the connector securely.

b. Engage the claw to lock the connector lock as shown in the illustration.

Fig. 15: Identifying Claw To Lock Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the claw to connect the connector as shown in the illustration.

Fig. 16: Identifying Connector Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be sure to engage the connector securely.

d. Install the instrument panel junction block assembly with the bolt and 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) e. Connect each connector. NOTE:

Be sure to engage each connector securely.

3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY Refer to INSTALLATION

INTEGRATION RELAY COMPONENTS ILLUSTRATION

Fig. 17: Identifying Integration Relay Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (SIGNAL READING CHECK) NOTE:

Both present and history signal readings will be cleared if the engine room junction block assembly is removed. Make sure not to remove it before inspection.

HINT: The signal readings of the engine room junction block assembly can be checked by inspecting the voltage at the diagnosis terminal.

a. Signal reading check 1. Turn the ignition switch to ON. 2. Connect the positive (+) terminal of a voltmeter to the engine room junction block assembly and the negative (-) terminal to the body ground.

Fig. 18: Identifying Engine Room Junction Block Assembly Voltmeter To Body Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component with *a harness connected (Engine Room

Junction Block Assembly) Diagnosis *b Terminal 3. Using the illustration below as a reference, determine whether any channels are malfunctioning based on the observed signal reading.

Fig. 19: Engine Room Junction Block Assembly Blinking Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: 



Present signal reading and history signal reading will be displayed alternately after the ignition switch is turned to ON. By measuring the duration of each header, the present signal reading and history signal reading can be recognized. A unit malfunction indicates an internal malfunction of the engine room junction block assembly. If a malfunction is detected for any channel from channel 0 to 9, an electrical load connected to the engine room junction block assembly may be malfunctioning or there may be a short in the engine room junction block assembly







circuit or in the wire harness. The present signal reading will be stored as a history signal reading when electrical loads are operated after a malfunctioning part returns to normal. Both present and history signal readings can be cleared by disconnecting the cable from the negative (-) battery terminal. Depending on the specification, different electrical loads connected to channels 0 to 9 are provided. Refer to the table below: Connected Electrical Load for 2AR-FE Channel for w/ w/o w/ Front Mirror Mirror 2GR-FE Fog Light Heater Heater Radiator Magnetic ch0 fan motor clutch Condenser ch1 fan motor Mirror Mirror Mirror ch2 heater heater heater ch3 ch4 Rear Rear window window ch5 defogger defogger wire wire Front fog Condenser Condenser Front fog ch6 lights fan motor fan motor lights Rear Rear window Radiator Radiator window ch7 defogger fan motor fan motor defogger wire wire ch8 High beam headlight LH ch9 High beam headlight RH

2. INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (RESULTS OF SIGNAL READING CHECK) a. Results of signal reading check 1. Depending on the signal reading, perform troubleshooting according the table below. Output Signal Reading

Repair Method

Normal

Continue troubleshooting for each

system. Replace the The unit is engine room malfunctioning. junction block.

A malfunction in a channel (ch0 to ch9)

a. Check for a short in the wire harnesses between the engine room junction block assembly and each electrical load. b. Inspect each of the electrical loads. c. Replace the engine room junction block.

HINT: Make sure to clear the signal readings by disconnecting the cable from the negative (-) battery terminal after replacement or repair of the malfunctioning part. 2. If no signal readings are output, perform troubleshooting according to the following troubleshooting procedure.

Fig. 20: Identifying Engine Room Junction Block Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Remove the engine room junction block assembly. Refer to REMOVAL.

b. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Switch Specified Connection Condition Condition 1F-15 Ignition (IGN) switch 11 to 14 V Body ON ground TEXT IN ILLUSTRATION Component without engine room junction block assembly *a (Engine Room Relay Block and Junction Block Assembly) If the result is not as specified, repair or replace the wire harness or connector. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE NO. 1 RELAY BLOCK COVER

a. Disengage the 2 claws and remove the No. 1 relay block cover as shown in the illustration.

Fig. 21: Removing No. 1 Relay Block Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE ENGINE ROOM JUNCTION BLOCK ASSEMBLY a. Disengage the 2 claws as shown in the illustration.

Fig. 22: Removing Engine Room Junction Block Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective Pulled *1 *a Tape Position

b. Using pliers, pull up the engine room junction block assembly at the position indicated in the illustration and disconnect the 4 connectors from the engine room relay block assembly. NOTE:

When pulling a engine room junction block assembly, take care not to damage the engine room junction block assembly.

HINT: Tape the pliers tip before use. c. Disconnect the 2 connectors and remove the engine room junction block assembly.

Fig. 23: Identifying Engine Room Junction Block Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not drop or allow any impact on parts. Do not touch the connector.

INSTALLATION INSTALLATION

1. INSTALL ENGINE ROOM JUNCTION BLOCK ASSEMBLY a. Connect the 2 connectors. b. Connect the 4 connectors to the engine room relay block assembly.

Fig. 24: Identifying Engine Room Junction Block Assembly Connectors And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 2 claws to install the engine room junction block assembly. 2. INSTALL NO. 1 RELAY BLOCK COVER a. Engage the 2 claws to install the No. 1 relay block cover.

Fig. 25: Identifying No. 1 Relay Block Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

2012-2017 ELECTRICAL Power Outlets (Interior) (Service Information) - Camry (Except Hybrid)

POWER OUTLET SOCKET COMPONENTS ILLUSTRATION

Fig. 1: Identifying Power Outlet Socket Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Power Outlet Socket Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 2. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 4. REMOVE NO. 3 POWER OUTLET SOCKET ASSEMBLY a. Using a screwdriver, disengage the claw and remove the No. 3 power outlet socket assembly.

Fig. 3: Removing No. 3 Power Outlet Socket Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. 5. REMOVE NO. 2 POWER OUTLET SOCKET COVER a. Disengage the 2 claws and remove the No. 2 power outlet socket cover.

Fig. 4: Removing No. 2 Power Outlet Socket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 POWER OUTLET SOCKET COVER a. Engage the 2 claws to install the No. 2 power outlet socket cover.

Fig. 5: Installing No. 2 Power Outlet Socket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 3 POWER OUTLET SOCKET ASSEMBLY a. Engage the claw to install the No. 3 power outlet socket assembly.

Fig. 6: Installing No. 3 Power Outlet Socket Assembly Claw

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 4. INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 5. INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

REAR POWER OUTLET SOCKET COMPONENTS ILLUSTRATION

Fig. 7: Identifying Rear Power Outlet Socket Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. 2. 3. 4. 5. 6.

REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 11 REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 14 REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 15 REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE UPPER CONSOLE BOX SUB-ASSEMBLY . Refer to REMOVAL - Step 5 REMOVE NO. 3 POWER OUTLET SOCKET ASSEMBLY a. Turn the No. 3 power outlet socket assembly in the direction shown in the illustration to disengage the claw.

Fig. 8: Turning No. 3 Power Outlet Socket Assembly To Disengage Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, disengage the claw, and then push in the No. 3 power outlet socket assembly until the protrusion of the No. 3 power outlet socket assembly comes into contact with the No. 2 power outlet socket cover.

Fig. 9: Identifying No. 3 Power Outlet Socket Assembly Claw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. As shown in the illustration, align the protrusion of the No. 3 power outlet socket assembly and the notch of the No. 2 power outlet socket cover.

Fig. 10: Aligning Protrusion Of No. 3 Power Outlet Socket Assembly And No. 2 Power Outlet Socket Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a screwdriver, disengage the claw and remove the No. 3 power outlet socket assembly from the No. 2 power outlet socket cover.

Fig. 11: Identifying No. 3 Power Outlet Socket Assembly And No. 2 Power Outlet Socket Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE NO. 2 POWER OUTLET SOCKET COVER a. Disengage the 2 claws and remove the No. 2 power outlet socket cover.

Fig. 12: Identifying No. 2 Power Outlet Socket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL NO. 2 POWER OUTLET SOCKET COVER a. Engage the 2 claws to install the No. 2 power outlet socket cover.

Fig. 13: Identifying No. 2 Power Outlet Socket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 3 POWER OUTLET SOCKET ASSEMBLY a. As shown in the illustration, align the protrusion of the No. 3 power outlet socket assembly and the notch of the No. 2 power outlet socket cover.

Fig. 14: Aligning Protrusion Of No. 3 Power Outlet Socket Assembly And No. 2 Power Outlet Socket Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. 4. 5. 6. 7.

b. Engage the 2 claws to install the No. 3 power outlet socket assembly to the No. 2 power outlet socket cover. INSTALL UPPER CONSOLE BOX SUB-ASSEMBLY . Refer to INSTALLATION - Step 4 INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 37 INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 38 INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 39 INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 42

2012-2017 STEERING Power Steering System (Service Information) - Camry (Hybrid)

POWER STEERING ECU COMPONENTS ILLUSTRATION

Fig. 1: Identifying Power Steering ECU Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Power Steering ECU Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STEERING COLUMN ASSEMBLY Refer to REMOVAL 2. REMOVE STEERING LOCK ACTUATOR ASSEMBLY . Refer to DISASSEMBLY - Step 1 3. REMOVE POWER STEERING ECU PROTECTOR . Refer to DISASSEMBLY - Step 2 4. DISCONNECT ECU WIRE SUB-ASSEMBLY a. Disconnect the 2 connectors from the power steering ECU assembly.

Fig. 3: Identifying Power Steering ECU Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE POWER STEERING ECU WITH MOTOR ASSEMBLY . Refer to DISASSEMBLY Step 4 6. REMOVE POWER STEERING ECU ASSEMBLY a. Disengage the 4 claws to remove the protector.

Fig. 4: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts.

Fig. 5: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 2 bolts to remove the power steering ECU assembly from the power steering motor assembly.

Fig. 6: Identifying Power Steering ECU Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL POWER STEERING ECU ASSEMBLY a. Install the power steering ECU assembly to the power steering motor assembly with 2 new bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) b. Install 3 new bolts. Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf)

2. 3. 4. 5.

c. Engage the 4 claws to install a new protector. INSTALL POWER STEERING ECU WITH MOTOR ASSEMBLY . Refer to REASSEMBLY Step 2 CONNECT ECU WIRE SUB-ASSEMBLY a. Connect the 2 connectors to the power steering ECU assembly. INSTALL POWER STEERING ECU PROTECTOR . Refer to REASSEMBLY - Step 4 INSTALL STEERING LOCK ACTUATOR ASSEMBLY . Refer to REASSEMBLY - Step 5

6. INSTALL STEERING COLUMN ASSEMBLY Refer to INSTALLATION 7. ASSIST MAP WRITING Refer to CALIBRATION

2012-2017 STEERING Power Steering System (W/O Wireless Door Lock System) (Service Information) - Camry (Except Hybrid)

POWER STEERING ECU (W/O WIRELESS DOOR LOCK SYSTEM) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Power Steering ECU Replacement Components With Torque Specifications (W/O Wireless Door Lock System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STEERING COLUMN ASSEMBLY Refer to REMOVAL 2. REMOVE POWER STEERING ECU ASSEMBLY a. Disconnect the 4 connectors from the power steering ECU assembly.

Fig. 2: Identifying Power Steering ECU Assembly Connectors And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts to remove the power steering ECU assembly from the steering column assembly. INSTALLATION INSTALLATION

1. INSTALL POWER STEERING ECU ASSEMBLY a. Install the power steering ECU assembly to the steering column assembly with the 2 bolts. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) b. Connect the 4 connectors to the power steering ECU assembly. 2. INSTALL STEERING COLUMN ASSEMBLY Refer to INSTALLATION 3. TORQUE SENSOR ZERO POINT CALIBRATION Refer to CALIBRATION 4. ASSIST MAP WRITING Refer to CALIBRATION

2012-2017 STEERING Power Steering System (W/ Wireless Door Lock System) (Service Information) - Camry (Except Hybrid)

POWER STEERING ECU (W/ WIRELESS DOOR LOCK SYSTEM) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Power Steering ECU Replacement Components With Torque Specifications (W/Wireless Door Lock System) (2AR-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Power Steering ECU Replacement Components With Torque Specifications (W/Wireless Door Lock System) (2GR-FE - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Power Steering ECU Replacement Components With Torque Specifications (W/Wireless Door Lock System) (2GR-FE - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STEERING COLUMN ASSEMBLY Refer to REMOVAL 2. REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (w/o Smart Key System) . Refer to DISASSEMBLY - Step 1 3. REMOVE STEERING LOCK ACTUATOR ASSEMBLY (w/ Smart Key System) . Refer to DISASSEMBLY - Step 2 4. REMOVE POWER STEERING ECU PROTECTOR (for 2AR-FE) . Refer to DISASSEMBLY Step 6 5. DISCONNECT ECU WIRE SUB-ASSEMBLY (for 2AR-FE) a. Disconnect the 2 connectors from the power steering ECU assembly.

Fig. 4: Identifying Power Steering ECU Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE POWER STEERING ECU WITH MOTOR ASSEMBLY (for 2AR-FE) . Refer to DISASSEMBLY - Step 8 7. REMOVE POWER STEERING ECU PROTECTOR (for 2GR-FE) . Refer to DISASSEMBLY Step 9 8. DISCONNECT ECU WIRE SUB-ASSEMBLY (for 2GR-FE) a. Disconnect the 2 connectors from the power steering ECU assembly.

Fig. 5: Identifying Power Steering ECU Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE POWER STEERING ECU WITH MOTOR ASSEMBLY (for 2GR-FE) . Refer to DISASSEMBLY - Step 11 10. REMOVE POWER STEERING ECU ASSEMBLY (for 2GR-FE) a. Disengage the 4 claws to remove the protector.

Fig. 6: Identifying Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 bolts.

Fig. 7: Identifying Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the 2 bolts to remove the power steering ECU assembly from the power steering motor assembly.

Fig. 8: Identifying Power Steering ECU Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL POWER STEERING ECU WITH MOTOR ASSEMBLY (for 2AR-FE) . Refer to REASSEMBLY - Step 10 2. CONNECT ECU WIRE SUB-ASSEMBLY (for 2AR-FE) a. Connect the 2 connectors to the power steering ECU assembly. 3. INSTALL POWER STEERING ECU PROTECTOR (for 2AR-FE) . Refer to REASSEMBLY Step 12 4. INSTALL POWER STEERING ECU ASSEMBLY (for 2GR-FE) a. Install the power steering ECU assembly to the power steering motor assembly with the 2 new bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) b. Install the 3 new bolts. Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf)

5. 6. 7. 8. 9. 10.

c. Engage the 4 claws to install the new protector. INSTALL POWER STEERING ECU WITH MOTOR ASSEMBLY (for 2GR-FE) . Refer to REASSEMBLY - Step 14 CONNECT ECU WIRE SUB-ASSEMBLY (for 2GR-FE) a. Connect the 2 connectors to the power steering ECU assembly. INSTALL POWER STEERING ECU PROTECTOR (for 2GR-FE) . Refer to REASSEMBLY Step 16 INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (w/o Smart Key System) . Refer to REASSEMBLY - Step 17 INSTALL STEERING LOCK ACTUATOR ASSEMBLY (w/ Smart Key System) . Refer to REASSEMBLY - Step 18 INSTALL STEERING COLUMN ASSEMBLY Refer to INSTALLATION

11. TORQUE SENSOR ZERO POINT CALIBRATION (for 2AR-FE) Refer to CALIBRATION 12. ASSIST MAP WRITING (for 2AR-FE) Refer to CALIBRATION 13. ASSIST MAP WRITING (for 2GR-FE) Refer to CALIBRATION

2012-2017 SUSPENSION Rear Suspension (Service Information) (Hybrid)

REAR SHOCK ABSORBER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Rear Shock Absorber Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Rear Shock Absorber Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE REAR SIDE SEATBACK ASSEMBLY Refer to REMOVAL 2. REMOVE REAR WHEEL 3. SEPARATE REAR STABILIZER LINK ASSEMBLY a. Remove the nut and separate the rear stabilizer link assembly from the rear shock absorber with coil spring.

Fig. 3: Identifying Rear Stabilizer Link Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 4. SEPARATE SKID CONTROL SENSOR WIRE a. Remove the 2 bolts, and disconnect the rear flexible hose and skid control sensor wire from the rear shock absorber with coil spring.

Fig. 4: Locating Rear Brake Flexible Hose Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR NO. 1 SUSPENSION SUPPORT COVER a. Using a screwdriver, disengage the 4 claws and remove the rear No. 1 suspension support cover.

Fig. 5: Removing Rear Suspension Support No. 1 Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR SHOCK ABSORBER WITH COIL SPRING a. Support the rear axle carrier sub-assembly with a jack using a wooden block.

Fig. 6: Identifying Jack Placment On Rear Axle Carrier Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack Wooden *2 Block HINT: Support the rear axle carrier sub-assembly until reinstallation of the rear shock absorber with coil spring is complete. b. Loosen the rear support to rear shock absorber nut of the rear shock absorber with coil spring.

Fig. 7: Locating Rear Shock Absorber Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the rear support to rear shock absorber nut. Loosen the nut only when the rear shock absorber with coil spring needs to be disassembled.

c. Remove the 2 bolts and 2 nuts, and separate the rear shock absorber with coil spring from the rear axle carrier sub-assembly.

Fig. 8: Locating Rear Shock Absorber Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

d. Remove the 3 nuts and rear shock absorber with coil spring.

Fig. 9: Locating Rear Shock Absorber Nuts Upper Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the skid control sensor wire and rear flexible hose are disconnected from the rear shock absorber with coil spring.

7. SECURE REAR SHOCK ABSORBER WITH COIL SPRING a. Install the bolt and nut to the rear shock absorber assembly as shown in the illustration and secure the rear shock absorber assembly in a vise using aluminum plates. Standard length A 28 mm (1.10 in.)

Fig. 10: Securing Rear Shock Absorber In Vise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR SUPPORT TO REAR SHOCK ABSORBER NUT a. Using SST, compress the rear coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 11: Compressing Rear Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

9. 10. 11. 12. 13. 14.

Do not use an impact wrench. It will damage SST.

b. Remove the rear support to rear shock absorber nut to the rear shock absorber assembly. REMOVE REAR SUPPORT TO REAR SHOCK ABSORBER COLLAR REMOVE REAR SUSPENSION SUPPORT ASSEMBLY REMOVE REAR COIL SPRING REMOVE REAR NO. 1 SPRING BUMPER REMOVE REAR LOWER COIL SPRING INSULATOR REMOVE REAR SHOCK ABSORBER ASSEMBLY

INSPECTION INSPECTION

1. INSPECT REAR SHOCK ABSORBER ASSEMBLY a. Compress and extend the shock absorber rod 4 or more times. Standard There is no abnormal resistance or sound and operation resistance is normal. If there is any abnormality, replace the rear shock absorber assembly with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. SECURE REAR SHOCK ABSORBER ASSEMBLY a. Install the bolt and nut to the rear shock absorber assembly as shown in the illustration and secure the rear shock absorber assembly in a vise using aluminum plates.

Fig. 12: Securing Rear Shock Absorber In Vise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 2. INSTALL REAR LOWER COIL SPRING INSULATOR a. Install the rear lower coil spring insulator onto the rear shock absorber assembly.

Fig. 13: Installing Rear Lower Coil Spring Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Protrusion NOTE:

Align the protrusion of the rear lower coil spring insulator and the hole in the rear shock absorber assembly.

3. INSTALL REAR NO. 1 SPRING BUMPER a. Install the rear No. 1 spring bumper to rear shock absorber assembly. NOTE:

Face the smaller diameter end of the rear No. 1 spring bumper downward.

4. INSTALL REAR COIL SPRING a. Install SST to the rear coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 14: Compressing Rear Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

b. Using SST, compress the rear coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031 NOTE:

Do not use an impact wrench. It will damage SST.

c. Install the rear coil spring to the rear shock absorber assembly.

Fig. 15: Installing Coil Spring To Rear Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

The smaller diameter end must face upward. Make sure that the end of the rear coil spring is positioned in the depression of the rear coil spring lower insulator.

5. INSTALL REAR SUSPENSION SUPPORT ASSEMBLY a. Install the rear suspension support assembly to the rear shock absorber assembly.

Fig. 16: Identifying Notches Of Piston Rod And Rear Suspension Support Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Notch NOTE:

Align the notches of the piston rod and the rear suspension support assembly as shown in the illustration before installing the rear suspension support assembly.

b. Align the notches of the rear shock absorber assembly with the notch of the rear suspension support assembly so that the notches face the outside of the vehicle.

Fig. 17: Identifying Notches Of Rear Shock Absorber Assembly And Rear Suspension Support Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Notch Outside of the Vehicle 6. INSTALL REAR SUPPORT TO REAR SHOCK ABSORBER COLLAR a. Install the rear support to rear shock absorber collar to the rear shock absorber assembly. 7. TEMPORARILY TIGHTEN REAR SUPPORT TO REAR SHOCK ABSORBER NUT a. Temporarily tighten a new rear support to rear shock absorber nut to the rear shock absorber assembly.

b. Release the rear coil spring while adjusting the rear suspension support assembly to the position shown in the illustration, and remove SST from the rear coil spring.

Fig. 18: Identifying Rear Suspension Support Assembly Component To Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use an impact wrench. It will damage SST.

HINT: Make sure to align the outer stud bolt on the rear suspension support assembly to within +/- 5° of the center of the rear shock absorber lower bracket as shown in the illustration. 8. INSTALL REAR SHOCK ABSORBER WITH COIL SPRING a. Install the rear shock absorber with coil spring to the rear axle carrier sub-assembly and insert the 2 bolts from the rear of the vehicle.

Fig. 19: Identifying Rear Shock Absorber Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slowly jack up the suspension using a wooden block and install the rear shock absorber with coil spring (upper side) to the vehicle. c. Install the 3 nuts to the upper side of the rear shock absorber with coil spring. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) d. Install the 2 nuts to the lower side of the rear shock absorber with coil spring. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

When installing the nuts, keep the bolts from rotating.

e. Fully tighten the rear support to rear shock absorber nut. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 9. INSTALL SKID CONTROL SENSOR WIRE a. Install the skid control sensor wire and rear flexible hose to the rear shock absorber with coil spring with the 2 bolts.

Fig. 20: Identifying Skid Control Sensor Wire And Rear Flexible Hose Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt *a (A) Bolt *b (B) Bolt (A) Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) 10. INSTALL REAR STABILIZER LINK ASSEMBLY a. Install the rear stabilizer link assembly to the rear shock absorber with coil spring with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 11. INSTALL REAR NO. 1 SUSPENSION SUPPORT COVER a. Engage the 4 claws and install the rear No. 1 suspension support cover.

12. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 13. INSTALL REAR SIDE SEATBACK ASSEMBLY Refer to INSTALLATION 14. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT DISPOSAL DISPOSAL

1. DISPOSE OF REAR SHOCK ABSORBER ASSEMBLY a. Fully extend the rear shock absorber piston rod.

Fig. 21: Identifying Hole In Cylinder Component Between A And B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside. WARNING: Be careful when drilling as shards of metal may fly about, so always use proper safety equipment.

HINT: The gas is colorless, odorless and non-poisonous.

REAR LOWER ARM COMPONENTS ILLUSTRATION

Fig. 22: Identifying Rear Lower Arm Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 23: Identifying Rear Lower Arm Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:   

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. The rear No. 2 suspension arm assembly can be removed directly from the vehicle.

1. REMOVE REAR WHEELS 2. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL 3. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Remove the bolt and nut, and separate the rear No. 2 suspension arm assembly (outer side) from the rear axle carrier sub-assembly.

Fig. 24: Identifying Rear No. 2 Suspension Arm (Outer Side) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

4. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Remove the bolt and rear No. 2 suspension arm assembly from the rear suspension member subassembly.

Fig. 25: Identifying Rear No. 2 Suspension Arm (Inner Side) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY Refer to REMOVAL 6. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Remove the bolt and rear No. 1 suspension arm assembly from the rear suspension member subassembly.

Fig. 26: Identifying Rear No. 1 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:   

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. The rear No. 2 suspension arm assembly can be installed directly to the vehicle.

1. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Temporarily tighten the rear No. 1 suspension arm assembly (inner side) with the bolt.

Fig. 27: Identifying Paint Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt

Front of the Vehicle Paint Mark HINT: Ensure that the paint mark faces the rear of the vehicle. b. Set the rear No. 1 suspension arm assembly in the position shown in the illustration, and fully tighten the bolt.

Fig. 28: Identifying Rear No. 1 Suspension Arm Component In Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 2. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY See step 10 3. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Temporarily tighten the rear No. 2 suspension arm assembly (inside) with the bolt.

Fig. 29: Identifying Rear No. 2 Suspension Arm Assembly (Inside) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Paint Mark HINT: Ensure that the paint mark faces the rear of the vehicle. 4. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Connect the rear No. 2 suspension arm assembly (outer side) to the rear axle carrier sub-assembly with the bolt and nut. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the rear of the vehicle. 5. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10 6. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Fully tighten the bolt (A).

Fig. 30: Identifying Rear No. 2 Suspension Arm Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) b. Fully tighten the bolt (B). Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) NOTE:

When fully tightening the bolt, keep the nut from rotating.

7. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION 8. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 9. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT 10. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION

11. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT

REAR STRUT ROD COMPONENTS ILLUSTRATION

Fig. 31: Identifying Rear Strut Rod Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE REAR WHEEL 2. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the bolt and separate the No. 3 parking brake cable assembly from the vehicle.

Fig. 32: Identifying No. 3 Parking Brake Cable Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE REAR STRUT ROD ASSEMBLY a. Support the rear axle carrier sub-assembly with a jack using a wooden block.

Fig. 33: Identifying Jack Placment On Rear Axle Carrier Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block

b. Remove the 2 bolts and separate the rear strut rod assembly (front side).

Fig. 34: Identifying Rear Strut Rod Front Side Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt, nut and rear strut rod assembly from the rear axle carrier sub-assembly.

Fig. 35: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY a. Temporarily tighten rear strut rod assembly (rear side) with the bolt and nut.

Fig. 36: Locating Rear Strut Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the inside of the vehicle. b. Support the rear axle carrier sub-assembly with a jack and a wooden block. c. Connect the rear strut rod assembly (front side) with the 2 bolts. 2. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10 3. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY a. Fully tighten the bolt (rear side). Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

b. Fully tighten the 2 bolts (front side). Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 4. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Connect the No. 3 parking brake cable assembly with the bolt.

Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 5. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR STABILIZER BAR COMPONENTS ILLUSTRATION

Fig. 37: Identifying Rear Stabilizer Bar Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 38: Identifying Rear Stabilizer Bar Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR WHEELS 2. REMOVE NO. 2 FLOOR UNDER COVER a. Remove the 2 bolts and 2 clips.

Fig. 39: Identifying No. 2 Floor Under Cover Bolts And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) b. Disengage the 3 nuts and remove the No. 2 floor under cover. 3. REMOVE NO. 1 FLOOR UNDER COVER a. Remove the 2 bolts.

Fig. 40: Identifying No. 1 Floor Under Cover Nuts And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) b. Disengage the 3 nuts and 2 clips, and remove the No. 1 floor under cover. 4. REMOVE REAR STABILIZER LINK ASSEMBLY LH a. Remove the nut and separate the rear stabilizer link assembly LH from the rear shock absorber with coil spring.

Fig. 41: Identifying Rear Stabilizer Link Assembly LH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. b. Remove the nut and rear stabilizer link assembly LH from the rear stabilizer bar.

Fig. 42: Identifying Rear Stabilizer Link Assembly LH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 5. REMOVE REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 6. REMOVE REAR STABILIZER BAR a. Remove the 4 bolts, rear stabilizer bar, 2 rear No. 1 stabilizer bar brackets, 2 rear No. 2 stabilizer bar brackets and 2 rear stabilizer bushings from the rear suspension member sub-assembly.

Fig. 43: Removing Rear Stabilizer Bar Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE REAR NO. 2 STABILIZER BAR BRACKET a. Remove the 2 rear No. 2 stabilizer bar brackets from the rear stabilizer bar. 8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET a. Remove the 2 rear No. 1 stabilizer bar brackets from the rear stabilizer bar. 9. REMOVE REAR STABILIZER BUSHING a. Remove the 2 rear stabilizer bushings from the rear stabilizer bar. INSPECTION

INSPECTION

1. INSPECT REAR STABILIZER LINK ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 44: Inspecting Front Stabilizer Link Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the rear stabilizer link assembly in a vise using aluminum plates. 2. Install the nut to the rear stabilizer link assembly stud. 3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.05 to 1.0 N*m (0.5 to 10 kgf*cm, 0.4 to 8.7 in.*lbf) If the turning torque is not within the specified range, replace the rear stabilizer link assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If there is any abnormality, replace the rear stabilizer link assembly with a new one. INSTALLATION

INSTALLATION

1. INSTALL REAR STABILIZER BUSHING (for LH Side) a. Install the rear stabilizer bushing to the outside of the stopper ring on the rear stabilizer bar as shown in the illustration.

Fig. 45: Identifying Rear Stabilizer Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stopper *a Ring *b Cutout Front of the Vehicle Outside of the Vehicle NOTE:

Install the rear stabilizer bushing so that the cutout face rearward.

2. INSTALL REAR STABILIZER BUSHING (for RH Side) HINT:

Perform the same procedure as for the LH side. 3. INSTALL REAR NO. 1 STABILIZER BAR BRACKET (for LH Side) a. Install the rear No. 1 stabilizer bar bracket to the rear stabilizer bar.

Fig. 46: Identifying Rear No. 1 Stabilizer Bar Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle NOTE:

Be sure to install the rear No. 1 stabilizer bar bracket in the correct direction.

4. INSTALL REAR NO. 1 STABILIZER BAR BRACKET (for RH Side) HINT: Perform the same procedure as for the LH side. 5. INSTALL REAR NO. 2 STABILIZER BAR BRACKET (for LH Side) a. Install the rear No. 2 stabilizer bar bracket to the rear stabilizer bar.

Fig. 47: Identifying Rear No. 2 Stabilizer Bar Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL REAR NO. 2 STABILIZER BAR BRACKET (for RH Side) HINT: Perform the same procedure as for the LH side. 7. INSTALL REAR STABILIZER BAR a. Install the rear stabilizer bar with the 4 bolts.

Fig. 48: Installing Rear Stabilizer Bar Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Front of the Vehicle Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 8. INSTALL REAR STABILIZER LINK ASSEMBLY LH a. Install the rear stabilizer link assembly LH to the rear shock absorber with coil spring with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. b. Install the rear stabilizer link assembly LH to the rear stabilizer bar with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 9. INSTALL REAR STABILIZER LINK ASSEMBLY RH HINT:

Perform the same procedure as for the LH side. 10. INSTALL NO. 2 FLOOR UNDER COVER a. Install the No. 2 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 11. INSTALL NO. 1 FLOOR UNDER COVER a. Install the No. 1 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 12. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR SUSPENSION MEMBER COMPONENTS ILLUSTRATION

Fig. 49: Identifying Rear Suspension Member Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 50: Identifying Rear Suspension Member Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 51: Identifying Rear Suspension Member Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 52: Identifying Rear Suspension Member Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 53: Identifying Rear Suspension Member Replacement Components (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR WHEELS 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY Refer to REMOVAL 3. REMOVE NO. 2 FLOOR UNDER COVER See step 2 4. REMOVE NO. 1 FLOOR UNDER COVER See step 3 5. REMOVE NO. 3 EXHAUST PIPE SUPPORT BRACKET a. Remove the 2 bolts and No. 3 exhaust pipe support bracket from the rear suspension member subassembly.

Fig. 54: Identifying No. 3 Exhaust Pipe Support Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR SUSPENSION MEMBER DAMPER a. Remove the 2 bolts and rear suspension member damper from the rear suspension member subassembly.

Fig. 55: Identifying Rear Suspension Member Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle 7. SEPARATE REAR STABILIZER LINK ASSEMBLY LH a. Remove the nut and separate the rear stabilizer link assembly LH from the rear stabilizer bar.

Fig. 56: Identifying Rear Stabilizer Link Assembly LH Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 8. SEPARATE REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 9. REMOVE REAR STABILIZER BAR See step 6 10. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL

11. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 3 12. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 13. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 4 14. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 15. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to REMOVAL - Step 12 16. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 17. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY a. Support the rear suspension member sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

Fig. 57: Identifying Rear Suspension Member Sub-Assembly Lifting Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine

*1 Lifter *2 Attachment Attachment Placement Location NOTE:





Make sure to secure the rear suspension member sub-assembly to prevent it from dropping. Use the attachments to keep the rear suspension member subassembly level.

b. Remove the 2 bolts, 4 nuts, 2 rear suspension member lower stopper sub-assemblies and 2 rear suspension member lower stoppers.

Fig. 58: Identifying Rear Suspension Member Lower Stopper Sub-Assemblies Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Slowly lower the rear suspension member sub-assembly. NOTE:

When lowering the rear suspension member sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

18. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY LH See step 6 19. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT:

Perform the same procedure as for the LH side. 20. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION LH a. Using SST and a press, remove the rear suspension member body mounting front cushion LH from the rear suspension member sub-assembly.

Fig. 59: Removing Rear Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09527-17011  SST: 09950-60010 09951-00340  SST: 09950-70010 09951-07100 21. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION RH 

HINT: Perform the same procedure as the LH side. 22. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for LH Side) a. Using SST and a press, remove the rear suspension member body mounting rear cushion from the rear suspension member sub-assembly.

Fig. 60: Removing Rear Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09527-17011  SST: 09950-60010 09951-00340  SST: 09950-70010 09951-07100 23. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for RH Side) 

HINT: Perform the same procedure as the LH side. 24. REMOVE HOLE PLUG a. Remove the 4 hole plugs from the rear suspension member sub-assembly.

Fig. 61: Identifying Rear Suspension Member Sub-Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL HOLE PLUG a. Install the 4 hole plugs to the rear suspension member sub-assembly. 2. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION LH a. Temporarily install a new rear suspension member body mounting front cushion LH to the position shown in the illustration.

Fig. 62: Identifying Rear Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting front cushion LH to the rear suspension member sub-assembly.

Fig. 63: Installing Rear Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09710-30012





09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting front cushion LH. c. While observing from the side, press in the rear suspension member body mounting front cushion LH until there is no clearance between the rear suspension member body mounting front cushion LH and the rear suspension member sub-assembly as shown in the illustration.

Fig. 64: Identifying Clearance Of Rear Suspension Member Body Mounting Front Cushion

LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

3. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION RH a. Temporarily install a new rear suspension member body mounting front cushion RH to the position shown in the illustration.

Fig. 65: Identifying Rear Suspension Member Body Mounting Front Cushion RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting front cushion RH to the rear suspension member sub-assembly.

Fig. 66: Installing Rear Suspension Member Body Mounting Front Cushion RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 





SST: 09710-30012 09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting front cushion RH. c. While observing from the side, press in the rear suspension member body mounting front cushion RH until there is no clearance between the rear suspension member body mounting front cushion RH and the rear suspension member sub-assembly as shown in the illustration.

Fig. 67: Identifying Clearance Of Rear Suspension Member Body Mounting Front Cushion RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

4. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for LH Side) a. Temporarily install a new rear suspension member body mounting rear cushion (LH side) to the position shown in the illustration.

Fig. 68: Identifying Rear Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting rear cushion (LH side) to the rear suspension member sub-assembly.

Fig. 69: Installing Rear Suspension Member Body Mounting Rear Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09710-30012





09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting rear cushion. c. While observing from the side, press in the rear suspension member body mounting rear cushion (LH side) until there is no clearance between the rear suspension member body mounting rear cushion (LH side) and the rear suspension member sub-assembly as shown in the illustration.

Fig. 70: Identifying Clearance Of Rear Suspension Member Body Mounting Rear Cushion

LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

5. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for RH Side) HINT: Perform the same procedure as the LH side. 6. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH See step 1 7. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 8. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 3 9. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 10. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY a. Support the rear suspension member sub-assembly with an engine lifter using 4 attachments or equivalent tools.

Fig. 71: Identifying Rear Suspension Member Sub-Assembly Lifting Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine

*1 Lifter *2 Attachment Attachment Placement Location NOTE:





Make sure to secure the rear suspension member sub-assembly to prevent it from dropping. Use the attachments to keep the rear suspension member subassembly level.

b. Raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and the vehicle body. NOTE:

When raising the rear suspension member sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

c. Install the rear suspension member sub-assembly, rear suspension member lower stopper subassembly LH and rear suspension member lower stopper sub-assembly RH with the 4 nuts.

Fig. 72: Identifying Rear Suspension Member Lower Stopper Sub-Assemblies Bolts And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1

Rear -suspension member

lower stopper Nut A Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut B Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) d. Install the 2 rear suspension member lower stoppers with the 2 bolts to the rear suspension member sub-assembly. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) NOTE:

Be sure to install the rear suspension member sub-assembly with the rear suspension member lower stoppers in the correct direction, as shown in the illustration.

11. INSTALL NO. 3 EXHAUST PIPE SUPPORT BRACKET a. Install the No. 3 exhaust pipe support bracket to the rear suspension member sub-assembly with the 2 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 12. INSTALL REAR SUSPENSION MEMBER DAMPER a. Install the rear suspension member damper to the rear suspension member sub-assembly with the 2 bolts.

Fig. 73: Identifying Rear Suspension Member Damper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 13. CONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to INSTALLATION - Step 2 14. CONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 15. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 4 16. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 17. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10

18. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to INSTALLATION - Step 11 19. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 20. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 6 21. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 22. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION 23. INSTALL REAR STABILIZER BAR See step 7 24. CONNECT REAR STABILIZER LINK ASSEMBLY LH a. Connect the rear stabilizer link assembly LH to the rear stabilizer bar with nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 25. CONNECT REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 26. INSTALL CENTER EXHAUST PIPE ASSEMBLY Refer to INSTALLATION 27. INSTALL NO. 2 FLOOR UNDER COVER See step 10 28. INSTALL NO. 1 FLOOR UNDER COVER See step 11 29. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 30. INSPECT AND ADJUST REAR WHEEL ALIGNMENT

Refer to ADJUSTMENT 31. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION 32. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT

2012-2017 SUSPENSION Rear Suspension (Service Information) - Camry (Except Hybrid)

REAR SHOCK ABSORBER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Rear Shock Absorber Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 2: Identifying Rear Shock Absorber Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE REAR SIDE SEATBACK ASSEMBLY Refer to REMOVAL 2. REMOVE REAR WHEEL 3. SEPARATE REAR STABILIZER LINK ASSEMBLY a. Remove the nut and separate the rear stabilizer link assembly from the rear shock absorber with coil spring.

Fig. 3: Identifying Rear Stabilizer Link Assembly Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 4. SEPARATE SKID CONTROL SENSOR WIRE a. Remove the 2 bolts, and disconnect the rear flexible hose and skid control sensor wire from the rear shock absorber with coil spring.

Fig. 4: Locating Rear Brake Flexible Hose Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR NO. 1 SUSPENSION SUPPORT COVER a. Using a screwdriver, disengage the 4 claws and remove the rear No. 1 suspension support cover.

Fig. 5: Removing Rear Suspension Support No. 1 Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR SHOCK ABSORBER WITH COIL SPRING a. Support the rear axle carrier sub-assembly with a jack using a wooden block.

Fig. 6: Identifying Jack And Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack Wooden *2 Block HINT: Support the rear axle carrier sub-assembly until reinstallation of the rear shock absorber with coil spring is complete. b. Loosen the rear support to rear shock absorber nut of the rear shock absorber with coil spring.

Fig. 7: Locating Rear Shock Absorber Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not remove the rear support to rear shock absorber nut. Loosen the nut only when the rear shock absorber with coil spring needs to be disassembled.

c. Remove the 2 bolts and 2 nuts, and separate the rear shock absorber with coil spring from the rear axle carrier sub-assembly.

Fig. 8: Locating Rear Shock Absorber Nuts And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the nuts, keep the bolts from rotating.

d. Remove the 3 nuts and rear shock absorber with coil spring.

Fig. 9: Locating Rear Shock Absorber Nuts Upper Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the skid control sensor wire and rear flexible hose are disconnected from the rear shock absorber with coil spring.

7. SECURE REAR SHOCK ABSORBER WITH COIL SPRING a. Install the bolt and nut to the rear shock absorber assembly as shown in the illustration and secure the rear shock absorber assembly in a vise using aluminum plates. Standard length A 28 mm (1.10 in.)

Fig. 10: Identifying Standard Length A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR SUPPORT TO REAR SHOCK ABSORBER NUT a. Using SST, compress the rear coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 11: Compressing Rear Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

9. 10. 11. 12. 13. 14.

Do not use an impact wrench. It will damage SST.

b. Remove the rear support to rear shock absorber nut to the rear shock absorber assembly. REMOVE REAR SUPPORT TO REAR SHOCK ABSORBER COLLAR REMOVE REAR SUSPENSION SUPPORT ASSEMBLY REMOVE REAR COIL SPRING REMOVE REAR NO. 1 SPRING BUMPER REMOVE REAR LOWER COIL SPRING INSULATOR REMOVE REAR SHOCK ABSORBER ASSEMBLY

INSPECTION INSPECTION

1. INSPECT REAR SHOCK ABSORBER ASSEMBLY a. Compress and extend the shock absorber rod 4 or more times. Standard There is no abnormal resistance or sound and operation resistance is normal. If there is any abnormality, replace the rear shock absorber assembly with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. SECURE REAR SHOCK ABSORBER ASSEMBLY a. Install the bolt and nut to the rear shock absorber assembly as shown in the illustration and secure the rear shock absorber assembly in a vise using aluminum plates.

Fig. 12: Identifying Standard Length A Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard length A 28 mm (1.10 in.) 2. INSTALL REAR LOWER COIL SPRING INSULATOR a. Install the rear lower coil spring insulator onto the rear shock absorber assembly.

Fig. 13: Installing Rear Lower Coil Spring Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Protrusion NOTE:

Align the protrusion of the rear lower coil spring insulator and the hole in the rear shock absorber assembly.

3. INSTALL REAR NO. 1 SPRING BUMPER a. Install the rear No. 1 spring bumper to rear shock absorber assembly. NOTE:

Face the smaller diameter end of the rear No. 1 spring bumper downward.

4. INSTALL REAR COIL SPRING a. Install SST to the rear coil spring with the hooks spread as far apart as possible from each other.  SST: 09727-30021 09727-00010 09727-00021 09727-00031

Fig. 14: Installing SST To Rear Coil Spring With Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the claws on the hooks are securely engaged to the spring.

b. Using SST, compress the rear coil spring.  SST: 09727-30021 09727-00010 09727-00021 09727-00031 NOTE:

Do not use an impact wrench. It will damage SST.

c. Install the rear coil spring to the rear shock absorber assembly.

Fig. 15: Installing Coil Spring To Rear Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

The smaller diameter end must face upward. Make sure that the end of the rear coil spring is positioned in the depression of the rear coil spring lower insulator.

5. INSTALL REAR SUSPENSION SUPPORT ASSEMBLY a. Install the rear suspension support assembly to the rear shock absorber assembly.

Fig. 16: Identifying Rear Suspension Support Assembly And Rear Shock Absorber Assembly Notch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Notch NOTE:

Align the notches of the piston rod and the rear suspension support assembly as shown in the illustration before installing the rear suspension support assembly.

b. Align the notches of the rear shock absorber assembly with the notch of the rear suspension support assembly so that the notches face the outside of the vehicle.

Fig. 17: Identifying Notch Faces Outside Of Vehicle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Notch Outside of the Vehicle 6. INSTALL REAR SUPPORT TO REAR SHOCK ABSORBER COLLAR a. Install the rear support to rear shock absorber collar to the rear shock absorber assembly. 7. TEMPORARILY TIGHTEN REAR SUPPORT TO REAR SHOCK ABSORBER NUT a. Temporarily tighten a new rear support to rear shock absorber nut to the rear shock absorber assembly. b. Release the rear coil spring while adjusting the rear suspension support assembly to the position

shown in the illustration, and remove SST from the rear coil spring.

Fig. 18: Adjusting Rear Suspension Support Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not use an impact wrench. It will damage SST.

HINT: Make sure to align the outer stud bolt on the rear suspension support assembly to within +/- 5° of the center of the rear shock absorber lower bracket as shown in the illustration. 8. INSTALL REAR SHOCK ABSORBER WITH COIL SPRING a. Install the rear shock absorber with coil spring to the rear axle carrier sub-assembly and insert the 2 bolts from the rear of the vehicle.

Fig. 19: Insert Bolts To Rear Shock Absorber With Coil Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slowly jack up the suspension using a wooden block and install the rear shock absorber with coil spring (upper side) to the vehicle. c. Install the 3 nuts to the upper side of the rear shock absorber with coil spring. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) d. Install the 2 nuts to the lower side of the rear shock absorber with coil spring. Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) NOTE:

When installing the nuts, keep the bolts from rotating.

e. Fully tighten the rear support to rear shock absorber nut. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 9. INSTALL SKID CONTROL SENSOR WIRE a. Install the skid control sensor wire and rear flexible hose to the rear shock absorber with coil spring with the 2 bolts.

Fig. 20: Identifying Skid Control Sensor Wire And Rear Flexible Hose Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt *a (A) Bolt *b (B) Bolt (A) Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) 10. INSTALL REAR STABILIZER LINK ASSEMBLY a. Install the rear stabilizer link assembly to the rear shock absorber with coil spring with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 11. INSTALL REAR NO. 1 SUSPENSION SUPPORT COVER a. Engage the 4 claws and install the rear No. 1 suspension support cover.

12. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 13. INSTALL REAR SIDE SEATBACK ASSEMBLY Refer to INSTALLATION 14. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT DISPOSAL DISPOSAL

1. DISPOSE OF REAR SHOCK ABSORBER ASSEMBLY a. Fully extend the rear shock absorber piston rod.

Fig. 21: Drilling Hole Between A And B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside. WARNING: Be careful when drilling as shards of metal may fly about, so always use proper safety equipment.

HINT: The gas is colorless, odorless and non-poisonous.

REAR LOWER ARM COMPONENTS ILLUSTRATION

Fig. 22: Identifying Rear Lower Arm Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 23: Identifying Rear Lower Arm Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:   

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. The rear No. 2 suspension arm assembly can be removed directly from the vehicle.

1. REMOVE REAR WHEELS 2. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL 3. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Remove the bolt and nut, and separate the rear No. 2 suspension arm assembly (outer side) from the rear axle carrier sub-assembly.

Fig. 24: Identifying Rear No. 2 Suspension Arm Assembly Bolt And Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

4. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Remove the bolt and rear No. 2 suspension arm assembly from the rear suspension member subassembly.

Fig. 25: Identifying Rear No. 2 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY Refer to REMOVAL 6. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Remove the bolt and rear No. 1 suspension arm assembly from the rear suspension member subassembly.

Fig. 26: Identifying Rear No. 1 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

HINT:   

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side. The rear No. 2 suspension arm assembly can be installed directly to the vehicle.

1. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY a. Temporarily tighten the rear No. 1 suspension arm assembly (inner side) with the bolt.

Fig. 27: Identifying Rear No. 1 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt

Front of the Vehicle Paint Mark HINT: Ensure that the paint mark faces the rear of the vehicle. b. Set the rear No. 1 suspension arm assembly in the position shown in the illustration, and fully tighten the bolt.

Fig. 28: Positioning No. 1 Suspension Arm Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 2. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY Refer to INSTALLATION 3. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Temporarily tighten the rear No. 2 suspension arm assembly (inside) with the bolt.

Fig. 29: Tightening Rear No. 2 Suspension Arm Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Paint Mark HINT: Ensure that the paint mark faces the rear of the vehicle. 4. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Connect the rear No. 2 suspension arm assembly (outer side) to the rear axle carrier sub-assembly with the bolt and nut. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the rear of the vehicle. 5. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10 6. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY a. Fully tighten the 2 bolts.

Fig. 30: Tightening Rear No. 2 Suspension Arm Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 7. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION 8. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 9. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT 10. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION 11. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT

REAR STRUT ROD

COMPONENTS ILLUSTRATION

Fig. 31: Identifying Rear Strut Rod Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. REMOVE REAR WHEEL 2. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Remove the bolt and separate the No. 3 parking brake cable assembly from the vehicle.

Fig. 32: Identifying No. 3 Parking Brake Cable Assembly Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE REAR STRUT ROD ASSEMBLY a. Support the rear axle carrier sub assembly with a jack using a wooden block.

Fig. 33: Identifying Jack And Wooden Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Jack

*2

Wooden Block

b. Remove the 2 bolts and separate the rear strut rod assembly (front side).

Fig. 34: Identifying Rear Strut Rod Assembly And Bolts (Front Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt, nut and rear strut rod assembly from the rear axle carrier sub-assembly.

Fig. 35: Locating Rear Strut Rod Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the bolt, keep the nut from rotating.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY a. Temporarily tighten rear strut rod assembly (rear side) with the bolt and nut.

Fig. 36: Locating Rear Strut Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When temporarily tightening the bolt, keep the nut from rotating.

HINT: Insert the bolt from the inside of the vehicle. b. Support the rear axle carrier sub-assembly with a jack and a wooden block. c. Connect the rear strut rod assembly (front side) with the 2 bolts. 2. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10 3. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY a. Fully tighten the bolt (rear side). Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTE:

Since a stopper nut is used, fully tighten the bolt.

b. Fully tighten the 2 bolts (front side). Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 4. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY a. Connect the No. 3 parking brake cable assembly with the bolt.

Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 5. INSTALL REAR WHEEL Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR STABILIZER BAR COMPONENTS ILLUSTRATION

Fig. 37: Identifying Rear Stabilizer Bar Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 38: Identifying Rear Stabilizer Bar Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR WHEELS 2. REMOVE NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) a. Remove the 2 bolts and 2 clips.

Fig. 39: Identifying No. 2 Floor Under Cover Fasteners (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) b. Disengage the 3 nuts and remove the No. 2 floor under cover. 3. REMOVE NO. 1 FLOOR UNDER COVER a. Remove the 2 bolts.

Fig. 40: Identifying No. 1 Floor Under Cover Fasteners (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Nut (attached to under cover) b. Disengage the 3 nuts and 2 clips, and remove the No. 1 floor under cover. 4. REMOVE REAR STABILIZER LINK ASSEMBLY LH a. Remove the nut and separate the rear stabilizer link assembly LH from the rear shock absorber with coil spring.

Fig. 41: Identifying Rear Stabilizer Link Assembly Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. b. Remove the nut and rear stabilizer link assembly LH from the rear stabilizer bar.

Fig. 42: Identifying Rear Stabilizer Assembly Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 5. REMOVE REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 6. REMOVE REAR STABILIZER BAR a. Remove the 4 bolts, rear stabilizer bar, 2 rear No. 1 stabilizer bar brackets, 2 rear No. 2 stabilizer bar brackets and 2 rear stabilizer bushings from the rear suspension member sub-assembly.

Fig. 43: Identifying Rear Stabilizer Bar Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE REAR NO. 2 STABILIZER BAR BRACKET a. Remove the 2 rear No. 2 stabilizer bar brackets from the rear stabilizer bar. 8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET a. Remove the 2 rear No. 1 stabilizer bar brackets from the rear stabilizer bar. 9. REMOVE REAR STABILIZER BUSHING a. Remove the 2 rear stabilizer bushings from the rear stabilizer bar. INSPECTION

INSPECTION

1. INSPECT REAR STABILIZER LINK ASSEMBLY a. Inspect the turning torque of the ball joint.

Fig. 44: Inspecting Rear Stabilizer Link Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Secure the rear stabilizer link assembly in a vise using aluminum plates. 2. Install the nut to the rear stabilizer link assembly stud. 3. Using a torque wrench, turn the stud continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque 0.05 to 1.0 N*m (0.5 to 10 kgf*cm, 0.4 to 8.7 in.*lbf) If the turning torque is not within the specified range, replace the rear stabilizer link assembly with a new one. b. Inspect the dust cover. 1. Check that the dust cover is not cracked and that there is no grease on it. If there is any abnormality, replace the rear stabilizer link assembly with a new one. INSTALLATION

INSTALLATION

1. INSTALL REAR STABILIZER BUSHING (for LH Side) a. Install the rear stabilizer bushing to the outside of the stopper ring on the rear stabilizer bar as shown in the illustration.

Fig. 45: Installing Rear Stabilizer Bushing (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stopper *a Ring *b Cutout Front of the Vehicle Outside of the Vehicle NOTE:

Install the rear stabilizer bushing so that the cutout face rearward.

2. INSTALL REAR STABILIZER BUSHING (for RH Side) HINT:

Perform the same procedure as for the LH side. 3. INSTALL REAR NO. 1 STABILIZER BAR BRACKET (for LH Side) a. Install the rear No. 1 stabilizer bar bracket to the rear stabilizer bar.

Fig. 46: Installing Rear No. 1 Stabilizer Bar Bracket (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle NOTE:

Be sure to install the rear No. 1 stabilizer bar bracket in the correct direction.

4. INSTALL REAR NO. 1 STABILIZER BAR BRACKET (for RH Side) HINT: Perform the same procedure as for the LH side. 5. INSTALL REAR NO. 2 STABILIZER BAR BRACKET (for LH Side) a. Install the rear No. 2 stabilizer bar bracket to the rear stabilizer bar.

Fig. 47: Identifying No. 2 Stabilizer Bar Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL REAR NO. 2 STABILIZER BAR BRACKET (for RH Side) HINT: Perform the same procedure as for the LH side. 7. INSTALL REAR STABILIZER BAR a. Install the rear stabilizer bar with the 4 bolts.

Fig. 48: Identifying Rear Stabilizer Bar Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Bolt Front of the Vehicle Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 8. INSTALL REAR STABILIZER LINK ASSEMBLY LH a. Install the rear stabilizer link assembly LH to the rear shock absorber with coil spring with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. b. Install the rear stabilizer link assembly LH to the rear stabilizer bar with the nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 9. INSTALL REAR STABILIZER LINK ASSEMBLY RH HINT:

Perform the same procedure as for the LH side. 10. INSTALL NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) a. Install the No. 2 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 11. INSTALL NO. 1 FLOOR UNDER COVER a. Install the No. 1 floor under cover with the 2 bolts, 3 nuts and 2 clips. Bolt Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Nut Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 12. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

REAR SUSPENSION MEMBER COMPONENTS ILLUSTRATION

Fig. 49: Identifying Rear Suspension Member Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 50: Identifying Rear Suspension Member Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 51: Identifying Rear Suspension Member Replacement Components With Torque Specifications (3 Of 5)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 52: Identifying Rear Suspension Member Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 53: Identifying Rear Suspension Member Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE REAR WHEELS 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY  for 2GR-FE: Refer to REMOVAL  for 2AR-FE: Refer to REMOVAL

3. REMOVE NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) See step 2 4. REMOVE NO. 1 FLOOR UNDER COVER See step 3 5. REMOVE NO. 3 EXHAUST PIPE SUPPORT BRACKET a. Remove the 2 bolts and No. 3 exhaust pipe support bracket from the rear suspension member subassembly.

Fig. 54: Identifying No. 3 Exhaust Pipe Support Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE JACK UP BRACKET (for 2GR-FE) a. Remove the 2 bolts and jack up bracket from the rear suspension member sub-assembly.

Fig. 55: Identifying Jack Up Bracket Bolts (For 2GR-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE REAR SUSPENSION MEMBER DAMPER (w/ Dynamic Damper) a. Remove the 2 bolts and rear suspension member damper from the rear suspension member subassembly.

Fig. 56: Identifying Rear Suspension Member Damper Bolts (W/Dynamic Damper) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle 8. SEPARATE REAR STABILIZER LINK ASSEMBLY LH a. Remove the nut and separate the rear stabilizer link assembly LH from the rear stabilizer bar.

Fig. 57: Identifying Rear Stabilizer Assembly Nut LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 9. SEPARATE REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 10. REMOVE REAR STABILIZER BAR See step 6 11. REMOVE REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to REMOVAL

12. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 3 13. SEPARATE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 14. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 4 15. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 16. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to REMOVAL - Step 10 17. SEPARATE REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 18. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY a. Support the rear suspension member sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

Fig. 58: Identifying Engine Lifter And Attachment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine

*1 Lifter *2 Attachment Attachment Placement Location NOTE:





Make sure to secure the rear suspension member sub-assembly to prevent it from dropping. Use the attachments to keep the rear suspension member subassembly level.

b. Remove the 2 bolts, 4 nuts, 2 rear suspension member lower stopper sub-assemblies and 2 rear suspension member lower stoppers.

Fig. 59: Identifying Rear Suspension Lower Stopper Sub-Assemblies Bolts & Nuts And Rear Suspension Member Lower Stoppers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Slowly lower the rear suspension member sub-assembly. NOTE:

When lowering the rear suspension member sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

d. w/ Member Cushion: 1. Remove the 2 differential support member cushions and 2 differential support member upper stoppers from the rear suspension member sub-assembly. 19. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY LH See step 6

20. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 21. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION LH a. Using SST and a press, remove the rear suspension member body mounting front cushion LH from the rear suspension member sub-assembly.

Fig. 60: Identifying Rear Suspension Member Body Mounting Front Cushion And SST LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09527-17011  SST: 09950-60010 09951-00340  SST: 09950-70010 09951-07100 22. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION RH 

HINT: Perform the same procedure as the LH side. 23. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for LH Side)

a. Using SST and a press, remove the rear suspension member body mounting rear cushion from the rear suspension member sub-assembly.

Fig. 61: Identifying Rear Suspension Member Body Mounting Rear Cushion And SST (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09527-17011  SST: 09950-60010 09951-00340  SST: 09950-70010 09951-07100 24. REMOVE REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for RH Side) 

HINT: Perform the same procedure as the LH side. 25. REMOVE HOLE PLUG a. Remove the 4 hole plugs from the rear suspension member sub-assembly.

Fig. 62: Identifying Rear Suspension Member Sub-Assembly Hole Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL HOLE PLUG a. Install the 4 hole plugs to the rear suspension member sub-assembly. 2. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION LH a. Temporarily install a new rear suspension member body mounting front cushion LH to the position shown in the illustration.

Fig. 63: Position Rear Suspension Member Body Mounting Front Cushion LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type *A A: Type *B B: Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting front cushion LH to the rear suspension member sub-assembly.

Fig. 64: Installing Rear Suspension Member Body Mounting Front Cushion Using SST LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 





SST: 09710-30012 09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting front cushion LH. c. While observing from the side, press in the rear suspension member body mounting front cushion LH until there is no clearance between the rear suspension member body mounting front cushion LH and the rear suspension member sub-assembly as shown in the illustration.

Fig. 65: Identifying No Clearance Between Rear Suspension Member Body Mounting Front Cushion LH And Rear Suspension Member Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

3. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION RH a. Temporarily install a new rear suspension member body mounting front cushion RH to the position shown in the illustration.

Fig. 66: Position Rear Suspension Member Body Mounting Front Cushion RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type *A A: Type *B B: Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting front cushion RH to the rear suspension member sub-assembly.

Fig. 67: Installing Rear Suspension Member Body Mounting Front Cushion Using SST RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

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SST: 09710-30012 09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting front cushion RH. c. While observing from the side, press in the rear suspension member body mounting front cushion RH until there is no clearance between the rear suspension member body mounting front cushion RH and the rear suspension member sub-assembly as shown in the illustration.

Fig. 68: Identifying No Clearance Between Rear Suspension Member Body Mounting Front Cushion RH And Rear Suspension Member Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

4. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for LH Side) a. Temporarily install a new rear suspension member body mounting rear cushion (LH side) to the position shown in the illustration.

Fig. 69: Positioning Rear Suspension Member Body Mounting Rear Cushion (LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Type *A A: Type *B B: Front of the Vehicle b. Using SST and a press, install the rear suspension member body mounting rear cushion (LH side) to the rear suspension member sub-assembly.

Fig. 70: Installing Rear Suspension Body Mounting Rear Cushion (LH Side) To Rear Suspension Member Sub-Assembly Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

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SST: 09710-30012 09710-04061 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07100

HINT: Slowly press in the rear suspension member body mounting rear cushion. c. While observing from the side, press in the rear suspension member body mounting rear cushion (LH side) until there is no clearance between the rear suspension member body mounting rear cushion (LH side) and the rear suspension member sub-assembly as shown in the illustration.

Fig. 71: Identifying No Clearance Between Rear Suspension Member Body Mounting Rear Cushion (LH Side) And Rear Suspension Member Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not press the rear suspension member excessively, or it will easily deform.

5. INSTALL REAR SUSPENSION MEMBER BODY MOUNTING REAR CUSHION (for RH Side) HINT: Perform the same procedure as the LH side. 6. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH See step 1 7. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT: Perform the same procedure as the LH side. 8. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 3 9. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 10. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY a. w/ Member Cushion: 1. Install 2 new differential support member cushions and 2 new differential support member upper stoppers to the rear suspension member sub-assembly. b. Support the rear suspension member sub-assembly with an engine lifter using 4 attachments or equivalent tools.

Fig. 72: Identifying Engine Lifter And Attachment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Engine

*1 Lifter *2 Attachment Attachment Placement Location NOTE:

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Make sure to secure the rear suspension member sub-assembly to prevent it from dropping. Use the attachments to keep the rear suspension member subassembly level.

c. Raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and the vehicle body. NOTE:

When raising the rear suspension member sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

d. Install the rear suspension member sub-assembly, rear suspension member lower stopper subassembly LH and rear suspension member lower stopper sub-assembly RH with the 4 nuts.

Fig. 73: Identifying Rear Suspension Member Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Nut A Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut B

Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) e. Install the rear suspension member sub-assembly and 2 rear suspension member lower stoppers with the 2 bolts.

Fig. 74: Identifying Rear Suspension Member Sub-Assembly And Rear Suspension Member Lower Stopper Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) NOTE:

Be sure to install the rear suspension member sub-assembly with the rear suspension member lower stoppers in the correct direction, as shown in the illustration.

11. INSTALL NO. 3 EXHAUST PIPE SUPPORT BRACKET a. Install the No. 3 exhaust pipe support bracket to the rear suspension member sub-assembly with the 2 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 12. INSTALL JACK UP BRACKET (for 2GR-FE) a. Install the jack up bracket to the rear suspension member sub-assembly with the 2 bolts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 13. INSTALL REAR SUSPENSION MEMBER DAMPER (w/ Dynamic Damper) a. Install the rear suspension member damper to the rear suspension member sub-assembly with the 2 bolts.

Fig. 75: Identifying Rear Suspension Member Damper Bolts (W/Dynamic Damper) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front of the Vehicle Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 14. CONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to INSTALLATION - Step 2 15. CONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 16. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 4 17. CONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 18. STABILIZE SUSPENSION . Refer to INSTALLATION - Step 10

19. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH . Refer to INSTALLATION - Step 11 20. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 21. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH See step 6 22. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Perform the same procedure as the LH side. 23. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Refer to INSTALLATION 24. INSTALL REAR STABILIZER BAR See step 7 25. CONNECT REAR STABILIZER LINK ASSEMBLY LH a. Connect the rear stabilizer link assembly LH to the rear stabilizer bar with nut. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) If the ball joint turns together with the nut, use a hexagon wrench to hold the stud. 26. CONNECT REAR STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as the LH side. 27. INSTALL CENTER EXHAUST PIPE ASSEMBLY  for 2GR-FE: Refer to INSTALLATION  for 2AR-FE: Refer to INSTALLATION 28. INSTALL NO. 2 FLOOR UNDER COVER (w/ Floor Under Cover) See step 10 29. INSTALL NO. 1 FLOOR UNDER COVER See step 11 30. INSTALL REAR WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 31. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Refer to ADJUSTMENT

32. HEIGHT CONTROL SENSOR SIGNAL INITIALIZE (w/ Height Control Sensor) Refer to INITIALIZATION 33. ADJUST HEADLIGHT AIMING (w/ Height Control Sensor) Refer to ADJUSTMENT

2012-2017 RESTRAINTS Seat Belt (Service Information) - Camry (Hybrid)

FRONT SEAT INNER BELT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Seat Inner Belt Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY

for Manual Seat: Refer to REMOVAL for Power Seat: Refer to REMOVAL 2. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. Disengage each clamp under the front seat assembly. b. Disengage the clamp.

Fig. 2: Identifying Front Seat Inner Belt Assembly Clamp And Nut LH (For Driver Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the nut and front seat inner belt assembly LH. 3. REMOVE FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) for Manual Seat: Refer to DISASSEMBLY - Step 6 for Power Seat: Refer to DISASSEMBLY - Step 8 4. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat) a. Disconnect the connector.

Fig. 3: Identifying Front Seat Inner Belt Assembly Connector And Fasteners RH (For Front Passenger Seat) (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Limit *1 Switch b. Remove the screw and disconnect the limit switch. c. Remove the nut and front seat inner belt assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. Install the front seat inner belt assembly LH with the nut.

Fig. 4: Identifying Front Seat Inner Belt Assembly Nut LH (For Driver Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly LH to overlap the protruding part of the front seat adjuster.

b. Engage the clamp. c. Engage each clamp under the front seat assembly. 2. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat)

a. Install the front seat inner belt assembly RH with the nut.

Fig. 5: Locating Front Seat Inner Belt Assembly Protruding Part, Limit Switch Connector And Fasteners RH (For Front Passenger Seat) (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Limit *2 Switch Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly RH

to overlap the protruding part of the front seat adjuster. b. Connect the limit switch with the screw. c. Connect the connector. 3. INSTALL FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) for Manual Seat: Refer to REASSEMBLY - Step 23 for Power Seat: Refer to REASSEMBLY - Step 27 4. INSTALL FRONT SEAT ASSEMBLY for Manual Seat: Refer to INSTALLATION for Power Seat: Refer to INSTALLATION

FRONT SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER PRECAUTION PRECAUTION

WARNING: Replace any faulty parts of the seat belt systems (outer belt, inner belt, bolts, nuts, adjustable shoulder anchor, tether anchor hardware and other related parts). When inspecting a vehicle that was in a collision, be sure to check all of the seat belt systems regardless of whether or not the system was activated in the collision. Replace any damaged or malfunctioning systems.

Fig. 6: Checking Belts Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. ROAD TEST (IN SAFE AREA) WARNING: Conduct this test in a safe area.

a. Fasten the front seat belts. b. Drive the vehicle at 16 km/h (10 mph) and firmly depress the brake pedal. Check that the belts lock and cannot be extended at this time. If a belt does not lock, replace the seat belt assembly. Refer to REMOVAL. HINT: Inspect the seat belt assembly before installing it. Refer to INSPECTION. COMPONENTS ILLUSTRATION

Fig. 7: Identifying Front Seat Outer Belt Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 8: Identifying Front Seat Outer Belt Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front seat outer belt assembly. 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Built-in Type Yaw Rate Sensor) b. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Separate Type Yaw Rate Sensor) c. Visually check for defects with the front seat outer belt assembly installed on the vehicle. 1. The defects are as follows:  Cuts on the front seat outer belt assembly  Small cracks on the front seat outer belt assembly  Significant discoloration on the front seat outer belt assembly OK No defects are found. HINT: If any of the defects is found, replace the front seat outer belt assembly with a new one. 2. INSPECT FRONT SEAT OUTER BELT ASSEMBLY (for Vehicle Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Built-in Type Yaw Rate Sensor) b. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Separate Type Yaw Rate Sensor) c. Visually check for defects with the front seat outer belt assembly removed from the vehicle. 1. The defects are as follows:  Cuts on the front seat outer belt assembly  Small cracks on the front seat outer belt assembly  Significant discoloration on the front seat outer belt assembly  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the front seat outer belt assembly with a new one. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 4 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP a. Disconnect the front door opening trim weatherstrip. 6. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 19 7. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP a. Disconnect the rear door opening trim weatherstrip. 8. REMOVE LAP BELT OUTER ANCHOR COVER a. Disengage the 3 claws and remove the lap belt outer anchor cover.

Fig. 9: Identifying Lap Belt Outer Anchor Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY a. Remove the bolt and disconnect the floor anchor of the front seat outer belt assembly.

Fig. 10: Locating Front Seat Outer Belt Assembly Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 23 11. REMOVE CENTER PILLAR UPPER GARNISH . Refer to REMOVAL - Step 24 12. REMOVE FRONT SEAT OUTER BELT ASSEMBLY a. Remove the nut and disconnect the shoulder anchor of the front seat outer belt assembly.

Fig. 11: Identifying Front Seat Outer Belt Assembly Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, pull out the locking button in the direction shown by the arrow in the illustration to release the lock, and disconnect the pretensioner connector as shown in the illustration.

Fig. 12: Removing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the screwdriver tip before use. c. Remove the 2 bolts and front seat outer belt assembly.

Fig. 13: Identifying Front Seat Outer Belt Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY a. Remove the 2 bolts.

Fig. 14: Identifying Front Shoulder Belt Anchor Adjuster Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front shoulder belt anchor adjuster assembly. INSPECTION INSPECTION

1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY a. Before installing the front seat outer belt assembly, check the ELR function.

Fig. 15: Checking ELR Function Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked *c 45° If the result is not as specified, replace the front seat outer belt assembly. INSTALLATION INSTALLATION

1. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY a. Engage the guide.

Fig. 16: Identifying Front Shoulder Belt Anchor Adjuster Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the bolt first, then the bolt to temporarily install the front shoulder belt anchor adjuster assembly. c. Fully tighten the 2 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. INSPECT FRONT SEAT OUTER BELT ASSEMBLY See step 1 3. INSTALL FRONT SEAT OUTER BELT ASSEMBLY a. Install the bolt first, then the bolt to temporarily install the front seat outer belt assembly.

Fig. 17: Identifying Front Seat Outer Belt Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Fully tighten the 2 bolts. Bolt Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Bolt Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) c. Connect the pretensioner connector and lock the locking button as shown in the illustration.

Fig. 18: Installing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Securely lock the locking button.

d. Connect the shoulder anchor of the front seat outer belt assembly with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 4. INSTALL CENTER PILLAR UPPER GARNISH . Refer to INSTALLATION - Step 22 5. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 23 6. CONNECT FRONT SEAT OUTER BELT ASSEMBLY a. Install the floor anchor of the front seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) b. Check if the ELR locks. NOTE:

The check should be performed with the front seat outer belt assembly installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. 7. INSTALL LAP BELT OUTER ANCHOR COVER a. Engage the 3 claws to install the lap belt outer anchor cover. 8. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 26 for RH Side: Refer to INSTALLATION - Step 33 9. INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 27 10. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP for LH Side: Refer to INSTALLATION - Step 43 for RH Side: Refer to INSTALLATION - Step 47 11. INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 45 12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 14. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

DISPOSAL WITH PRETENSIONER DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS component, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a seat belt (with a seat belt pretensioner), always perform the procedure described below. If any abnormality occurs during deployment of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. DISPOSAL

1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When Installed in Vehicle) WARNING:

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NOTE:

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Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner. When deploying a seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference. When disposing of a seat belt with a pretensioner, never deploy the pretensioner in the customer's vehicle.

Never dispose of a seat belt with a pretensioner that has not been deployed. The seat belt produces an exploding sound when the pretensioner deploys, so perform the operation outdoors where it will not disturb local residents. When deploying a seat belt pretensioner, perform the operation at least 10 m (33 ft.) away from the seat belt. Be sure to follow the procedure listed below when deploying a seat belt pretensioner.

a. Check the function of SST.

Fig. 19: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the seat belt pretensioner, always use the specified SST.

1. Connect the red clip of SST to the 12 V battery positive (+) terminal and the black clip to the 12 V battery negative (-) terminal.

Fig. 20: Identifying SST & Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 battery HINT: At this time, do not connect the yellow connector. It will be connected to the seat belt pretensioner in a later step. 2. Press the SST deployment switch and check that the LED of the SST deployment switch illuminates.

Fig. 21: Pressing SST Deployment Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the LED is illuminated when the deployment switch is not pressed, SST may be malfunctioning. In this case, do not use the malfunctioning SST. b. Disconnect the seat belt pretensioner connector. 1. Disconnect the cable from the negative (-) auxiliary battery terminal. 2. Remove the front door scuff plate. Refer to REMOVAL - Step 4 . 3. Disconnect the front door opening trim weatherstrip See step 5. 4. Remove the rear door scuff plate. Refer to REMOVAL - Step 19 . 5. Disconnect the rear door opening trim weatherstrip See step 7. 6. Remove the center pillar lower garnish. Refer to REMOVAL - Step 23 . 7. Using a screwdriver, pull out the locking button in the direction shown by the arrow in the illustration to release the lock, and disconnect the pretensioner connector as shown in the illustration.

Fig. 22: Removing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the screwdriver tip before use. c. Connect SST.

Fig. 23: Connecting SST's To Front Seat Outer Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect 2 SST, and then connect them to the seat belt pretensioner.  SST: 09082-00700  SST: 09082-00770 NOTE:

To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector.

2. Move SST at least 10 m (33 ft.) away from the front of the vehicle.

Fig. 24: Identifying SST Safe Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m *a or more 3. Close all the doors and windows of the vehicle. NOTE:

Do not damage the SST wire harness.

d. Deploy the seat belt pretensioner. 1. Confirm that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. 2. Connect the red clip of SST to the 12 V battery positive (+) terminal and the black clip to the 12 V battery negative (-) terminal. 3. Press the SST deployment switch to deploy the seat belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of SST illuminates. e. Dispose of the seat belt.

Fig. 25: Identifying Disposal Of Front Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the seat belt and SST. 2. Place the seat belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. WARNING:

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The seat belt becomes very hot when the pretensioner is deployed, so leave it untouched for at least 30 minutes after the pretensioner is deployed. Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner.

HINT: When scrapping a vehicle, deploy the seat belt pretensioner, and then scrap the vehicle with the seat belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When Not Installed in Vehicle)

WARNING:

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NOTE:

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Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner. When deploying a seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference. When disposing of a seat belt with a pretensioner, never deploy the pretensioner in the customer's vehicle.

Never dispose of a seat belt with a pretensioner that has not been deployed. The seat belt produces an exploding sound when the pretensioner deploys, so perform the operation outdoors where it will not disturb local residents. When deploying a seat belt pretensioner, perform the operation at least 10 m (33 ft.) away from the seat belt. Be sure to follow the procedure listed below when deploying a seat belt pretensioner.

a. Remove the seat belt. Refer to REMOVAL. b. Wind the seat belt webbing with the retractor.

Fig. 26: Identifying Seat Belt Webbing Cutting Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cut 100 *b mm c. When the seat belt webbing is sufficiently wound, cut the seat belt webbing approximately 100 mm (3.94 in.) from the retractor, as shown in the illustration. HINT: The retractor resistance increases in correlation with how much the seat belt webbing is wound. d. Check the function of SST.

Fig. 27: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the seat belt pretensioner, always use the specified SST.

1. Connect the red clip of SST to the 12 V battery positive (+) terminal and the black clip to the 12 V battery negative (-) terminal.

Fig. 28: Identifying SST & Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 battery HINT: At this time, do not connect the yellow connector. It will be connected to the seat belt pretensioner in a later step. 2. Press the SST deployment switch and check that the LED of the SST deployment switch illuminates.

Fig. 29: Pressing SST Deployment Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the LED is illuminated when the deployment switch is not pressed, SST may be malfunctioning. In this case, do not use the malfunctioning SST. e. Connect SST.

Fig. 30: Connecting SST's To Front Seat Outer Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect 2 SST, and then connect them to the seat belt pretensioner.  SST: 09082-00700  SST: 09082-00770 NOTE:

To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector.

2. Place the seat belt on the ground and cover it with a tire and wheel assembly.

Fig. 31: Positioning Outer Belt Under Tire And Wheel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

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Position the seat belt as shown in the illustration. Use a scrap tire and wheel assembly when disposing of a seat belt pretensioner.

3. Position and hold SST at least 10 m (33 ft.) away from the wheel. NOTE:

Do not damage the SST wire harness.

f. Deploy the seat belt pretensioner.

Fig. 32: Identifying SST Safe Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m *a or more 1. Check that no one is within a 10 m (33 ft.) radius of the wheel. 2. Connect the red clip of SST to the 12 V battery positive (+) terminal and the black clip to the 12 V battery negative (-) terminal. 3. Press the SST deployment switch to deploy the seat belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of SST illuminates. g. Dispose of the seat belt.

Fig. 33: Identifying Disposal Of Front Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the wheel and SST. 2. Place the seat belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. WARNING:









The seat belt becomes very hot when the pretensioner is deployed, so leave it untouched for at least 30 minutes after the pretensioner is deployed. Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner.

HINT: When scrapping a vehicle, deploy the seat belt pretensioner, and then scrap the vehicle with the seat belt installed.

REAR SEAT INNER BELT ASSEMBLY

COMPONENTS ILLUSTRATION

Fig. 34: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 35: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 36: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 37: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat inner with center belt assembly LH. 1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for Vehicle not Involved in Collision) a. Visually check for defects with the rear seat inner with center belt assembly LH installed on the vehicle. 1. The defects are as follows:  Cuts on the rear seat inner with center belt assembly LH  Small cracks on the rear seat inner with center belt assembly LH  Significant discoloration on the rear seat inner with center belt assembly LH OK No defects are found. HINT: If any of the defects is found, replace the rear seat inner with center belt assembly LH with a new one. 2. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for Vehicle Involved in Collision) a. Visually check for defects with the rear seat inner with center belt assembly LH removed from the vehicle. 1. The defects are as follows:  Cuts on the rear seat inner with center belt assembly LH  Small cracks on the rear seat inner with center belt assembly LH  Significant discoloration on the rear seat inner with center belt assembly LH  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the rear seat inner with center belt assembly LH with a new one.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7. 8. 9.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH See step 12 REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH a. Remove the bolt and rear seat inner with center belt assembly RH.

Fig. 38: Locating Rear Seat Inner Center Belt Assembly Bolt RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. 11. 12. 13.

REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the rear door opening trim weatherstrip LH. 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH a. Disconnect the rear door opening trim weatherstrip RH. 15. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 16. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 17. 18. 19. 20.

DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) See step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) See step 15 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Remove the bolt and disconnect the floor anchor of the rear seat inner with center belt assembly LH.

Fig. 39: Locating Rear Seat Inner Center Belt Assembly Bolt LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. 22. 23. 24. 25.

REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER See step 19 REMOVE REAR SEAT SHOULDER BELT COVER See step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY See step 21 REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Remove the bolt.

Fig. 40: Identifying Rear Seat Inner With Center Belt Assembly Guide LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to remove the rear seat inner with center belt assembly LH. INSPECTION INSPECTION

1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Before installing the rear seat inner with center belt assembly LH, check the ELR function.

Fig. 41: Inspecting Rear Seat Inner With Center Belt Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked *c 45° If the result is not as specified, replace the rear seat inner with center belt assembly LH. INSTALLATION INSTALLATION

1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH See step 1 2. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Engage the guide to temporarily install the rear seat inner with center belt assembly LH. b. Install the bolt.

Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) c. Check if the ELR locks. NOTE:

3. 4. 5. 6. 7.

The check should be performed with the rear seat inner with center belt assembly LH installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY See step 3 INSTALL REAR SEAT SHOULDER BELT COVER See step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER See step 5 INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Connect the floor anchor of the rear seat inner with center belt assembly LH with the bolt.

Fig. 42: Locating Rear Seat Inner Center Belt Assembly Bolt LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:





8. 9. 10. 11. 12.

Install the rear seat inner with center belt assembly LH with the arrow on the anchor part facing the front of the vehicle. Do not allow the anchor part of the rear seat inner with center belt assembly LH to overlap the protruding parts of the floor panel.

INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) See step 9 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) See step 10 INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 16. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 17. INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 18. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH a. Install the rear seat inner with center belt assembly RH with the bolt.

Fig. 43: Locating Rear Seat Inner Center Belt Assembly Bolt RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:





Install the rear seat inner with center belt assembly RH with the arrow on the anchor part facing the front of the vehicle. Do not allow the anchor part of the rear seat inner with center belt assembly RH to overlap the protruding parts of the floor panel.

19. 20. 21. 22. 23. 24.

INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH See step 2 INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

25. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 26. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR SEAT OUTER BELT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 44: Identifying Rear Seat Outer Belt Assembly Replacement Components With Torque

Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 45: Identifying Rear Seat Outer Belt Assembly Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 46: Identifying Rear Seat Outer Belt Assembly Replacement Components With Torque Specifications (3 Of 3)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat outer belt assembly. 1. INSPECT REAR SEAT OUTER BELT ASSEMBLY (for Vehicle not Involved in Collision) a. Visually check for defects with the rear seat outer belt assembly installed on the vehicle. 1. The defects are as follows:  Cuts on the rear seat outer belt assembly  Small cracks on the rear seat outer belt assembly  Significant discoloration on the rear seat outer belt assembly OK No defects are found. HINT: If any of the defects is found, replace the rear seat outer belt assembly with a new one. 2. INSPECT REAR SEAT OUTER BELT ASSEMBLY (for Vehicle Involved in Collision) a. Visually check for defects with the rear seat outer belt assembly removed from the vehicle. 1. The defects are as follows:  Cuts on the rear seat outer belt assembly  Small cracks on the rear seat outer belt assembly  Significant discoloration on the rear seat outer belt assembly  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the rear seat outer belt assembly with a new one. REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH See step 13 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH See step 14 REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

14. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) a. Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

Fig. 47: Identifying Rear Seat Outer Belt Assembly Bolt (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) a. Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

Fig. 48: Identifying Rear Seat Outer Belt Assembly Bolt (For RH Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. 17. 18. 19.

REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH See step 20 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER a. Using a moulding remover, disengage the 2 claws and 2 guides to remove the child restraint seat tether anchor cover.

Fig. 49: Identifying Child Restraint Seat Tether Anchor Cover Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor covers. 20. REMOVE REAR SEAT SHOULDER BELT COVER a. Using a moulding remover, disengage the 2 claws and 4 guides and remove the rear seat shoulder belt cover.

Fig. 50: Identifying Rear Seat Shoulder Belt Cover Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 rear seat shoulder belt covers. 21. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY a. Using pliers, disengage the 3 clips from inside the luggage compartment as shown in the illustration.

Fig. 51: Identifying Luggage Compartment Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the tip of the pliers before use. b. Disengage the 5 guides. c. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly then remove the package tray trim panel assembly. 22. REMOVE REAR SEAT OUTER BELT ASSEMBLY a. Remove the bolt.

Fig. 52: Identifying Rear Seat Outer Belt Assembly Guide And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Disengage the guide to remove the rear seat outer belt assembly. HINT: Use the same procedure for the RH side and LH side. INSPECTION INSPECTION

1. INSPECT REAR SEAT OUTER BELT ASSEMBLY a. Before installing the rear seat outer belt assembly, check the ELR function.

Fig. 53: Inspecting Rear Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked *c 45°

If the result is not as specified, replace the rear seat outer belt assembly. INSTALLATION INSTALLATION

1. INSPECT REAR SEAT OUTER BELT ASSEMBLY See step 1 2. INSTALL REAR SEAT OUTER BELT ASSEMBLY a. Engage the guide to temporarily install the rear seat outer belt assembly. b. Install the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) HINT: Use the same procedure for the RH side and LH side. c. Check if the ELR locks. NOTE:

The check should be performed with the rear seat outer belt assembly installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY a. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly. b. Engage the 5 guides and 3 clips to install the package tray trim panel assembly.

Fig. 54: Identifying Package Tray Trim Panel Assembly Guides And Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL REAR SEAT SHOULDER BELT COVER a. Engage the 4 guides and 2 claws to install the rear seat shoulder belt cover.

Fig. 55: Identifying Rear Seat Shoulder Belt Cover Guides And Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 rear seat shoulder belt covers. 5. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER a. Engage the 2 guides and 2 claws to install the child restraint seat tether anchor cover.

Fig. 56: Identifying Child Restraint Seat Tether Anchor Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor covers. 6. 7. 8. 9.

INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH See step 7 INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) a. Connect the floor anchor of the rear seat outer belt assembly with the bolt.

Fig. 57: Identifying Rear Seat Outer Belt Assembly Bolt And Protruding Parts (For LH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel.

10. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) a. Connect the floor anchor of the rear seat outer belt assembly with the bolt.

Fig. 58: Identifying Rear Seat Outer Belt Assembly Bolt And Protruding Parts (For RH Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel.

11. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 12. INSTALL ROOF SIDE INNER GARNISH RH

HINT: Use the same procedure as for the LH side. 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 16. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 17. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 18. INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 19. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 20. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 21. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 23. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

TONGUE PLATE STOPPER COMPONENTS ILLUSTRATION

Fig. 59: Identifying Tongue Plate Stopper Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

1. REMOVE TONGUE PLATE STOPPER a. Slide the tongue plate above the installation position of the tongue plate stopper, and temporarily hold it with adhesive tape.

Fig. 60: Identifying Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove any pieces of the original tongue plate stopper in the belt webbing with a pair of pliers. NOTE:

Be careful not to damage the belt webbing during repair.

TEXT IN ILLUSTRATION Adhesive *1 Tape Tongue *2 Plate Broken Tongue *a Plate Stopper 2. INSTALL TONGUE PLATE STOPPER a. Position a new tongue plate stopper in the hole of the belt webbing.

Fig. 61: Identifying Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tongue

Plate Stopper Belt *2 Webbing *a Male *b Female *1

HINT: Make sure that the installation direction of the tongue plate stopper is as shown in the illustration. b. Hold the tongue plate stopper in the hole of the belt webbing using an adjustable wrench, and turn the adjustment screw of the adjustable wrench by hand to compress the tongue plate stopper.

Fig. 62: Identifying Compressing Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:





When using the adjustable wrench, make sure to position the male and female parts of the tongue plate stopper parallel to each other. Do not use pliers to compress the pin of the tongue plate

stopper. They may damage the tongue plate stopper and belt webbing. HINT: Tape the jaws of the adjustable wrench before use. c. When the adjustment screw of the adjustable wrench cannot be turned by hand, tighten the adjustment screw using a pair of adjustable joint pliers until the tongue plate stopper thickness is 4.5 to 5.0 mm (0.177 to 0.197 in.). (Refer to the illustrations.)

Fig. 63: Tightening Adjustment Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Make sure that the male pin of the tongue plate stopper has expanded evenly in the hole of the female part and is firmly held to the belt webbing. (Refer to the illustrations.)

Fig. 64: Identifying Male Pin Of Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT

*b INCORRECT

CHILD RESTRAINT SEAT TETHER ANCHOR COMPONENTS ILLUSTRATION

Fig. 65: Identifying Child Restraint Seat Tether Anchor Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 66: Identifying Child Restraint Seat Tether Anchor Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 67: Identifying Child Restraint Seat Tether Anchor Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH See step 13 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH See step 14 REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

14. 15. 16. 17. 18. 19.

DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) See step 14 DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) See step 15 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH See step 20 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER See step 19

20. REMOVE REAR SEAT SHOULDER BELT COVER See step 20 21. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY See step 21 22. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET a. Remove the bolt and child restraint seat tether anchor bracket.

Fig. 68: Identifying Child Restraint Seat Tether Anchor Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor brackets. INSTALLATION INSTALLATION

1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET a. Install the child restraint seat tether anchor bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Use the same procedure for the other 2 child restraint seat tether anchor brackets. 2. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY See step 3

3. 4. 5. 6. 7. 8. 9. 10. 11.

INSTALL REAR SEAT SHOULDER BELT COVER See step 4 INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER See step 5 INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH See step 7 INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH See step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) See step 9 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) See step 10 INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

12. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 14. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 15. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 16. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 17. INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 18. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 19. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 20. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

21. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 22. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

CHILD RESTRAINT SEAT ANCHOR BRACKET COMPONENTS ILLUSTRATION

Fig. 69: Identifying Restraint Seat Anchor Bracket Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 70: Identifying Restraint Seat Anchor Bracket Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7. 8. 9. 10. 11.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 6 REMOVE NO. 2 ROOM PARTITION COVER . Refer to REMOVAL - Step 7 REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 10 REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH a. Remove the 2 nuts and child restraint seat anchor bracket sub-assembly LH.

Fig. 71: Identifying Child Restraint Seat Anchor Bracket Sub-Assembly Nuts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH a. Remove the 2 nuts and child restraint seat anchor bracket sub-assembly RH.

Fig. 72: Identifying Child Restraint Seat Anchor Bracket Sub-Assembly Nuts RH

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH a. Install the child restraint seat anchor bracket sub-assembly LH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH a. Install the child restraint seat anchor bracket sub-assembly RH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 3. 4. 5. 6. 7. 8. 9. 10.

INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 1 INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 2 INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 3 INSTALL NO. 2 ROOM PARTITION COVER . Refer to INSTALLATION - Step 4 INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 5 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

11. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 12. INSPECT SRS WARNING LIGHT for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

2012-2017 RESTRAINTS Seat Belt (Service Information) (Except Hybrid) - Camry

FRONT SEAT INNER BELT ASSEMBLY (FOR MANUAL SEAT) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Seat Inner Belt Assembly (For Manual Seat) (For TMMK Made) Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Front Seat Inner Belt Assembly (For Manual Seat) (For SIA Made) Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY

For TMMK Made: Refer to REMOVAL . For SIA Made: Refer to REMOVAL . 2. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. for TMMK Made: 1. Disengage each clamp under the front seat assembly. 2. Disengage the clamp.

Fig. 3: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For TMMK Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the nut and front seat inner belt assembly LH. b. for SIA Made: 1. Disengage each clamp under the front seat assembly. 2. Disengage the clamp.

Fig. 4: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For SIA Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the nut and front seat inner belt assembly LH. 3. REMOVE FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) For TMMK Made: Refer to DISASSEMBLY - Step 6 . For SIA Made: Refer to DISASSEMBLY - Step 8 . 4. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat) a. for TMMK Made: 1. Disconnect the connector.

Fig. 5: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For TMMK Made) Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Limit *1 Switch 2. Remove the screw and disconnect the limit switch. 3. Remove the nut and front seat inner belt assembly RH. b. for SIA Made: 1. Disengage each clamp under the front seat assembly. 2. Remove the screw and disconnect the limit switch.

Fig. 6: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For SIA Made) Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Limit *1 Switch 3. Remove the nut and front seat inner belt assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. for TMMK Made: 1. Install the front seat inner belt assembly LH with the nut.

Fig. 7: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For TMMK Made) Protruding Part And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly LH to overlap the protruding part of the front seat adjuster.

2. Engage the clamp.

3. Engage each clamp under the front seat assembly. b. for SIA Made: 1. Install the front seat inner belt assembly LH with the nut.

Fig. 8: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For SIA Made) Protruding Part And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt

assembly LH to overlap the protruding part of the front seat adjuster. 2. Engage the clamp. 3. Engage each clamp under the front seat assembly. 2. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat) a. for TMMK Made: 1. Install the front seat inner belt assembly RH with the nut.

Fig. 9: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For TMMK Made) Protruding Part, Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding

*1 Part Limit *2 Switch Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly RH to overlap the protruding part of the front seat adjuster.

2. Connect the limit switch with the screw. 3. Connect the connector. b. for SIA Made: 1. Install the front seat inner belt assembly RH with the nut.

Fig. 10: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For SIA Made) Protruding Part, Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Limit *2 Switch Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly RH to overlap the protruding part of the front seat adjuster.

2. Connect the limit switch with the screw. 3. Engage each clamp under the front seat assembly. 3. INSTALL FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) For TMMK Made: Refer to REASSEMBLY - Step 23 . For SIA Made: Refer to REASSEMBLY - Step 21 . 4. INSTALL FRONT SEAT ASSEMBLY For TMMK Made: Refer to INSTALLATION . For SIA Made: Refer to INSTALLATION .

FRONT SEAT INNER BELT ASSEMBLY (FOR POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 11: Identifying Front Seat Inner Belt Assembly (For Power Seat) (For TMMK Made) Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 12: Identifying Front Seat Inner Belt Assembly (For Power Seat) (For SIA Made) Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY

For TMMK Made: Refer to REMOVAL . For SIA Made: Refer to REMOVAL . 2. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. for TMMK Made: 1. Disengage each clamp under the front seat assembly. 2. Disengage the clamp.

Fig. 13: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For TMMK Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the nut and front seat inner belt assembly LH. b. for SIA Made: 1. Disengage each clamp under the front seat assembly. 2. Disengage the clamp.

Fig. 14: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For SIA Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the nut and front seat inner belt assembly LH. 3. REMOVE FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) For TMMK Made: Refer to DISASSEMBLY - Step 8 . For SIA Made: Refer to DISASSEMBLY - Step 11 . 4. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat) a. for TMMK Made: 1. Disconnect the connector.

Fig. 15: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For TMMK Made) Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Limit *1 Switch 2. Remove the screw and disconnect the limit switch. 3. Remove the nut and front seat inner belt assembly RH. b. for SIA Made: 1. Disengage each clamp under the front seat assembly. 2. Remove the screw and disconnect the limit switch.

Fig. 16: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For SIA Made) Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Limit *1 Switch 3. Remove the nut and front seat inner belt assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (for Driver Seat) a. for TMMK Made: 1. Install the front seat inner belt assembly LH with the nut.

Fig. 17: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For TMMK Made) Protruding Part And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly LH to overlap the protruding part of the front seat adjuster.

2. Engage the clamp.

3. Engage each clamp under the front seat assembly. b. for SIA Made: 1. Install the front seat inner belt assembly LH with the nut.

Fig. 18: Locating Front Seat Inner Belt Assembly LH (For Driver Seat) (For SIA Made) Protruding Part And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt

assembly LH to overlap the protruding part of the front seat adjuster. 2. Engage the clamp. 3. Engage each clamp under the front seat assembly. 2. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH (for Front Passenger Seat) a. for TMMK Made: 1. Install the front seat inner belt assembly RH with the nut.

Fig. 19: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For TMMK Made) Protruding Part, Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding

*1 Part Limit *2 Switch Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly RH to overlap the protruding part of the front seat adjuster.

2. Connect the limit switch with the screw. 3. Connect the connector. b. for SIA Made: 1. Install the front seat inner belt assembly RH with the nut.

Fig. 20: Locating Front Seat Inner Belt Assembly RH (For Front Passenger Seat) (For SIA Made) Protruding Part, Limit Switch Connector And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Limit *2 Switch Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the front seat inner belt assembly RH to overlap the protruding part of the front seat adjuster.

2. Connect the limit switch with the screw. 3. Engage each clamp under the front seat assembly. 3. INSTALL FRONT SEAT INNER CUSHION SHIELD RH (for Front Passenger Seat) For TMMK Made: Refer to REASSEMBLY - Step 27 . For SIA Made: Refer to REASSEMBLY - Step 25 . 4. INSTALL FRONT SEAT ASSEMBLY For TMMK Made: Refer to INSTALLATION . For SIA Made: Refer to INSTALLATION .

FRONT SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER PRECAUTION PRECAUTION

WARNING: Replace any faulty parts of the seat belt systems (outer belt, inner belt, bolts, nuts, adjustable shoulder anchor, tether anchor hardware and other related parts). When inspecting a vehicle that was in a collision, be sure to check all of the seat belt systems regardless of whether or not the system was activated in the collision. Replace any damaged or malfunctioning systems.

Fig. 21: Checking Belts Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. ROAD TEST (IN SAFE AREA) WARNING: Conduct this test in a safe area.

a. Fasten the front seat belts. b. Drive the vehicle at 16 km/h (10 mph) and firmly depress the brake pedal. Check that the belts lock and cannot be extended at this time. If a belt does not lock, replace the seat belt assembly. Refer to REMOVAL. HINT: Inspect the seat belt assembly before installing it. Refer to INSPECTION. COMPONENTS ILLUSTRATION

Fig. 22: Identifying Front Seat Outer Belt Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front seat outer belt assembly. 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Built-in Type Yaw Rate Sensor) b. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Separate Type Yaw Rate Sensor) c. Visually check for defects with the front seat outer belt assembly installed on the vehicle. 1. The defects are as follows:  Cuts on the front seat outer belt assembly  Small cracks on the front seat outer belt assembly  Significant discoloration on the front seat outer belt assembly OK No defects are found. HINT: If any of the defects is found, replace the front seat outer belt assembly with a new one. 2. INSPECT FRONT SEAT OUTER BELT ASSEMBLY (for Vehicle Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Built-in Type Yaw Rate Sensor) b. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . (for Separate Type Yaw Rate Sensor) c. Visually check for defects with the front seat outer belt assembly removed from the vehicle. 1. The defects are as follows:  Cuts on the front seat outer belt assembly  Small cracks on the front seat outer belt assembly  Significant discoloration on the front seat outer belt assembly  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the front seat outer belt assembly with a new one. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 3 . 4. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP a. Disconnect the front door opening trim weatherstrip. 5. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 18 . 6. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP a. Disconnect the rear door opening trim weatherstrip. 7. REMOVE LAP BELT OUTER ANCHOR COVER a. Disengage the 3 claws and remove the lap belt outer anchor cover.

Fig. 23: Identifying Lap Belt Outer Anchor Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY a. Remove the bolt and disconnect the floor anchor of the front seat outer belt assembly.

Fig. 24: Locating Front Seat Outer Belt Assembly Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 22 . 10. REMOVE CENTER PILLAR UPPER GARNISH . Refer to REMOVAL - Step 23 . 11. REMOVE FRONT SEAT OUTER BELT ASSEMBLY a. Remove the nut and disconnect the shoulder anchor of the front seat outer belt assembly.

Fig. 25: Identifying Front Seat Outer Belt Assembly Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, pull out the locking button in the direction shown by the arrow in the illustration to release the lock, and disconnect the pretensioner connector as shown in the illustration.

Fig. 26: Removing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the screwdriver tip before use. c. Remove the 2 bolts and front seat outer belt assembly.

Fig. 27: Identifying Front Seat Outer Belt Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY a. Remove the 2 bolts.

Fig. 28: Identifying Front Shoulder Belt Anchor Adjuster Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the front shoulder belt anchor adjuster assembly. INSPECTION INSPECTION

1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY a. Before installing the front seat outer belt assembly, check the ELR function.

Fig. 29: Checking ELR Function Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked *c 45° If the result is not as specified, replace the front seat outer belt assembly. INSTALLATION INSTALLATION

1. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY a. Engage the guide.

Fig. 30: Identifying Front Shoulder Belt Anchor Adjuster Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the bolt first, then the bolt to temporarily install the front shoulder belt anchor adjuster assembly. c. Fully tighten the 2 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. INSPECT FRONT SEAT OUTER BELT ASSEMBLY . See step 1. 3. INSTALL FRONT SEAT OUTER BELT ASSEMBLY a. Install the bolt first, then the bolt to temporarily install the front seat outer belt assembly.

Fig. 31: Identifying Front Seat Outer Belt Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Fully tighten the 2 bolts. Bolt Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Bolt Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) c. Connect the pretensioner connector and lock the locking button as shown in the illustration.

Fig. 32: Installing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Securely lock the locking button.

d. Connect the shoulder anchor of the front seat outer belt assembly with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 4. INSTALL CENTER PILLAR UPPER GARNISH . Refer to INSTALLATION - Step 21 . 5. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 22 . 6. CONNECT FRONT SEAT OUTER BELT ASSEMBLY a. Install the floor anchor of the front seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) b. Check if the ELR locks. NOTE:

The check should be performed with the front seat outer belt assembly installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. 7. INSTALL LAP BELT OUTER ANCHOR COVER a. Engage the 3 claws to install the lap belt outer anchor cover. 8. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP For LH Side: Refer to INSTALLATION - Step 25 . For RH Side: Refer to INSTALLATION - Step 32 . 9. INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 26 . 10. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP For LH Side: Refer to INSTALLATION - Step 42 . For RH Side: Refer to INSTALLATION - Step 46 . 11. INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 44 . 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

13. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

DISPOSAL WITH PRETENSIONER DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS component, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a seat belt (with a seat belt pretensioner), always deploy the procedures described below. If any abnormality occurs during deployment of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. 1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) WARNING:

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

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NOTE:

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Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner. When deploying a seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference. When disposing of a seat belt with a pretensioner, never deploy the pretensioner in the customer's vehicle.

Never dispose of a seat belt with a pretensioner that has not been deployed. The seat belt produces an exploding sound when the pretensioner deploys, so perform the operation outdoors where it will not disturb local residents. When deploying a seat belt pretensioner, perform the operation at least 10 m (33 ft.) away from the seat belt. Be sure to follow the procedure listed below when deploying a seat belt pretensioner.

a. Check the function of SST.

Fig. 33: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the seat belt pretensioner, always use the specified SST.

1. Connect the red clip of SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal.

Fig. 34: Identifying SST & Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery HINT: At this time, do not connect the yellow connector. It will be connected to the seat belt pretensioner in a later step. 2. Press the SST deployment switch and check that the LED of the SST deployment switch illuminates.

Fig. 35: Identifying SST Deployment Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the LED is illuminated when the deployment switch is not pressed, SST may be malfunctioning. In this case, do not use the malfunctioning SST. b. Disconnect the seat belt pretensioner connector. 1. Disconnect the cable from the negative (-) battery terminal. 2. Remove the front door scuff plate. Refer to REMOVAL - Step 3 . 3. Disconnect the front door opening trim weatherstrip, See step 4. 4. Remove the rear door scuff plate. Refer to REMOVAL - Step 18 . 5. Disconnect the rear door opening trim weatherstrip, See step 6. 6. Remove the center pillar lower garnish. Refer to REMOVAL - Step 22 . 7. Using a screwdriver, pull out the locking button in the direction shown by the arrow in the illustration to release the lock, and disconnect the pretensioner connector as shown in the illustration.

Fig. 36: Removing Front Seat Outer Belt Assembly Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the screwdriver tip before use. c. Connect SST.

Fig. 37: Connecting SST's To Front Seat Outer Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect 2 SST, and then connect them to the seat belt pretensioner.  SST: 09082-00700  SST: 09082-00770 NOTE:

To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector.

2. Move SST at least 10 m (33 ft.) away from the front of the vehicle.

Fig. 38: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m *a or more 3. Close all the doors and windows of the vehicle. NOTE:

Do not damage the SST wire harness.

d. Deploy the seat belt pretensioner. 1. Confirm that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. 2. Connect the red clip of SST to the battery positive (+) terminal and the black clip to the negative (-) terminal. 3. Press the SST deployment switch to deploy the seat belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of SST illuminates. e. Dispose of the seat belt.

Fig. 39: Identifying Disposal Of Front Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the seat belt and SST. 2. Place the seat belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. WARNING:

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The seat belt becomes very hot when the pretensioner is deployed, so leave it untouched for at least 30 minutes after the pretensioner is deployed. Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner.

HINT: When scrapping a vehicle, deploy the seat belt pretensioner, and then scrap the vehicle with the seat belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE)

WARNING:

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

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NOTE:

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Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner. When deploying a seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference.

When disposing of a seat belt with a pretensioner, never deploy the pretensioner in the customer's vehicle. Never dispose of a seat belt with a pretensioner that has not been deployed. The seat belt produces an exploding sound when the pretensioner deploys, so perform the operation outdoors where it will not disturb local residents. When deploying a seat belt pretensioner, perform the operation at least 10 m (33 ft.) away from the seat belt. Be sure to follow the procedure listed below when deploying a seat belt pretensioner.

a. Remove the seat belt. Refer to REMOVAL. b. Wind the seat belt webbing with the retractor.

Fig. 40: Identifying Seat Belt Webbing Cutting Dimension Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cut 100 *b mm c. When the seat belt webbing is sufficiently wound, cut the seat belt webbing approximately 100 mm (3.94 in.) from the retractor, as shown in the illustration. HINT: The retractor resistance increases in correlation with how much the seat belt webbing is wound. d. Check the function of SST.

Fig. 41: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the seat belt pretensioner, always use the specified SST.

1. Connect the red clip of SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal.

Fig. 42: Identifying SST & Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Battery HINT: At this time, do not connect the yellow connector. It will be connected to the seat belt pretensioner in a later step. 2. Press the SST deployment switch and check that the LED of the SST deployment switch illuminates.

Fig. 43: Identifying SST Deployment Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: If the LED is illuminated when the deployment switch is not pressed, SST may be malfunctioning. In this case, do not use the malfunctioning SST. e. Connect SST.

Fig. 44: Connecting SST's To Front Seat Outer Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect 2 SST, and then connect them to the seat belt pretensioner.  SST: 09082-00700  SST: 09082-00770 NOTE:

To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector.

2. Place the seat belt on the ground and cover it with a tire and wheel assembly.

Fig. 45: SST Connected To Front Seat Outer Belt Pretensioner Under Tire And Wheel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

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Position the seat belt as shown in the illustration. Use a scrap tire and wheel assembly when disposing of a seat belt pretensioner.

3. Position and hold SST at least 10 m (33 ft.) away from the wheel. NOTE:

Do not damage the SST wire harness.

f. Deploy the seat belt pretensioner.

Fig. 46: Identifying SST Safe Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m *a or more 1. Check that no one is within a 10 m (33 ft.) radius of the wheel. 2. Connect the red clip of SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 3. Press the SST deployment switch to deploy the seat belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of SST illuminates. g. Dispose of the seat belt.

Fig. 47: Identifying Disposal Of Front Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the wheel and SST. 2. Place the seat belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. WARNING:

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

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The seat belt becomes very hot when the pretensioner is deployed, so leave it untouched for at least 30 minutes after the pretensioner is deployed. Use gloves and safety glasses when handling a seat belt with a deployed pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a seat belt with a deployed pretensioner.

REAR SEAT INNER BELT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 48: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 49: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 50: Identifying Rear Seat Inner Belt Assembly Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat inner with center belt assembly LH. 1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for Vehicle not Involved in Collision) a. Visually check for defects with the rear seat inner with center belt assembly LH installed on the vehicle. 1. The defects are as follows:  Cuts on the rear seat inner with center belt assembly LH  Small cracks on the rear seat inner with center belt assembly LH  Significant discoloration on the rear seat inner with center belt assembly LH OK No defects are found. HINT: If any of the defects is found, replace the rear seat inner with center belt assembly LH with a new one. 2. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for Vehicle Involved in Collision) a. Visually check for defects with the rear seat inner with center belt assembly LH removed from the vehicle. 1. The defects are as follows:  Cuts on the rear seat inner with center belt assembly LH  Small cracks on the rear seat inner with center belt assembly LH  Significant discoloration on the rear seat inner with center belt assembly LH  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the rear seat inner with center belt assembly LH with a new one.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7. 8. 9.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 7 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH . See step 11. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH a. Remove the bolt and rear seat inner with center belt assembly RH.

Fig. 51: Locating Rear Seat Inner Center Belt Assembly RH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . 11. REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . 12. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH a. Disconnect the rear door opening trim weatherstrip LH. 13. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH a. Disconnect the rear door opening trim weatherstrip RH. 14. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 24 . 15. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. 16. 17. 18. 19.

DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . See step 13. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . See step 14. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 10. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Remove the bolt and disconnect the floor anchor of the rear seat inner with center belt assembly LH.

Fig. 52: Locating Rear Seat Inner Center Belt Assembly LH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. 21. 22. 23. 24.

REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 . REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . See step 18. REMOVE REAR SEAT SHOULDER BELT COVER . See step 19. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . See step 20. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Remove the bolt.

Fig. 53: Identifying Rear Seat Inner Center Belt Assembly LH Bolt And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide to remove the rear seat inner with center belt assembly LH. INSPECTION INSPECTION

1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Before installing the rear seat inner with center belt assembly LH, check the ELR function.

Fig. 54: Inspecting Rear Seat Inner With Center Belt Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked *c 45° If the result is not as specified, replace the rear seat inner with center belt assembly LH. INSTALLATION INSTALLATION

1. INSPECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . See step 1. 2. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Engage the guide to temporarily install the rear seat inner with center belt assembly LH. b. Install the bolt.

Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) c. Check if the ELR locks. NOTE:

3. 4. 5. 6. 7.

The check should be performed with the rear seat inner with center belt assembly LH installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . See step 3. INSTALL REAR SEAT SHOULDER BELT COVER . See step 4. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . See step 5. INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 . CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH a. Connect the floor anchor of the rear seat inner with center belt assembly LH with the bolt.

Fig. 55: Locating Rear Seat Inner Center Belt Assembly LH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

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8. 9. 10. 11. 12.

Install the rear seat inner with center belt assembly LH with the arrow on the anchor part facing the front of the vehicle. Do not allow the anchor part of the rear seat inner with center belt assembly LH to overlap the protruding parts of the floor panel.

INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 1. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . See step 9. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . See step 10. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 20 . INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . 16. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . 17. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH a. Install the rear seat inner with center belt assembly RH with the bolt.

Fig. 56: Locating Rear Seat Inner Center Belt Assembly RH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

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Install the rear seat inner with center belt assembly RH with the arrow on the anchor part facing the front of the vehicle. Do not allow the anchor part of the rear seat inner with center belt assembly RH to overlap the protruding parts of the floor panel.

18. 19. 20. 21.

INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH . See step 2. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 3 . INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 22. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 23. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

25. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR SEAT OUTER BELT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 57: Identifying Rear Seat Outer Belt Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 58: Identifying Rear Seat Outer Belt Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat outer belt assembly. 1. INSPECT REAR SEAT OUTER BELT ASSEMBLY (for Vehicle not Involved in Collision) a. Visually check for defects with the rear seat outer belt assembly installed on the vehicle. 1. The defects are as follows:  Cuts on the rear seat outer belt assembly  Small cracks on the rear seat outer belt assembly  Significant discoloration on the rear seat outer belt assembly OK No defects are found. HINT: If any of the defects is found, replace the rear seat outer belt assembly with a new one. 2. INSPECT REAR SEAT OUTER BELT ASSEMBLY (for Vehicle Involved in Collision) a. Visually check for defects with the rear seat outer belt assembly removed from the vehicle. 1. The defects are as follows:  Cuts on the rear seat outer belt assembly  Small cracks on the rear seat outer belt assembly  Significant discoloration on the rear seat outer belt assembly  Cracks or other damage to the connector OK No defects are found. HINT: If any of the defects is found, replace the rear seat outer belt assembly with a new one. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . See step 12. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . See step 13. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 24 . REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

13. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) a. Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

Fig. 59: Identifying Rear Seat Outer Belt Assembly (For LH Side) Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) a. Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

Fig. 60: Identifying Rear Seat Outer Belt Assembly (For RH Side) Bolt

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. 16. 17. 18.

REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 10. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . See step 19. REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 . REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER a. Using a moulding remover, disengage the 2 claws and 2 guides to remove the child restraint seat tether anchor cover.

Fig. 61: Removing Child Restraint Seat Tether Anchor Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor covers. 19. REMOVE REAR SEAT SHOULDER BELT COVER a. Using a moulding remover, disengage the 2 claws and 4 guides and remove the rear seat shoulder belt cover.

Fig. 62: Removing Rear Seat Shoulder Belt Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 rear seat shoulder belt covers. 20. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY a. Using pliers, disengage the 3 clips from inside the luggage compartment as shown in the illustration.

Fig. 63: Removing Package Tray Trim Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective

*1 Tape HINT: Tape the tip of the pliers before use. b. Disengage the 5 guides. c. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly then remove the package tray trim panel assembly. 21. REMOVE REAR SEAT OUTER BELT ASSEMBLY a. Remove the bolt.

Fig. 64: Identifying Rear Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Disengage the guide to remove the rear seat outer belt assembly. HINT: Use the same procedure for the RH side and LH side. INSPECTION INSPECTION

1. INSPECT REAR SEAT OUTER BELT ASSEMBLY a. Before installing the rear seat outer belt assembly, check the ELR function.

Fig. 65: Inspecting Rear Seat Outer Belt Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not disassemble the retractor.

1. When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. TEXT IN ILLUSTRATION *1 Retractor *a Unlocked *b Locked

*c 45° If the result is not as specified, replace the rear seat outer belt assembly. INSTALLATION INSTALLATION

1. INSPECT REAR SEAT OUTER BELT ASSEMBLY . See step 1. 2. INSTALL REAR SEAT OUTER BELT ASSEMBLY a. Engage the guide to temporarily install the rear seat outer belt assembly. b. Install the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) HINT: Use the same procedure for the RH side and LH side. c. Check if the ELR locks. NOTE:

The check should be performed with the rear seat outer belt assembly installed.

1. With the belt assembly installed, check that the belt locks when it is pulled out quickly. 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY a. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly. b. Engage the 5 guides and 3 clips to install the package tray trim panel assembly.

Fig. 66: Identifying Package Tray Trim Panel Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL REAR SEAT SHOULDER BELT COVER a. Engage the 4 guides and 2 claws to install the rear seat shoulder belt cover.

Fig. 67: Identifying Rear Seat Shoulder Belt Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 rear seat shoulder belt covers. 5. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER a. Engage the 2 guides and 2 claws to install the child restraint seat tether anchor cover.

Fig. 68: Identifying Child Restraint Seat Tether Anchor Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor covers. 6. 7. 8. 9.

INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 . CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . See step 7. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 1. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) a. Connect the floor anchor of the rear seat outer belt assembly with the bolt.

Fig. 69: Identifying Rear Seat Outer Belt Assembly (For LH Side) Bolt And Protruding Parts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel.

10. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) a. Connect the floor anchor of the rear seat outer belt assembly with the bolt.

Fig. 70: Identifying Rear Seat Outer Belt Assembly (For RH Side) Bolt And Protruding Parts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protruding *1 Part Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTE:

Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel.

11. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 20 . 12. INSTALL ROOF SIDE INNER GARNISH RH

HINT: Use the same procedure as for the LH side. 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 15. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . 16. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . 17. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . 18. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 19. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 20. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

22. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

TONGUE PLATE STOPPER COMPONENTS ILLUSTRATION

Fig. 71: Identifying Tongue Plate Stopper Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT REPLACEMENT

1. REMOVE TONGUE PLATE STOPPER a. Slide the tongue plate above the installation position of the tongue plate stopper, and temporarily hold it with adhesive tape.

Fig. 72: Removing Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove any pieces of the original tongue plate stopper in the belt webbing with a pair of pliers. NOTE:

Be careful not to damage the belt webbing during repair.

TEXT IN ILLUSTRATION Adhesive *1 Tape Tongue *2 Plate Broken Tongue *a Plate Stopper 2. INSTALL TONGUE PLATE STOPPER a. Position a new tongue plate stopper in the hole of the belt webbing.

Fig. 73: View Of Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tongue

Plate Stopper Belt *2 Webbing *a Male *b Female *1

HINT: Make sure that the installation direction of the tongue plate stopper is as shown in the illustration. b. Hold the tongue plate stopper in the hole of the belt webbing using an adjustable wrench, and turn the adjustment screw of the adjustable wrench by hand to compress the tongue plate stopper.

Fig. 74: Compressing Tongue Plate Stopper Using Adjustable Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape NOTE:





When using the adjustable wrench, make sure to position the male and female parts of the tongue plate stopper parallel to each other. Do not use pliers to compress the pin of the tongue plate

stopper. They may damage the tongue plate stopper and belt webbing. HINT: Tape the jaws of the adjustable wrench before use. c. When the adjustment screw of the adjustable wrench cannot be turned by hand, tighten the adjustment screw using a pair of adjustable joint pliers until the tongue plate stopper thickness is 4.5 to 5.0 mm (0.177 to 0.197 in.). (Refer to Fig. 75.)

Fig. 75: Tightening Adjustment Screw Using Adjustable Joint Pliers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Make sure that the male pin of the tongue plate stopper has expanded evenly in the hole of the female part and is firmly held to the belt webbing. (Refer to Fig. 76.)

Fig. 76: View Of Correct/Incorrect Expanded Male Pin Of Tongue Plate Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a CORRECT

*b INCORRECT

CHILD RESTRAINT SEAT TETHER ANCHOR COMPONENTS ILLUSTRATION

Fig. 77: Identifying Child Restraint Seat Tether Anchor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 78: Identifying Child Restraint Seat Tether Anchor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . See step 12. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . See step 13. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 24 . REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

13. 14. 15. 16. 17. 18. 19. 20.

DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . See step 13. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . See step 14. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 10. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . See step 19. REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 . REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . See step 18. REMOVE REAR SEAT SHOULDER BELT COVER . See step 19. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . See step 20.

21. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET a. Remove the bolt and child restraint seat tether anchor bracket.

Fig. 79: Identifying Child Restraint Seat Tether Anchor Bracket And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the other 2 child restraint seat tether anchor brackets. INSTALLATION INSTALLATION

1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET a. Install the child restraint seat tether anchor bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Use the same procedure for the other 2 child restraint seat tether anchor brackets. 2. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . See step 3. 3. INSTALL REAR SEAT SHOULDER BELT COVER . See step 4. 4. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . See step 5.

5. 6. 7. 8. 9. 10. 11.

INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 . CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . See step 7. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . See step 1. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . See step 9. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . See step 10. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 20 . INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side.

12. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 14. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . 15. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . 16. INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . 17. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 18. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 19. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

21. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

CHILD RESTRAINT SEAT ANCHOR BRACKET COMPONENTS ILLUSTRATION

Fig. 80: Identifying Child Restraint Seat Anchor Bracket Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7. 8. 9. 10.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to REMOVAL - Step 5 . REMOVE REAR SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 6 . REMOVE REAR SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 7 . REMOVE REAR SIDE SEATBACK ASSEMBLY LH . Refer to REMOVAL - Step 8 . REMOVE REAR SIDE SEATBACK ASSEMBLY RH . Refer to REMOVAL - Step 9 . REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH a. Remove the 2 nuts and child restraint seat anchor bracket sub-assembly LH.

Fig. 81: Identifying Child Restraint Seat Anchor Bracket Sub-Assembly LH Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH a. Remove the 2 nuts and child restraint seat anchor bracket sub-assembly RH.

Fig. 82: Identifying Child Restraint Seat Anchor Bracket Sub-Assembly RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH a. Install the child restraint seat anchor bracket sub-assembly LH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH a. Install the child restraint seat anchor bracket sub-assembly RH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 3. 4. 5. 6.

INSTALL REAR SIDE SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 2 . INSTALL REAR SIDE SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 1 . INSTALL REAR SEATBACK ASSEMBLY LH . Refer to INSTALLATION - Step 4 . INSTALL REAR SEATBACK ASSEMBLY RH . Refer to INSTALLATION - Step 3 .

7. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . Refer to INSTALLATION - Step 5. 8. INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . 9. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

11. INSPECT SRS WARNING LIGHT For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 ACCESSORIES & EQUIPMENT Seats (Service Information) - Camry (Hybrid)

FRONT SEAT ASSEMBLY (FOR MANUAL SEAT) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (1 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (2 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (3 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (4 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 5: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (5 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 6: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (6 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 7: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (7 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 8: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (8 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 9: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (9 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 10: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Manual Seat) (10 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION



NOTE:

If the side airbag was deployed, replace the front seat airbag assembly, front seatback frame sub-assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT SEAT HEADREST ASSEMBLY 5. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Disengage the 2 claws and remove the rear outer seat track bracket cover.

Fig. 11: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws and remove the rear inner seat track bracket cover.

Fig. 12: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 13: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Lift up the seat track adjusting handle and move the seat to the rearmost position. Remove the 2 bolts on the front side of the seat. Disconnect each connector and clamp under the seat. Lift up the seat track adjusting handle and move the seat to the center position. Then, operate the reclining adjuster release handle and move the seatback to the upright position. f. Remove the front seat assembly. NOTE:

Be careful not to damage the vehicle body.

DISASSEMBLY DISASSEMBLY

1. REMOVE SEAT ADJUSTER COVER CAP a. Remove the 2 seat adjuster cover caps.

Fig. 14: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RECLINING ADJUSTER RELEASE HANDLE a. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the reclining adjuster release handle.

Fig. 15: Removing Reclining Adjuster Release Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape 3. REMOVE VERTICAL ADJUSTING HANDLE (for Driver Side) a. Remove the screw and vertical adjusting handle.

Fig. 16: Identifying Vertical adjusting Handle Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 17: Identifying Rubber Bands Of Front Seatback Cover (For Manual Seat)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT CUSHION SHIELD a. Remove the 2 screws.

Fig. 18: Locating Front Seat Cushion Shield Claws And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the front seat cushion shield. 6. REMOVE FRONT SEAT INNER CUSHION SHIELD a. Remove the 2 screws and front seat inner cushion shield.

Fig. 19: Locating Front Seat Inner Cushion Shield Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 9. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disengage the claw and 3 clamps to separate the front seat airbag assembly wire harness.

Fig. 20: Identifying Front Seatback Cover Claw And Clamps (For Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for Driver Side: 1. Separate the separate type front seat cushion cover.

Fig. 21: Identifying Driver Side Front Seat Cushion Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. for Front Passenger Side: 1. Separate the separate type front seat cushion cover.

Fig. 22: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 23: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 12 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 24: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Disengage the hook.

Fig. 25: Locating Front Seatback Cover Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners.

Fig. 26: Identifying Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the separate type front seatback cover.

Fig. 27: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage the 2 hooks.

Fig. 28: Identifying Front Seatback Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the 4 clips. 2. Slide each hook to disengage them. e. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 29: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the separate type front seatback cover with pad.

Fig. 30: Identifying Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 7 13. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 2 hog rings.

Fig. 31: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners to remove the separate type front seatback cover from the separate type front seatback pad. 14. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 32: Removing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield LH. 15. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 33: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield RH. 16. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield LH.

Fig. 34: Identifying Front Seat Lower Cushion Shield Claws LH (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield RH.

Fig. 35: Identifying Front Seat Lower Cushion Shield Claws RH (For Front Passenger Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE FRONT UPPER SEAT TRACK COVER LH a. Disengage the 2 claws to remove the front upper seat track cover LH.

Fig. 36: Locating Front Upper Seat Track Cover Claws LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE FRONT UPPER SEAT TRACK COVER RH a. Disengage the 2 claws to remove the front upper seat track cover RH.

Fig. 37: Locating Front Upper Seat Track Cover Claws RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover LH.

Fig. 38: Identifying Rear Upper Seat Track Cover Claws LH (For Front Passenger Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover RH.

Fig. 39: Locating Rear Upper Seat Track Cover Claws RH (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 23. REMOVE FRONT SEAT WIRE RH (for Front Passenger Side) a. Disconnect each connector and disengage each wire harness clamp to remove the front seat wire RH. 24. REMOVE RECLINING CONTROL LEVER a. Remove the bolt and reclining control lever.

Fig. 40: Identifying Reclining Control Lever Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Remove the 4 bolts and front seat cushion panel sub-assembly.

Fig. 41: Locating Front Seat Cushion Panel Sub-Assembly Bolts (For Driver Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE FRONT SEATBACK FRAME SUB-ASSEMBLY a. Remove the 4 bolts and the front seatback frame sub-assembly.

Fig. 42: Locating Front Seatback Frame Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Disengage the 4 claws.

Fig. 43: Removing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the separate type front seatback spring assembly. c. Remove the 2 front seatback hooks from the separate type front seatback spring assembly. 28. REMOVE SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Remove the separate type front seat cushion spring assembly.

Fig. 44: Identifying Front Seat Cushion Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Install the separate type front seat cushion spring assembly. 2. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Install the 2 front seatback hooks to the separate type front seatback spring assembly. b. Engage the 2 guides.

Fig. 45: Installing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 4 claws to install the separate type front seatback spring assembly. 3. INSTALL FRONT SEATBACK FRAME SUB-ASSEMBLY a. Install the front seatback frame sub-assembly with the 4 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 4. INSTALL FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Install the front seat cushion panel sub-assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 5. INSTALL RECLINING CONTROL LEVER

a. Install the reclining control lever with the bolt. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 6. INSTALL FRONT SEAT WIRE RH (for Front Passenger Side) a. Connect each connector and engage each wire harness clamp to install the front seat wire RH. 7. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 8. INSTALL REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover LH. 9. INSTALL REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover RH. 10. INSTALL FRONT UPPER SEAT TRACK COVER LH a. Engage the 2 claws to install the front upper seat track cover LH. 11. INSTALL FRONT UPPER SEAT TRACK COVER RH a. Engage the 2 claws to install the front upper seat track cover RH. 12. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield LH.

Fig. 46: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw.

Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 13. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield RH.

Fig. 47: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 14. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield LH. 15. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield RH. 16. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 2 new hog rings.

Fig. 48: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Engage the 2 fasteners. 17. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 18. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Engage the 2 hooks. WARNING:







For vehicles with a front seat airbag assembly, the separate type front seatback cover must be securely installed. Otherwise, the front seat airbag assembly may not deploy properly. Make sure that the strap is not twisted after engaging the 2 hooks. Engage the 2 hooks securely.

1. Slide each hook to engage them. 2. Install the 4 clips. d. Engage the 2 fasteners. e. Engage the hook. 19. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 12 new hog rings.

Fig. 49: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

20. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. for Driver Side: 1. Install the separate type front seat cushion cover.

Fig. 50: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for Front Passenger Side: 1. Install the separate type front seat cushion cover.

Fig. 51: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Engage the claw and 3 clamps to install the front seat airbag assembly wire harness. 21. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 22. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 23. INSTALL FRONT SEAT INNER CUSHION SHIELD a. Install front seat inner cushion shield with the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 24. INSTALL FRONT SEAT CUSHION SHIELD a. Engage the 2 claws to install a new front seat cushion shield. b. Install the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 25. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the 2 rubber bands of the separate type front seatback cover. 26. INSTALL VERTICAL ADJUSTING HANDLE (for Driver Side) a. Install the vertical adjusting handle with the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf)

27. INSTALL RECLINING ADJUSTER RELEASE HANDLE a. Engage the claw to install the reclining adjuster release handle. 28. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY a. Place the front seat assembly in the cabin. NOTE: b. c. d. e.

Be careful not to damage the vehicle body.

Connect each connector and clamp under the seat. Temporarily install the front seat assembly with the 4 bolts. Lift up the seat track adjusting handle and move the seat to the rearmost position. Tighten the 2 bolts on the front side of the seat.

Fig. 52: Tightening Front Seat Assembly Front Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

f. Lift up the seat track adjusting handle and move the seat to the foremost position. g. Tighten the 2 bolts on the rear side of the seat.

Fig. 53: Tightening Seat Tracking Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSPECT SEAT SLIDE ADJUSTER LOCKS a. During the sliding operation of the front seat, check that the left and right adjusters move together smoothly and lock simultaneously. If the seat adjusters do not lock simultaneously, loosen the seat installation bolts to adjust the adjuster position. 3. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Engage the 2 claws to install the rear inner seat track bracket cover. 4. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 5. INSTALL FRONT SEAT HEADREST ASSEMBLY 6. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION

7. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 8. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Side) Refer to INITIALIZATION 9. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

FRONT SEAT ASSEMBLY (FOR POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 54: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (1 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 55: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (2 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 56: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (3 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 57: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (4 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 58: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (5 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 59: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (6 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 60: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (7 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 61: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (8 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 62: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (9 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 63: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (10 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 64: Identifying Front Seat Assembly Replacement Components With Torque Specifications (For Power Seat) (11 Of 11) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION



NOTE:



If the side airbag has deployed, replace the front seat airbag assembly, front seatback frame sub-assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable

from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. REMOVE FRONT SEAT HEADREST ASSEMBLY 4. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Operate the slide and vertical power seat switch knob and move the seat to the foremost position. b. Disengage the 2 claws and remove the rear outer seat track bracket cover.

Fig. 65: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws and remove the rear inner seat track bracket cover.

Fig. 66: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 67: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. c. Remove the 2 bolts on the front side of the seat. d. Operate the slide and vertical power seat switch knob and move the seat to the center position. Then, operate the reclining power seat switch knob and move the seatback to the upright position. e. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

f. Disconnect each connector and clamp under the seat. g. Remove the front seat assembly. NOTE: DISASSEMBLY DISASSEMBLY

Be careful not to damage the vehicle body.

1. REMOVE SEAT ADJUSTER COVER CAP a. Remove the 2 seat adjuster cover caps.

Fig. 68: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Using a moulding remover, disengage the 4 claws to remove the slide and vertical power seat switch knob.

Fig. 69: Identifying Slide And Vertical Power Switch Knob Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE RECLINING POWER SEAT SWITCH KNOB

a. Using a moulding remover, disengage the 4 claws to remove the reclining power seat switch knob.

Fig. 70: Identifying Reclining Power Seat Switch Knob Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 71: Identifying Rubber Bands Of Front Seatback Cover (For Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT CUSHION SHIELD a. Remove the screw.

Fig. 72: Locating Front Seat Cushion Shield Claws And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the front seat cushion shield. c. Disengage the wire harness clamp.

Fig. 73: Locating Front Power Seat Shield Switch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the front power seat switch connector. e. for Driver Side: 1. Disengage 4 claws to remove the front lumbar power seat switch from the front seat cushion shield.

Fig. 74: Locating Front Lumbar Power Seat Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT POWER SEAT SWITCH See step 6 7. REMOVE FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) See step 2 8. REMOVE FRONT SEAT INNER CUSHION SHIELD a. Remove the 2 screws and front seat inner cushion shield.

Fig. 75: Locating Front Seat Inner Cushion Shield Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 10. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 11. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disconnect the connector (A).

Fig. 76: Identifying Front Seatback Cover Connectors, Claw And Clamps (For Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp (B). c. Disengage the claw (D) and 3 clamps (C) to separate the front seat airbag assembly wire harness. d. w/ Seat Heater System: 1. Disconnect the connector (E). 2. Disengage the clamp (F). e. for Driver Side: 1. Separate the separate type front seat cushion cover.

Fig. 77: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. for Front Passenger Side: 1. Separate the separate type front seat cushion cover.

Fig. 78: Identifying Passenger Side Front Seat Cushion Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disengage the 4 hooks.

Fig. 79: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 80: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 12 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 81: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) See step 5 14. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Disengage the hook.

Fig. 82: Locating Front Seatback Cover Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners.

Fig. 83: Identifying Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the separate type front seatback cover.

Fig. 84: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage the 2 hooks.

Fig. 85: Identifying Front Seatback Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the 4 clips. 2. Slide each hook to disengage them. e. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 86: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the separate type front seatback cover with pad.

Fig. 87: Identifying Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 7 16. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 2 hog rings.

Fig. 88: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners to remove the separate type front seatback cover from the separate type front seatback pad. 17. REMOVE FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) See step 6 18. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 89: Removing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield LH. 19. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 90: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield RH. 20. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield LH.

Fig. 91: Locating Front Seat Lower Cushion Shield Claws LH (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield RH.

Fig. 92: Locating Front Seat Lower Cushion Shield Claws RH (For Front Passenger Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Disconnect the connector.

Fig. 93: Locating Seat Heater Control Sub-Assembly (W/ Seat Heater System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

23. 24. 25.

26.

b. Disengage the clamp and remove the seat heater control sub-assembly. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 REMOVE FRONT SEAT WIRE a. Disconnect each connector and disengage each wire harness clamp to remove the front seat wire. REMOVE FRONT NO. 2 SEAT WIRE a. Disconnect each connector and disengage each wire harness clamp to remove the front No. 2 seat wire. REMOVE FRONT UPPER SEAT TRACK COVER LH a. Disengage the 2 claws to remove the front upper seat track cover LH.

Fig. 94: Locating Front Upper Seat Track Cover Claws LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE FRONT UPPER SEAT TRACK COVER RH a. Disengage the 2 claws to remove the front upper seat track cover RH.

Fig. 95: Locating Front Upper Seat Track Cover Claws RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover LH.

Fig. 96: Locating Rear Upper Seat Track Cover Claws LH (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover RH.

Fig. 97: Locating Rear Upper Seat Track Cover Claws RH (For Front Passenger Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Remove the 4 bolts and front seat cushion panel sub-assembly.

Fig. 98: Locating Front Seat Cushion Panel Sub-Assembly Bolts (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE FRONT SEATBACK FRAME SUB-ASSEMBLY a. Remove the 4 bolts and the front seatback frame sub-assembly.

Fig. 99: Locating Front Seatback Frame Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY (for Driver Side) See step 5 33. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY (for Front Passenger Side) a. Disengage the 4 claws.

Fig. 100: Removing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the separate type front seatback spring assembly. c. Remove the 2 front seatback hooks from the separate type front seatback spring assembly. 34. REMOVE SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Remove the separate type front seat cushion spring assembly.

Fig. 101: Identifying Front Seat Cushion Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEAT FRAME WITH ADJUSTER ASSEMBLY LH a. Check the operation of the slide motor.

Fig. 102: Identifying Slide Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the auxiliary battery is connected to the slide motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Slide *a Motor (Front Seat Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Auxiliary battery positive (+) -> Terminal 3

Auxiliary battery Forward negative (-) -> Terminal 4 Auxiliary battery positive (+) -> Terminal 4 Backward Auxiliary battery negative (-) -> Terminal 3 If the result is not as specified, replace the front seat frame with adjuster assembly LH. b. Check the operation of the lifter motor.

Fig. 103: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the auxiliary battery is connected to the lifter motor connector terminals. TEXT IN ILLUSTRATION Component without harness

connected (Lifter Motor (Front Seat *a Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Auxiliary battery positive (+) -> Terminal 2 Upward Auxiliary battery negative (-) -> Terminal 1 Auxiliary battery positive (+) -> Terminal 1 Downward Auxiliary battery negative (-) -> Terminal 2 If the result is not as specified, replace the front seat frame with adjuster assembly LH. c. Check the operation of the front vertical motor.

Fig. 104: Identifying Separate Type Front Seatback Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the auxiliary battery is connected to the front vertical motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Front Vertical *a Motor (Front Seat Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Auxiliary battery

positive (+) -> Terminal 1 Auxiliary Upward battery negative (-) -> Terminal 2 Auxiliary battery positive (+) -> Terminal 2 Downward Auxiliary battery negative (-) -> Terminal 1 If the result is not as specified, replace the front seat frame with adjuster assembly LH. 2. INSPECT FRONT SEAT FRAME WITH ADJUSTER ASSEMBLY RH a. Check the operation of the slide motor.

Fig. 105: Identifying Slide Motor Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the auxiliary battery is connected to the slide motor connector terminals. TEXT IN ILLUSTRATION

Component without harness connected (Slide *a Motor (Front Seat Frame with Adjuster Assembly RH)) OK Measurement Operational Condition Direction Auxiliary battery positive (+) -> Terminal 3 Forward Auxiliary battery negative (-) -> Terminal 4 Auxiliary battery positive (+) -> Terminal 4 Backward Auxiliary battery negative (-) -> Terminal 3 If the result is not as specified, replace the front seat frame with adjuster assembly RH. 3. INSPECT FRONT SEATBACK FRAME SUB-ASSEMBLY LH a. Check the operation of the reclining motor.

Fig. 106: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seatback moves smoothly when the auxiliary battery is connected to the reclining motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Reclining Motor *a (Front Seatback Frame Subassembly LH)) OK Measurement Operational Condition Direction Auxiliary battery positive (+) --

> Terminal 2 Auxiliary Forward battery negative (-) -> Terminal 1 Auxiliary battery negative (+) -> Terminal 1 Rearward Auxiliary battery positive (-) -> Terminal 2 If the result is not as specified, replace the front seatback frame sub-assembly LH. 4. INSPECT FRONT SEATBACK FRAME SUB-ASSEMBLY RH a. Check the operation of the reclining motor.

Fig. 107: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seatback moves smoothly when the auxiliary battery is connected to the reclining motor connector terminals. TEXT IN ILLUSTRATION

Component without harness connected (Reclining Motor *a (Front Seatback Frame Subassembly RH)) OK Measurement Operational Condition Direction Auxiliary battery positive (+) -> Terminal 2 Forward Auxiliary battery negative (-) -> Terminal 1 Auxiliary battery negative (+) -> Terminal 1 Rearward Auxiliary battery positive (-) -> Terminal 2 If the result is not as specified, replace the front seatback frame sub-assembly RH. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Install the separate type front seat cushion spring assembly. 2. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY (for Driver Side) See step 1 3. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY (for Front Passenger Side) a. Install the 2 front seatback hooks to the separate type front seatback spring assembly.

b. Engage the 2 guides.

Fig. 108: Installing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 4 claws to install the separate type front seatback spring assembly. 4. INSTALL FRONT SEATBACK FRAME SUB-ASSEMBLY a. Install the front seatback frame sub-assembly with the 4 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 5. INSTALL FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Install the front seat cushion panel sub-assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

6. INSTALL FRONT UPPER SEAT TRACK COVER LH a. Engage the 2 claws to install the front upper seat track cover LH. 7. INSTALL FRONT UPPER SEAT TRACK COVER RH a. Engage the 2 claws to install the front upper seat track cover RH. 8. INSTALL REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover LH. 9. INSTALL REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover RH. 10. INSTALL FRONT NO. 2 SEAT WIRE a. Connect each connector and engage each wire harness clamp to install the front No. 2 seat wire. 11. INSTALL FRONT SEAT WIRE a. Connect each connector and engage each wire harness clamp to install the front seat wire. 12. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 13. INSTALL SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Engage the clamp to install the seat heater control sub-assembly. b. Connect the connector. 14. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield LH.

Fig. 109: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Engage the hook as shown in the illustration. c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 15. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield RH.

Fig. 110: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 16. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield LH. 17. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield RH. 18. INSTALL FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) See step 1 19. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 2 new hog rings.

Fig. 111: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Engage the 2 fasteners. 20. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 21. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Engage the 2 hooks. WARNING:







For vehicles with a front seat airbag assembly, the separate type front seatback cover must be securely installed. Otherwise, the front seat airbag assembly may not deploy properly. Make sure that the strap is not twisted after engage the 2 hooks. Engage the 2 hooks securely.

1. Slide each hook to engage them. 2. Install the 4 clips. d. Engage the 2 fasteners. e. Engage the hook. 22. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) See step 1 23. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 12 new hog rings.

Fig. 112: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

24. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. for Driver Side: 1. Install the separate type front seat cushion cover.

Fig. 113: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for Front Passenger Side: 1. Install the separate type front seat cushion cover.

Fig. 114: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Engage the claw (D) and 3 clamps (C) to install the front seat airbag assembly wire harness.

Fig. 115: Identifying Front Seatback Cover Connectors, Claw And Clamps (For Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

f. Engage the clamp (B). g. Connect the connector (A). h. w/ Seat Heater System: 1. Connect the connector (E). 2. Engage the clamp (F). 25. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 26. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 27. INSTALL FRONT SEAT INNER CUSHION SHIELD a. Install the front seat inner cushion shield with the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 28. INSTALL FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) See step 1 29. INSTALL FRONT POWER SEAT SWITCH See step 1 30. INSTALL FRONT SEAT CUSHION SHIELD a. for Driver Side: 1. Engage the 4 claws to install the front lumbar power seat switch to the front seat cushion shield. b. Connect the front power seat switch connector. c. Engage the wire harness clamp. d. Engage the 2 claws to install the front seat cushion shield. e. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 31. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the 2 rubber bands of the separate type front seatback cover. 32. INSTALL RECLINING POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the reclining power seat switch knob. 33. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the slide and vertical power seat switch knob. 34. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY

a. Place the front seat assembly in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Connect each connector and clamp under the seat. c. Connect the cable to the negative (-) auxiliary battery terminal. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

d. Temporarily install the front seat assembly with the 4 bolts. e. Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. f. Tighten the 2 bolts on the front side of the seat.

Fig. 116: Tightening Front Seat Assembly Front Bolts In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

g. Operate the slide and vertical power seat switch knob and move the seat to the foremost position. h. Tighten the 2 bolts on the rear side of the seat.

Fig. 117: Tightening Rear Side Of Seat In Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear inner seat track bracket cover. 3. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 4. INSTALL FRONT SEAT HEADREST ASSEMBLY 5. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 6. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Side) Refer to INITIALIZATION 7. INSPECT FRONT SEAT ASSEMBLY a. Check the power seat operation. Refer to OPERATION CHECK . b. w/ Seat Heater System: Check the seat heater operation. 1. Turn the power switch on (IG).

2. Turn the seat heater switch on. 3. Wait 5 minutes or more and confirm that the seat surface becomes warm. 8. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR SEAT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 118: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 119: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 120: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 121: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 122: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

WARNING:



Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION



NOTE:

If the side airbag was deployed, replace the rear seat airbag assembly, rear side seatback frame sub-assembly, rear side seatback cover sub-assembly and rear side seatback pad with the necessary parts in accordance with the extent of the collision damage.

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR SEAT CUSHION ASSEMBLY a. Disengage the hook of the seat cushion from the vehicle body as shown in the illustration. NOTE:

Follow the instructions below carefully as the cushion frame can be deformed easily.

1. Choose a hook to disengage first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to disengage the hook.

Fig. 123: Removing Rear Seat Cushion Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT 100 mm (3.94 a in.) or less 2. Repeat the step above for the other hook. b. Remove the rear seat cushion assembly. 5. REMOVE REAR SEAT CUSHION LOCK HOOK a. Disengage the claw and remove the rear seat cushion lock hook.

Fig. 124: Removing Rear Seat Cushion Lock Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Rear seat cushion lock hooks must not be reused.

HINT: Use the same procedure for the RH side and the LH side. 6. REMOVE REAR SEATBACK ASSEMBLY RH a. Fold down the rear seatback assembly RH. b. Disengage the 3 fasteners as shown in the illustration.

Fig. 125: Locating Rear Seatback Assembly Fasteners RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener c. Remove the 2 bolts and rear seatback assembly RH.

Fig. 126: Identifying Rear Seatback Assembly RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the vehicle body.

7. REMOVE NO. 2 ROOM PARTITION COVER a. Using a moulding remover, disengage the claw and guide, and remove the No. 2 room partition cover.

Fig. 127: Identifying No. 2 Room Partition Cover Claw And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR SEATBACK ASSEMBLY LH a. Disconnect the rear seat inner with center belt assembly LH from the rear seat center shoulder belt guide. b. Pull the cable in the direction shown in the illustration to release the rear seatback lock and then fold the rear seatback assembly LH forward.

Fig. 128: Pulling Cable To Release The Rear Seatback Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 2 fasteners as shown in the illustration.

Fig. 129: Locating Rear Seatback Assembly Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *1 Fastener d. Remove the 2 bolts and rear seatback assembly LH.

Fig. 130: Identifying Rear Seatback Assembly Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the vehicle body.

9. REMOVE REAR SIDE SEATBACK ASSEMBLY LH a. Disconnect the rear seat outer belt from the rear seat shoulder belt guide LH. b. Disconnect the connector. c. Remove the 2 bolts.

Fig. 131: Identifying Rear Side Seatback Assembly Connector, Bolts And Hook LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the hook and remove the rear side seatback assembly LH. 10. REMOVE REAR SIDE SEATBACK ASSEMBLY RH a. Disconnect the rear seat outer belt from the rear seat shoulder belt guide RH. b. Disconnect the connector. c. Remove the 2 bolts.

Fig. 132: Identifying Rear Side Seatback Assembly Connector, Bolts And Hook RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the hook and remove the rear side seatback assembly RH. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR SEAT CUSHION FRAME SUB-ASSEMBLY a. Disengage the 16 hooks and remove the rear seat cushion frame sub-assembly.

Fig. 133: Identifying Rear Seat Cushion Frame Sub-Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE BENCH TYPE REAR SEAT CUSHION COVER a. Remove the 12 hog rings and disengage the 4 fasteners, and remove the bench type rear seat cushion cover from the bench type rear seat cushion pad.

Fig. 134: Identifying Bench Type Rear Seat Cushion Cover Fasteners And Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener - 3. REMOVE REAR SEAT SHOULDER BELT GUIDE LH a. Remove the 2 screws.

Fig. 135: Identifying Rear Seat Shoulder Belt Guide Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat shoulder belt guide LH from the rear side seatback assembly LH. 4. REMOVE REAR SEAT AIRBAG ASSEMBLY LH . Refer to REMOVAL - Step 9 5. REMOVE REAR NO. 2 SEAT COVER BEZEL a. Remove the 4 screws and rear No. 2 seat cover bezel from the rear side seatback frame subassembly LH.

Fig. 136: Identifying Rear No. 2 Seat Cover Bezel Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE AIR INTAKE SEAL a. Remove the air intake seal from the rear No. 2 seat cover bezel.

Fig. 137: Removing Air Intake Seal

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE REAR SIDE SEATBACK COVER SUB-ASSEMBLY LH a. Remove the rear side seatback cover sub-assembly LH from the rear side seatback pad LH.

Fig. 138: Removing Rear Side Seatback Cover Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE REAR SEAT SHOULDER BELT GUIDE RH HINT: Use the same procedure as for the LH side. 9. REMOVE REAR SEAT AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 9 . 10. REMOVE REAR SIDE SEATBACK COVER SUB-ASSEMBLY RH a. Remove the rear side seatback cover sub-assembly RH from the rear side seatback pad RH.

Fig. 139: Removing Rear Side Seatback Cover Sub-Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE REAR SEAT CENTER SHOULDER BELT GUIDE a. Remove the 2 screws.

Fig. 140: Identifying Rear Seat Center Shoulder Belt Guide Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat center shoulder belt guide from the rear seatback assembly LH. 12. REMOVE REAR SEATBACK CARPET LH a. Using a clip remover, remove the 3 clips.

Fig. 141: Locating Rear Seatback Carpet Clips And Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners and remove the rear seatback carpet LH. TEXT IN ILLUSTRATION *1 Fastener 13. REMOVE REAR SEATBACK FRAME SUB-ASSEMBLY LH a. Disengage the 20 claws and remove the rear seatback frame sub-assembly LH from the separate type rear seatback cover with pad LH.

Fig. 142: Identifying Rear Seatback Frame Sub-Assembly Claws LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. REMOVE SEPARATE TYPE REAR SEATBACK COVER LH a. Remove the 10 hog rings and the separate type rear seatback cover LH from the separate type rear seatback pad LH.

Fig. 143: Identifying Separate Type Rear Seatback Cover Hog Rings LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE REAR SEAT CENTER ARMREST ASSEMBLY a. Remove the bolt and washer.

Fig. 144: Identifying Rear Seat Center Armrest Assembly With Fastener

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat center armrest assembly. 16. REMOVE REAR SEATBACK CARPET RH a. Using a clip remover, remove the 5 clips.

Fig. 145: Identifying Rear Seatback Carpet Fasteners RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 fasteners and remove the rear seatback carpet RH. TEXT IN ILLUSTRATION *1 Fastener 17. REMOVE REAR SEATBACK FRAME SUB-ASSEMBLY RH a. Disengage the 20 claws and remove the rear seatback frame sub-assembly RH from the separate type rear seatback cover with pad RH.

Fig. 146: Locating Rear Seatback Frame Sub-Assembly Claws RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE SEPARATE TYPE REAR SEATBACK COVER RH a. Remove the 13 hog rings and separate type rear seatback cover RH from the separate type rear seatback pad RH.

Fig. 147: Identifying Separate Type Rear Seatback Cover Hog Rings RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE REAR SEATBACK COVER LH a. Using hog ring pliers, install the separate type rear seatback cover LH to the separate type rear seatback pad LH with 10 new hog rings.

Fig. 148: Installing Separate Type Rear Seatback Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

2. INSTALL REAR SEATBACK FRAME SUB-ASSEMBLY LH a. Engage the 20 claws to install the rear seatback frame sub-assembly LH to the separate type rear seatback cover with pad LH.

Fig. 149: Identifying Rear Seatback Frame Sub-Assembly Claws LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR SEATBACK CARPET LH a. Engage the 2 fasteners.

Fig. 150: Locating Rear Seatback Carpet Clips And Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Install the rear seatback carpet with the 3 clips. 4. INSTALL REAR SEAT CENTER SHOULDER BELT GUIDE a. Engage the guide.

Fig. 151: Identifying Rear Seat Center Shoulder Belt Guide Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat center shoulder belt guide to the rear seatback assembly LH with the 2 screws. 5. INSTALL SEPARATE TYPE REAR SEATBACK COVER RH a. Using hog ring pliers, install the separate type rear seatback cover RH to the separate type rear seatback pad RH with 13 new hog rings.

Fig. 152: Installing Separate Type Rear Seatback Cover RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

6. INSTALL REAR SEATBACK FRAME SUB-ASSEMBLY RH a. Engage the 20 claws to install the rear seatback frame sub-assembly RH to the separate type rear seatback cover with pad RH.

Fig. 153: Locating Rear Seatback Frame Sub-Assembly Claws RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL REAR SEATBACK CARPET RH a. Engage the 3 fasteners.

Fig. 154: Identifying Rear Seatback Carpet Fasteners RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Install the rear seatback carpet RH with the 5 clips. 8. INSTALL REAR SEAT CENTER ARMREST ASSEMBLY a. Engage the guide.

Fig. 155: Identifying Rear Seat Center Armrest Assembly With Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat center armrest assembly with the bolt and washer. 9. INSTALL REAR SIDE SEATBACK COVER SUB-ASSEMBLY LH a. Install the rear side seatback cover sub-assembly LH to the rear side seatback pad LH.

Fig. 156: Installing Rear Side Seatback Cover Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL AIR INTAKE SEAL a. Clean the installation surface of the rear No. 2 seat cover bezel. b. Install a new air intake seal to the rear No. 2 seat cover bezel.

Fig. 157: Installing Air Intake Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. INSTALL REAR NO. 2 SEAT COVER BEZEL a. Install the rear No. 2 seat cover bezel to the rear side seatback frame sub-assembly LH with the 4 screws.

Fig. 158: Identifying Rear No. 2 Seat Cover Bezel Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. INSTALL REAR SEAT AIRBAG ASSEMBLY LH . Refer to INSTALLATION - Step 1 13. INSTALL REAR SEAT SHOULDER BELT GUIDE LH a. Engage the guide.

Fig. 159: Identifying Rear Seat Shoulder Belt Guide Fasteners LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat shoulder belt guide LH to the rear side seatback assembly LH with the 2 screws. 14. INSTALL REAR SIDE SEATBACK COVER SUB-ASSEMBLY RH a. Install the rear side seatback cover sub-assembly RH to the rear side seatback pad RH.

Fig. 160: Installing Rear Side Seatback Cover Sub-Assembly RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL REAR SEAT AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 1 . 16. INSTALL REAR SEAT SHOULDER BELT GUIDE RH HINT: Use the same procedure as for the LH side. 17. INSTALL BENCH TYPE REAR SEAT CUSHION COVER a. Engage the 4 fasteners to install the bench type rear seat cushion cover to the bench type rear seat cushion pad. b. Using hog ring pliers, install 12 new hog rings.

Fig. 161: Installing Bench Type Rear Seat Cushion Cover Fasteners And Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener - 18. INSTALL REAR SEAT CUSHION FRAME SUB-ASSEMBLY a. Engage the 16 hooks to install the rear seat cushion frame sub-assembly.

Fig. 162: Identifying Rear Seat Cushion Frame Sub-Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL REAR SIDE SEATBACK ASSEMBLY LH

a. Engage the hook to install the rear side seatback assembly LH. b. Install the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Connect the connector. d. Connect the rear seat outer belt to the rear seat shoulder belt guide LH. 2. INSTALL REAR SIDE SEATBACK ASSEMBLY RH a. Engage the hook to install the rear side seatback assembly RH. b. Install the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Connect the connector. d. Connect the rear seat outer belt to the rear seat shoulder belt guide RH. 3. INSTALL REAR SEATBACK ASSEMBLY LH a. Place the rear seatback assembly LH in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Install the rear seatback assembly LH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Connect the rear seat inner with center belt assembly LH to the rear seat center shoulder belt guide. 4. INSTALL NO. 2 ROOM PARTITION COVER a. Engage the guide and claw to install the No. 2 room partition cover.

Fig. 163: Identifying No. 2 Room Partition Cover Claw And Guide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL REAR SEATBACK ASSEMBLY RH a. Place the rear seatback assembly RH in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Install the rear seatback assembly RH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 6. INSTALL REAR SEAT CUSHION LOCK HOOK a. Engage the claw to install a new rear seat cushion lock hook.

Fig. 164: Installing Rear Seat Cushion Lock Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Rear seat cushion lock hooks must not be reused.

HINT: Use the same procedure for the RH side and the LH side. 7. INSTALL REAR SEAT CUSHION ASSEMBLY a. Place the rear seat cushion assembly in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Engage the 2 hooks of the seat cushion to the vehicle body as shown in the illustration.

Fig. 165: Installing Rear Seat Cushion Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Confirm that the seat cushion is firmly installed. NOTE:

When installing the seat cushion, make sure that the seat belt buckles are not under the seat cushion.

8. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 10. INSPECT SRS WARNING LIGHT

for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

POWER SEAT SWITCH COMPONENTS ILLUSTRATION

Fig. 166: Identifying Power Seat Switch Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY Refer to REMOVAL 2. 3. 4. 5.

REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB See step 2 REMOVE RECLINING POWER SEAT SWITCH KNOB See step 3 DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 4 REMOVE FRONT SEAT CUSHION SHIELD See step 5

6. REMOVE FRONT POWER SEAT SWITCH a. Remove the 3 screws and front power seat switch from the front seat cushion shield.

Fig. 167: Identifying Front Power Seat Switch Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT POWER SEAT SWITCH LH

Fig. 168: Inspecting Front Power Seat Switch LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Front *1 Vertical Switch Slide *2 Switch Lifter *3 Switch Reclining *4 Switch Component without harness connected *a (Front Power Seat Switch LH) Standard Resistance SLIDE SWITCH Tester Switch Specified Connection Condition Condition 5-7 5-8 Front 2 - 11 2 - 12 5 - 11 5 - 12 Below 1 Off ohms 2 - 11 2 - 12 5 - 11 5 - 12 Rear 2-7 2-8 FRONT VERTICAL SWITCH Tester Switch Specified Connection Condition Condition 1-7 1-8 Up 6 - 11 6 - 12 1 - 11

1 - 12 6 - 11 6 - 12 1 - 11 1 - 12 6-7 6-8

Off Below 1 ohms Down

LIFTER SWITCH Tester Switch Specified Connection Condition Condition 3-7 3-8 Up 4 - 11 4 - 12 3 - 11 3 - 12 Below 1 Off ohms 4 - 11 4 - 12 3 - 11 3 - 12 Down 4-7 4-8 RECLINING SWITCH Tester Switch Specified Connection Condition Condition 10 - 7 10 - 8 Front 9 - 11 9 - 12 10 - 11 10 - 12 Below 1 Off ohms 9 - 11 9 - 12 10 - 11 10 - 12 Rear 9-7 9-8 If the result is not as specified, replace the front power seat switch LH. 2. INSPECT FRONT POWER SEAT SWITCH RH

Fig. 169: Inspecting Front Power Seat Switch RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Slide *1 Switch Reclining *2 Switch Component without harness connected *a (Front Power Seat Switch RH) Standard Resistance SLIDE SWITCH Tester Switch Specified Connection Condition Condition 2 - 13 Front 5 - 10 2 - 10 Below 1 Off ohms 5 - 10 2 - 10 Rear 5 - 13 RECLINING SWITCH Tester Switch Specified Connection Condition Condition 11 - 13 Front 12 - 10 11 - 10 Below 1 Off ohms 12 - 10 11 - 10 Rear 12 - 13 If the result is not as specified, replace the front power seat switch RH. INSTALLATION INSTALLATION

1. INSTALL FRONT POWER SEAT SWITCH a. Install the front power seat switch to a new front seat cushion shield with the 3 screws.

2. 3. 4. 5. 6.

INSTALL FRONT SEAT CUSHION SHIELD See step 30 CONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 31 INSTALL RECLINING POWER SEAT SWITCH KNOB See step 32 INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB See step 33 INSTALL FRONT SEAT ASSEMBLY Refer to INSTALLATION

LUMBAR SWITCH COMPONENTS ILLUSTRATION

Fig. 170: Identifying Lumbar Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT POWER SEAT SWITCH Refer to REMOVAL 2. REMOVE FRONT LUMBAR POWER SEAT SWITCH a. Disconnect the connector to remove the front lumbar power seat switch.

Fig. 171: Identifying Front Lumbar Power Seat Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUMBAR FRONT POWER SEAT SWITCH

Fig. 172: Inspecting Lumbar Front Power Seat Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Hold *1 Switch Release *2 Switch Component without harness connected *a (Lumbar Front Power Seat Switch) Standard Resistance Tester Switch Specified Connection Condition Condition 3-5 Hold 1-2 3-2 Below 1 Off ohms 1-2 3-2 Release 1-5 If the result is not as specified, replace the lumbar front power seat switch. INSTALLATION INSTALLATION

1. INSTALL FRONT LUMBAR POWER SEAT SWITCH a. Connect the connector to install the front lumbar power seat switch. 2. INSTALL FRONT POWER SEAT SWITCH Refer to INSTALLATION

LUMBAR SUPPORT ADJUSTER ASSEMBLY (FOR POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 173: Identifying Lumbar Support Adjuster Assembly Replacement Components (For Power Seat) (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 174: Identifying Lumbar Support Adjuster Assembly Replacement Components (For Power Seat) (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH Refer to REMOVAL 2. 3. 4. 5.

DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 4 DISCONNECT CONNECTORS See step 3 REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD See step 14 REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY a. Disconnect the connector.

Fig. 175: Removing Lumbar Support Adjuster Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws. c. Disengage the 2 guides to remove the lumbar support adjuster assembly. d. Remove the 2 front seatback hooks from the lumbar support adjuster assembly. INSPECTION INSPECTION

1. INSPECT LUMBAR SUPPORT ADJUSTER ASSEMBLY LH a. Check the operation of the lumbar support adjuster assembly.

Fig. 176: Identifying Separate Type Front Seatback Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check that the front seatback moves smoothly when the auxiliary battery is connected to the lumbar support adjuster assembly connector terminals. OK Measurement Operational Condition Direction Auxiliary battery

positive (+) -> Terminal 1 Auxiliary battery negative (-) -> Terminal 2 Auxiliary battery positive (+) -> Terminal 2 Auxiliary battery negative (-) -> Terminal 1

Seatback moves forward

Seatback moves backward

TEXT IN ILLUSTRATION Component without harness connected *a (Lumbar Support Adjuster Assembly LH) If the result is not as specified, replace the lumbar support adjuster assembly LH. INSTALLATION INSTALLATION

1. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY a. Install the 2 front seatback hooks to the lumbar support adjuster assembly. b. Engage the 2 guides.

Fig. 177: Installing Lumbar Support Adjuster Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3. 4. 5.

c. Engage the 4 claws to install the lumbar support adjuster assembly. d. Connect the connector. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD See step 21 CONNECT CONNECTORS See step 4 CONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 31 INSTALL FRONT SEAT ASSEMBLY LH Refer to INSTALLATION

SEAT HEATER SWITCH COMPONENTS

ILLUSTRATION

Fig. 178: Identifying Seat Heater Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 12 REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 15 REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 16 REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 17 REMOVE SEAT HEATER SWITCH a. Disengage the 4 claws to remove the 2 seat heater switches.

Fig. 179: Identifying Seat Heater Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT SEAT HEATER SWITCH (for LH) a. Check the seat heater switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 180: Identifying Seat Heater Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for LH)) Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms 8-6 OFF or higher 350 ohms 8-6 ON to 3.4 kohms Below 1 8-3 ON ohms If the result is not as specified, replace the seat heater switch (for LH).

b. Check that the LED illuminates. 1. Apply auxiliary battery voltage to the seat heater switch (for LH) and check that the LED illuminates.

Fig. 181: Identifying Seat Heater Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for LH)) OK Measurement Switch Specified Condition Condition Condition Auxiliary battery positive (+) -> Terminal 7 Auxiliary

-

battery negative (-) -> Terminal 2 Auxiliary battery positive (+) -> Terminal 8 Auxiliary battery negative (-) -> Terminal 4

LED illuminates ON

If the result is not as specified, replace the seat heater switch (for LH). 2. INSPECT SEAT HEATER SWITCH (for RH) a. Check the seat heater switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 182: Identifying Seat Heater Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component *a without harness connected

(Seat Heater Switch (for RH)) Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms 7-5 OFF or higher 350 ohms to 3.4 7-5 ON kohms Below 1 7-2 ON ohms If the result is not as specified, replace the seat heater switch (for RH). b. Check that the LED illuminates. 1. Apply auxiliary battery voltage to the seat heater switch (for RH) and check that the LED illuminates.

Fig. 183: Identifying Seat Heater Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for RH)) OK Measurement Switch Specified Condition Condition Condition Auxiliary battery positive (+) -> Terminal 6 Auxiliary battery negative (-) -> Terminal 1 LED illuminates Auxiliary battery positive (+) -> Terminal 7 ON Auxiliary battery negative (-) -> Terminal 3 If the result is not as specified, replace the seat heater switch (for RH). INSTALLATION INSTALLATION

1. INSTALL SEAT HEATER SWITCH a. Engage the 4 claws to install the 2 seat heater switches. 2. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 35 3. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 36 4. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 40 5. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 37

FRONT SEATBACK HEATER COMPONENTS ILLUSTRATION

Fig. 184: Identifying Front Seatback Heater Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 185: Identifying Front Seatback Heater Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY Refer to REMOVAL 2. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 4 3. DISCONNECT CONNECTORS a. Disconnect the connector (A).

Fig. 186: Identifying Front Seatback Cover Connectors, Claw And Clamps (For Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp (B). c. Disengage the claw (D) and 3 clamps (C) to separate the front seat airbag assembly wire harness. d. Disconnect the connector (E). e. Disengage the clamp (F). 4. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD See step 14 5. REMOVE SEPARATE TYPE FRONT SEATBACK COVER See step 16 6. REMOVE FRONT SEATBACK HEATER ASSEMBLY a. Remove the 8 tag pins and the front seatback heater assembly from the separate type front seatback cover.

Fig. 187: Identifying Front Seatback Heater Assembly Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEATBACK HEATER ASSEMBLY LH a. Measure the resistance according to the value(s) in the table below.

Fig. 188: Identifying Front Seat Back Heater Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seatback Heater Assembly LH) Standard Resistance Tester Specified Condition Connection Condition 3.26 to 4 1-2 Always ohms If the result is not as specified, replace the front seatback heater assembly LH. 2. INSPECT FRONT SEATBACK HEATER ASSEMBLY RH a. Measure the resistance according to the value(s) in the table below.

Fig. 189: Identifying Front Seat Back Heater Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seatback Heater Assembly RH) Standard Resistance Tester Specified Condition Connection Condition 3.26 to 4 1-2 Always ohms If the result is not as specified, replace the front seatback heater assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEATBACK HEATER ASSEMBLY a. Using a tacker, install the front seatback heater assembly to the separate type front seatback cover with 8 new tag pins. 2. INSTALL SEPARATE TYPE FRONT SEATBACK COVER See step 19 3. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD See step 21 4. CONNECT CONNECTORS a. Engage the claw (D) and 3 clamps (C) to install the front seat airbag assembly wire harness.

Fig. 190: Identifying Front Seatback Cover Connectors, Claw And Clamps (For Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clamp (B). c. Connect the connector (A). d. Connect the connector (E). e. Engage the clamp (F). 5. CONNECT SEPARATE TYPE FRONT SEATBACK COVER See step 31 6. INSTALL FRONT SEAT ASSEMBLY Refer to INSTALLATION

FRONT SEAT CUSHION HEATER COMPONENTS

ILLUSTRATION

Fig. 191: Identifying Front Seat Cushion Heater Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 192: Identifying Front Seat Cushion Heater Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT POWER SEAT SWITCH Refer to REMOVAL 2. 3. 4. 5.

REMOVE FRONT SEAT INNER CUSHION SHIELD See step 8 REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD See step 11 REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER See step 12 REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY

a. Remove the 20 tag pins and the front seat cushion heater assembly from the separate type front seat cushion cover.

Fig. 193: Identifying Front Seat Cushion Heater Assembly Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY LH (for TMMK Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 194: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly LH) Standard Resistance Tester Specified Condition Connection Condition Below 1 A-1 - B-3 Always ohms 20°C (68° 9 to 13.8 A-2 - A-5 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 A-2 - B-1 F) to 25°C kohms (77°F)

A-2 - C-1

A-2 - C-1

A-2 - C-2

A-2 - A-3 A-3 - C-1 A-3 - B-1

A-3 - A-5

A-3 - C-2 A-4 - B-2 A-5 - B-1 A-5 - C-2 A-5 - C-1

20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) Below 1 Always ohms Below 1 Always ohms Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F)

If the result is not as specified, replace the front seat cushion heater assembly LH. 2. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY RH (for TMMK Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 195: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly RH) Standard Resistance Tester Specified Condition Connection Condition Below 1 A-1 - B-3 Always ohms 20°C (68° 9 to 13.8 A-2 - A-5 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 A-2 - B-1 F) to 25°C kohms (77°F)

A-2 - C-1

A-2 - C-1

A-2 - C-2

A-2 - A-3 A-3 - C-1 A-3 - B-1

A-3 - A-5

A-3 - C-2 A-4 - B-2 A-5 - B-1 A-5 - C-2 A-5 - C-1

20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) Below 1 Always ohms Below 1 Always ohms Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F)

If the result is not as specified, replace the front seat cushion heater assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY a. Using a tacker, install the front seat cushion heater assembly to the separate type front seat cushion cover with 20 new tag pins. 2. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER See step 23 3. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD See step 24 4. INSTALL FRONT SEAT INNER CUSHION SHIELD See step 27

5. INSTALL FRONT POWER SEAT SWITCH Refer to INSTALLATION

REAR SEAT RECLINING CONTROL CABLE COMPONENTS ILLUSTRATION

Fig. 196: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 197: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 198: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 199: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing.

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. 5. 6. 7. 8. 9. 10. 11.

REMOVE REAR SEAT CUSHION ASSEMBLY See step 4 REMOVE REAR SEAT CUSHION LOCK HOOK See step 5 REMOVE REAR SEATBACK ASSEMBLY RH See step 6 REMOVE NO. 2 ROOM PARTITION COVER See step 7 REMOVE REAR SEATBACK ASSEMBLY LH See step 8 REMOVE REAR SIDE SEATBACK ASSEMBLY LH See step 9 REMOVE REAR SIDE SEATBACK ASSEMBLY RH See step 10 DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 13 12. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 14 13. REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 25 14. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 25 . 15. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 14 16. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 15 17. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to

18. 19. 20. 21. 22. 23.

REMOVAL - Step 11 DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 20 REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 19 REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 20 REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE NO. 1 ROOM PARTITION BOARD a. Using a clip remover, remove the 4 clips.

Fig. 200: Identifying No. 1 Room Partition Board Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Disengage the 5 clips and remove the No. 1 room partition board. 24. REMOVE REAR SEATBACK LOCK SUB-ASSEMBLY LH a. Remove the 2 nuts and rear seatback lock sub-assembly LH.

Fig. 201: Identifying Rear Seatback Lock Sub-Assembly Nuts LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE REAR SEATBACK LOCK SUB-ASSEMBLY RH a. Disengage the hook as shown in the illustration.

Fig. 202: Identifying Rear Seatback Lock Sub-Assembly Hook RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and rear seatback lock sub-assembly RH.

Fig. 203: Identifying Rear Seatback Lock Sub-Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL REAR SEATBACK LOCK SUB-ASSEMBLY LH a. Install the rear seatback lock sub-assembly LH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL REAR SEATBACK LOCK SUB-ASSEMBLY RH a. Install the rear seatback lock sub-assembly RH with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) b. Engage the hook as shown in the illustration.

Fig. 204: Identifying Rear Seatback Lock Sub-Assembly Hook And Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NO. 1 ROOM PARTITION BOARD a. Engage the 5 clips to install the No. 1 room partition board. b. Install the 4 clips. 4. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 5. INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 6. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 7. INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 8. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 7 9. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to

10. 11. 12. 13.

INSTALLATION - Step 1 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 21 INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 21 .

14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 26 15. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 33 16. INSTALL REAR SIDE SEATBACK ASSEMBLY LH See step 1 17. INSTALL REAR SIDE SEATBACK ASSEMBLY RH See step 2 18. INSTALL REAR SEATBACK ASSEMBLY LH See step 3 19. INSTALL NO. 2 ROOM PARTITION COVER See step 4 20. INSTALL REAR SEATBACK ASSEMBLY RH See step 5 21. INSTALL REAR SEAT CUSHION LOCK HOOK See step 6 22. INSTALL REAR SEAT CUSHION ASSEMBLY See step 7 23. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

24. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 25. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

2012-2017 ACCESSORIES & EQUIPMENT Seats (Service Information) (Except Hybrid) - Camry

FRONT SEAT ASSEMBLY (FOR TMMK MADE MANUAL SEAT) COMPONENTS ILLUSTRATION

Fig. 1: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components With Torque Specifications (1 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components With Torque Specifications (2 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components (3 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 4: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components With Torque Specifications (4 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 5: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components (5 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 6: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components With Torque Specifications (6 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 7: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components With Torque Specifications (7 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 8: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components (8 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 9: Identifying Front Seat Assembly (For TMMK Made Manual Seat) Replacement Components (9 Of 9) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION .



NOTE:

If the side airbag was deployed, replace the front seat airbag assembly, front seatback frame sub-assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery

terminal notices before proceeding with work. Refer to PRECAUTION . 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT SEAT HEADREST ASSEMBLY 4. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Disengage the 2 claws and remove the rear outer seat track bracket cover.

Fig. 10: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws and remove the rear inner seat track bracket cover.

Fig. 11: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 12: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Lift up the seat track adjusting handle and move the seat to the rearmost position. Remove the 2 bolts on the front side of the seat. Disconnect each connector and clamp under the seat. Lift up the seat track adjusting handle and move the seat to the center position. Then, operate the reclining adjuster release handle and move the seatback to the upright position. f. Remove the front seat assembly. NOTE:

Be careful not to damage the vehicle body.

DISASSEMBLY DISASSEMBLY

1. REMOVE SEAT ADJUSTER COVER CAP a. Remove the 2 seat adjuster cover caps.

Fig. 13: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RECLINING ADJUSTER RELEASE HANDLE a. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the reclining adjuster release handle.

Fig. 14: Removing Reclining Adjuster Release Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape 3. REMOVE VERTICAL ADJUSTING HANDLE (for Driver Side) a. Remove the screw and vertical adjusting handle.

Fig. 15: Identifying Vertical Adjusting Handle (For Driver Side) And Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 16: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Manual

Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT CUSHION SHIELD a. Remove the 2 screws.

Fig. 17: Locating Front Seat Cushion Shield Claws And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the front seat cushion shield. 6. REMOVE FRONT SEAT INNER CUSHION SHIELD a. Remove the 2 screws and front seat inner cushion shield.

Fig. 18: Locating Front Seat Inner Cushion Shield Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 . 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 . 9. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disengage the claw and 3 clamps to separate the front seat airbag assembly wire harness.

Fig. 19: Identifying Front Seatback Cover Claw And Clamps (For TMMK Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for Driver Side: 1. Separate the separate type front seat cushion cover.

Fig. 20: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. for Front Passenger Side: 1. Separate the separate type front seat cushion cover.

Fig. 21: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 22: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 12 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 23: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Disengage the hook.

Fig. 24: Locating Front Seatback Cover Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners.

Fig. 25: Identifying Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the separate type front seatback cover.

Fig. 26: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage the 2 hooks.

Fig. 27: Identifying Front Seatback Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the 4 clips. 2. Slide each hook to disengage them. e. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 28: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the separate type front seatback cover with pad.

Fig. 29: Identifying Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 13 . 13. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 2 hog rings.

Fig. 30: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners to remove the separate type front seatback cover from the separate type front seatback pad. 14. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 31: Removing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield LH. 15. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 32: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield RH. 16. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield LH.

Fig. 33: Locating Front Seat Lower Cushion Shield LH (For Front Passenger Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield RH.

Fig. 34: Locating Front Seat Lower Cushion Shield RH (For Front Passenger Side) Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. REMOVE FRONT UPPER SEAT TRACK COVER LH a. Disengage the 2 claws to remove the front upper seat track cover LH.

Fig. 35: Locating Front Upper Seat Track Cover LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE FRONT UPPER SEAT TRACK COVER RH a. Disengage the 2 claws to remove the front upper seat track cover RH.

Fig. 36: Locating Front Upper Seat Track Cover RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover LH.

Fig. 37: Locating Rear Upper Seat Track Cover LH (For Front Passenger Side) Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover RH.

Fig. 38: Locating Rear Upper Seat Track Cover RH (For Front Passenger Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 . 23. REMOVE FRONT SEAT WIRE RH (for Front Passenger Side) a. Disconnect the connectors and disengage the wire harness clamps to remove the front seat wire RH. 24. REMOVE RECLINING CONTROL LEVER a. Remove the bolt and reclining control lever.

Fig. 39: Identifying Reclining Control Lever Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Remove the 4 bolts and front seat cushion panel sub-assembly.

Fig. 40: Locating Front Seat Cushion Panel Sub-Assembly (For Driver Side) Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE FRONT SEATBACK FRAME SUB-ASSEMBLY a. Remove the 4 bolts and the front seatback frame sub-assembly.

Fig. 41: Locating Front Seatback Frame Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Disengage the 4 claws.

Fig. 42: Removing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the separate type front seatback spring assembly. c. Remove the 2 front seatback hooks from the separate type front seatback spring assembly. 28. REMOVE SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Remove the separate type front seat cushion spring assembly.

Fig. 43: Identifying Front Seat Cushion Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Install the separate type front seat cushion spring assembly. 2. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Install the 2 front seatback hooks to the separate type front seatback spring assembly. b. Engage the 2 guides.

Fig. 44: Installing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 4 claws to install the separate type front seatback spring assembly. 3. INSTALL FRONT SEATBACK FRAME SUB-ASSEMBLY a. Install the front seatback frame sub-assembly with the 4 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 4. INSTALL FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Install the front seat cushion panel sub-assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 5. INSTALL RECLINING CONTROL LEVER

a. Install the reclining control lever with the bolt. Torque: 16 N*m (158 kgf*cm, 11 ft.*lbf) 6. INSTALL FRONT SEAT WIRE RH (for Front Passenger Side) a. Connect the connectors and engage the wire harness clamps to install the front seat wire RH. 7. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 . 8. INSTALL REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover LH. 9. INSTALL REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover RH. 10. INSTALL FRONT UPPER SEAT TRACK COVER LH a. Engage the 2 claws to install the front upper seat track cover LH. 11. INSTALL FRONT UPPER SEAT TRACK COVER RH a. Engage the 2 claws to install the front upper seat track cover RH. 12. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield LH.

Fig. 45: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw.

Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 13. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield RH.

Fig. 46: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 14. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield LH. 15. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield RH. 16. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 2 new hog rings.

Fig. 47: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Engage the 2 fasteners. 17. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 18. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Engage the 2 hooks. WARNING:







For vehicles with a front seat airbag assembly, the separate type front seatback cover must be securely installed. Otherwise, the front seat airbag assembly may not deploy properly. Make sure that the strap is not twisted after engaging the 2 hooks. Engage the 2 hooks securely.

1. Slide each hook to engage them. 2. Install the 4 clips. d. Engage the 2 fasteners. e. Engage the hook. 19. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 12 new hog rings.

Fig. 48: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

20. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. for Driver Side: 1. Install the separate type front seat cushion cover.

Fig. 49: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for Front Passenger Side: 1. Install the separate type front seat cushion cover.

Fig. 50: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Engage the claw and 3 clamps to install the front seat airbag assembly wire harness. 21. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 . 22. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 . 23. INSTALL FRONT SEAT INNER CUSHION SHIELD a. Install front seat inner cushion shield with the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 24. INSTALL FRONT SEAT CUSHION SHIELD a. Engage the 2 claws to install a new front seat cushion shield. b. Install the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 25. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the 2 rubber bands of the separate type front seatback cover. 26. INSTALL VERTICAL ADJUSTING HANDLE (for Driver Side) a. Install the vertical adjusting handle with the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf)

27. INSTALL RECLINING ADJUSTER RELEASE HANDLE a. Engage the claw to install the reclining adjuster release handle. 28. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY a. Place the front seat assembly in the cabin. NOTE: b. c. d. e.

Be careful not to damage the vehicle body.

Connect each connector and clamp under the seat. Temporarily install the front seat assembly with the 4 bolts. Lift up the seat track adjusting handle and move the seat to the rearmost position. Tighten the 2 bolts on the front side of the seat.

Fig. 51: Locating Front Seat Assembly Front Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

f. Lift up the seat track adjusting handle and move the seat to the foremost position. g. Tighten the 2 bolts on the rear side of the seat.

Fig. 52: Locating Front Seat Assembly Rear Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSPECT SEAT SLIDE ADJUSTER LOCKS a. During the sliding operation of the front seat, check that the left and right adjusters move together smoothly and lock simultaneously. If the seat adjusters do not lock simultaneously, loosen the seat installation bolts to adjust the adjuster position. 3. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Engage the 2 claws to install the rear inner seat track bracket cover. 4. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 5. INSTALL FRONT SEAT HEADREST ASSEMBLY 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Side) Refer to INITIALIZATION . 8. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

FRONT SEAT ASSEMBLY (FOR TMMK MADE POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 53: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components With Torque Specifications (1 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 54: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components With Torque Specifications (2 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 55: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components (3 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 56: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components With Torque Specifications (4 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 57: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components (5 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 58: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components With Torque Specifications (6 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 59: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components (7 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 60: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components With Torque Specifications (8 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 61: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components (9 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 62: Identifying Front Seat Assembly (For TMMK Made Power Seat) Replacement Components (10 Of 10) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION .



NOTE:



If the side airbag has deployed, replace the front seat airbag assembly, front seatback frame sub-assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the

negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION . 2. REMOVE FRONT SEAT HEADREST ASSEMBLY 3. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Operate the slide and vertical power seat switch knob and move the seat to the foremost position. b. Disengage the 2 claws and remove the rear outer seat track bracket cover.

Fig. 63: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws and remove the rear inner seat track bracket cover.

Fig. 64: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 65: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. c. Remove the 2 bolts on the front side of the seat. d. Operate the slide and vertical power seat switch knob and move the seat to the center position. Then, operate the reclining power seat switch knob and move the seatback to the upright position. e. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

f. Disconnect each connector and clamp under the seat. g. Remove the front seat assembly. NOTE:

Be careful not to damage the vehicle body.

DISASSEMBLY DISASSEMBLY

1. REMOVE SEAT ADJUSTER COVER CAP

a. Remove the 2 seat adjuster cover caps.

Fig. 66: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Using a moulding remover, disengage the 4 claws to remove the slide and vertical power seat switch knob.

Fig. 67: Removing Slide And Vertical Power Seat Switch Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE RECLINING POWER SEAT SWITCH KNOB a. Using a moulding remover, disengage the 4 claws to remove the reclining power seat switch knob.

Fig. 68: Removing Reclining Power Seat Switch Knob

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 69: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT CUSHION SHIELD a. Remove the screw.

Fig. 70: Locating Front Seat Cushion Shield Claws And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the front seat cushion shield. c. Disengage the wire harness clamp.

Fig. 71: Locating Front Power Seat Shield Switch Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the front power seat switch connector. e. for Driver Side: 1. Disengage 4 claws to remove the front lumbar power seat switch from the front seat cushion shield.

Fig. 72: Locating Front Lumbar Power Seat Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT POWER SEAT SWITCH . See step 6. 7. REMOVE FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) . See step 2. 8. REMOVE FRONT SEAT INNER CUSHION SHIELD a. Remove the 2 screws and front seat inner cushion shield.

Fig. 73: Locating Front Seat Inner Cushion Shield Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 . 10. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 . 11. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disconnect the connector (A).

Fig. 74: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp (B). c. Disengage the claw (D) and 3 clamps (C) to separate the front seat airbag assembly wire harness. d. w/ Seat Heater System: 1. Disconnect the connector (E). 2. Disengage the clamp (F). e. for Driver Side: 1. Separate the separate type front seat cushion cover.

Fig. 75: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. for Front Passenger Side: 1. Separate the separate type front seat cushion cover.

Fig. 76: Identifying Passenger Side Front Seat Cushion Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disengage the 4 hooks.

Fig. 77: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 78: Identifying Front Seat Cushion Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 12 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 79: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) . See step 5. 14. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Disengage the hook.

Fig. 80: Locating Front Seatback Cover Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners.

Fig. 81: Identifying Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn back the separate type front seatback cover.

Fig. 82: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage the 2 hooks.

Fig. 83: Identifying Front Seatback Cover Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove the 4 clips. 2. Slide each hook to disengage them. e. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 84: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Remove the separate type front seatback cover with pad.

Fig. 85: Identifying Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 13 . 16. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 2 hog rings.

Fig. 86: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners to remove the separate type front seatback cover from the separate type front seatback pad. 17. REMOVE FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) . See step 6. 18. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 87: Removing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield LH. 19. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 88: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the 2 claws to remove the front seat lower cushion shield RH. 20. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield LH.

Fig. 89: Locating Front Seat Lower Cushion Shield LH (For Front Passenger Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Disengage the 2 claws to remove the front seat lower cushion shield RH.

Fig. 90: Locating Front Seat Lower Cushion Shield RH (For Front Passenger Side) Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Disconnect the connector.

Fig. 91: Locating Seat Heater Control Sub-Assembly (w/ Seat Heater System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

23. 24. 25.

26.

b. Disengage the clamp and remove the seat heater control sub-assembly. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 . REMOVE FRONT SEAT WIRE a. Disconnect the connectors and disengage the wire harness clamps to remove the front seat wire. REMOVE FRONT NO. 2 SEAT WIRE a. Disconnect the connectors and disengage the wire harness clamps to remove the front No. 2 seat wire. REMOVE FRONT UPPER SEAT TRACK COVER LH a. Disengage the 2 claws to remove the front upper seat track cover LH.

Fig. 92: Locating Front Upper Seat Track Cover LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE FRONT UPPER SEAT TRACK COVER RH a. Disengage the 2 claws to remove the front upper seat track cover RH.

Fig. 93: Locating Front Upper Seat Track Cover RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover LH.

Fig. 94: Locating Rear Upper Seat Track Cover LH (For Front Passenger Side) Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 29. REMOVE REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Disengage the 2 claws to remove the rear upper seat track cover RH.

Fig. 95: Locating Rear Upper Seat Track Cover RH (For Front Passenger Side) Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Remove the 4 bolts and front seat cushion panel sub-assembly.

Fig. 96: Locating Front Seat Cushion Panel Sub-Assembly (For Driver Side) Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE FRONT SEATBACK FRAME SUB-ASSEMBLY a. Remove the 4 bolts and the front seatback frame sub-assembly.

Fig. 97: Locating Front Seatback Frame Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 32. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY (for Driver Side) . See step 5. 33. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY (for Front Passenger Side) a. Disengage the 4 claws.

Fig. 98: Removing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 guides to remove the separate type front seatback spring assembly. c. Remove the 2 front seatback hooks from the separate type front seatback spring assembly. 34. REMOVE SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Remove the separate type front seat cushion spring assembly.

Fig. 99: Identifying Front Seat Cushion Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEAT FRAME WITH ADJUSTER ASSEMBLY LH a. Check the operation of the slide motor.

Fig. 100: Identifying Slide Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the slide motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Slide *a Motor (Front Seat Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Battery positive (+) -- Forward > Terminal 3 Battery

negative (-) -> Terminal 4 Battery positive (+) -> Terminal 4 Backward Battery negative (-) -> Terminal 3 If the result is not as specified, replace the front seat frame with adjuster assembly LH. b. Check the operation of the lifter motor.

Fig. 101: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the lifter motor connector terminals. TEXT IN ILLUSTRATION Component without harness *a connected (Lifter Motor (Front Seat

Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 2 Upward Battery negative (-) -> Terminal 1 Battery positive (+) -> Terminal 1 Downward Battery negative (-) -> Terminal 2 If the result is not as specified, replace the front seat frame with adjuster assembly LH. c. Check the operation of the front vertical motor.

Fig. 102: Identifying Motor Connector Terminals

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the front vertical motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Front Vertical *a Motor (Front Seat Frame with Adjuster Assembly LH)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 1 Upward Battery negative (-) -> Terminal 2 Battery positive (+) -> Terminal 2 Downward Battery negative (-) -> Terminal 1 If the result is not as specified, replace the front seat frame with adjuster assembly LH. 2. INSPECT FRONT SEAT FRAME WITH ADJUSTER ASSEMBLY RH a. Check the operation of the slide motor.

Fig. 103: Identifying Slide Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the slide motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Slide *a Motor (Front Seat Frame with Adjuster Assembly RH)) OK Measurement Operational Condition Direction Battery positive (+) -- Forward > Terminal 3 Battery

negative (-) -> Terminal 4 Battery positive (+) -> Terminal 4 Backward Battery negative (-) -> Terminal 3 If the result is not as specified, replace the front seat frame with adjuster assembly RH. 3. INSPECT FRONT SEAT BACK FRAME SUB-ASSEMBLY LH a. Check the operation of the reclining motor.

Fig. 104: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat back moves smoothly when the battery is connected to the reclining motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Reclining

Motor (Front Seat Back *a Frame Subassembly LH)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 2 Forward Battery negative (-) -> Terminal 1 Battery negative (+) -> Terminal 1 Rearward Battery positive (-) -> Terminal 2 If the result is not as specified, replace the front seat back frame sub-assembly LH. 4. INSPECT FRONT SEAT BACK FRAME SUB-ASSEMBLY RH a. Check the operation of the reclining motor.

Fig. 105: Identifying Lifter/Reclining Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat back moves smoothly when the battery is connected to the reclining motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Reclining Motor *a (Front Seat Back Frame Subassembly RH)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 2

Battery negative (-) -- Forward > Terminal 1 Battery negative (+) -> Terminal 1 Rearward Battery positive (-) -> Terminal 2 If the result is not as specified, replace the front seat back frame sub-assembly RH. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Install the separate type front seat cushion spring assembly. 2. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY (for Driver Side) . See step 1. 3. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY (for Front Passenger Side) a. Install the 2 front seatback hooks to the separate type front seatback spring assembly. b. Engage the 2 guides.

Fig. 106: Installing Front Seatback Spring Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 4 claws to install the separate type front seatback spring assembly. 4. INSTALL FRONT SEATBACK FRAME SUB-ASSEMBLY a. Install the front seatback frame sub-assembly with the 4 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 5. INSTALL FRONT SEAT CUSHION PANEL SUB-ASSEMBLY (for Driver Side) a. Install the front seat cushion panel sub-assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 6. INSTALL FRONT UPPER SEAT TRACK COVER LH

7. 8. 9. 10. 11. 12. 13.

14.

a. Engage the 2 claws to install the front upper seat track cover LH. INSTALL FRONT UPPER SEAT TRACK COVER RH a. Engage the 2 claws to install the front upper seat track cover RH. INSTALL REAR UPPER SEAT TRACK COVER LH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover LH. INSTALL REAR UPPER SEAT TRACK COVER RH (for Front Passenger Side) a. Engage the 2 claws to install the rear upper seat track cover RH. INSTALL FRONT NO. 2 SEAT WIRE a. Connect the connectors and engage the wire harness clamps to install the front No. 2 seat wire. INSTALL FRONT SEAT WIRE a. Connect the connectors and engage the wire harness clamps to install the front seat wire. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 . INSTALL SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Engage the clamp to install the seat heater control sub-assembly. b. Connect the connector. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield LH.

Fig. 107: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration.

c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 15. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the 2 claws to install the front seat lower cushion shield RH.

Fig. 108: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 16. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield LH. 17. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Front Passenger Side) a. Engage the 2 claws to install the front seat lower cushion shield RH. 18. INSTALL FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) . See step 1. 19. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 2 new hog rings.

Fig. 109: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Engage the 2 fasteners. 20. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 21. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Engage the 2 hooks. WARNING:







For vehicles with a front seat airbag assembly, the separate type front seatback cover must be securely installed. Otherwise, the front seat airbag assembly may not deploy properly. Make sure that the strap is not twisted after engage the 2 hooks. Engage the 2 hooks securely.

1. Slide each hook to engage them. 2. Install the 4 clips. d. Engage the 2 fasteners. e. Engage the hook. 22. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) . See step 1. 23. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 12 new hog rings.

Fig. 110: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

24. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. for Driver Side: 1. Install the separate type front seat cushion cover.

Fig. 111: Identifying Driver Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. for Front Passenger Side: 1. Install the separate type front seat cushion cover.

Fig. 112: Identifying Passenger Side Front Seat Cushion Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Engage the claw (D) and 3 clamps (C) to install the front seat airbag assembly wire harness.

Fig. 113: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Engage the clamp (B). g. Connect the connector (A). h. w/ Seat Heater System: 1. Connect the connector (E). 2. Engage the clamp (F). 25. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 . 26. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 . 27. INSTALL FRONT SEAT INNER CUSHION SHIELD a. Install the front seat inner cushion shield with the 2 screws. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 28. INSTALL FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) . See step 1. 29. INSTALL FRONT POWER SEAT SWITCH . See step 1. 30. INSTALL FRONT SEAT CUSHION SHIELD a. for Driver Side: 1. Engage the 4 claws to install the front lumbar power seat switch to the front seat cushion shield. b. Connect the front power seat switch connector. c. Engage the wire harness clamp. d. Engage the 2 claws to install the front seat cushion shield. e. Install the screw. Torque: 0.6 N*m (6 kgf*cm, 5 in.*lbf) 31. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the 2 rubber bands of the separate type front seatback cover. 32. INSTALL RECLINING POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the reclining power seat switch knob. 33. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the slide and vertical power seat switch knob. 34. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY a. Place the front seat assembly in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Connect each connector and clamp under the seat. c. Connect the cable to the negative (-) battery terminal. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

d. Temporarily install the front seat assembly with the 4 bolts. e. Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. f. Tighten the 2 bolts on the front side of the seat.

Fig. 114: Locating Front Seat Assembly Front Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

g. Operate the slide and vertical power seat switch knob and move the seat to the foremost position. h. Tighten the 2 bolts on the rear side of the seat.

Fig. 115: Locating Front Seat Assembly Rear Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear inner seat track bracket cover. 3. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 4. INSTALL FRONT SEAT HEADREST ASSEMBLY 5. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Side) Refer to INITIALIZATION . 6. INSPECT FRONT SEAT ASSEMBLY a. Check the power seat operation. Refer to OPERATION CHECK . b. w/ Seat Heater System: Check the seat heater operation. 1. Turn the ignition switch to ON. 2. Turn the seat heater switch on.

3. Wait 5 minutes or more and confirm that the seat surface becomes warm. 7. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

FRONT SEAT ASSEMBLY (FOR SIA MADE MANUAL SEAT) COMPONENTS ILLUSTRATION

Fig. 116: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components With Torque Specifications (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 117: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components With Torque Specifications (2 Of 7)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 118: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 119: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components With Torque Specifications (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 120: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 121: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components (6 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 122: Identifying Front Seat Assembly (For SIA Made Manual Seat) Replacement Components With Torque Specifications (7 Of 7)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION .



NOTE:

If the side airbag was deployed, replace the front seat airbag assembly, separate type front seatback spring assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT SEAT HEADREST ASSEMBLY 4. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Disengage the 2 claws to remove the rear outer seat track bracket cover.

Fig. 123: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws to remove the rear inner seat track bracket cover.

Fig. 124: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 125: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e.

Lift up the seat track adjusting handle and move the seat to the rearmost position. Remove the 2 bolts on the front side of the seat. Disconnect each connector and clamp under the seat. Lift up the seat track adjusting handle and move the seat to the center position. Then, operate the reclining adjuster release handle and move the seatback to the upright position. f. Remove the front seat assembly. NOTE:

Be careful not to damage the vehicle body.

DISASSEMBLY DISASSEMBLY

1. REMOVE SEAT ADJUSTER COVER CAP a. Remove the 2 seat adjuster cover caps.

Fig. 126: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RECLINING ADJUSTER RELEASE HANDLE a. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the reclining adjuster release handle.

Fig. 127: Removing Reclining Adjuster Release Handle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape 3. REMOVE VERTICAL ADJUSTING HANDLE (for Driver Side) a. Remove the screw and vertical adjusting handle.

Fig. 128: Identifying Vertical Adjusting Handle (For Driver Side) And Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the rubber band of the separate type front seatback cover.

Fig. 129: Identifying Rubber Band Of Front Seatback Cover (For SIA Made Manual Seat)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT CUSHION SHIELD (for Driver Side) a. Remove the screw.

Fig. 130: Identifying Front Seat Cushion Shield (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 5 claws, 6 guides and clip to remove the front seat cushion shield. 6. REMOVE FRONT SEAT CUSHION SHIELD (for Front Passenger Side) a. Remove the screw.

Fig. 131: Identifying Front Seat Cushion Shield (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 5 claws, 7 guides and clip to remove the front seat cushion shield. 7. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Driver Side)

a. Disengage the 5 claws and 6 guides to remove the front seat inner cushion shield.

Fig. 132: Locating Front Seat Inner Cushion Shield (For Driver Side) Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

8. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Front Passenger Side) a. Disengage the 5 claws and 7 guides to remove the front seat inner cushion shield.

Fig. 133: Locating Front Seat Inner Cushion Shield (For Passenger Side) Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 . 10. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 . 11. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disengage the fastener and separate the front seat airbag assembly wire harness.

Fig. 134: Identifying Front Seatback Cover Airbag Wire Harness (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and 3 clamps to separate the front seat airbag assembly wire harness.

Fig. 135: Identifying Front Seatback Cover Claw And Clamps (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the hook.

Fig. 136: Identifying Front Seatback Cover Hook (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 137: Identifying Front Seatback Cover Hooks (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 2 hog rings.

Fig. 138: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 16 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 139: Locating Front Seat Cushion Cover Hog Rings

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Remove the 5 hog rings.

Fig. 140: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 hog rings.

Fig. 141: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 hog rings.

Fig. 142: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Turn back the separate type front seatback cover. e. Remove the 2 nuts and the 3 brackets.

Fig. 143: Locating Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 144: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the separate type front seatback cover with pad. 14. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 13 . 15. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 6 hog rings and separate type front seatback cover from the separate type front seatback pad.

Fig. 145: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 146: Removing Front Seat Lower Cushion Shield LH (For Driver Side)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the clip and remove the front seat lower cushion shield LH. 17. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 147: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the clip and remove the front seat lower cushion shield RH. 18. REMOVE RECLINING ADJUSTER INSIDE COVER LH a. Disengage the guide and remove the reclining adjuster inside cover LH.

Fig. 148: Locating Reclining Adjuster Guide Inside Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE RECLINING ADJUSTER INSIDE COVER RH a. Disengage the guide and remove the reclining adjuster inside cover RH.

Fig. 149: Locating Reclining Adjuster Guide Inside Cover RH

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR LH (for Driver Side) a. Remove the screw.

Fig. 150: Locating Front Seat Cushion Edge Protector LH (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector LH. 21. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR RH (for Driver Side) a. Remove the screw.

Fig. 151: Locating Front Seat Cushion Edge Protector RH (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector RH. 22. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR LH (for Front Passenger Side) a. Remove the screw.

Fig. 152: Locating Front Seat Cushion Edge Protector LH (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector LH. 23. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR RH (for Front Passenger Side) a. Remove the screw.

Fig. 153: Locating Front Seat Cushion Edge Protector RH (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector RH. 24. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 . 25. REMOVE FRONT SEAT WIRE RH (for Front Passenger Side) a. Disconnect the connectors and disengage the wire harness clamps to remove the front seat wire RH. 26. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Remove the 4 bolts.

Fig. 154: Locating Front Seatback Spring Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 guides to remove the separate type front seatback spring assembly. 27. REMOVE SEAT TRACK ADJUSTING HANDLE a. Disengage the 2 springs to remove the seat track adjusting handle.

Fig. 155: Locating Seat Track Adjusting Handle Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL SEAT TRACK ADJUSTING HANDLE a. Engage the 2 springs to install the seat track adjusting handle. 2. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Engage the 4 guides to install the separate type front seatback spring assembly. b. Install the 4 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf)

3. INSTALL FRONT SEAT WIRE RH (for Front Passenger Side) a. Connect the connectors and engage the wire harness clamps to install the front seat wire RH. 4. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 . 5. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR LH (for Driver Side) a. Engage the 3 claws to install the front seat cushion edge protector LH. b. Install the screw. 6. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR RH (for Driver Side) a. Engage the 3 claws to install the front seat cushion edge protector RH. b. Install the screw. 7. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR LH (for Front Passenger Side) a. Engage the 3 claws to install the front seat cushion edge protector LH. b. Install the screw. 8. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR RH (for Front Passenger Side) a. Engage the 3 claws to install the front seat cushion edge protector RH. b. Install the screw. 9. INSTALL RECLINING ADJUSTER INSIDE COVER LH a. Engage the guide to install the reclining adjuster inside cover LH. 10. INSTALL RECLINING ADJUSTER INSIDE COVER RH a. Engage the guide to install the reclining adjuster inside cover RH. 11. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the clip to install the front seat lower cushion shield LH.

Fig. 156: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. 12. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the clip to install the front seat lower cushion shield RH.

Fig. 157: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. 13. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 6 new hog rings.

Fig. 158: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

14. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 15. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Install the 3 brackets with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) WARNING:







For vehicles with a front seat airbag assembly, the separate type front seatback cover must be securely installed. Otherwise, the front seat airbag assembly may not deploy properly. Make sure that the strap is not twisted after installing the nut. Install the bracket securely.

d. Turn back the separate type front seatback cover.

Fig. 159: Installing Hog Rings And Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using hog ring pliers, install the 2 new hog rings.

NOTE:





Be careful not to damage the separate type front seatback cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

f. Using hog ring pliers, install 3 new hog rings.

Fig. 160: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Using hog ring pliers, install 5 new hog rings.

Fig. 161: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to damage the separate type front seatback cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

16. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 16 new hog rings.

Fig. 162: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Using hog ring pliers, install 2 new hog rings.

Fig. 163: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to damage the separate type front seat cushion cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

17. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. Engage the claw and 3 clamps to install the front seat airbag assembly wire harness. d. Engage the fastener to secure the front seat airbag assembly wire harness. 18. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 . 19. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 . 20. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Driver Side) a. Engage the 5 claws and 6 guides to install the front seat inner cushion shield. 21. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Front Passenger Side) a. Engage the 5 claws and 7 guides to install the front seat inner cushion shield. 22. INSTALL FRONT SEAT CUSHION SHIELD (for Driver Side) a. Engage the 5 claws, 6 guides and clip to install the front seat cushion shield. b. Install the screw. 23. INSTALL FRONT SEAT CUSHION SHIELD (for Front Passenger Side) a. Engage the 5 claws, 7 guides and clip to install the front seat cushion shield. b. Install the screw. 24. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the rubber band of the separate type front seatback cover. 25. INSTALL VERTICAL ADJUSTING HANDLE (for Driver Side) a. Install the vertical adjusting handle with the screw. 26. INSTALL RECLINING ADJUSTER RELEASE HANDLE a. Engage the claw to install the reclining adjuster release handle. 27. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY a. Place the front seat assembly in the cabin. NOTE: b. c. d. e.

Be careful not to damage the vehicle body.

Connect each connector and clamp under the seat. Temporarily install the front seat assembly with the 4 bolts. Lift up the seat track adjusting handle and move the seat to the rearmost position. Tighten the 2 bolts on the front side of the seat.

Fig. 164: Locating Front Seat Assembly Front Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

f. Lift up the seat track adjusting handle and move the seat to the foremost position. g. Tighten the 2 bolts on the rear side of the seat.

Fig. 165: Locating Front Seat Assembly Rear Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSPECT SEAT SLIDE ADJUSTER LOCKS a. During the sliding operation of the front seat, check that the left and right adjusters move together smoothly and lock simultaneously. If the seat adjusters do not lock simultaneously, loosen the seat installation bolts to adjust the adjuster position. 3. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Lift up the seat track adjusting handle and move the seat to the foremost position. b. Engage the 2 claws to install the rear inner seat track bracket cover. 4. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 5. INSTALL FRONT SEAT HEADREST ASSEMBLY 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Side)

Refer to INITIALIZATION . 8. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

FRONT SEAT ASSEMBLY (FOR SIA MADE POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 166: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components With Torque Specifications (1 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 167: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components With Torque Specifications (2 Of 7)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 168: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components (3 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 169: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components With Torque Specifications (4 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 170: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components (5 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 171: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components (6 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 172: Identifying Front Seat Assembly (For SIA Made Power Seat) Replacement Components With Torque Specifications (7 Of 7) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. PRECAUTION WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION .



NOTE:



If the side airbag has deployed, replace the front seat airbag assembly, front seatback spring assembly, separate type front seatback pad and separate type front seatback cover with the necessary parts in accordance with the extent of the collision damage.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE FRONT SEAT HEADREST ASSEMBLY 3. REMOVE REAR OUTER SEAT TRACK BRACKET COVER a. Operate the slide and vertical power seat switch knob and move the seat to the foremost position. b. Disengage the 2 claws to remove the rear outer seat track bracket cover.

Fig. 173: Locating Rear Outer Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE REAR INNER SEAT TRACK BRACKET COVER a. Disengage the 2 claws to remove the rear inner seat track bracket cover.

Fig. 174: Locating Rear Inner Seat Track Bracket Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT SEAT ASSEMBLY a. Remove the 2 bolts on the rear side of the seat.

Fig. 175: Locating Front Seat Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. c. Remove the 2 bolts on the front side of the seat. d. Operate the slide and vertical power seat switch knob and move the seat to the center position. Then, operate the reclining power seat switch knob and move the seatback to the upright position. e. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

f. Disconnect each connector and clamp under the seat. g. Remove the front seat assembly. NOTE:

Be careful not to damage the vehicle body.

DISASSEMBLY DISASSEMBLY

1. REMOVE SEAT ADJUSTER COVER CAP

a. Remove the 2 seat adjuster cover caps.

Fig. 176: Locating Seat Adjuster Cover Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Using a moulding remover, disengage the 4 claws to remove the slide and vertical power seat switch knob.

Fig. 177: Removing Slide And Vertical Power Seat Switch Knob Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE RECLINING POWER SEAT SWITCH KNOB a. Using a moulding remover, disengage the 4 claws to remove the reclining power seat switch knob.

Fig. 178: Removing Reclining Power Seat Switch Knob

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Disconnect the rubber band of the separate type front seatback cover.

Fig. 179: Identifying Rubber Band Of Front Seatback Cover (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE FRONT NO. 1 SEAT INNER CUSHION SHIELD a. Remove the screw.

Fig. 180: Removing Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the clip from the front No. 1 seat inner cushion shield as shown in the illustration. c. Disengage the 3 claws and 3 guides to remove the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 181: Locating Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a clip remover, remove the clip.

Fig. 182: Identifying Front No. 1 Seat Inner Cushion Shield Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT SEAT CUSHION SHIELD (for Driver Side) a. Disengage the 4 claws, 7 guides and clip to remove the front seat cushion shield.

Fig. 183: Identifying Front Seat Cushion Shield (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws and open the wire harness cover.

Fig. 184: Identifying Front Power Seat Switch Connector And Wire Harness Claws (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wire *1 Harness Cover c. d. e. f.

Remove the wire harness from the wire harness cover. Disengage the 2 wire harness clamps. Disconnect the front power seat switch connector. Disconnect the front lumbar power seat switch connector.

Fig. 185: Locating Front Lumbar Power Seat Switch Connector (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT CUSHION SHIELD (for Front Passenger Side) a. Disengage the 4 claws, 8 guides and clip to remove the front seat cushion shield.

Fig. 186: Identifying Front Seat Cushion Shield (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws and open the wire harness cover.

Fig. 187: Identifying Front Power Seat Switch Connector And Wire Harness Claws (For Front Passenger Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Wire *1 Harness Cover c. Remove the wire harness from the wire harness cover. d. Disengage the 2 wire harness clamps. e. Disconnect the front power seat switch connector. 8. REMOVE FRONT POWER SEAT SWITCH . See step 14. 9. REMOVE FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) . See step 7. 10. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Driver Side) a. Disengage the 5 claws and 6 guides to remove the front seat inner cushion shield.

Fig. 188: Locating Front Seat Inner Cushion Shield (For Driver Side) Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Front Passenger Side) a. Disengage the 5 claws and 7 guides to remove the front seat inner cushion shield.

Fig. 189: Locating Front Seat Inner Cushion Shield (For Passenger Side) Claws And Guides Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to REMOVAL Step 2 .

13. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to REMOVAL - Step 4 . 14. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Disengage the fastener and separate the front seat airbag assembly wire harness.

Fig. 190: Identifying Front Seatback Cover Airbag Wire Harness (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and 3 clamps to separate the front seat airbag assembly wire harness.

Fig. 191: Identifying Front Seatback Cover Claw And Clamps (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. w/ Seat Heater System: 1. Disconnect the connector.

Fig. 192: Identifying Front Seatback Cover Connector And Clamp (For SIA Made

Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disengage the clamp. 3. Disconnect the connector.

Fig. 193: Identifying Front Seatback Cover Connector And Clamps (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Disengage the 2 clamps to separate the seat heater wire harness. d. Disengage the hook.

Fig. 194: Identifying Front Seatback Cover Hook (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disengage each hook and remove the separate type front seat cushion cover with pad.

Fig. 195: Identifying Front Seatback Cover Hooks (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a. Remove the 2 hog rings.

Fig. 196: Locating Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 16 hog rings and the separate type front seat cushion cover from the separate type front seat cushion pad.

Fig. 197: Locating Front Seat Cushion Cover Hog Rings

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) . See step 15. 17. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Remove the 5 hog rings.

Fig. 198: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 hog rings.

Fig. 199: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 hog rings.

Fig. 200: Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Turn back the separate type front seatback cover. e. Remove the 2 nuts and the 3 brackets.

Fig. 201: Locating Front Seatback Cover Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Disengage the 4 claws and remove the 2 front seat headrest supports.

Fig. 202: Identifying Front Seatback Cover Headrest Support Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Remove the separate type front seatback cover with pad. 18. REMOVE FRONT SEAT AIRBAG ASSEMBLY . Refer to REMOVAL - Step 13 . 19. REMOVE SEPARATE TYPE FRONT SEATBACK COVER a. Remove the 6 hog rings and separate type front seatback cover from the separate type front seatback pad.

Fig. 203: Locating Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) . See step 12. 21. REMOVE FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Remove the screw.

Fig. 204: Removing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the clip and remove the front seat lower cushion shield LH. 22. REMOVE FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Remove the screw.

Fig. 205: Removing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the hook as shown in the illustration. c. Disengage the clip and remove the front seat lower cushion shield RH. 23. REMOVE UPPER RECLINING ADJUSTER INSIDE COVER LH a. Disengage the 2 guides to remove the upper reclining adjuster inside cover LH.

Fig. 206: Locating Upper Reclining Adjuster Guides Inside Cover LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE UPPER RECLINING ADJUSTER INSIDE COVER RH a. Disengage the 2 guides to remove the upper reclining adjuster inside cover RH.

Fig. 207: Locating Upper Reclining Adjuster Guides Inside Cover RH

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR LH (for Driver Side) a. Remove the screw.

Fig. 208: Locating Front Seat Cushion Edge Protector LH (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector LH. 26. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR RH (for Driver Side) a. Remove the screw.

Fig. 209: Locating Front Seat Cushion Edge Protector RH (For Driver Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector RH. 27. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR LH (for Front Passenger Side) a. Remove the screw.

Fig. 210: Locating Front Seat Cushion Edge Protector LH (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector LH. 28. REMOVE FRONT SEAT CUSHION EDGE PROTECTOR RH (for Front Passenger Side) a. Remove the screw.

Fig. 211: Locating Front Seat Cushion Edge Protector RH (For Front Passenger Side) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 claws to remove the front seat cushion edge protector RH. 29. REMOVE SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Disconnect the connector.

Fig. 212: Locating Seat Heater Control Sub-Assembly (w/ Seat Heater System) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

30. 31. 32.

33. 34.

b. Disengage the 2 clamps and remove the seat heater control sub-assembly. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to REMOVAL Step 3 . REMOVE FRONT SEAT WIRE a. Disconnect the connectors and disengage the wire harness clamps to remove the front seat wire. REMOVE FRONT NO. 2 SEAT WIRE a. Disconnect the connectors and disengage the wire harness clamps to remove the front No. 2 seat wire. REMOVE FRONT SEAT WIRE RH (for Front Passenger Side) a. Disconnect the connectors and disengage the wire harness clamps to remove the front seat wire RH. REMOVE SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Remove the 4 bolts

Fig. 213: Locating Front Seatback Spring Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 guides to remove the separate type front seatback spring assembly. INSPECTION INSPECTION

1. INSPECT SEPARATE TYPE FRONT SEAT CUSHION SPRING ASSEMBLY a. Check the operation of the slide motor.

Fig. 214: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the slide motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Slide Motor *a (Separate Type Front Seat Cushion Spring Assembly)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 1

Battery negative (-) -- Forward > Terminal 2 Battery positive (+) -> Terminal 2 Backward Battery negative (-) -> Terminal 1 If the result is not as specified, replace the separate type front seat cushion spring assembly. b. Check the operation of the lifter motor. (for Driver)

Fig. 215: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the lifter motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Lifter Motor

(Separate Type Front Seat *a Cushion Spring Assembly)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 1 Upward Battery negative (-) -> Terminal 2 Battery positive (+) -> Terminal 2 Downward Battery negative (-) -> Terminal 1 If the result is not as specified, replace the separate type front seat cushion spring assembly. c. Check the operation of the front vertical motor. (for Driver)

Fig. 216: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat cushion moves smoothly when the battery is connected to the front vertical motor connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Front Vertical *a Motor (Separate Type Front Seat Cushion Spring Assembly)) OK Measurement Operational Condition Direction Battery positive (+) --

> Terminal 1 Battery Upward negative (-) -> Terminal 2 Battery positive (+) -> Terminal 2 Downward Battery negative (-) -> Terminal 1 If the result is not as specified, replace the separate type front seat cushion spring assembly. 2. INSPECT SEPARATE TYPE FRONT SEAT BACK SPRING ASSEMBLY a. Check the operation of the reclining motor.

Fig. 217: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if the front seat back moves smoothly when the battery is connected to the reclining motor connector terminals. TEXT IN ILLUSTRATION Component without harness

connected (Reclining Motor (Separate *a Type Front Seat Back Spring Assembly)) OK Measurement Operational Condition Direction Battery positive (+) -> Terminal 1 Forward Battery negative (-) -> Terminal 2 Battery negative (+) -> Terminal 2 Rearward Battery positive (-) -> Terminal 1 If the result is not as specified, replace the separate type front seat back spring assembly. b. Check the operation of the lumbar support adjuster assembly. (for Driver)

Fig. 218: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check that the front seat back moves smoothly when the battery is connected to the lumbar support adjuster assembly connector terminals. TEXT IN ILLUSTRATION Component without harness connected (Lumbar Support *a Adjuster Assembly (Separate Type Front Seat Back Spring Assembly)) OK Measurement Operational Condition Direction Battery positive (+) --

> Terminal 1 Battery negative (-) -> Terminal 2 Battery positive (+) -> Terminal 2 Battery negative (-) -> Terminal 1

Seat back moves forward

Seat back moves backward

If the result is not as specified, replace the separate type front seat back spring assembly. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE FRONT SEATBACK SPRING ASSEMBLY a. Engage the 4 guides to install the separate type front seatback spring assembly. b. Install the 4 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. REMOVE FRONT SEAT WIRE RH (for Front Passenger Side) a. Connect the connectors and engage the wire harness clamps to install the front seat wire RH. 3. INSTALL FRONT NO. 2 SEAT WIRE a. Connect the connectors and engage the wire harness clamps to install the front No. 2 seat wire. 4. INSTALL FRONT SEAT WIRE a. Connect the connectors and engage the wire harness clamps to install the front seat wire. 5. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) . Refer to INSTALLATION - Step 1 . 6. INSTALL SEAT HEATER CONTROL SUB-ASSEMBLY (w/ Seat Heater System) a. Engage the 2 clamps to install the seat heater control sub-assembly. b. Connect the connector. 7. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR LH (for Driver Side) a. Engage the 3 claws to install the front seat cushion edge protector LH. b. Install the screw. 8. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR RH (for Driver Side) a. Engage the 3 claws to install the front seat cushion edge protector RH. b. Install the screw. 9. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR LH (for Front Passenger Side) a. Engage the 3 claws to install the front seat cushion edge protector LH.

10.

11. 12. 13.

b. Install the screw. INSTALL FRONT SEAT CUSHION EDGE PROTECTOR RH (for Front Passenger Side) a. Engage the 3 claws to install the front seat cushion edge protector RH. b. Install the screw. INSTALL UPPER RECLINING ADJUSTER INSIDE COVER LH a. Engage the 2 guides to install the upper reclining adjuster inside cover LH. INSTALL UPPER RECLINING ADJUSTER INSIDE COVER RH a. Engage the 2 guides to install the upper reclining adjuster inside cover RH. INSTALL FRONT SEAT LOWER CUSHION SHIELD LH (for Driver Side) a. Engage the clip to install the front seat lower cushion shield LH.

Fig. 219: Installing Front Seat Lower Cushion Shield LH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. 14. INSTALL FRONT SEAT LOWER CUSHION SHIELD RH (for Driver Side) a. Engage the clip to install the front seat lower cushion shield RH.

Fig. 220: Installing Front Seat Lower Cushion Shield RH (For Driver Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the hook as shown in the illustration. c. Install the screw. 15. INSTALL FRONT SEATBACK HEATER ASSEMBLY (w/ Seat Heater System) . See step 7. 16. INSTALL SEPARATE TYPE FRONT SEATBACK COVER a. Using hog ring pliers, install the separate type front seatback cover to the separate type front seatback pad with 6 new hog rings.

Fig. 221: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seatback cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

17. INSTALL FRONT SEAT AIRBAG ASSEMBLY . Refer to INSTALLATION - Step 1 . 18. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD a. Temporarily install the separate type front seatback cover with pad. b. Engage the 4 claws to install the 2 front seat headrest supports. c. Install the 3 brackets with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) WARNING:







For vehicles with side airbags, the separate type front seatback cover must be securely installed. Otherwise, the side airbags may not deploy properly. Make sure that the strap is not twisted after installing the nut. Install the bracket securely.

d. Turn back the separate type front seatback cover.

Fig. 222: Installing Hog Rings And Turning Back Front Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using hog ring pliers, install the 2 new hog rings.

NOTE:





Be careful not to damage the separate type front seatback cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

f. Using hog ring pliers, install 3 new hog rings.

Fig. 223: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When installing the hog rings, take care to minimize wrinkles as much as possible.

g. Using hog ring pliers, install 5 new hog rings.

Fig. 224: Installing Front Seatback Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:





Be careful not to damage the separate type front seatback cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

19. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY (w/ Seat Heater System) . See step 6. 20. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a. Using hog ring pliers, install the separate type front seat cushion cover to the separate type front seat cushion pad with 16 new hog rings.

Fig. 225: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the separate type front seat cushion cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

b. Using hog ring pliers, install 2 new hog rings.

Fig. 226: Installing Front Seat Cushion Cover Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





Be careful not to damage the separate type front seat cushion cover. When installing the hog rings, take care to minimize wrinkles as much as possible.

21. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD a. Temporarily install the separate type front seat cushion cover with pad. b. Engage each hook. c. w/ Seat Heater System: 1. Engage the 2 clamps to install the seat heater wire harness. 2. Connect the connector. 3. Engage the clamp. 4. Connect the connector. d. Engage the claw and 3 clamps to install the front seat airbag assembly wire harness. e. Engage the fastener to secure the front seat airbag assembly wire harness. 22. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) . Refer to INSTALLATION - Step 1 . 23. INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) . Refer to INSTALLATION - Step 2 . 24. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Driver Side) a. Engage the 5 claws and 6 guides to install the front seat inner cushion shield. 25. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Front Passenger Side) a. Engage the 5 claws and 7 guides to install the front seat inner cushion shield. 26. INSTALL FRONT LUMBAR POWER SEAT SWITCH (for Driver Side) . See step 3. 27. INSTALL FRONT POWER SEAT SWITCH . See step 7. 28. INSTALL FRONT SEAT CUSHION SHIELD (for Driver Side) a. Connect the front lumbar power seat switch connector. b. Connect the front power seat switch connector. c. Engage the 2 wire harness clamps. d. Install the wire harness to the wire harness cover. e. Engage the 2 claws to close the wire harness cover. f. Engage the 4 claws, 7 guides and clip to install the front seat cushion shield. 29. INSTALL FRONT SEAT CUSHION SHIELD (for Front Passenger Side) a. Connect the front power seat switch connector. b. Engage the 2 wire harness clamps. c. Install the wire harness to the wire harness cover.

d. Engage the 3 claws to close the wire harness cover. e. Engage the 4 claws, 8 guides and clip to install the front seat cushion shield. 30. INSTALL FRONT NO. 1 SEAT INNER CUSHION SHIELD a. Install the clip. b. Engage the 3 claws and 3 guides to install the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 227: Locating Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Engage the 2 claws to install the clip to the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 228: Installing Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

31. 32. 33. 34.

d. Install the screw. CONNECT SEPARATE TYPE FRONT SEATBACK COVER a. Connect the rubber band of the separate type front seatback cover. INSTALL RECLINING POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the reclining power seat switch knob. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB a. Engage the 4 claws to install the slide and vertical power seat switch knob. INSTALL SEAT ADJUSTER COVER CAP a. Install the 2 seat adjuster cover caps.

INSTALLATION

INSTALLATION

1. INSTALL FRONT SEAT ASSEMBLY a. Place the front seat assembly in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Connect each connector and clamp under the seat. c. Connect the cable to the negative (-) battery terminal. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

d. Temporarily install the front seat assembly with the 4 bolts. e. Operate the power seat switch knob and move the seat to the rearmost position. f. Tighten the 2 bolts on the front side of the seat.

Fig. 229: Locating Front Seat Assembly Front Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

g. Operate the power seat switch knob and move the seat to the foremost position.

h. Tighten the 2 bolts on the rear side of the seat.

Fig. 230: Locating Front Seat Assembly Rear Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NOTE:

Tighten the bolts in the order indicated in the illustration.

2. INSTALL REAR INNER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear inner seat track bracket cover. 3. INSTALL REAR OUTER SEAT TRACK BRACKET COVER a. Engage the 2 claws to install the rear outer seat track bracket cover. 4. INSTALL FRONT SEAT HEADREST ASSEMBLY 5. INSPECT FRONT SEAT ASSEMBLY a. Check the power seat operation. Refer to OPERATION CHECK . b. w/ Seat Heater System: Check the seat heater operation. 1. Turn the ignition switch to ON. 2. Turn the seat heater switch on. 3. Wait 5 minutes or more and confirm that the seat surface becomes warm. 6. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK

Refer to INITIALIZATION . 7. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR SEAT ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 231: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 232: Identifying Rear Seat Assembly Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 233: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 234: Identifying Rear Seat Assembly Replacement Components With Torque Specifications (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION .



NOTE:

If the side airbag was deployed, replace the rear seat airbag assembly, rear side seatback frame sub-assembly, rear side seatback cover sub-assembly and rear side seatback pad with the necessary parts in accordance with the extent of the collision damage.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE REAR SEAT CUSHION ASSEMBLY a. Disengage the hook of the seat cushion from the vehicle body as shown in the illustration. NOTE:

Follow the instructions below carefully as the cushion frame can be deformed easily.

1. Choose a hook to disengage first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to disengage the hook.

Fig. 235: Removing Rear Seat Cushion Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STANDARD MEASUREMENT 100 mm (3.94 a in.) or less 2. Repeat the step above for the other hook. b. Remove the rear seat cushion assembly. 4. REMOVE REAR SEAT CUSHION LOCK HOOK a. Disengage the claw and remove the rear seat cushion lock hook.

Fig. 236: Removing Rear Seat Cushion Lock Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Rear seat cushion lock hooks must not be reused.

HINT: Use the same procedure for the RH side and the LH side. 5. REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD a. Remove the inner luggage compartment trim pad.

Fig. 237: Locating Inner Luggage Compartment Trim Pad Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR SEATBACK ASSEMBLY LH a. Disengage the 2 fasteners as shown in the illustration.

Fig. 238: Locating Rear Seatback Assembly LH Fasteners

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Remove the 2 bolts and rear seatback assembly LH.

Fig. 239: Identifying Rear Seatback Assembly LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the vehicle body.

7. REMOVE REAR SEATBACK ASSEMBLY RH a. Disengage the 3 fasteners as shown in the illustration.

Fig. 240: Locating Rear Seatback Assembly RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Remove the 2 bolts and rear seatback assembly RH.

Fig. 241: Identifying Rear Seatback Assembly RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Be careful not to damage the vehicle body.

8. REMOVE REAR SIDE SEATBACK ASSEMBLY LH a. Disconnect the rear seat outer belt from the rear seat shoulder belt guide. b. Disconnect the connector. c. Remove the 2 bolts.

Fig. 242: Identifying Rear Side Seatback Assembly LH Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the hook and remove the rear side seatback assembly LH. 9. REMOVE REAR SIDE SEATBACK ASSEMBLY RH a. Disconnect the rear seat outer belt from the rear seat shoulder belt guide. b. Disconnect the connector. c. Remove the 2 bolts.

Fig. 243: Identifying Rear Side Seatback Assembly RH Connector And Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the hook and remove the rear side seatback assembly RH. DISASSEMBLY DISASSEMBLY

1. REMOVE REAR SEAT CUSHION FRAME SUB-ASSEMBLY a. Disengage the 13 hooks and remove the rear seat cushion frame sub-assembly.

Fig. 244: Identifying Rear Seat Cushion Frame Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE BENCH TYPE REAR SEAT CUSHION COVER a. Remove the 12 hog rings and disengage the 4 fasteners, and remove the bench type rear seat cushion cover from the bench type rear seat cushion pad.

Fig. 245: Identifying Bench Type Rear Seat Cushion Cover Fasteners And Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener - 3. REMOVE REAR SEAT SHOULDER BELT GUIDE LH a. Remove the 2 screws.

Fig. 246: Identifying Rear Seat Shoulder Belt Guide LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat shoulder belt guide LH. 4. REMOVE REAR SEAT AIRBAG ASSEMBLY LH . Refer to REMOVAL - Step 7 . 5. REMOVE REAR SIDE SEATBACK COVER SUB-ASSEMBLY LH a. Remove the rear side seatback cover sub-assembly LH from the rear side seatback pad LH.

Fig. 247: Removing Rear Side Seatback Cover Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE REAR SEAT SHOULDER BELT GUIDE RH HINT: Use the same procedure as for the LH side. 7. REMOVE REAR SEAT AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to REMOVAL - Step 7 . 8. REMOVE REAR SIDE SEATBACK COVER SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. 9. REMOVE REAR SEAT CENTER SHOULDER BELT GUIDE a. Remove the 2 screws.

Fig. 248: Identifying Rear Seat Center Shoulder Belt Guide Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat center shoulder belt guide. 10. REMOVE REAR SEATBACK CARPET LH a. Using a clip remover, remove the 3 clips.

Fig. 249: Locating Rear Seatback Carpet LH Clips And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 fasteners and remove the rear seatback carpet LH. TEXT IN ILLUSTRATION *1 Fastener 11. REMOVE REAR SEATBACK FRAME SUB-ASSEMBLY LH a. Disengage the 20 claws and remove the rear seatback frame sub-assembly LH.

Fig. 250: Identifying Rear Seatback Frame Sub-Assembly LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE SEPARATE TYPE REAR SEATBACK COVER LH

a. Remove the 8 hog rings and the separate type rear seatback cover LH from the separate type rear seatback pad LH.

Fig. 251: Identifying Rear Seatback Cover LH Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE REAR SEAT CENTER ARMREST ASSEMBLY a. Remove the bolt and washer.

Fig. 252: Identifying Rear Seat Center Armrest Assembly With Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the guide and remove the rear seat center armrest assembly. 14. REMOVE REAR SEATBACK CARPET RH a. Using a clip remover, remove the 5 clips.

Fig. 253: Identifying Rear Seatback Carpet RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 3 fasteners and remove the rear seatback carpet RH. TEXT IN ILLUSTRATION *1 Fastener 15. REMOVE REAR SEATBACK FRAME SUB-ASSEMBLY RH a. Disengage the 20 claws and remove the rear seatback frame sub-assembly RH.

Fig. 254: Locating Rear Seatback Frame Sub-Assembly RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. REMOVE SEPARATE TYPE REAR SEATBACK COVER RH

a. Remove the 10 hog rings and separate type rear seatback cover RH from the separate type rear seatback pad RH.

Fig. 255: Locating Rear Seatback Cover RH Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY REASSEMBLY

1. INSTALL SEPARATE TYPE REAR SEATBACK COVER LH a. Using hog ring pliers, install the separate type rear seatback cover LH to the separate type rear seatback pad LH with 8 new hog rings.

Fig. 256: Installing Rear Seatback Cover LH Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

2. INSTALL REAR SEATBACK FRAME SUB-ASSEMBLY LH a. Engage the 20 claws to install the rear seatback frame sub-assembly LH to the separate type rear seatback cover with pad LH.

Fig. 257: Identifying Rear Seatback Frame Sub-Assembly LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL REAR SEATBACK CARPET LH a. Engage the 2 fasteners.

Fig. 258: Locating Rear Seatback Carpet LH Clips And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Install the rear seatback carpet with the 3 clips. 4. INSTALL REAR SEAT CENTER SHOULDER BELT GUIDE a. Engage the guide.

Fig. 259: Identifying Rear Seat Center Shoulder Belt Guide Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat center shoulder belt guide with the 2 screws. 5. INSTALL SEPARATE TYPE REAR SEATBACK COVER RH a. Using hog ring pliers, install the separate type rear seatback cover RH to the separate type rear seatback pad RH with 10 new hog rings.

Fig. 260: Installing Rear Seatback Cover RH Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



Be careful not to damage the cover.



When installing the hog rings, take care to minimize wrinkles as much as possible.

6. INSTALL REAR SEATBACK FRAME SUB-ASSEMBLY RH a. Engage the 20 claws to install the rear seatback frame sub-assembly RH to the separate type rear seatback cover with pad RH.

Fig. 261: Locating Rear Seatback Frame Sub-Assembly RH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL REAR SEATBACK CARPET RH a. Engage the 3 fasteners.

Fig. 262: Identifying Rear Seatback Carpet RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener b. Install the rear seatback carpet RH with the 5 clips. 8. INSTALL REAR SEAT CENTER ARMREST ASSEMBLY a. Engage the guide.

Fig. 263: Identifying Rear Seat Center Armrest Assembly With Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat center armrest assembly with the bolt and washer. 9. INSTALL REAR SIDE SEATBACK COVER SUB-ASSEMBLY LH a. Install the rear side seatback cover sub-assembly LH to the rear side seatback pad LH.

Fig. 264: Installing Rear Side Seatback Cover Sub-Assembly LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL REAR SEAT AIRBAG ASSEMBLY LH . Refer to INSTALLATION - Step 1 . 11. INSTALL REAR SEAT SHOULDER BELT GUIDE LH a. Engage the guide.

Fig. 265: Identifying Rear Seat Shoulder Belt Guide LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rear seat shoulder belt guide LH with the 2 screws. 12. INSTALL REAR SIDE SEATBACK COVER SUB-ASSEMBLY RH HINT: Use the same procedure as for the LH side. 13. INSTALL REAR SEAT AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 1 . 14. INSTALL REAR SEAT SHOULDER BELT GUIDE RH HINT:

Use the same procedure as for the LH side. 15. INSTALL BENCH TYPE REAR SEAT CUSHION COVER a. Engage the 4 fasteners. b. Using hog ring pliers, install the bench type rear seat cushion cover to the bench type rear seat cushion pad with 12 new hog rings.

Fig. 266: Installing Bench Type Rear Seat Cushion Cover Fasteners And Hog Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Fastener - 16. INSTALL REAR SEAT CUSHION FRAME SUB-ASSEMBLY a. Engage the 13 hooks to install the rear seat cushion frame sub-assembly.

Fig. 267: Identifying Rear Seat Cushion Frame Hooks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION INSTALLATION

1. INSTALL REAR SIDE SEATBACK ASSEMBLY RH a. Engage the hook. b. Install the rear side seatback assembly RH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Connect the connector. d. Connect the rear seat outer belt to the rear seat shoulder belt guide. 2. INSTALL REAR SIDE SEATBACK ASSEMBLY LH a. Engage the hook. b. Install the rear side seatback assembly LH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) c. Connect the connector. d. Connect the rear seat outer belt to the rear seat shoulder belt guide. 3. INSTALL REAR SEATBACK ASSEMBLY RH a. Place the rear seatback assembly RH in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Install the rear seatback assembly RH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 4. INSTALL REAR SEATBACK ASSEMBLY LH a. Place the rear seatback assembly LH in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Install the rear seatback assembly LH with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 5. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD a. Install the inner luggage compartment trim pad. 6. INSTALL REAR SEAT CUSHION LOCK HOOK

a. Engage the claw to install a new rear seat cushion lock hook.

Fig. 268: Installing Rear Seat Cushion Lock Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Rear seat cushion lock hooks must not be reused.

HINT: Use the same procedure for the RH side and the LH side. 7. INSTALL REAR SEAT CUSHION ASSEMBLY a. Place the rear seat cushion assembly in the cabin. NOTE:

Be careful not to damage the vehicle body.

b. Engage the 2 hooks of the seat cushion to the vehicle body as shown in the illustration.

Fig. 269: Installing Rear Seat Cushion Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Confirm that the seat cushion is firmly installed. NOTE:

When installing the seat cushion, make sure that the seat belt buckles are not under the seat cushion.

8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

POWER SEAT SWITCH COMPONENTS ILLUSTRATION

Fig. 270: Identifying Power Seat Switch (For TMMK Made) Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 271: Identifying Power Seat Switch (For SIA Made) Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY (for TMMK Made) Refer to REMOVAL. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for TMMK Made) . See step 2. 3. REMOVE RECLINING POWER SEAT SWITCH KNOB (for TMMK Made) . See step 3. 4. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 4. 5. REMOVE FRONT SEAT CUSHION SHIELD (for TMMK Made) . See step 5. 6. REMOVE FRONT POWER SEAT SWITCH (for TMMK Made) a. Remove the 3 screws and front power seat switch from the front seat cushion shield.

Fig. 272: Identifying Front Power Seat Switch (For TMMK Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT ASSEMBLY (for SIA Made) Refer to REMOVAL. 8. 9. 10. 11.

REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for SIA Made) . See step 2. REMOVE RECLINING POWER SEAT SWITCH KNOB (for SIA Made) . See step 3. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 4. REMOVE NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) a. Remove the screw.

Fig. 273: Removing Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 2 claws to remove the clip from the front No. 1 seat inner cushion shield as shown in the illustration. c. Disengage the 3 claws and 3 guides to remove the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 274: Locating Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE FRONT SEAT CUSHION SHIELD (for SIA Made Driver Side) . See step 6. 13. REMOVE FRONT SEAT CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 7. 14. REMOVE FRONT POWER SEAT SWITCH (for SIA Made) a. Remove the 3 screws and front power seat switch from the front seat cushion shield.

Fig. 275: Identifying Front Power Seat Switch (For SIA Made) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT POWER SEAT SWITCH LH

Fig. 276: Inspecting Front Power Seat Switch LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Front *1 Vertical Switch Slide *2 Switch Lifter *3 Switch Reclining *4 Switch Component without harness connected *a (Front Power Seat Switch LH) Standard Resistance SLIDE SWITCH Tester Switch Specified Connection Condition Condition 5-7 5-8 Front 2 - 11 2 - 12 5 - 11 5 - 12 Below 1 Off ohms 2 - 11 2 - 12 5 - 11 5 - 12 Rear 2-7 2-8 FRONT VERTICAL SWITCH Tester Switch Specified Connection Condition Condition 1-7 1-8 Up 6 - 11 6 - 12 1 - 11

1 - 12 6 - 11 6 - 12 1 - 11 1 - 12 6-7 6-8

Off Below 1 ohms Down

LIFTER SWITCH Tester Switch Specified Connection Condition Condition 3-7 3-8 Up 4 - 11 4 - 12 3 - 11 3 - 12 Below 1 Off ohms 4 - 11 4 - 12 3 - 11 3 - 12 Down 4-7 4-8 RECLINING SWITCH Tester Switch Specified Connection Condition Condition 10 - 7 10 - 8 Front 9 - 11 9 - 12 10 - 11 10 - 12 Below 1 Off ohms 9 - 11 9 - 12 10 - 11 10 - 12 Rear 9-7 9-8 If the result is not as specified, replace the front power seat switch LH. 2. INSPECT FRONT POWER SEAT SWITCH RH

Fig. 277: Inspecting Front Power Seat Switch RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Slide *1 Switch Reclining *2 Switch Component without harness connected *a (Front Power Seat Switch RH) Standard Resistance SLIDE SWITCH Tester Switch Specified Connection Condition Condition 2 - 13 Front 5 - 10 2 - 10 Below 1 Off ohms 5 - 10 2 - 10 Rear 5 - 13 RECLINING SWITCH Tester Switch Specified Connection Condition Condition 11 - 13 Front 12 - 10 11 - 10 Below 1 Off ohms 12 - 10 11 - 10 Rear 12 - 13 If the result is not as specified, replace the front power seat switch RH. INSTALLATION INSTALLATION

1. INSTALL FRONT POWER SEAT SWITCH (for TMMK Made) a. Install the front power seat switch to a new front seat cushion shield with the 3 screws.

2. 3. 4. 5.

INSTALL FRONT SEAT CUSHION SHIELD (for TMMK Made) . See step 30. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 31. INSTALL RECLINING POWER SEAT SWITCH KNOB (for TMMK Made) . See step 32. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for TMMK Made) . See step 33. 6. INSTALL FRONT SEAT ASSEMBLY (for TMMK Made) Refer to INSTALLATION. 7. INSTALL FRONT POWER SEAT SWITCH (for SIA Made) a. Install the front power seat switch to the front seat cushion shield with the 3 screws. 8. INSTALL FRONT SEAT CUSHION SHIELD (for SIA Made Driver Side) . See step 28. 9. INSTALL FRONT SEAT CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 29. 10. INSTALL NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) a. Engage the 3 claws and 3 guides to install the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 278: Locating Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 claws to install the clip to the front No. 1 seat inner cushion shield as shown in the illustration.

Fig. 279: Installing Front No. 1 Seat Inner Cushion Shield And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

11. 12. 13. 14.

c. Install the screw. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 31. INSTALL RECLINING POWER SEAT SWITCH KNOB (for SIA Made) . See step 32. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for SIA Made) . See step 33. INSTALL FRONT SEAT ASSEMBLY (for SIA Made) Refer to INSTALLATION.

LUMBAR SWITCH COMPONENTS

ILLUSTRATION

Fig. 280: Identifying Lumbar Switch (For TMMK Made) Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 281: Identifying Lumbar Switch (For SIA Made) Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE FRONT POWER SEAT SWITCH (for TMMK Made) Refer to REMOVAL. 2. REMOVE FRONT LUMBAR POWER SEAT SWITCH (for TMMK Made) a. Disconnect the connector to remove the front lumbar power seat switch.

Fig. 282: Identifying Front Lumbar Power Seat Switch (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FRONT SEAT ASSEMBLY (for SIA Made) Refer to REMOVAL. 4. 5. 6. 7.

DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 4. REMOVE NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) . See step 11. REMOVE FRONT SEAT CUSHION SHIELD (for SIA Made) . See step 6. REMOVE FRONT LUMBAR POWER SEAT SWITCH (for SIA Made) a. Disengage the 4 claws to remove the front lumbar power seat switch from the front seat cushion shield.

Fig. 283: Identifying Front Lumbar Power Seat Switch (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT LUMBAR FRONT POWER SEAT SWITCH

Fig. 284: Inspecting Lumbar Front Power Seat Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below.

TEXT IN ILLUSTRATION Hold *1 Switch Release *2 Switch Component without harness connected *a (Lumbar Front Power Seat Switch) Standard Resistance Tester Switch Specified Connection Condition Condition 3-5 Hold 1-2 3-2 Below 1 Off ohms 1-2 3-2 Release 1-5 If the result is not as specified, replace the lumbar front power seat switch. INSTALLATION INSTALLATION

1. INSTALL FRONT LUMBAR POWER SEAT SWITCH (for TMMK Made) a. Connect the connector to install the front lumbar power seat switch. 2. INSTALL FRONT POWER SEAT SWITCH (for TMMK Made) Refer to INSTALLATION. 3. INSTALL FRONT LUMBAR POWER SEAT SWITCH (for SIA Made) a. Engage the 4 claws to install the front lumbar power seat switch to the front seat cushion shield. 4. INSTALL FRONT SEAT CUSHION SHIELD (for SIA Made) . See step 28. 5. INSTALL NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) . See step 10. 6. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 31. 7. INSTALL FRONT SEAT ASSEMBLY (for SIA Made)

Refer to INSTALLATION.

LUMBAR SUPPORT ADJUSTER ASSEMBLY (FOR TMMK MADE POWER SEAT) COMPONENTS ILLUSTRATION

Fig. 285: Identifying Lumbar Support Adjuster Assembly (For TMMK Made Power Seat) Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 286: Identifying Lumbar Support Adjuster Assembly (For TMMK Made Power Seat) Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY LH Refer to REMOVAL. 2. 3. 4. 5.

DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER . See step 4. DISCONNECT CONNECTORS . See step 3. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD . See step 14. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY a. Disconnect the connector.

Fig. 287: Removing Lumbar Support Adjuster Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 4 claws. c. Disengage the 2 guides to remove the lumbar support adjuster assembly. d. Remove the 2 front seatback hooks from the lumbar support adjuster assembly. INSPECTION INSPECTION

1. INSPECT LUMBAR SUPPORT ADJUSTER ASSEMBLY LH a. Check the operation of the lumbar support adjuster assembly.

Fig. 288: Identifying Motor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check that the front seat back moves smoothly when the battery is connected to the lumbar support adjuster assembly connector terminals. OK Measurement Operational Condition Direction Battery positive (+) -Seat back > Terminal 1 moves Battery forward negative (-) -> Terminal 2 Battery positive (+) -Seat back > Terminal 2 moves Battery backward negative (-) -> Terminal 1 TEXT IN ILLUSTRATION Component without harness

connected (Lumbar Support *a Adjuster Assembly LH) If the result is not as specified, replace the lumbar support adjuster assembly LH. INSTALLATION INSTALLATION

1. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY a. Install the 2 front seatback hooks to the lumbar support adjuster assembly. b. Engage the 2 guides.

Fig. 289: Installing Lumbar Support Adjuster Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. 3. 4. 5.

c. Engage the 4 claws to install the lumbar support adjuster assembly. d. Connect the connector. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD . See step 21. CONNECT CONNECTORS . See step 4. CONNECT SEPARATE TYPE FRONT SEATBACK COVER . See step 31. INSTALL FRONT SEAT ASSEMBLY LH Refer to INSTALLATION.

SEAT HEATER SWITCH COMPONENTS

ILLUSTRATION

Fig. 290: Identifying Seat Heater Switch Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. 2. 3. 4. 5.

REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 11 . REMOVE FRONT PANEL GARNISH RH . Refer to REMOVAL - Step 14 . REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to REMOVAL - Step 15 . REMOVE REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 16 . REMOVE SEAT HEATER SWITCH a. Disengage the 4 claws to remove the 2 seat heater switches.

Fig. 291: Identifying Seat Heater Switch Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT SEAT HEATER SWITCH (for LH) a. Check the seat heater switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 292: Identifying Seat Heater Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for LH)) Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms 8-6 OFF or higher 350 ohms 8-6 ON to 3.4 kohms Below 1 8-3 ON ohms If the result is not as specified, replace the seat heater switch (for LH).

b. Check that the LED illuminates. 1. Apply battery voltage to the seat heater switch (for LH) and check that the LED illuminates.

Fig. 293: Identifying Seat Heater Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for LH)) OK Measurement Switch Specified Condition Condition Condition Battery positive (+) -> Terminal 7 Battery negative (-) -> Terminal 2 LED

Battery positive (+) -> Terminal 8 Battery negative (-) -> Terminal 4

illuminates ON

If the result is not as specified, replace the seat heater switch (for LH). 2. INSPECT SEAT HEATER SWITCH (for RH) a. Check the seat heater switch. 1. Measure the resistance according to the value(s) in the table below.

Fig. 294: Identifying Seat Heater Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Seat Heater Switch (for RH))

Standard Resistance Tester Switch Specified Connection Condition Condition 10 kohms 7-5 OFF or higher 350 ohms 7-5 ON to 3.4 kohms Below 1 7-2 ON ohms If the result is not as specified, replace the seat heater switch (for RH). b. Check that the LED illuminates. 1. Apply battery voltage to the seat heater switch (for RH) and check that the LED illuminates.

Fig. 295: Identifying Seat Heater Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without *a harness connected (Seat

Heater Switch (for RH)) OK Measurement Switch Specified Condition Condition Condition Battery positive (+) -> Terminal 6 Battery negative (-) -> Terminal 1 LED illuminates Battery positive (+) -> Terminal 7 ON Battery negative (-) -> Terminal 3 If the result is not as specified, replace the seat heater switch (for RH). INSTALLATION INSTALLATION

1. INSTALL SEAT HEATER SWITCH a. Engage the 4 claws to install the 2 seat heater switches. 2. INSTALL REAR CONSOLE UPPER PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 37 . 3. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to INSTALLATION - Step 38 . 4. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 42 . 5. INSTALL FRONT PANEL GARNISH RH . Refer to INSTALLATION - Step 39 .

FRONT SEATBACK HEATER COMPONENTS ILLUSTRATION

Fig. 296: Identifying Front Seatback Heater (For TMMK Made) Replacement Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 297: Identifying Front Seatback Heater (For TMMK Made) Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 298: Identifying Front Seatback Heater (For SIA Made) Replacement Components With Torque Specifications (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 299: Identifying Front Seatback Heater (For SIA Made) Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY (for TMMK Made) Refer to REMOVAL. 2. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 4. 3. DISCONNECT CONNECTORS (for TMMK Made) a. Disconnect the connector (A).

Fig. 300: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp (B). c. Disengage the claw (D) and 3 clamps (C) to separate the front seat airbag assembly wire harness. d. Disconnect the connector (E). e. Disengage the clamp (F). 4. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made) . See step 14. 5. REMOVE SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 16. 6. REMOVE FRONT SEATBACK HEATER ASSEMBLY (for TMMK Made) a. Remove the 8 tag pins and the front seatback heater assembly from the separate type front seatback cover.

Fig. 301: Identifying Front Seatback Heater Assembly (For TMMK Made) Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE FRONT SEAT ASSEMBLY (for SIA Made) Refer to REMOVAL. 8. DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 4. 9. DISCONNECT CONNECTOR (for SIA Made) a. Disconnect the connector.

Fig. 302: Identifying Front Seatback Cover Connector And Clamp (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp. 10. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made) . See step 17. 11. REMOVE SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 19. 12. REMOVE FRONT SEATBACK HEATER ASSEMBLY (for SIA Made) a. Remove the 12 tag pins and the front seatback heater assembly from the separate type front seatback cover.

Fig. 303: Identifying Front Seatback Heater Assembly (For SIA Made) Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEAT BACK HEATER ASSEMBLY LH a. Measure the resistance according to the value(s) in the table below.

Fig. 304: Identifying Front Seat Back Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Back Heater Assembly LH) Standard Resistance Tester Specified Condition Connection Condition 3.26 to 4 1-2 Always ohms If the result is not as specified, replace the front seat back heater assembly LH. 2. INSPECT FRONT SEAT BACK HEATER ASSEMBLY RH a. Measure the resistance according to the value(s) in the table below.

Fig. 305: Identifying Front Seat Back Heater Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Back Heater Assembly RH) Standard Resistance Tester Specified Condition Connection Condition 3.26 to 4 1-2 Always ohms If the result is not as specified, replace the front seat back heater assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEATBACK HEATER ASSEMBLY (for TMMK Made) a. Using a tacker, install the front seatback heater assembly to the separate type front seatback cover with 8 new tag pins. 2. INSTALL SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 19. 3. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made) . See step 21. 4. CONNECT CONNECTORS (for TMMK Made) a. Engage the claw (D) and 3 clamps (C) to install the front seat airbag assembly wire harness.

Fig. 306: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clamp (B). c. Connect the connector (A). d. Connect the connector (E). e. Engage the clamp (F). 5. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for TMMK Made) . See step 31. 6. INSTALL FRONT SEAT ASSEMBLY (for TMMK Made) Refer to INSTALLATION. 7. INSTALL FRONT SEATBACK HEATER ASSEMBLY (for SIA Made) a. Using a tacker, install the front seatback heater assembly to the separate type front seatback cover

8. 9. 10.

11. 12.

with 12 new tag pins. INSTALL SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 16. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made) . See step 18. CONNECT CONNECTOR (for SIA Made) a. Engage the clamp. b. Connect the connector. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 31. INSTALL FRONT SEAT ASSEMBLY (for SIA Made) Refer to INSTALLATION.

FRONT SEAT CUSHION HEATER COMPONENTS ILLUSTRATION

Fig. 307: Identifying Front Seat Cushion Heater (For TMMK Made) Replacement Components With Torque Specifications (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 308: Identifying Front Seat Cushion Heater (For TMMT Made) Replacement Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 309: Identifying Front Seat Cushion Heater (For SIA Made) Replacement Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 310: Identifying Front Seat Cushion Heater (For SIA Made) Replacement Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE FRONT POWER SEAT SWITCH (for TMMK Made) Refer to REMOVAL. 2. REMOVE FRONT SEAT INNER CUSHION SHIELD (for TMMK Made) . See step 8. 3. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (for TMMK Made) . See step 11. 4. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER (for TMMK Made) . See step 12. 5. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY (for TMMK Made) a. Remove the 20 tag pins and the front seat cushion heater assembly from the separate type front seat cushion cover.

Fig. 311: Locating Front Seat Cushion Heater Assembly (For TMMK Made) Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FRONT SEAT ASSEMBLY (for SIA Made) Refer to REMOVAL. 7. 8. 9. 10. 11. 12.

DISCONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 4. REMOVE NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) . See step 11. REMOVE FRONT SEAT CUSHION SHIELD (for SIA Made Driver Side) . See step 6. REMOVE FRONT SEAT CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 7. REMOVE FRONT SEAT INNER CUSHION SHIELD (for SIA Made Driver Side) . See step 10. REMOVE FRONT SEAT INNER CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 11. 13. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (for SIA Made) . See step 14. 14. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER (for SIA Made) . See step 15. 15. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY (for SIA Made) a. Remove the 34 tag pins and the front seat cushion heater assembly from the separate type front seat cushion cover.

Fig. 312: Locating Front Seat Cushion Heater Assembly (For SIA Made) Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY LH (for TMMK Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 313: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly LH) Standard Resistance Tester Specified Condition Connection Condition Below 1 A-1 - B-3 Always ohms 20°C (68° 9 to 13.8 A-2 - A-5 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 A-2 - B-1 F) to 25°C kohms (77°F)

A-2 - C-1

A-2 - C-1

A-2 - C-2

A-2 - A-3 A-3 - C-1 A-3 - B-1

A-3 - A-5

A-3 - C-2 A-4 - B-2 A-5 - B-1 A-5 - C-2 A-5 - C-1

20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) Below 1 Always ohms Below 1 Always ohms Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F)

If the result is not as specified, replace the front seat cushion heater assembly LH. 2. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY RH (for TMMK Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 314: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For TMMK Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly RH) Standard Resistance Tester Specified Condition Connection Condition Below 1 A-1 - B-3 Always ohms 20°C (68° 9 to 13.8 A-2 - A-5 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 A-2 - B-1 F) to 25°C kohms (77°F)

A-2 - C-1

A-2 - C-1

A-2 - C-2

A-2 - A-3 A-3 - C-1 A-3 - B-1

A-3 - A-5

A-3 - C-2 A-4 - B-2 A-5 - B-1 A-5 - C-2 A-5 - C-1

20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) 20°C (68° 9 to 13.8 F) to 25°C kohms (77°F) Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F) Below 1 Always ohms Below 1 Always ohms Below 1 Always ohms 20°C (68° 3.2 to 4.1 F) to 25°C ohms (77°F)

If the result is not as specified, replace the front seat cushion heater assembly RH. 3. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY LH (for SIA Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 315: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly LH) Standard Resistance Tester Specified Condition Connection Condition Below 1 A-1 - B-1 Always ohms Below 1 A-4 - B-2 Always ohms 3.21 to A-1 - A-4 Always 3.85 ohms B-1 - B-2

Always

3.39 to

A-2 - A-3

4.07 ohms 15°C (59° 4.9 to 8.2 F) to 30°C kohms (86°F)

If the result is not as specified, replace the front seat cushion heater assembly LH. 4. INSPECT FRONT SEAT CUSHION HEATER ASSEMBLY RH (for SIA Made) a. Measure the resistance according to the value(s) in the table below.

Fig. 316: Identifying Front Seat Cushion Heater Assembly Connector Terminals (For SIA Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component without harness connected *a (Front Seat Cushion Heater Assembly RH) Standard Resistance

Tester Specified Condition Connection Condition Below 1 A-1 - B-1 Always ohms Below 1 A-4 - B-2 Always ohms 3.21 to A-1 - A-4 Always 3.85 ohms 3.39 to B-1 - B-2 Always 4.07 ohms 15°C (59° 4.9 to 8.2 A-2 - A-3 F) to 30°C kohms (86°F) If the result is not as specified, replace the front seat cushion heater assembly RH. INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY (for TMMK Made) a. Using a tacker, install the front seat cushion heater assembly to the separate type front seat cushion cover with 20 new tag pins.

Fig. 317: Locating Front Seat Cushion Heater Assembly (For TMMK Made) Tag Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (for TMMK Made) . See step 23. 3. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (for TMMK Made) . See step 24. 4. INSTALL FRONT SEAT INNER CUSHION SHIELD (for TMMK Made) . See step 27. 5. INSTALL FRONT POWER SEAT SWITCH (for TMMK Made) Refer to INSTALLATION. 6. INSTALL FRONT SEAT CUSHION HEATER ASSEMBLY (for SIA Made) a. Using a tacker, install the front seat cushion heater assembly to the separate type front seat cushion cover with 34 new tag pins. 7. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (for SIA Made) . See step 20. 8. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (for SIA Made) . See step 21. 9. INSTALL FRONT SEAT INNER CUSHION SHIELD (for SIA Made Driver Side) . See step 24. 10. INSTALL FRONT SEAT INNER CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 25. 11. INSTALL FRONT SEAT CUSHION SHIELD (for SIA Made Driver Side) . See step 28. 12. INSTALL FRONT SEAT CUSHION SHIELD (for SIA Made Front Passenger Side) . See step 29. 13. INSTALL NO. 1 FRONT SEAT INNER CUSHION SHIELD (for SIA Made) . See step 10. 14. CONNECT SEPARATE TYPE FRONT SEATBACK COVER (for SIA Made) . See step 31. 15. INSTALL FRONT SEAT ASSEMBLY (for SIA Made) Refer to INSTALLATION.

REAR SEAT RECLINING CONTROL CABLE COMPONENTS ILLUSTRATION

Fig. 318: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 319: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ILLUSTRATION

Fig. 320: Identifying Rear Seat Reclining Control Cable Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing.

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . See step 3. REMOVE REAR SEAT CUSHION LOCK HOOK . See step 4. REMOVE INNER LUGGAGE COMPARTMENT TRIM PAD . See step 5. REMOVE REAR SEATBACK ASSEMBLY LH . See step 6. REMOVE REAR SEATBACK ASSEMBLY RH . See step 7. REMOVE REAR SIDE SEATBACK ASSEMBLY LH . See step 8. REMOVE REAR SIDE SEATBACK ASSEMBLY RH . See step 9. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 12 . DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to REMOVAL Step 13 . DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to REMOVAL Step 13 . DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to REMOVAL Step 14 . REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to REMOVAL - Step 10 . DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to REMOVAL - Step 19 . REMOVE ROOF SIDE INNER GARNISH LH . Refer to REMOVAL - Step 24 . REMOVE ROOF SIDE INNER GARNISH RH HINT:

Use the same procedure as for the LH side. Refer to REMOVAL - Step 24 . 18. REMOVE CENTER STOP LIGHT SET . Refer to REMOVAL - Step 1 . 19. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to REMOVAL - Step 18 . 20. REMOVE REAR SEAT SHOULDER BELT COVER . Refer to REMOVAL - Step 19 . 21. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to REMOVAL - Step 20 . 22. REMOVE ROOM PARTITION BOARD LH a. Disengage the guide, 2 claws and 4 clips, and remove the room partition board LH.

Fig. 321: Locating Room Partition Board LH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE ROOM PARTITION BOARD RH a. Using a clip remover, remove the 2 clips.

Fig. 322: Locating Room Partition Board RH Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the 5 clips and remove the room partition board RH. 24. REMOVE REAR SEATBACK LOCK ASSEMBLY LH (REAR SEAT LOCK CONTROL CABLE LH) a. Disengage the hook as shown in the illustration.

Fig. 323: Removing Rear Seatback Lock Assembly LH (Rear Seat Lock Control Cable LH) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and rear seatback lock assembly LH (rear seat lock control cable LH).

Fig. 324: Locating Rear Seatback Lock Assembly LH (Rear Seat Lock Control Cable LH) Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE REAR SEATBACK LOCK ASSEMBLY RH (REAR SEAT LOCK CONTROL CABLE RH) HINT: Use the same procedure as for the LH side. INSTALLATION INSTALLATION

1. INSTALL REAR SEATBACK LOCK ASSEMBLY LH (REAR SEAT LOCK CONTROL CABLE LH) a. Install the rear seatback lock assembly LH (rear seat lock control cable LH) with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) b. Engage the hook as shown in the illustration.

Fig. 325: Installing Rear Seatback Lock Assembly LH (Rear Seat Lock Control Cable LH) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL REAR SEATBACK LOCK ASSEMBLY RH (REAR SEAT LOCK CONTROL CABLE RH) HINT: Use the same procedure as for the LH side. 3. INSTALL ROOM PARTITION BOARD RH a. Engage the 5 clips to install the room partition board RH. b. Install the 2 clips. 4. INSTALL ROOM PARTITION BOARD LH a. Engage the 4 clips, 2 claws and guide to install the room partition board LH.

5. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY . Refer to INSTALLATION - Step 3 . 6. INSTALL REAR SEAT SHOULDER BELT COVER . Refer to INSTALLATION - Step 4 . 7. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR COVER . Refer to INSTALLATION Step 5 . 8. INSTALL CENTER STOP LIGHT SET . Refer to INSTALLATION - Step 1 . 9. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedure as for the LH side. Refer to INSTALLATION - Step 20 . 10. INSTALL ROOF SIDE INNER GARNISH LH . Refer to INSTALLATION - Step 20 . 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH . Refer to INSTALLATION - Step 7 . 12. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 1 13. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) . Refer to INSTALLATION Step 10 . 14. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) . Refer to INSTALLATION Step 9 . 15. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH . Refer to INSTALLATION Step 32 . 16. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 25 . 17. INSTALL REAR SIDE SEATBACK ASSEMBLY RH . See step 1. 18. INSTALL REAR SIDE SEATBACK ASSEMBLY LH . See step 2. 19. INSTALL REAR SEATBACK ASSEMBLY RH . See step 3. 20. INSTALL REAR SEATBACK ASSEMBLY LH . See step 4. 21. INSTALL INNER LUGGAGE COMPARTMENT TRIM PAD . See step 5. 22. INSTALL REAR SEAT CUSHION LOCK HOOK . See step 6. 23. INSTALL REAR SEAT CUSHION ASSEMBLY . See step 7. 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

25. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

2012-2017 ACCESSORIES & EQUIPMENT Sliding Roof (Service Information) (Hybrid)

SLIDING ROOF HOUSING COMPONENTS ILLUSTRATION

Fig. 1: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 2. REMOVE SLIDING ROOF SIDE GARNISH LH a. Disengage the 2 claws and remove the sliding roof side garnish LH.

Fig. 4: Locating Sliding Roof Side Garnish LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedure as for the LH side. 4. REMOVE SLIDING ROOF GLASS SUB-ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 4 screws and sliding roof glass sub-assembly.

Fig. 5: Locating Sliding Roof Glass Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

To prevent the sliding roof glass and sliding roof drive gear from being displaced, fully close the sliding roof glass (sliding roof drive cable), and then remove the sliding roof glass sub-assembly.

5. REMOVE SLIDING ROOF WEATHERSTRIP a. Remove the sliding roof weatherstrip from the sliding roof panel sub-assembly. 6. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY LH . Refer to REMOVAL - Step 3 7. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. 8. REMOVE REAR NO. 2 SIDE RAIL SPACER LH a. Using a screwdriver, disengage the 2 claws and remove the rear No. 2 side rail spacer LH.

Fig. 6: Locating Rear No. 2 Side Rail Spacer LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. 9. REMOVE REAR NO. 2 SIDE RAIL SPACER RH HINT: Use the same procedure as for the LH side. 10. REMOVE SLIDING ROOF HOUSING SUB-ASSEMBLY a. for Clamp Type:

Fig. 7: Identifying Sliding Roof Housing Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disengage the claw and disconnect the sliding roof drain hose. HINT: Use the same procedure for the other 3 sliding roof drain hoses. b. for Clip Type:

Fig. 8: Identifying Sliding Roof Housing Sub-Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Expand the clip and disconnect the sliding roof drain hose. HINT: Use the same procedure for the other 3 sliding roof drain hoses. c. Remove the 8 bolts, 8 nuts and sliding roof housing sub-assembly.

Fig. 9: Identifying Sliding Roof Housing Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY a. Disengage the claw.

Fig. 10: Identifying Sliding Roof Drive Gear Sub-Assembly Guide And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Pin b. Disengage the guide and pin, and remove the map light bracket. c. Remove the 2 bolts and sliding roof drive gear sub-assembly.

Fig. 11: Identifying Sliding Roof Drive Gear Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SUNSHADE TRIM SUB-ASSEMBLY a. Remove the screw and the sliding roof piece sub-assembly LH.

Fig. 12: Identifying Sunshade Trim Sub-Assembly Fastener

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side. b. Slide and remove the sunshade trim sub-assembly.

Fig. 13: Removing Sunshade Trim Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE REAR SLIDING ROOF PANEL a. Disengage the 2 claws. Then slide the rear sliding roof panel rearward to remove it.

Fig. 14: Removing Rear Sliding Roof Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY NOTE:

Do not disassemble the sliding roof drive cable sub-assembly except when replacing it.

a. Hold down the roof wind deflector panel sub-assembly.

Fig. 15: Holding Down Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to remove it.

Fig. 16: Removing Sliding Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use.  Use the same procedure for the other sliding roof drive cable sub-assembly. 5. REMOVE ROOF WIND DEFLECTOR PANEL SUB-ASSEMBLY a. Pull the spring in the direction indicated by the arrow (1) in the illustration to disengage the 2 springs. 

Fig. 17: Removing Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Spring *2 Guide b. Pull the roof wind deflector panel sub-assembly in the direction indicated by the arrow (2) in the illustration to disengage the 2 guides and remove it. REASSEMBLY REASSEMBLY

1. INSTALL ROOF WIND DEFLECTOR PANEL SUB-ASSEMBLY a. Engage the 2 guides in the direction indicated by the arrow (1) in the illustration to install the roof wind deflector panel sub-assembly.

Fig. 18: Installing Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Spring b. Engage the 2 springs in the direction indicated by the arrow (2) in the illustration. NOTE:

Make sure that the springs are securely installed.

2. INSTALL SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY a. Hold down the roof wind deflector panel sub-assembly.

Fig. 19: Holding Down Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to install it.

Fig. 20: Installing Sliding Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use.  Use the same procedure for the other sliding roof drive cable sub-assembly. 3. INSTALL REAR SLIDING ROOF PANEL a. Insert the rear sliding roof panel in the direction indicated by the arrow (1) in the illustration. 

Fig. 21: Installing Rear Sliding Roof Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 claws in the direction indicated by the arrow (2) in the illustration to install the rear sliding roof panel. 4. ADJUST FULLY CLOSED POSITION a. Using a screwdriver, slide the sliding roof drive cable sub-assembly in either direction indicated by the arrows in the illustration and alignment marks.

Fig. 22: Adjusting Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment *1 Mark HINT: Tape the screwdriver tip before use. 5. INSTALL SUNSHADE TRIM SUB-ASSEMBLY a. Insert the sunshade trim sub-assembly into the sliding roof housing sub-assembly.

Fig. 23: Installing Sunshade Trim Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the sliding roof piece sub-assembly LH with the screw.

Fig. 24: Identifying Sunshade Trim Sub-Assembly Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) HINT: Use the same procedure for the RH side. 6. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY a. Install the sliding roof drive gear sub-assembly with the 2 bolts.

Fig. 25: Identifying Sliding Roof Drive Gear Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) b. Engage the guide and pin.

Fig. 26: Identifying Sliding Roof Drive Gear Sub-Assembly Guide And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Pin c. Engage the claw and install the map light bracket. INSTALLATION INSTALLATION

1. INSTALL SLIDING ROOF HOUSING SUB-ASSEMBLY a. Loosen the 8 bolts from the sliding roof housing sub-assembly. b. Install the sliding roof housing sub-assembly with the 8 bolts and 8 nuts. Nut Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Bolt Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Tighten the 8 bolts to the sliding roof housing sub-assembly.

Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) d. for Clamp Type:

Fig. 27: Identifying Sliding Roof Housing Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Clamp *2 Marking 1. Insert the sliding roof drain hose. HINT: The hose should be inserted to the base of the drain pipe. 2. Engage the claw to connect the sliding roof drain hose. HINT: Make sure that the clamp is on the marking or between the marking and hose end.  Use the same procedure for the other 3 sliding roof drain hoses. e. for Clip Type: 

Fig. 28: Identifying Sliding Roof Housing Sub-Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Clip

*2 Marking Front *a Side *b Outside 1. Expand the clip to insert the sliding roof drain hose. HINT: The hose should be inserted to the base of the drain pipe. 2. Release the clip to connect the sliding roof drain hose. NOTE:

The clip must face toward the outside of the vehicle and also be above the lower surface of the sliding roof housing when installing the drain hoses.

HINT: Make sure that the clip is on the marking or between the marking and hose end.  Use the same procedure for the other 3 sliding roof drain hoses. 2. INSTALL REAR NO. 2 SIDE RAIL SPACER LH a. Engage the 2 claws to install the rear No. 2 side rail spacer LH. 

Fig. 29: Locating Rear No. 2 Side Rail Spacer LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSTALL REAR NO. 2 SIDE RAIL SPACER RH HINT: Use the same procedure as for the LH side. 4. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY LH . Refer to INSTALLATION - Step 1 5. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. 6. INSTALL SLIDING ROOF WEATHERSTRIP a. Install the sliding roof weatherstrip as follows: 1. Position the joint of the weatherstrip at the rear center. 2. Align the alignment mark (yellow) on the weatherstrip with the middle marks at the corners of the sliding roof panel sub-assembly and install the weatherstrip. 3. Install the lip of the weatherstrip firmly.

Fig. 30: Identifying Sliding Roof Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Joint *2 Rear Alignment Middle *3 Mark *4 Mark (Yellow)

*A Normal *a Pinched Gap (raised, *c wavy, etc.)

*B Abnormal *b Exposed - -

7. INSTALL SLIDING ROOF GLASS SUB-ASSEMBLY a. Using a T25 "TORX" socket wrench, temporarily install the sliding roof glass sub-assembly with the 4 screws. b. Perform a level check.

Fig. 31: Installing The Sliding Roof Glass Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check the difference in level for "a" between the roof panel and the upper surface of the weatherstrip when the sliding roof glass is fully closed. Standard Area Measurement 0 + 1.0 mm (0 A - + 0.0394 in.) A 0 - 2.0 mm (0 - 0.0787 in.) 0 + 2.0 mm (0 B - + 0.0787 in.) B 0 - 1.0 mm (0 - 0.0394 in.)

0 + 1.5 mm (0 C - + 0.0591 in.) C 0 - 1.5 mm (0 - 0.0591 in.) 0 + 1.5 mm (0 D - + 0.0591 in.) D 0 - 1.0 mm (0 - 0.0394 in.) HINT: "+" represents the condition that the glass is above the panel level. "-" represents the condition that the glass is below the panel level. c. Perform a gap check.

Fig. 32: Perform A Gap Check Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check the gap between the roof panel and roof glass. TEXT IN ILLUSTRATION *a Even NOTE:

The gap must be even all around.

d. After adjusting the sliding roof glass, using a T25 "TORX" socket wrench, install the sliding roof glass sub-assembly with the 4 screws.

Fig. 33: Locating Sliding Roof Glass Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 8. CHECK FOR WATER LEAK a. After adjusting the sliding roof glass sub-assembly, check for water leaks. b. If there are any leaks, readjust the sliding roof glass sub-assembly. 9. INSTALL SLIDING ROOF SIDE GARNISH LH a. Engage the 2 claws and install the sliding roof side garnish LH. 10. INSTALL SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedure as for the LH side. 11. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION 12. RESET SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY Refer to INITIALIZATION

13. CHECK SLIDING ROOF SYSTEM Refer to OPERATION CHECK 14. INSPECT FOR WATER LEAK a. After adjusting the sliding roof glass sub-assembly, inspect for water leaks. b. If there are any leaks, readjust the sliding roof glass sub-assembly.

SLIDING ROOF SWITCH ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 34: Identifying Sliding Roof Switch Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY . Refer to REMOVAL - Step 2 INSPECTION INSPECTION

1. INSPECT SLIDING ROOF SWITCH (ROOF CONSOLE BOX ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 35: Inspecting Sliding Roof Switch (Roof Console Box Assembly) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Switch Specified Connection Condition Condition 6 (UP) - 10 UP switch Below 1 (GND) is pressed ohms UP switch 6 (UP) - 10 10 kohms is not (GND) or higher pressed DOWN 7 (DOWN) Below 1 switch is - 10 (GND) ohms pressed DOWN 7 (DOWN) switch is 10 kohms - 10 (GND) not or higher pressed OPEN 8 (OPN) Below 1 switch is 10 (GND) ohms pressed OPEN 8 (OPN) - switch is 10 kohms 10 (GND) not or higher pressed CLOSE 9 (CLS) Below 1 switch is 10 (GND) ohms pressed CLOSE 9 (CLS) - switch is 10 kohms 10 (GND) not or higher pressed TEXT IN ILLUSTRATION Component without harness connected (Sliding *a Roof Switch (Roof Console Box Assembly)) If the result is not as specified, replace the sliding roof switch (roof console box assembly). INSTALLATION

INSTALLATION

1. INSTALL ROOF CONSOLE BOX ASSEMBLY . Refer to INSTALLATION - Step 3

2012-2017 ACCESSORIES & EQUIPMENT Sliding Roof (Service Information) (Except Hybrid) - Camry

SLIDING ROOF HOUSING COMPONENTS ILLUSTRATION

Fig. 1: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 3: Identifying Sliding Roof Housing Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL . 2. REMOVE SLIDING ROOF SIDE GARNISH LH a. Disengage the 2 claws and remove the sliding roof side garnish LH.

Fig. 4: Locating Sliding Roof Side Garnish LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedure as for the LH side. 4. REMOVE SLIDING ROOF GLASS SUB-ASSEMBLY a. Using a T25 "TORX" socket wrench, remove the 4 screws and sliding roof glass sub-assembly.

Fig. 5: Locating Sliding Roof Glass Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

To prevent the sliding roof glass and sliding roof drive gear from being displaced, fully close the sliding roof glass (sliding roof drive cable), and then remove the sliding roof glass sub-assembly.

5. REMOVE SLIDING ROOF WEATHERSTRIP a. Remove the sliding roof weatherstrip from the sliding roof panel sub-assembly. 6. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY LH . Refer to REMOVAL - Step 3 . 7. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. 8. REMOVE REAR NO. 2 SIDE RAIL SPACER LH a. Using a screwdriver, disengage the 2 claws and remove the rear No. 2 side rail spacer LH.

Fig. 6: Locating Rear No. 2 Side Rail Spacer LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use. 9. REMOVE REAR NO. 2 SIDE RAIL SPACER RH HINT: Use the same procedure as for the LH side. 10. REMOVE SLIDING ROOF HOUSING SUB-ASSEMBLY a. For Clamp Type:

Fig. 7: Identifying Sliding Roof Housing Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disengage the claw and disconnect the sliding roof drain hose. HINT: Use the same procedure for the other 3 sliding roof drain hoses. b. For Clip Type:

Fig. 8: Identifying Sliding Roof Housing Sub-Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Expand the clip and disconnect the sliding roof drain hose. HINT: Use the same procedure for the other 3 sliding roof drain hoses. c. Remove the 8 bolts, 8 nuts and sliding roof housing sub-assembly.

Fig. 9: Identifying Sliding Roof Housing Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY a. Disengage the claw.

Fig. 10: Identifying Sliding Roof Drive Gear Sub-Assembly Guide And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Pin b. Disengage the guide and pin, and remove the map light bracket. c. Remove the 2 bolts and sliding roof drive gear sub-assembly.

Fig. 11: Identifying Sliding Roof Drive Gear Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SUNSHADE TRIM SUB-ASSEMBLY a. Remove the screw and the sliding roof piece sub-assembly LH.

Fig. 12: Identifying Sunshade Trim Sub-Assembly Fastener

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Use the same procedure for the RH side. b. Slide and remove the sunshade trim sub-assembly.

Fig. 13: Removing Sunshade Trim Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE REAR SLIDING ROOF PANEL a. Disengage the 2 claws. Then slide the rear sliding roof panel rearward to remove it.

Fig. 14: Removing Rear Sliding Roof Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY NOTE:

Do not disassemble the sliding roof drive cable sub-assembly except when replacing it.

a. Hold down the roof wind deflector panel sub-assembly.

Fig. 15: Holding Down Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to remove it.

Fig. 16: Removing Sliding Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use.  Use the same procedure for the other sliding roof drive cable sub-assembly. 5. REMOVE ROOF WIND DEFLECTOR PANEL SUB-ASSEMBLY a. Pull the spring in the direction indicated by the arrow (1) in the illustration to disengage the 2 springs. 

Fig. 17: Removing Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Spring *2 Guide b. Pull the roof wind deflector panel sub-assembly in the direction indicated by the arrow (2) in the illustration to disengage the 2 guides and remove it. REASSEMBLY REASSEMBLY

1. INSTALL ROOF WIND DEFLECTOR PANEL SUB-ASSEMBLY a. Engage the 2 guides in the direction indicated by the arrow (1) in the illustration to install the roof wind deflector panel sub-assembly.

Fig. 18: Installing Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Spring b. Engage the 2 springs in the direction indicated by the arrow (2) in the illustration. NOTE:

Make sure that the springs are securely installed.

2. INSTALL SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY a. Hold down the roof wind deflector panel sub-assembly.

Fig. 19: Holding Down Roof Wind Deflector Panel Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to install it.

Fig. 20: Installing Sliding Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape HINT: Tape the screwdriver tip before use.  Use the same procedure for the other sliding roof drive cable sub-assembly. 3. INSTALL REAR SLIDING ROOF PANEL a. Insert the rear sliding roof panel in the direction indicated by the arrow (1) in the illustration. 

Fig. 21: Installing Rear Sliding Roof Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the 2 claws in the direction indicated by the arrow (2) in the illustration to install the rear sliding roof panel. 4. ADJUST FULLY CLOSED POSITION a. Using a screwdriver, slide the sliding roof drive cable sub-assembly in either direction indicated by the arrows in the illustration and alignment marks.

Fig. 22: Adjusting Roof Drive Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Alignment *1 Mark HINT: Tape the screwdriver tip before use. 5. INSTALL SUNSHADE TRIM SUB-ASSEMBLY a. Insert the sunshade trim sub-assembly into the sliding roof housing sub-assembly.

Fig. 23: Installing Sunshade Trim Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the sliding roof piece sub-assembly LH with the screw.

Fig. 24: Identifying Sunshade Trim Sub-Assembly Fastener Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) HINT: Use the same procedure for the RH side. 6. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY a. Install the sliding roof drive gear sub-assembly with the 2 bolts.

Fig. 25: Identifying Sliding Roof Drive Gear Sub-Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) b. Engage the guide and pin.

Fig. 26: Identifying Sliding Roof Drive Gear Sub-Assembly Guide And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Guide *2 Pin c. Engage the claw and install the map light bracket. INSTALLATION INSTALLATION

1. INSTALL SLIDING ROOF HOUSING SUB-ASSEMBLY a. Loosen the 8 bolts from the sliding roof housing sub-assembly. b. Install the sliding roof housing sub-assembly with the 8 bolts and 8 nuts. Nut Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Bolt Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) c. Tighten the 8 bolts to the sliding roof housing sub-assembly.

Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) d. For Clamp Type:

Fig. 27: Identifying Sliding Roof Housing Sub-Assembly Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Clamp *2 Marking 1. Insert the sliding roof drain hose. HINT: The hose should be inserted to the base of the drain pipe. 2. Engage the claw to connect the sliding roof drain hose. HINT: Make sure that the clamp is on the marking or between the marking and hose end.  Use the same procedure for the other 3 sliding roof drain hoses. e. For Clip Type: 

Fig. 28: Identifying Sliding Roof Housing Sub-Assembly Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Marking

*2 Clip Front *a Side *b Outside 1. Expand the clip to insert the sliding roof drain hose. HINT: The hose should be inserted to the base of the drain pipe. 2. Release the clip to connect the sliding roof drain hose. NOTE:

The clip must face toward the outside of the vehicle and also be above the lower surface of the sliding roof housing when installing the drain hoses.

HINT: Make sure that the clip is on the marking or between the marking and hose end.  Use the same procedure for the other 3 sliding roof drain hoses. 2. INSTALL REAR NO. 2 SIDE RAIL SPACER LH a. Engage the 2 claws to install the rear No. 2 side rail spacer LH. 

Fig. 29: Locating Rear No. 2 Side Rail Spacer LH Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSTALL REAR NO. 2 SIDE RAIL SPACER RH HINT: Use the same procedure as for the LH side. 4. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY LH . Refer to INSTALLATION - Step 1 . 5. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedure as for the LH side. 6. INSTALL SLIDING ROOF WEATHERSTRIP a. Install the sliding roof weatherstrip as follows: 1. Position the joint of the weatherstrip at the rear center. 2. Align the alignment mark (yellow) on the weatherstrip with the middle marks at the corners of the sliding roof panel sub-assembly and install the weatherstrip. 3. Install the lip of the weatherstrip firmly.

Fig. 30: Identifying Sliding Roof Weatherstrip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Joint *2 Rear Alignment Middle *3 Mark *4 Mark (Yellow)

*A Normal *a Pinched Gap (raised, *c wavy, etc.)

*B Abnormal *b Exposed - -

7. INSTALL SLIDING ROOF GLASS SUB-ASSEMBLY a. Using a T25 "TORX" socket wrench, temporarily install the sliding roof glass sub-assembly with the 4 screws. b. Perform a level check.

Fig. 31: Installing The Sliding Roof Glass Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check the difference in level for "a" between the roof panel and the upper surface of the weatherstrip when the sliding roof glass is fully closed. Standard Area Measurement 0 + 1.0 mm (0 A - + 0.0394 in.) A 0 - 2.0 mm (0 - 0.0787 in.) 0 + 2.0 mm (0 B - + 0.0787 in.) B 0 - 1.0 mm (0 - 0.0394 in.)

0 + 1.5 mm (0 C - + 0.0591 in.) C 0 - 1.5 mm (0 - 0.0591 in.) 0 + 1.5 mm (0 D - + 0.0591 in.) D 0 - 1.0 mm (0 - 0.0394 in.) HINT: "+" represents the condition that the glass is above the panel level. "-" represents the condition that the glass is below the panel level. c. Perform a gap check.

Fig. 32: Perform A Gap Check Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check the gap between the roof panel and roof glass. TEXT IN ILLUSTRATION *a Even NOTE:

The gap must be even all around.

d. After adjusting the sliding roof glass, using a T25 "TORX" socket wrench, install the sliding roof glass sub-assembly with the 4 screws.

Fig. 33: Locating Sliding Roof Glass Sub-Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 8. CHECK FOR WATER LEAK a. After adjusting the sliding roof glass sub-assembly, check for water leaks. b. If there are any leaks, readjust the sliding roof glass sub-assembly. 9. INSTALL SLIDING ROOF SIDE GARNISH LH a. Engage the 2 claws and install the sliding roof side garnish LH. 10. INSTALL SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedure as for the LH side. 11. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION . 12. RESET SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY Refer to INITIALIZATION .

13. CHECK SLIDING ROOF SYSTEM Refer to OPERATION CHECK . 14. INSPECT FOR WATER LEAK a. After adjusting the sliding roof glass sub-assembly, inspect for water leaks. b. If there are any leaks, readjust the sliding roof glass sub-assembly.

SLIDING ROOF SWITCH ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 34: Identifying Sliding Roof Switch Assembly Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE ROOF CONSOLE BOX ASSEMBLY . Refer to REMOVAL - Step 2 . INSPECTION INSPECTION

1. INSPECT SLIDING ROOF SWITCH (ROOF CONSOLE BOX ASSEMBLY) a. Measure the resistance according to the value(s) in the table below.

Fig. 35: Inspecting Sliding Roof Switch (Roof Console Box Assembly) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance

Tester Switch Specified Connection Condition Condition 6 (UP) - 10 UP switch Below 1 (GND) is pressed ohms UP switch 6 (UP) - 10 10 kohms is not (GND) or higher pressed DOWN 7 (DOWN) Below 1 switch is - 10 (GND) ohms pressed DOWN 7 (DOWN) switch is 10 kohms - 10 (GND) not or higher pressed OPEN 8 (OPN) Below 1 switch is 10 (GND) ohms pressed OPEN 8 (OPN) - switch is 10 kohms 10 (GND) not or higher pressed CLOSE 9 (CLS) Below 1 switch is 10 (GND) ohms pressed CLOSE 9 (CLS) - switch is 10 kohms 10 (GND) not or higher pressed TEXT IN ILLUSTRATION Component without harness connected (Sliding *a Roof Switch (Roof Console Box Assembly)) If the result is not as specified, replace the sliding roof switch (roof console box assembly). INSTALLATION

INSTALLATION

1. INSTALL ROOF CONSOLE BOX ASSEMBLY . Refer to INSTALLATION - Step 3 .

2012-2017 COMMON SPECS & PROCEDURES Camry (Hybrid)

COMMON SPECS & PROCEDURES CAMRY HYBRID COMMON SPECS & PROCEDURES System Air Conditioning Service Torque Axle Nut/Hub Nut Front Rear Hub / Bearing Battery Brakes Bleeding Sequence Brakes Torque Charging Generator Torque Drive Belts Adjustment Belt Routing Engine Cooling General Service Specifications Radiator Cap Pressure Standard Value Minimum Standard Value Thermostat R & I Water Pump R & I Engine Mechanical Compression Oil Pressure Overhaul Torque Flywheel/Flex plate (Drive Plate) Torque

Specification/Procedure SERVICE DATA TORQUE SPECIFICATIONS 294 N.m (217 ft lbs) 60 N.m (44 ft lbs) SERVICE DATA BLEEDING Front: SERVICE DATA Rear: SERVICE DATA Front: TORQUE SPECIFICATIONS Rear: TORQUE SPECIFICATIONS

N/A. Refer to: ON-VEHICLE INSPECTION N/A N/A N/A SERVICE DATA 93.3 to 122.7 kPa (1.0 to 1.3 kgf/cm2 , 13.5 to 18 psi) 78.5 kPa (0.8 kgf/cm2 , 11.4 psi) THERMOSTAT WATER PUMP SERVICE DATA at 1000 RPM, 145 kPa (1.5 kgf.cm2 , 21 psi) at 2, 500 RPM, 340 kPa (3.5 kgf.cm2 , 49 psi) SERVICE DATA TORQUE SPECIFICATIONS

(A/T) Fuel System Pressure Specification Fuel Pressure Test Procedure Fuel Filter Location Ignition Firing Order & Cylinder Identification Spark Plug Type Gap Torque Starting Starter Torque Wheel Alignment Front Adjustment Specifications Torque Rear Adjustment Specifications Torque Wheel & Tire Wheel Lug Nut Torque

130 N.m (96 ft.lb.) 304 to 343 kPa (3.1 to 3.5 kgf/cm2 , 44 to 50 psi) ON-VEHICLE INSPECTION FUEL PUMP FIRING ORDER & CYLINDER IDENTIFICATION

DENSO SK20R11 NGK 1FR6A11 Standard electrode gap:1.0 - 1.1 mm (0.039 - 0.043 in.) Maximum standard gap:1.3 mm (0.051 in.) 19 N.m (194 kgf.cm, 14 ft. lbs) N/A. Refer to SERVICE DATA N/A

SERVICE DATA TORQUE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS 103 N.m (1, 149 kgf.cm, 76 ft lbs.)

2012-2017 SPECIFICATIONS INDEX Camry

SPECIFICATIONS INDEX CAMRY SPECIFICATIONS INDEX System Air Conditioning Service Torque Axle Nut/Hub Nut Front Rear Hub / Bearing Assembly Battery Brakes Bleeding Sequence Disc/Drum Brakes Torque

Specification/Procedure SERVICE DATA TORQUE SPECIFICATIONS 294 N.m (217 ft lbs) 60 N.m (44 ft lbs) SERVICE DATA (2AR-FE) SERVICE DATA (2GR-FE) BLEEDING Front: SERVICE DATA Rear: SERVICE DATA Front: TORQUE SPECIFICATIONS Rear: TORQUE SPECIFICATIONS

Charging 2AR-FE Generator Torque 2GR-FE Generator Torque Drive Belts 2AR-FE Adjustment Belt Routing 2GR-FE Adjustment Belt Routing Engine Cooling 2AR-FE General Service Specifications Radiator Cap Pressure

SERVICE DATA TORQUE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS

ON-VEHICLE INSPECTION INSTALLATION ON-VEHICLE INSPECTION INSTALLATION

SERVICE DATA Standard Value

Thermostat R & I Water Pump R & I 2GR-FE General Service Specifications Radiator Cap Pressure

93.3 to 122.7 kPa (.95 to 1.25 kgf/cm2 , 13.5 to 17.8 psi) Minimum Standard value 78.5 kPa (0.8 kgf/cm2 , 11.4 psi) THERMOSTAT WATER PUMP SERVICE DATA Standard Value 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm2 , 13.5 to 17.8 psi)

Thermostat R & I Water Pump R & I Engine Mechanical 2AR-FE Compression Oil Pressure Overhaul Torque 2GR-FE Compression Oil Pressure Overhaul Torque Fluid Specifications Flywheel/Flex plate (Drive Plate) Torque 2AR-FE 2GR-FE Fuel System 2AR-FE Pressure Specification Fuel Pressure Test Procedure Fuel Filter Location 2GR-FE Pressure Specification Fuel Pressure Test Procedure

Minimum Standard value 78.5 kPa (0.8 kgf/cm2 , 11.4 psi) THERMOSTAT WATER PUMP

SERVICE DATA 30 kPa (0.3 kgf/cm2 , 4.4 psi) or more at 4, 00 RPM, 260 kPa (2.7 kgf/cm2 , 38 psi) or more SERVICE DATA TORQUE SPECIFICATIONS SERVICE DATA at idle, 30 kPa (0.3 kgf.cm2 , 4.4 psi) or more at 3, 00 RPM, 200 (2.0 kgf.cm2 , 29 psi) or more SERVICE DATA TORQUE SPECIFICATIONS See FLUIDS under MAINTENANCE tab. 98 N.m (72 ft.lb.) 83 N.m (61 ft.lb.)

304 to 343 kPa (3.1 to 3.5 kgf/cm2 , 44 to 50 psi) ON-VEHICLE INSPECTION FUEL PUMP 380 to 420 kPa (3.9to 4.3kgf/cm2 , 55 to 61 psi) ON-VEHICLE INSPECTION

Fuel Filter Location Ignition Firing Order & Cylinder Identification 2AR-FE & 2GR-FE Spark Plug 2AR-FE Type Gap Torque 2GR-FE Type Gap Torque Starting 2AR-FE Starter Torque 2GR-FE Starter Torque Wheel Alignment Front & Rear Adjustment Specifications Torque Wheel & Tire Wheel Lug Nut Torque

FUEL PUMP

FIRING ORDER & CYLINDER IDENTIFICATION

DENSO SK16HR11 Standard electrode gap:1.0 - 1.1 mm (0.039 - 0.043 in.) Maximum electrode gap:1.3 mm (0.051 in.) 25 N.m (255 kgf*cm, 18 ft. lbs) DENSO FK20HR11 Standard electrode gap:1.0 - 1.1 mm (0.039 - 0.043 in.) Maximum electrode gap:1.4 mm (0.055 in.) 18 N.m (184 kgf.cm, 13 ft. lbs)

SERVICE DATA TORQUE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS

SERVICE DATA TORQUE SPECIFICATIONS 103 N.m (1, 50 kgf.cm, 76 ft lbs.)

2012-2017 RESTRAINTS Supplemental Restraint System (Service Information) - Camry (Hybrid)

STEERING PAD COMPONENTS ILLUSTRATION

Fig. 1: Identifying Steering Pad Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Steering Pad Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the horn button assembly. 1. INSPECT HORN BUTTON ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the horn button assembly installed on the vehicle. HINT:

The defects are as follows:   

Cuts on the surface or in the grooves Small cracks on the surface or in the grooves Significant discoloration on the surface or in the grooves

OK No defects are found. If any of the defects is found, replace the horn button assembly with a new one. 2. INSPECT HORN BUTTON ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the horn button assembly removed from the vehicle. HINT: The defects are as follows:       

Cuts on the surface or in the grooves Small cracks on the surface or in the grooves Significant discoloration on the surface or in the grooves Cracks or other damage to the connector Deformation of the steering wheel assembly Deformation of the horn button sub-assembly of the horn button assembly Interference or uneven clearance between the horn button assembly and steering wheel assembly when the new horn button assembly is installed on the steering wheel assembly

OK No defects are found. If any of the defects is found, replace the horn button assembly or steering wheel assembly with a new one. REMOVAL REMOVAL

REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE LOWER NO. 3 STEERING WHEEL COVER a. Disengage the claw and guide to remove the lower No. 3 steering wheel cover.

Fig. 3: Identifying Lower No. 3 Steering Wheel Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE LOWER NO. 2 STEERING WHEEL COVER a. Disengage the claw and guide to remove the lower No. 2 steering wheel cover.

Fig. 4: Identifying Lower No. 2 Steering Wheel Cover Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE HORN BUTTON ASSEMBLY WARNING: When storing the horn button assembly, keep the airbag deployment side facing upward. a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Using a screwdriver, push up the torsion spring to disengage the pin.

Fig. 5: Locating Horn Button Assembly Torsion Spring And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Torsion *1 Spring HINT: Insert the screwdriver from the installation hole of the lower No. 3 steering wheel cover.

d. Using a screwdriver, push in the 2 torsion springs to disengage the 2 pins.

Fig. 6: Locating Horn Button Assembly Torsion Spring And Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Torsion *1 Spring NOTE:

Do not drop the horn button assembly.

HINT: Insert the screwdriver from the installation holes in the lower No. 3 steering wheel cover and lower No. 2 steering wheel cover.

e. Pull out the horn button assembly from the steering wheel assembly and support the horn button assembly with one hand. NOTE:

When removing the horn button assembly, do not pull the airbag wire harness.

f. Disconnect the horn connector from the horn button assembly.

Fig. 7: Disconnecting Horn Connectors From Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Using a screwdriver with its tip wrapped with protective tape, release the 2 airbag connector locks. TEXT IN ILLUSTRATION *1 Protective

Tape Airbag *2 Connector Horn *3 Connector Airbag *4 Connector Lock h. Disconnect the 2 airbag connectors to remove the horn button assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

INSTALLATION INSTALLATION INSTALLATION

1. INSTALL HORN BUTTON ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Connect the 2 airbag connectors to the horn button assembly.

Fig. 8: Connecting Horn Connectors To Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Horn *2 Connector Airbag *3 Connector Lock NOTE:





When connecting any airbag connector, take care not to damage the airbag wire harness. Be sure to only connect the connectors to each corresponding

color. d. Push in the 2 locks to install the 2 airbag connectors. e. Connect the horn connector to the horn button assembly. f. Push the horn button assembly to engage the 3 pins carefully.

Fig. 9: Locating Horn Button Assembly Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:



 

Make sure that the pins are securely inserted into the steering holes. Make sure to engage the 2 upper pins first. Make sure that the horn button assembly is securely installed.

2. INSTALL LOWER NO. 3 STEERING WHEEL COVER a. Engage the claw and guide to install the lower No. 3 steering wheel cover. 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER a. Engage the claw and guide to install the lower No. 2 steering wheel cover. 4. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3

6. INSPECT HORN BUTTON ASSEMBLY a. Make sure that the horn sounds. If the horn does not sound, inspect the horn system. Refer to PROBLEM SYMPTOMS TABLE . 7. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 8. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:













An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a horn button assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the horn button assembly. The horn button assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.







Use gloves and safety glasses when handling a horn button assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the horn button assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF HORN BUTTON ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the horn button assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST.

Fig. 10: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool

1. Connect SST to the 12 V battery. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 11: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 2. Check the function of SST. Press the SST activation switch and check that the LED of the SST activation switch comes on.

Fig. 12: Identifying SST Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING:





Do not connect the yellow SST connector to the airbag. If the LED comes on when the activation switch is not being pressed, SST is malfunctioning. Replace SST.

3. Disconnect SST from the 12 V battery. b. Refer to Precaution. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Remove the lower steering column cover. Refer to REMOVAL - Step 7 . d. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. e. Disconnect the yellow airbag connector from the spiral cable. 1. Slide the slider to release the lock, and then disconnect the connector.

Fig. 13: Identifying Slider To Release Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

f. Install SST. WARNING: Check that there is no looseness in the steering wheel assembly and horn button assembly. 1. Connect the SST connector to the airbag connector of the spiral cable.

Fig. 14: Connecting SST Connector To Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00780

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 15: Identifying Distance Between SST & Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The horn button assembly becomes extremely hot







when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF HORN BUTTON ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST.

Fig. 16: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



SST: 09082-00700 WARNING: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool

1. Connect SST to the 12 V battery. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 17: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 2. Check the function of SST. Press the SST activation switch and check that the LED of the SST activation switch comes on.

Fig. 18: Identifying SST Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING:





Do not connect the yellow SST connector to the airbag. If the LED comes on when the activation switch is not being pressed, SST is malfunctioning. Replace SST.

3. Disconnect SST from the 12 V battery. b. Remove the horn button assembly. Refer to REMOVAL. WARNING:





Before removing the horn button assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the horn button assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the horn button assembly to an unneeded wheel.

Fig. 19: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire harness is too thin or an alternative object is used to tie down the horn button assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. After connecting the following SST to each other, connect them to the horn button assembly.

Fig. 20: Connecting SST To Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-30801 2. Wind 3 wires at least 2 times each around each of the snap pins. 

Fig. 21: Identifying Wires Wrapped Around Snap Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 2

times *a or more WARNING:





Tightly wind the wires around the snap pins without any slack. Make sure that the wires are tight. If there is slack in the wires, the horn button assembly may break loose when the airbag is deployed.

3. Face the airbag deployment side of the horn button assembly upward on top of an unneeded tire and wheel set. Separately tie the each sides of the horn button assembly to the wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole of the wheel.

Fig. 22: Identifying Face Of Airbag Deployment Side Of Steering Pad Component Upward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Minimum tire size Width 185 mm (7.28 in.) Inner diameter

360 mm (1.18 ft.) WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the horn button assembly may break loose when the airbag is deployed. Always tie down the horn button assembly with the airbag deployment side facing upward.

The wheel will be damaged by the airbag deployment, so use an unneeded wheel.

d. Install SST.

Fig. 23: Connect SST Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Place the wheel on level ground.

1. Connect the SST connector.  SST: 09082-00700 NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the wheel.

Fig. 24: Identifying SST & Airbag Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m (32.8 *a ft.) or more e. Cover the horn button assembly (using a cardboard box). 1. Cover the horn button assembly with a cardboard box.

Fig. 25: Covering Steering Pad With Cardboard Box Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Weight 2. Place weights on the cardboard box in 4 places totaling at least 190 N (19 kg, 42.7 lb). Minimum cardboard box size Must exceed the following dimensions X 460 mm (1.51 ft.) Y 650 mm (2.13 ft.) NOTE:



When dimension Y of the cardboard box exceeds the diameter of the wheel and tire to which the horn button assembly is tied, X should be the following size. X = 460 mm (1.51 ft.) + width of tire



If a cardboard box smaller than the specified size is used, it may be broken by the shock from the airbag deployment.

f. Cover the horn button assembly (using tires). 1. Place at least 3 tires without wheels onto the wheel and tire to which the horn button assembly is tied.

Fig. 26: Covering Horn Button Assembly (Using Tires) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (3 *1 or more) Inner *a Diameter

*b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) 2. Place a wheel and tire on top. WARNING: Do not use tires with wheels except for on the top and bottom. NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

3. Tie the tires together with the 2 wires.

Fig. 27: Identifying Tires Tied Together With Wires

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 28: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Using a

Cardboard Box Using *B Tires 12 V *1 Battery Horn *2 Button Assembly 10 m *a (32.8 ft.) or more

*A

2. Check that no one is within a 10 m (32.8 ft.) radius of the wheel to which the horn button assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the horn button assembly. WARNING:









The horn button assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the horn button assembly from the wheel. 2. Place the horn button assembly in a plastic bag, tie it tightly and dispose of it according to local regulations.

SPIRAL CABLE COMPONENTS

ILLUSTRATION

Fig. 29: Identifying Spiral Cable Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 30: Identifying Spiral Cable Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL REMOVAL

1. REMOVE STEERING WHEEL ASSEMBLY Refer to REMOVAL 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. INSPECT SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY a. Check the colored part as shown in the illustration.

Fig. 31: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part If the colored part shown in the illustration cannot be confirmed, it is possible that the spiral cable sub-assembly is broken. Replace the spiral cable with sensor sub-assembly with a new one. 4. REMOVE LOWER STEERING COLUMN COVER . Refer to REMOVAL - Step 7 5. REMOVE UPPER STEERING COLUMN COVER . Refer to REMOVAL - Step 8 6. REMOVE SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY

NOTE:

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



a. b. c. d.

Do not replace the spiral cable with sensor sub-assembly with the auxiliary battery connected and the power switch on (IG). Do not rotate the spiral cable with sensor sub-assembly without the steering wheel with the auxiliary battery connected and the power switch on (IG). Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.

Check that the power switch is off. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. Check that the front wheels are facing straight ahead. Slide the slider to release the lock, and then disconnect the yellow airbag connector from the spiral cable with sensor sub-assembly.

Fig. 32: Disconnecting Yellow Airbag Connector From Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Disconnect the other connector from the spiral cable with sensor sub-assembly. f. Disengage the 3 claws to remove the spiral cable with sensor sub-assembly.

Fig. 33: Locating Spiral Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE SPIRAL CABLE SUB-ASSEMBLY

NOTE:

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Remove the spiral cable sub-assembly from the steering sensor only when replacing it or the steering sensor. Removing the steering sensor from the spiral cable sub-assembly without using a lock pin may result in a misaligned center position of the steering sensor. Therefore, make sure to use the lock pin provided with a new spiral cable sub-assembly or steering sensor when removing the steering sensor from the spiral cable subassembly. When replacing the steering sensor: Refer to REMOVAL

a. Install the lock pin to the steering sensor.

Fig. 34: Locating Steering Sensor Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Use the lock pin provided with a new spiral cable sub-assembly. Do not remove the lock pin before the spiral cable subassembly is installed to the steering sensor.

b. Disengage the 6 claws and 2 pins to remove the spiral cable sub-assembly from the steering sensor.

Fig. 35: Locating Spiral Cable Sub-Assembly Lock Pin, Guides, Pins & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Do not damage the claw of the steering sensor. Do not damage the guide.

TEXT IN ILLUSTRATION *1 Guide INSPECTION INSPECTION

1. INSPECT SPIRAL CABLE SUB-ASSEMBLY NOTE:





Do not remove the steering sensor from the spiral cable subassembly. As the spiral cable sub-assembly may break, do not rotate the spiral cable sub-assembly more than the specified amount.

a. Remove the spiral cable with sensor sub-assembly from the vehicle See step 6. b. Visually check for defects with the spiral cable sub-assembly. 1. The defects are as follows:  Scratches

   

Small cracks Dents Chips Cracks or other damage to the connector OK No defects are found.

If any of the defects is found, replace the spiral cable sub-assembly with a new one. c. Check the spiral cable sub-assembly.

Fig. 36: Identification Spiral Cable Sub-Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Component without harness *a connected (Spiral Cable Subassembly) Color: *b Orange Color: *c Black Interlock NOTE:

When rotating the spiral cable, make sure to push on the interlock indicated in the illustration to release the interlock mechanism.

1. Set the spiral cable sub-assembly to the center position See step 1. 2. Measure the resistance between each terminal of the spiral cable sub-assembly according to the table below. Standard Resistance Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-3 3 ohms or (EAU) - z3- Always less 8 I28-4 3 ohms or (AU3) - z3- Always less 9 I28-5 3 ohms or (AU2) - z3- Always less 10 I28-6 3 ohms or (AU1) - z3- Always less 11 I28-9 (HO) 3 ohms or Always - z3-1 less I28-10

(+DP) - z32 I28-11 (DP) - z3-3 I28-13 (IL+2) - z35 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

3 ohms or less 3 ohms or Always less Always

Always Always Always Always Always

3 ohms or less Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms

3. After setting the spiral cable sub-assembly to the center position, rotate the spiral cable subassembly 2.5 times clockwise, and measure the resistance as shown in the table below. Then rotate the spiral cable sub-assembly 5 times counterclockwise, and measure the resistance as shown in the table below. Standard Resistance Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-3 3 ohms or (EAU) - z3- Always less 8 I28-4 3 ohms or (AU3) - z3- Always less 9 I28-5 3 ohms or (AU2) - z3- Always less 10 I28-6 3 ohms or (AU1) - z3- Always less 11 I28-9 (HO) Always 3 ohms or

- z3-1 I28-10 (+DP) - z32 I28-11 (DP) - z3-3 I28-13 (IL+2) - z35 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

less Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always Always Always Always

Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms

4. After setting the spiral cable sub-assembly to the center position, rotate the spiral cable subassembly 2.5 times clockwise. Then while rotating the spiral cable sub-assembly 5 times counterclockwise, measure the resistance as shown in the table below. Standard Resistance Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-3 3 ohms or (EAU) - z3- Always less 8 I28-4 3 ohms or (AU3) - z3- Always less 9 I28-5 3 ohms or (AU2) - z3- Always less 10 I28-6 3 ohms or (AU1) - z3- Always less 11

I28-9 (HO) - z3-1 I28-10 (+DP) - z32 I28-11 (DP) - z3-3 I28-13 (IL+2) - z35 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always Always Always Always

Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms

If the result is not as specified, replace the spiral cable with sensor sub-assembly. INSTALLATION INSTALLATION

1. INSPECT SPIRAL CABLE SUB-ASSEMBLY NOTE:

If the steering sensor is installed to a misaligned spiral cable subassembly, DTCs for an abnormal steering sensor value such as DTC B1801, C1231 and DTC C1433 are stored and it is impossible to repair them. If this happens, replace the spiral cable with sensor sub-assembly with a new one.

a. Check if the spiral cable sub-assembly is centered.

Fig. 37: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part HINT: When the spiral cable sub-assembly is centered, the part indicated by A is positioned at the top and the colored part shown in the illustration is visible. b. If the spiral cable sub-assembly is not centered, center it. If the cable cannot be centered, it is possible that the spiral cable sub-assembly is broken. Replace the spiral cable with sensor sub-assembly with a new one. 1. While pushing on the interlock indicated in the illustration, rotate the spiral cable subassembly counterclockwise slowly by hand until it stops.

Fig. 38: Rotating Spiral Cable Sub-Assembly Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Interlock NOTE:

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

When rotating the spiral cable sub-assembly, make sure to push on the interlock indicated in the illustration to release the interlock mechanism. Do not turn the spiral cable sub-assembly using the airbag wire harness.

2. Rotate the spiral cable sub-assembly clockwise approximately 2.5 turns to the position where the colored part shown in the illustration is visible.

Fig. 39: Rotating Spiral Cable Sub-Assembly Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part Interlock HINT: The spiral cable sub-assembly will rotate approximately 2.5 turns to both the left and right from the center. 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY a. Align the 2 pins and 2 guides, and engage the 6 claws to install the spiral cable sub-assembly to the steering sensor.

Fig. 40: Locating Spiral Cable Sub-Assembly Lock Pin, Guides, Pins & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Pin *2 Guide *3 Pin NOTE:





The spiral cable sub-assembly can be rotated up to 30° even when the interlock is engaged. Therefore, make sure that both guides are aligned properly when installing the steering sensor to the spiral cable sub-assembly. Do not remove the lock pin before the spiral cable subassembly is installed to the steering sensor.

b. Remove the lock pin from the steering sensor. 3. ALIGN FRONT WHEELS TO FACE STRAIGHT AHEAD 4. INSTALL SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY NOTE:





Do not replace the spiral cable with sensor sub-assembly with the auxiliary battery connected and the power switch on (IG). Do not rotate the spiral cable with sensor sub-assembly without the steering wheel with the auxiliary battery connected and the power switch on (IG).



Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.

a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Check that the front wheels are facing straight ahead. d. Set the turn signal switch to the neutral position. NOTE:

If it is not in the neutral position, the turn signal switch pin may snap.

e. Engage the 3 claws to install the spiral cable with sensor sub-assembly. f. Connect the each connector. 5. INSTALL UPPER STEERING COLUMN COVER . Refer to INSTALLATION - Step 6 6. INSTALL LOWER STEERING COLUMN COVER . Refer to INSTALLATION - Step 7 7. INSPECT AND ADJUST SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY NOTE:

Do not adjust the spiral cable with sensor sub-assembly with the auxiliary battery connected and the power switch on (IG).

a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Check if the spiral cable with sensor sub-assembly is centered.

Fig. 41: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part HINT: When the spiral cable with sensor sub-assembly is centered, the part indicated by A is positioned at the top and the colored part shown in the illustration is visible. d. If the spiral cable with sensor sub-assembly is not centered, center it. 1. While pushing on the interlock indicated in the illustration, rotate the spiral cable with sensor sub-assembly counterclockwise slowly by hand until it stops.

Fig. 42: Rotating Spiral Cable Sub-Assembly Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Interlock NOTE:





When rotating the spiral cable with sensor sub-assembly, make sure to push on the interlock indicated in the illustration to release the interlock mechanism. Do not turn the spiral cable with sensor sub-assembly using the airbag wire harness.

2. Rotate the spiral cable with sensor sub-assembly clockwise approximately 2.5 turns to the position where the colored part shown in the illustration is visible.

Fig. 43: Rotating Spiral Cable Sub-Assembly Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part Interlock HINT: The spiral cable sub-assembly will rotate approximately 2.5 turns to both the left and right from the center. 8. INSTALL STEERING WHEEL ASSEMBLY Refer to INSTALLATION - Step 9 9. ADJUST PARKING ASSIST MONITOR SYSTEM (w/ Parking Assist Monitor System) Refer to CALIBRATION

KNEE AIRBAG ASSEMBLY (FOR DRIVER SIDE) COMPONENTS ILLUSTRATION

Fig. 44: Identifying Knee Airbag Assembly Replacement Components With Torque Specifications (For Driver Side) (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 45: Identifying Knee Airbag Assembly Replacement Components With Torque Specifications (For Driver Side) (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the

lower No. 1 instrument panel airbag assembly. 1. INSPECT LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the lower No. 1 instrument panel airbag assembly installed on the vehicle. HINT: The defects are as follows:   

Cuts Small cracks Significant discoloration

OK No defects are found. If any of the defects is found, replace the lower No. 1 instrument panel airbag assembly with a new one. 2. INSPECT LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the lower No. 1 instrument panel airbag assembly removed from the vehicle. HINT: The defects are as follows:  

Cuts Small cracks

  

Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the lower No. 1 instrument panel airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 7. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7

8. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 9. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 14 10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY WARNING: When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward. a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Remove the 4 bolts.

Fig. 46: Locating Lower No. 1 Instrument Panel Airbag Assembly Bolts And DLC3 Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 claws to disconnect the DLC3. e. Disengage the 2 hooks to remove the lower No. 1 instrument panel airbag assembly.

Fig. 47: Locating Lower No. 1 Instrument Panel Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the lower No. 1 instrument panel airbag assembly, do not pull the airbag wire harness.

f. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock.

Fig. 48: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock g. Disconnect the airbag connector to remove the lower No. 1 instrument panel airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage

the airbag wire harness. INSTALLATION INSTALLATION

1. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Connect the airbag connector to the lower No. 1 instrument panel airbag assembly.

Fig. 49: Connecting Airbag Connector To Lower No. 1 Instrument Panel Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

d. Push in the lock to install the airbag connector. e. Temporarily install the lower No. 1 instrument panel airbag assembly with the 2 hooks.

f. Engage the 2 claws to install the DLC3. g. Install the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Confirm that the lower No. 1 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 38 3. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39 4. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 5. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH 6. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 7. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 8. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 10. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 11. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment.

1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a lower No. 1 instrument panel airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 1 instrument panel airbag assembly. The lower No. 1 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the lower No. 1 instrument panel airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





HINT:

When disposing of the lower No. 1 instrument panel airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.

Fig. 50: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Disconnect the lower No. 1 instrument panel airbag connector. 1. Using a screwdriver with the tip wrapped with protective tape, disconnect the airbag connector. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Install SST. WARNING: Check that there is no looseness in the lower No. 1 instrument panel airbag assembly. 1. Connect the SST connector to the lower No. 1 instrument panel airbag assembly.

Fig. 51: Connecting SST Connector To Lower No. 1 Instrument Panel Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 52: Identifying Distance Between SST & Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The lower No. 1 instrument panel airbag assembly







becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.

Fig. 53: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the lower No. 1 instrument panel airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the lower No. 1 instrument panel airbag assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the lower No. 1 instrument panel airbag assembly to an unneeded tire.

Fig. 54: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter

Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the lower No. 1 instrument panel airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4 1. Position the lower No. 1 instrument panel airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 55: View Of Lower No. 1 Instrument Panel Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION Inner *a Width *b Diameter WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the lower No. 1 instrument panel airbag assembly may break loose when the airbag is deployed. Always tie down the lower No. 1 instrument panel airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

d. Install SST. 1. After connecting the following SST to each other, connect them to the lower No. 1 instrument panel airbag assembly.

Fig. 56: View Of SST Connected To Lower No. 1 Instrument Panel Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00802 09082-10801

09082-20801 e. Place the tires. 1. Place at least 2 tires under the tire to which the lower No. 1 instrument panel airbag assembly is tied.

Fig. 57: Placing No. 1 Instrument Panel Airbag Assembly Under Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the lower No. 1 instrument panel airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 58: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 59: Identifying SST Distance From Lower No. 1 Instrument Panel Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lower No. 1 Instrument *1 Panel Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more



SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the lower No. 1 instrument panel airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the lower No. 1 instrument panel airbag assembly. WARNING:









The lower No. 1 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the lower No. 1 instrument panel airbag assembly from the tire. 2. Place the lower No. 1 instrument panel airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

KNEE AIRBAG ASSEMBLY (FOR FRONT PASSENGER SIDE) COMPONENTS ILLUSTRATION

Fig. 60: Identifying Knee Airbag Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 61: Identifying Knee Airbag Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the lower No. 2 instrument panel airbag assembly. 1. INSPECT LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the lower No. 2 instrument panel airbag assembly installed on the vehicle. HINT: The defects are as follows:   

Cuts Small cracks Significant discoloration

OK No defects are found. If any of the defects is found, replace the lower No. 2 instrument panel airbag assembly with a new one. 2. INSPECT LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the lower No. 2 instrument panel airbag assembly removed from the vehicle. HINT: The defects are as follows:  

Cuts Small cracks

  

Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the lower No. 2 instrument panel airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 4 .

5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 5 . 6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 6 . 7. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 34 8. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 35 9. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY WARNING: When storing the lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward. a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Remove the 3 bolts.

Fig. 62: Locating Lower No. 2 Instrument Panel Airbag Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 3 claws to remove the lower No. 2 instrument panel airbag assembly.

Fig. 63: Locating Lower No. 2 Instrument Panel Airbag Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the lower No. 2 instrument panel airbag assembly, do not pull the airbag wire harness.

e. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock.

Fig. 64: Disconnecting No. 2 Instrument Panel Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock f. Disconnect the airbag connector to remove the lower No. 2 instrument panel airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage

the airbag wire harness. INSTALLATION INSTALLATION

1. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Connect the airbag connector to the lower No. 2 instrument panel airbag assembly.

Fig. 65: Connecting No. 2 Instrument Panel Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock d. Push in the lock to install the airbag connector. e. Temporarily install the lower No. 2 instrument panel airbag assembly with the 3 claws.

f. Install the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Confirm that the lower No. 2 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 3. INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 4. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 44 . 6. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 45 . 7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 9. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 10. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a lower No. 2 instrument panel airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 2 instrument panel airbag assembly. The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the lower No. 2 instrument panel airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:



When disposing of the lower No. 2 instrument panel airbag assembly, never use the customer's vehicle to deploy the airbag.



Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.

Fig. 66: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Remove the No. 2 instrument panel under cover sub-assembly. Refer to REMOVAL - Step 35 .

e. Disconnect the lower No. 2 instrument panel airbag connector. 1. Using a screwdriver with the tip wrapped with protective tape, disconnect the airbag connector. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

f. Install SST. WARNING: Check that there is no looseness in the lower No. 2 instrument panel airbag assembly. 1. Connect the SST connector to the lower No. 2 instrument panel airbag assembly.

Fig. 67: Connecting SST Connector To Lower No. 2 Instrument Panel Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 68: Identifying Distance Between SST & Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:



Before deployment, make sure that no one is near









the vehicle. The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.

Fig. 69: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the lower No. 2 instrument panel airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the lower No. 2 instrument panel airbag assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the lower No. 2 instrument panel airbag assembly to an unneeded tire.

Fig. 70: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the lower No. 2 instrument panel airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the lower No. 2 instrument panel airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 71: Identifying Lower No. 2 Instrument Panel Airbag Assembly Positioned Inside Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Inner *a *b Width Diameter WARNING:





NOTE:

d. Install SST.

Make sure that the wires are tight. If there is slack in the wires, the lower No. 2 instrument panel airbag assembly may break loose when the airbag is deployed. Always tie down the lower No. 2 instrument panel airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

1. After connecting the following SST to each other, connect them to the lower No. 2 instrument panel airbag assembly.

Fig. 72: Connecting SST To Lower No. 2 Instrument Panel Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-20801 e. Place the tires. 1. Place at least 2 tires under the tire to which the lower No. 2 instrument panel airbag assembly is tied. 

Fig. 73: Placing No. 2 Instrument Panel Airbag Assembly Under Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the lower No. 2 instrument panel airbag assembly

is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 74: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 75: Identifying SST Distance From Lower No. 2 Instrument Panel Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lower No. 2 Instrument *1 Panel Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more



SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the lower No. 2 instrument panel airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the lower No. 2 instrument panel airbag assembly. WARNING:









The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the lower No. 2 instrument panel airbag assembly from the tire. 2. Place the lower No. 2 instrument panel airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 76: Identifying Front Passenger Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the instrument panel passenger airbag assembly. 1. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the instrument panel passenger airbag assembly installed on the vehicle.

HINT: The defects are as follows: 





Cuts on the instrument panel sub-assembly around the instrument panel passenger airbag assembly Small cracks on the instrument panel sub-assembly around the instrument panel passenger airbag assembly Significant discoloration on the instrument panel sub-assembly around the instrument panel passenger airbag assembly

OK No defects are found. If any of the defects is found, replace the instrument panel sub-assembly with a new one. 2. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the instrument panel passenger airbag assembly removed from the vehicle. HINT:     

Cuts Small cracks Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the instrument panel passenger airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL

REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY Refer to REMOVAL 3. DISCONNECT NO. 2 INSTRUMENT PANEL WIRE a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Slide the slider to release the lock, and then disconnect the connector.

Fig. 77: Disconnecting Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

4. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY . Refer to REMOVAL - Step 51 5. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WARNING: When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

a. Remove the 2 screws.

Fig. 78: Locating Instrument Panel Passenger Airbag Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lean the instrument panel safety pad assembly and disengage the 3 hooks.

Fig. 79: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 3 hooks to remove the instrument panel passenger airbag assembly from the instrument panel safety pad assembly.

Fig. 80: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE NO. 2 INSTRUMENT PANEL WIRE a. Disengage the clamp.

Fig. 81: Identifying Airbag Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with the tip wrapped with protective tape, release the 2 airbag connector locks. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock c. Disconnect the 2 airbag connectors to remove the No. 2 instrument panel wire from the instrument panel passenger airbag assembly.

NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

INSTALLATION INSTALLATION

1. INSTALL NO. 2 INSTRUMENT PANEL WIRE a. Connect the 2 airbag connectors of the No. 2 instrument panel wire to the instrument panel passenger airbag assembly.

Fig. 82: Identifying Airbag Connector And Airbag Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Airbag Connector Airbag *2 Connector Lock *1

NOTE:





When connecting any airbag connector, take care not to damage the airbag wire harness. Be sure to only connect the connectors to each corresponding color.

b. Push in the 2 locks to install the 2 airbag connectors to the instrument panel passenger airbag assembly. c. Engage the clamp. 2. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY NOTE:

If the hooks are not engaged in the correct order, the deployment part of the instrument panel passenger airbag assembly may be damaged.

a. Engage the 3 hooks as shown in the illustration.

Fig. 83: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the instrument panel passenger airbag assembly to engage the 3 hooks.

c. Install the 2 screws to install the instrument panel passenger airbag assembly. 3. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY . Refer to INSTALLATION - Step 1 4. CONNECT NO. 2 INSTRUMENT PANEL WIRE a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Connect the connector.

Fig. 84: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

5. INSTALL NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY Refer to INSTALLATION - Step 3 6. PERFORM DIAGNOSTIC SYSTEM CHECK

for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. Never dispose of a instrument panel passenger airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the instrument panel passenger airbag assembly. The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the instrument panel passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES,

U.S.A., INC. 2. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the instrument panel passenger airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.

Fig. 85: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION

c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Remove the lower instrument panel sub-assembly. Refer to REMOVAL - Step 37 . e. Disconnect the No. 2 instrument panel wire. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the connector.

Fig. 86: Disconnecting Airbag Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider f. Install SST. WARNING: Check that there is no looseness in the instrument panel passenger airbag assembly and instrument panel safety pad. 1. Connect the SST connector to the No. 2 instrument panel wire.

Fig. 87: Connecting SST To No. 2 Instrument Panel Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00780

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 88: Identifying Distance Between SST & Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The instrument panel passenger airbag assembly







becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.

Fig. 89: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the instrument panel passenger airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the instrument panel passenger airbag assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

c. Install SST. 1. After connecting the following SST to each other, connect them to the instrument panel passenger airbag assembly.

Fig. 90: Connecting SST To Instrument Panel Passenger Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-30801 d. Using braided wire, tie down the instrument panel passenger airbag assembly to an unneeded tire. 

Fig. 91: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the instrument panel passenger airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the instrument panel passenger airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 92: Identifying Instrument Panel Passenger Airbag Assembly Positioned Inside Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Inner *a *b Width Diameter WARNING:





NOTE:

e. Place the tires.

Make sure that the wires are tight. If there is slack in the wires, the instrument panel passenger airbag assembly may break loose when the airbag is deployed. Always tie down the instrument panel passenger airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

1. Place at least 2 tires under the tire to which the instrument panel passenger airbag assembly is tied.

Fig. 93: Identifying Tire Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it

could be damaged. 2. Place at least 2 tires onto the tire to which the instrument panel passenger airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 94: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 95: Identifying SST Distance From Instrument Panel Passenger Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Instrument Panel *1 Passenger Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more



SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the instrument panel passenger airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the instrument panel passenger airbag assembly. WARNING:









The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the instrument panel passenger airbag assembly from the tire. 2. Place the instrument panel passenger airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

CURTAIN SHIELD AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 96: Identifying Curtain Shield Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the curtain shield airbag assemblies. 1. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the curtain shield airbag assemblies installed on the vehicle. HINT: The defects are as follows: 

Cuts on each pillar garnish or the roof headlining assembly around the curtain shield airbag





assemblies Small cracks on each pillar garnish or the roof headlining assembly around the curtain shield airbag assemblies Significant discoloration on each pillar garnish or the roof headlining assembly around the curtain shield airbag assemblies

OK No defects are found. If any of the defects is found, replace each pillar garnish or the roof headlining assembly with a new one. 2. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the curtain shield airbag assemblies removed from the vehicle. HINT: The defects are as follows:    

Cuts Small cracks Significant discoloration Cracks or other damage to the connector

OK No defects are found. If any of the defects is found, replace the curtain shield airbag assembly with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL 3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY WARNING: When storing the curtain shield airbag assembly, keep the airbag deployment side facing upward. a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock and disconnect the curtain shield airbag connector.

Fig. 97: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

d. Using a clip remover, remove the pin.

Fig. 98: Removing Curtain Shield Airbag Assembly Connector Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform the same procedure for the other pins. e. Using 2 screw drivers, disengage the 2 claws and remove the clip from the body panel as shown in the illustration.

Fig. 99: Removing Clips From Body Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1

Body Curtain *2 Panel Shield Airbag

Assembly HINT: Perform the same procedure for the other clips. f. While holding the curtain shield airbag assembly, disengage the 5 claws.

Fig. 100: Locating Curtain Shield Airbag Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the curtain shield airbag assembly, have assistants hold it to prevent it from bending.

g. Remove the 2 bolts.

Fig. 101: Locating Curtain Shield Airbag Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Disengage the 2 hooks to remove the curtain shield airbag assembly. i. Remove the 2 spacers from the curtain shield airbag assembly.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Temporarily install the curtain shield airbag assembly with the 2 hooks.

Fig. 102: Locating Curtain Shield Airbag Assembly Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





When installing the curtain shield airbag assembly, have assistants hold it to prevent it from bending. Do not twist the curtain shield airbag assembly when installing it.

d. Install 2 new bolts in the order shown in the illustration. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) e. Install the curtain shield airbag assembly to the body panel with 5 claws, 6 new clips and 2 new spacers in the order shown in the illustration.

Fig. 103: Locating Curtain Shield Airbag Assembly Fasteners With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin *2 Clip Curtain Shield Body *3 *4 Airbag Panel Assembly *5 Spacer - f. Push in a new pin to each clip.

Fig. 104: Installing Curtain Shield Airbag Assembly Connector Pin

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the pins of the clips are pushed in firmly.

g. Connect the curtain shield airbag connector.

Fig. 105: Connect Curtain Shield Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock

NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

h. Push in the lock to install the curtain shield airbag connector. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION 3. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a curtain shield airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain shield airbag assembly. The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag.





Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the curtain shield airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.

Fig. 106: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Remove the roof headlining assembly. Refer to REMOVAL . e. Install SST. WARNING: Check that there is no looseness in the curtain shield airbag assembly. 1. Disconnect the connector from the curtain shield airbag assembly. NOTE:

When disconnecting the airbag connector, take care not to damage the airbag wire harness.

2. After connecting the following SST to each other, connect them to the curtain shield airbag assembly.

Fig. 107: Connecting SST To Curtain Shield Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

3. Move SST at least 10 m (32.8 ft.) away from the rear side window.

Fig. 108: Moving SST Away From Rear Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 4. Maintaining sufficient clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

5. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The curtain shield airbag assembly becomes







extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.

Fig. 109: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SST: 09082-00700 b. Remove the curtain shield airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the curtain shield airbag assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the curtain shield airbag assembly, keep the airbag deployment side facing upward.

c. Cut off the deployment section of the curtain shield airbag assembly.

Fig. 110: Identifying Cut Off Deployment Section Of Curtain Shield Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using braided wire, tie down the curtain shield airbag assembly to an unneeded tire.

Fig. 111: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the curtain shield airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the curtain shield airbag assembly inside the tire as shown in the illustration.

Fig. 112: Identifying Inner Diameter Of Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING: Make sure that the wires are tight. If there is slack in the wires, the curtain shield airbag assembly may break loose when the airbag is deployed. NOTE:

The tire may be damaged by the airbag deployment, so use an unneeded tire.

e. Install SST. 1. After connecting the following SST to each other, connect them to the curtain shield airbag assembly.

Fig. 113: Connecting SST To Curtain Shield Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-20801 f. Place the tires. 

WARNING: Do not face the deployment side of the curtain shield airbag assembly toward the ground. 1. Place at least 2 tires under the tire to which the curtain shield airbag assembly is tied.

Fig. 114: Identifying Tire Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the curtain shield airbag assembly is tied. The top

tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 115: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. g. Install SST. 1. Connect the SST connector.

Fig. 116: Identifying SST Distance From Curtain Shield Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Curtain Shield *1 Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more 

SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. h. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the curtain shield airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. i. Dispose of the curtain shield airbag assembly. WARNING:









The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the curtain shield airbag assembly from the tire. 2. Place the curtain shield airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

FRONT SEAT SIDE AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 117: Identifying Front Seat Side Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front seat airbag assemblies. 1. INSPECT FRONT SEAT AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the front seat airbag assemblies installed on the vehicle. HINT: The defects are as follows:   

Cuts on the front seatback assembly around the front seat airbag assemblies Small cracks on the front seatback assembly around the front seat airbag assemblies Significant discoloration on the front seatback assembly around the front seat airbag assemblies

OK No defects are found. If any of the defects is found, replace the separate type front seatback pad or separate type front seatback cover with a new one. 2. INSPECT FRONT SEAT AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the front seat airbag assemblies removed from the vehicle. HINT: The defects are as follows: 



Make sure that there are no scratches, broken or frayed threads on the surface of the front seat airbag assemblies base fabric Marks from being dropped

 

Deformation on the installation part of the front seat airbag assemblies Cracks or other damage to the wire harness or connector

OK No defects are found. If any of the defects is found, replace the front seat airbag assembly with a new one. REMOVAL REMOVAL

WARNING:



Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION





Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. If the side airbag was deployed, replace the front seat airbag assembly, front seatback frame sub-assembly or separate type front seatback spring assembly, separate type front seatback cover and separate type front seatback pad with the necessary parts in accordance with the extent of the collision damage. for Manual Seat: Refer to DISASSEMBLY for Power Seat: Refer to DISASSEMBLY

HINT:  

Use the same procedure for the LH side and RH side. The procedure listed below is for the LH side.

REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat) Refer to REMOVAL 2. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) Refer to REMOVAL

3. DISCONNECT AIRBAG WIRE HARNESS (for Manual Seat) a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 118: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and 3 clamps to disconnect the airbag wire harness.

Fig. 119: Identifying Front Seatback Cover Claw And Clamps (For TMMK Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. DISCONNECT AIRBAG WIRE HARNESS (for Power Seat) a. Disconnect the 2 rubber bands of the separate type front seatback cover.

Fig. 120: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector (A).

Fig. 121: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clamp (B). d. Disengage the claw (D) and 3 clamps (C) to disconnect the airbag wire harness. e. w/ Seat Heater System: 1. Disconnect the connector (E). 2. Disengage the clamp (F). 5. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for Manual Seat) . Refer to DISASSEMBLY - Step 11 6. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for Power Seat) . Refer to DISASSEMBLY - Step 14 7. REMOVE FRONT SEAT AIRBAG ASSEMBLY a. Disengage the 2 clamps.

Fig. 122: Locating Front Seat Airbag Assembly Clamps And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and the front seat airbag assembly. WARNING:

 

The nuts must not be reused. Make sure that the front seatback frame sub-assembly or separate type front seatback spring assembly is not deformed. If it is, replace it with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The procedure listed below is for the LH side.

1. INSTALL FRONT SEAT AIRBAG ASSEMBLY WARNING:

 

The nuts must not be reused. Make sure that the front seatback frame sub-assembly or separate type front seatback spring assembly is not deformed. If it is, replace it with a new one.

a. Install the front seat airbag assembly with 2 new nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

2. 3. 4.

5.

b. Engage the 2 clamps. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for Manual Seat) . Refer to REASSEMBLY - Step 18 INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for Power Seat) . Refer to REASSEMBLY - Step 21 CONNECT AIRBAG WIRE HARNESS (for Manual Seat) a. Engage the claw and 3 clamps to connect the airbag wire harness. b. Connect the 2 rubber bands of the separate type front seatback cover. CONNECT AIRBAG WIRE HARNESS (for Power Seat) a. Engage the claw (D) and 3 clamps (C) to Connect the airbag wire harness.

Fig. 123: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Engage the clamp (B). c. Connect the connector (A). d. w/ Seat Heater System: 1. Connect the connector (E). 2. Engage the clamp (F).

e. Connect the 2 rubber bands of the separate type front seatback cover. 6. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat) Refer to INSTALLATION 7. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) Refer to INSTALLATION 8. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a front seat airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the front seat airbag assembly. The front seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat





airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the front seat airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the front seat airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.

Fig. 124: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Disconnect the connector from the front seat airbag assembly under the front seat assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the yellow airbag connector as shown in the illustration.

Fig. 125: Identifying Harness Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Slider e. Install SST. WARNING: Check that there is no looseness in the front seat assembly.

1. Connect the SST connector to the front seat airbag assembly connector.

Fig. 126: Connecting SST To Front Seat Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00820

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window.

Fig. 127: Moving SST Away From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The front seat airbag assembly becomes extremely







hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.

Fig. 128: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SST: 09082-00700 b. Remove the front seat airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the front seat assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the front seat airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the front seat airbag assembly to an unneeded tire.

Fig. 129: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section

1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the front seat airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4 1. Install the 2 nuts to the front seat airbag assembly.

Fig. 130: Identifying Front Seat Airbag Assembly Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Wind the wires around the stud bolts of the front seat airbag assembly as shown in the illustration.

Fig. 131: Wires Around Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. Position the front seat airbag assembly inside the tire.

Fig. 132: Front Seat Airbag Assembly Inside Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING:





Make sure that the wires are tight. If there is slack in the wires, the front seat airbag assembly may break loose when the airbag is deployed. Face the front seat airbag assembly deployment surface toward the inside the tire to evenly distribute the force of deployment.

NOTE:

The tire may be damaged by the airbag deployment, so use an unneeded tire.

d. Install SST. 1. Connect the SST connector to the front seat airbag assembly connector.

Fig. 133: SST Connector To The Front Seat Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00820 e. Place the tires. 1. Place at least 2 tires under the tire to which the front seat airbag assembly is tied. 

Fig. 134: Placing Front Seat Airbag Assembly Under Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the front seat airbag assembly is tied. The top tire

should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 135: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 136: Identifying SST Distance From Front Seat Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Seat *1 Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more 

SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the front seat airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the front seat airbag assembly. WARNING:









The front seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the front seat airbag assembly from the tire. 2. Place the front seat airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

REAR SEAT SIDE AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 137: Identifying Rear Seat Side Airbag Assembly Replacement Components With Torque Specifications (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 138: Identifying Rear Seat Side Airbag Assembly Replacement Components With Torque Specifications (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 139: Identifying Rear Seat Side Airbag Assembly Replacement Components With Torque Specifications (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat airbag assemblies. 1. INSPECT REAR SEAT AIRBAG ASSEMBLY (for Vehicle not Involved in Collision)

a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the rear seat airbag assemblies installed on the vehicle. HINT: The defects are as follows:   

Cuts on the rear side seatback assembly around the rear seat airbag assemblies Small cracks on the rear side seatback assembly around the rear seat airbag assemblies Significant discoloration on the rear side seatback assembly around the rear seat airbag assemblies

OK No defects are found. If any of the defects is found, replace the rear side seatback pad or rear side seatback cover subassembly with a new one. 2. INSPECT REAR SEAT AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the rear seat airbag assemblies removed from the vehicle. HINT: The defects are as follows: 

  

OK

Make sure that there are no scratches, broken or frayed threads on the surface of the rear seat airbag assemblies base fabric Marks from being dropped Deformation on the installation part of the rear seat airbag assemblies Cracks or other damage to the wire harness or connector

No defects are found. If any of the defects is found, replace the rear seat airbag assembly with a new one. REMOVAL REMOVAL

WARNING: If the side airbag was deployed, replace the rear seat airbag assembly, rear side seatback frame sub-assembly, rear side seatback cover subassembly and rear side seatback pad with the necessary parts in accordance with the extent of the collision damage. HINT:  

Use the same procedure for the LH side and RH side. The procedure listed below is for the LH side.

REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 5. REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5

6. 7. 8. 9.

REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE REAR SEAT SHOULDER BELT GUIDE . Refer to DISASSEMBLY - Step 3 REMOVE REAR NO. 2 SEAT COVER BEZEL (for LH Side) . Refer to DISASSEMBLY - Step 5 REMOVE REAR SEAT AIRBAG ASSEMBLY a. for LH Side: 1. Disengage the 7 hooks.

Fig. 140: Identifying Rear Seat Airbag Assembly Hooks LH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. for RH Side: 1. Disengage the 8 hooks.

Fig. 141: Identifying Rear Seat Airbag Assembly Hooks RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clamp and remove the 2 nuts.

Fig. 142: Locating Rear Seat Airbag Assembly Clamp And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the rear side seatback frame sub-assembly and rear seat airbag assembly from the rear side seatback cover with pad.

Fig. 143: Identifying Rear Side Seatback Frame Sub-Assembly And Rear Seat Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Side Seatback *1 Frame Subassembly Rear Seat *2 Airbag Assembly Rear Side *3 Seatback Cover

with Pad WARNING:

 

The nuts must not be reused. Make sure that the rear side seatback frame sub-assembly is not deformed. If it is, replace it with a new one.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the LH side and RH side. The procedure listed below is for the LH side.

1. INSTALL REAR SEAT AIRBAG ASSEMBLY WARNING:

 

The nuts must not be reused. Make sure that the rear side seatback frame sub-assembly is not deformed. If it is, replace it with a new one.

a. Install the rear seat airbag assembly to the rear side seatback frame sub-assembly with 2 new nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

2. 3. 4. 5. 6. 7.

b. Engage the clamp to connect the airbag wire harness. c. for LH Side: 1. Engage the 7 hooks to install the rear side seatback cover with pad. d. for RH Side: 1. Engage the 8 hooks to install the rear side seatback cover with pad. INSTALL REAR NO. 2 SEAT COVER BEZEL (for LH Side) . Refer to REASSEMBLY - Step 11 INSTALL REAR SEAT SHOULDER BELT GUIDE . Refer to REASSEMBLY - Step 13 INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 9. PERFORM DIAGNOSTIC SYSTEM CHECK

for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 10. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a rear seat airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the rear seat airbag assembly. The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the rear seat airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF REAR SEAT AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the rear seat airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 2.  SST: 09082-00700

Fig. 144: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Refer to Precaution. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION

for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION c. Disconnect the cable from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. d. Remove the rear seat cushion assembly. Refer to REMOVAL - Step 4 . e. Disconnect the connector from the rear seat airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the yellow airbag connector. f. Install SST. WARNING: Check that there is no looseness in the rear side seatback assembly. 1. Connect the SST connector to the rear seat airbag assembly connector.  SST: 09082-00700  SST: 09082-00820

Fig. 145: Connecting SST To Rear Seat Airbag Assembly Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the rear side window.

Fig. 146: Moving SST Away From Rear Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 12 V *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag.

1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch to deploy the airbag. WARNING:











Before deployment, make sure that no one is near the vehicle. The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF REAR SEAT AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a 12 V battery as the power source to deploy the airbag. a. Check the function of SST See step 3.  SST: 09082-00700

Fig. 147: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the rear seat airbag assembly. Refer to REMOVAL. WARNING:





Before removing the rear side seatback assembly, wait at least 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal. When storing the rear seat airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the rear seat airbag assembly to an unneeded tire.

Fig. 148: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the rear seat airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Install the 2 nuts to the rear seat airbag assembly.

Fig. 149: Locating Rear Seat Airbag Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Wind the wires around the stud bolts of the rear seat airbag assembly as shown in the illustration.

Fig. 150: Identifying Wires Around Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Position the rear seat airbag assembly inside the tire.

Fig. 151: Identifying Width And Inner Diameter Of Inside Tire For Rear Seat Airbag Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the rear seat airbag assembly may break loose when the airbag is deployed. Face the rear seat airbag assembly deployment surface toward the inside the tire to evenly distribute the force of deployment.

The tire may be damaged by the airbag deployment, so use an unneeded tire.

d. Install SST. 1. Connect the SST connector to the rear seat airbag assembly connector.  SST: 09082-00820

Fig. 152: Connecting SST To Rear Seat Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Place the tires. 1. Place at least 2 tires under the tire to which the rear seat airbag assembly is tied.

Fig. 153: Placing Rear Seat Airbag Assembly Under Tires

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (2 *1 or more) Inner *a Diameter *b Width Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the rear seat airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 154: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.  SST: 09082-00700

Fig. 155: Identifying SST Distance From Rear Seat Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Seat *1 Airbag Assembly 12 V *2 Battery 10 m *a (32.8 ft.) or more NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some

slack for the SST wire harness inside the tire. 2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the rear seat airbag assembly is tied. 3. Press the SST activation switch to deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the rear seat airbag assembly. WARNING:









The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the rear seat airbag assembly from the tire. 2. Place the rear seat airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

CENTER AIRBAG SENSOR ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 156: Identifying Center Airbag Sensor Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 157: Identifying Center Airbag Sensor Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the airbag sensor assembly. 1. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision)

a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 2. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check for defects with the airbag sensor assembly installed on the vehicle. 1. The defects are as follows:  Cracks on the sensor housing  Dents on the sensor housing  Chips on the sensor housing  Cracks or other damage to the connector  Peeling of the label OK No defects are found. If any of the defects is found, replace the airbag sensor assembly with a new one. 3. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. Replace the airbag sensor assembly. HINT: The airbag sensor assembly should be replaced after any of the airbags has deployed, as it has been subjected to an impact. REMOVAL REMOVAL

1. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to REMOVAL

2. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL 3. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 4 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 5 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 6 6. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 7 7. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 13 8. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 14 9. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 37 10. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 24 11. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 25 12. REMOVE FRONT NO. 2 CONSOLE BOX INSERT . Refer to REMOVAL - Step 47 13. REMOVE CONSOLE BOX INSERT . Refer to REMOVAL - Step 48 14. REMOVE FLOOR CARPET BRACKET LH . Refer to REMOVAL - Step 26 15. REMOVE FLOOR CARPET BRACKET RH . Refer to REMOVAL - Step 29 16. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) . Refer to REMOVAL - Step 32 17. REMOVE AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Turn back the carpet. d. Disconnect the connectors from the airbag sensor assembly as shown in the illustration.

Fig. 158: Disconnecting Airbag Sensor Assembly Connectors And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Remove the 3 bolts and airbag sensor assembly. INSTALLATION INSTALLATION

1. INSTALL AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal.

WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Using SST, install the airbag sensor assembly with the 3 bolts.

Fig. 159: Identifying Airbag Sensor Assembly Fulcrum Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Fulcrum *a Length 

SST: 09961-00950

without SST Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) with SST Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE:

 

Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective when SST is parallel to a torque wrench.







If the airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between other parts. When the power switch is first turned on (IG) after the airbag sensor assembly has been replaced, make sure that no one is in the vehicle.

d. Connect the connectors to the airbag sensor assembly as shown in the illustration.

Fig. 160: Connecting Connectors to Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

e. Check that the waterproof sheet is properly set. TEXT IN ILLUSTRATION Waterproof *1 Sheet

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

f. Check that there is no looseness in the installation parts of the airbag sensor assembly. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) . Refer to INSTALLATION Step 7 INSTALL FLOOR CARPET BRACKET LH . Refer to INSTALLATION - Step 10 INSTALL FLOOR CARPET BRACKET RH . Refer to INSTALLATION - Step 14 INSTALL FRONT NO. 2 CONSOLE BOX INSERT . Refer to INSTALLATION - Step 5 INSTALL CONSOLE BOX INSERT . Refer to INSTALLATION - Step 4 INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 38 CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 39 INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 45 CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 44 INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 45 INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION

17. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to INSTALLATION 18. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION (for Built-in Type Yaw Rate Sensor) HINT: 

When the airbag sensor assembly is replaced, perform zero point learning for the yaw rate and acceleration sensor. Refer to CALIBRATION .



The yaw rate and acceleration sensor is built into the airbag sensor assembly.

FRONT AIRBAG SENSOR COMPONENTS ILLUSTRATION

Fig. 161: Identifying Front Airbag Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 162: Identifying Front Airbag Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front airbag sensors. 1. INSPECT FRONT AIRBAG SENSOR (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 2. INSPECT FRONT AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check the front airbag sensors for defects if the front bumper of the vehicle or the area around the bumper is damaged. HINT:

The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the front airbag sensor with a new one. 3. INSPECT FRONT AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all front airbag sensors in the damaged areas (anywhere in need of repair). b. Visually check the front airbag sensors in undamaged areas for defects. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a front airbag sensor has detected a major collision, replace the front airbag sensor with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT AIRBAG SENSOR a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Disconnect the connector from the front airbag sensor. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 163: Sliding Yellow CPA Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connector *a Lock is - Released 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting the connector.

d. Remove the bolt and front airbag sensor from the vehicle body.

Fig. 164: Identifying Front Airbag Sensor Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Loosen the bolt while holding the front airbag sensor because the front airbag sensor pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 165: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT AIRBAG SENSOR a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 166: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct d. Insert the pin (stopper) into the body hole and install the front airbag sensor to the vehicle body with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:



If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace







it with a new one. When installing the front airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the front airbag sensor because the front airbag sensor pin (stopper) is easily damaged.

e. Connect the connector to the front airbag sensor. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

Fig. 167: Connector Connectors To Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connection *a is - Completed HINT:

When engaged, the white housing lock will slide. Be sure not to hold the white housing lock or part (A), as it may result in an insecure fit. f. Check that there is no looseness in the installation parts of the front airbag sensor. 2. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 4. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 5. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

SIDE AIRBAG SENSOR (FOR FRONT SIDE) COMPONENTS ILLUSTRATION

Fig. 168: Identifying Side Airbag Sensor Replacement Components With Torque Specifications (For Front Side) (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 169: Identifying Side Airbag Sensor Replacement Components With Torque Specifications (For Front Side) (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the door side airbag sensors. 1. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 2. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check the door side airbag sensors for defects if a front door of the vehicle or the area around a front door is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the door side airbag sensor with a new one. 3. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all door side airbag sensors in the damaged areas (anywhere in need of repair). b. Visually check the door side airbag sensors in undamaged areas for defects. HINT:

The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a door side airbag sensor has detected a major collision, replace the door side airbag sensor with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 4 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 5 6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 6 7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 7 8. REMOVE FRONT ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 8 9. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 10 11. REMOVE DOOR SIDE AIRBAG SENSOR a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Disconnect the connector from the door side airbag sensor. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 170: Sliding Yellow CPA Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connector *a Lock is - Released 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting the connector.

d. Remove the bolt and door side airbag sensor from the front door panel.

Fig. 171: Identifying Door Side Airbag Sensor Clip And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Loosen the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 172: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL DOOR SIDE AIRBAG SENSOR a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 173: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct d. Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:



If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector,







replace it with a new one. When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the door hole. Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

e. Connect the connector to the door side airbag sensor. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

Fig. 174: Identifying Housing Lock, CPA & Completed Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connection *a is - Completed

HINT: When engaged, the white housing lock will slide. Be sure not to hold the white housing lock or part (A), as it may result in an insecure fit.

2. 3. 4. 5. 6. 7. 8. 9.

f. Check that there is no looseness in the installation parts of the door side airbag sensor. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 39 INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL FRONT ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 41 INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 42 INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 43 INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 44 INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 45 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

10. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 11. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 12. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

SIDE AIRBAG SENSOR (FOR REAR SIDE) COMPONENTS ILLUSTRATION

Fig. 175: Identifying Side Airbag Sensor Replacement Components With Torque Specifications (For Rear Side) (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 176: Identifying Side Airbag Sensor Replacement Components With Torque Specifications (For Rear Side) (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the side airbag sensor assemblies. 1. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 2. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check the side airbag sensor assemblies for defects if a center pillar of the vehicle or the area around a center pillar is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the side airbag sensor assembly with a new one. 3. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all side airbag sensor assemblies in the damaged areas (anywhere in need of repair). b. Visually check the side airbag sensor assemblies in undamaged areas for defects. HINT:

The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a side airbag sensor assembly has detected a major collision, replace the side airbag sensor assembly with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

4. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 4 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP HINT: Disconnect the front door opening trim weatherstrip to the extent that allows the removal of the center pillar lower garnish. 6. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 19 7. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP HINT: Disconnect the rear door opening trim weatherstrip to the extent that allows the removal of the center pillar lower garnish. 8. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 23 9. REMOVE SIDE AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Disconnect the connector from the side airbag sensor assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 177: Disconnecting Connector From Side Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock *a Slide *b Push 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting the connector.

d. Remove the bolt and side airbag sensor assembly from the vehicle body. NOTE:

Loosen the bolt while holding the side airbag sensor assembly because the side airbag sensor assembly pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 178: Identifying White Housing Lock Is Correct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL SIDE AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 179: Identifying White Housing Lock Is Correct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect d. Insert the pin (stopper) into the body hole and install the side airbag sensor assembly to the vehicle body with the bolt.

Fig. 180: Identifying White Housing Lock And Slide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White *1 Housing - Lock *a Slide -Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:



If the side airbag sensor assembly has been dropped, or there

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are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the side airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the side airbag sensor assembly because the side airbag sensor assembly pin (stopper) is easily damaged.

e. Connect the connector to the side airbag sensor assembly. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard). HINT: When engaged, the white housing lock will slide. Be sure not to hold the white housing lock or part (A), as it may result in an insecure fit.

2. 3. 4. 5. 6. 7.

f. Check that there is no looseness in the installation parts of the side airbag sensor assembly. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 23 CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 27 CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 45 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 9. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 10. INSPECT SRS WARNING LIGHT

for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

REAR AIRBAG SENSOR COMPONENTS ILLUSTRATION

Fig. 181: Identifying Rear Airbag Sensor Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 182: Identifying Rear Airbag Sensor Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the side No. 2 airbag sensor assemblies. 1. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 2. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check.

for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR b. Visually check the side No. 2 airbag sensor assemblies for defects if a quarter panel of the vehicle or the area around a quarter panel is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the side No. 2 airbag sensor assembly with a new one. 3. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all side No. 2 airbag sensor assemblies in the damaged areas (anywhere in need of repair). b. Visually check the side No. 2 airbag sensor assemblies in undamaged areas for defects. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a side No. 2 airbag sensor assembly has detected a major collision, replace the side No. 2 airbag sensor assembly with a new one.

REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION NOTE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER . Refer to REMOVAL - Step 2 3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. NOTE:

4. 5. 6. 7.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 4 REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 5 REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 9 REMOVE SIDE NO. 2 AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

c. Disconnect the connector from the side No. 2 airbag sensor assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 183: Disconnecting Connector From Side No. 2 Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock *a Slide *b Push 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting the connector.

d. Remove the bolt and side No. 2 airbag sensor assembly from the vehicle body. NOTE:

Loosen the bolt while holding the side No. 2 airbag sensor assembly because the side No. 2 airbag sensor assembly pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 184: Identifying White Housing Lock Is Correct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL SIDE NO. 2 AIRBAG SENSOR ASSEMBLY a. Check that the power switch is off. b. Check that the cable is disconnected from the negative (-) auxiliary battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 185: Identifying White Housing Lock Is Correct Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect d. Insert the pin (stopper) into the body hole and install the side No. 2 airbag sensor assembly to the vehicle body with the bolt.

Fig. 186: Identifying White Housing Lock And Slide Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White *1 Housing - Lock *a Slide -Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:

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If the side No. 2 airbag sensor assembly has been dropped, or

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there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the side No. 2 airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the side No. 2 airbag sensor assembly because the side No. 2 airbag sensor assembly pin (stopper) is easily damaged.

e. Connect the connector to the side No. 2 airbag sensor assembly. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard). HINT: When engaged, the white housing lock will slide. Be sure not to hold the white housing lock or part (A), as it may result in an insecure fit.

2. 3. 4. 5.

f. Check that there is no looseness in the installation parts of the side No. 2 airbag sensor assembly. INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 1 INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION - Step 3 7. PERFORM DIAGNOSTIC SYSTEM CHECK for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR 8. INSPECT SRS WARNING LIGHT for Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

for Built-in Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM

OCCUPANT CLASSIFICATION ECU COMPONENTS ILLUSTRATION

Fig. 187: Identifying Occupant Classification ECU Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the occupant detection ECU. 1. INSPECT OCCUPANT DETECTION ECU (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . 2. INSPECT OCCUPANT DETECTION ECU (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . b. Visually check for defects with the occupant detection ECU.

1. The defects are as follows:  Cracks on the ECU housing  Dents on the ECU housing  Chips on the ECU housing  Cracks or other damage to the connector  Damage to the serial number OK No defects are found. If any of the defects is found, replace the occupant detection ECU with a new one. 3. INSPECT OCCUPANT DETECTION ECU (for Vehicle Involved in Collision and Airbag is Deployed) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . b. Visually check for defects with the occupant detection ECU. 1. The defects are as follows:  Cracks on the ECU housing  Dents on the ECU housing  Chips on the ECU housing  Cracks or other damage to the connector  Damage to the serial number OK No defects are found. If any of the defects is found, replace the occupant detection ECU with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. for Separate Type Yaw Rate Sensor: Refer to PRECAUTION for Built-in Type Yaw Rate Sensor: Refer to PRECAUTION 2. REMOVE FRONT SEAT ASSEMBLY RH

HINT: Use the same procedure for the RH side and LH side. for Manual Seat: Refer to REMOVAL  for Power Seat: Refer to REMOVAL 3. REMOVE OCCUPANT DETECTION ECU a. Disconnect the 2 connectors. 

Fig. 188: Removing Occupant Detection ECU Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the occupant detection ECU. TEXT IN ILLUSTRATION Protective *1 Tape INSTALLATION INSTALLATION

1. INSTALL OCCUPANT DETECTION ECU a. Engage the claw to install the occupant detection ECU.

Fig. 189: Identifying Occupant Detection ECU Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the occupant detection ECU has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the occupant detection ECU with a new one.

b. Connect the 2 connectors. NOTE:

When installing the occupant detection ECU, be careful that the SRS wiring does not interfere with or is pinched between other parts.

2. INSTALL FRONT SEAT ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. for Manual Seat: Refer to INSTALLATION  for Power Seat: Refer to INSTALLATION 3. PERFORM DIAGNOSTIC SYSTEM CHECK 

for Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR for Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR

4. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK Refer to INITIALIZATION

2012-2017 RESTRAINTS Supplemental Restraint System (Service Information) (Except Hybrid) - Camry

STEERING PAD COMPONENTS ILLUSTRATION

Fig. 1: Identifying Steering Pad Replacement Components (For 4 Spoke) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Steering Pad Replacement Components (For 3 Spoke) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the horn button assembly. 1. INSPECT HORN BUTTON ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the horn button assembly installed on the vehicle. HINT:

The defects are as follows:   

Cuts on the surface or in the grooves Small cracks on the surface or in the grooves Significant discoloration on the surface or in the grooves

OK No defects are found. If any of the defects is found, replace the horn button assembly with a new one. 2. INSPECT HORN BUTTON ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-in Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the horn button assembly removed from the vehicle. HINT: The defects are as follows:       

Cuts on the surface or in the grooves Small cracks on the surface or in the grooves Significant discoloration on the surface or in the grooves Cracks or other damage to the connector Deformation of the steering wheel assembly Deformation of the horn button sub-assembly of the horn button assembly Interference or uneven clearance between the horn button assembly and steering wheel assembly when the new horn button assembly is installed on the steering wheel assembly

OK No defects are found. If any of the defects is found, replace the horn button assembly or steering wheel assembly with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the 4 spoke and 3 spoke. The procedure listed below is for the 4 spoke.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-in Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE LOWER NO. 3 STEERING WHEEL COVER a. Disengage the claw and guide to remove the lower No. 3 steering wheel cover.

Fig. 3: Identifying Lower No. 3 Steering Wheel Cover Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER a. Disengage the claw and guide to remove the lower No. 2 steering wheel cover.

Fig. 4: Identifying Lower No. 2 Steering Wheel Cover Claws

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE HORN BUTTON ASSEMBLY WARNING: When storing the horn button assembly, keep the airbag deployment side facing upward. a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Using a screwdriver, push up the torsion spring to disengage the pin.

Fig. 5: Locating Horn Button Assembly Torsion Spring And Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Torsion *1 Spring HINT: Insert the screwdriver from the installation hole of the lower No. 3 steering wheel cover.

d. Using a screwdriver, push in the 2 torsion springs to disengage the 2 pins.

Fig. 6: Locating Horn Button Assembly Torsion Spring And Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Torsion *1 Spring NOTE:

Do not drop the horn button assembly.

HINT: Insert the screwdriver from the installation holes in the lower No. 3 steering wheel cover and lower No. 2 steering wheel cover.

e. Pull out the horn button assembly from the steering wheel assembly and support the horn button assembly with one hand. NOTE:

When removing the horn button assembly, do not pull the airbag wire harness.

f. Disconnect the horn connector from the horn button assembly.

Fig. 7: Disconnecting Horn Connectors From Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Using a screwdriver with its tip wrapped with protective tape, release the 2 airbag connector locks. TEXT IN ILLUSTRATION *1 Protective

Tape Airbag *2 Connector Horn *3 Connector Airbag *4 Connector Lock h. Disconnect the 2 airbag connectors to remove the horn button assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the 4 spoke and 3 spoke. The procedure listed below is for the 4 spoke.

1. INSTALL HORN BUTTON ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Connect the 2 airbag connectors to the horn button assembly.

Fig. 8: Connecting Horn Connectors From Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Horn *2 Connector Airbag *3 Connector Lock NOTE:

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When connecting any airbag connector, take care not to damage the airbag wire harness. Be sure to only connect the connectors to each corresponding

color. d. Push in the 2 locks to install the 2 airbag connectors. e. Connect the horn connector to the horn button assembly. f. Push the horn button assembly to engage the 3 pins carefully.

Fig. 9: Locating Horn Button Assembly Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

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Make sure that the pins are securely inserted into the steering holes. Make sure to engage the 2 upper pins first. Make sure that the horn button assembly is securely installed.

2. INSTALL LOWER NO. 3 STEERING WHEEL COVER a. Engage the claw and guide to install the lower No. 3 steering wheel cover. 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER a. Engage the claw and guide to install the lower No. 2 steering wheel cover. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

5. INSPECT HORN BUTTON ASSEMBLY

a. Make sure that the horn sounds. If the horn does not sound, inspect the horn system. Refer to PROBLEM SYMPTOMS TABLE . 6. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 7. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:

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An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a horn button assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the horn button assembly. The horn button assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button

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assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the horn button assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF HORN BUTTON ASSEMBLY (When Installed in Vehicle) NOTE:

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When disposing of the horn button assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST.

Fig. 10: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700 WARNING: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool

1. Connect SST to the battery. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 11: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 2. Check the function of SST. Press the SST activation switch and check that the LED of the SST activation switch comes on.

Fig. 12: Identifying SST Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING:

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Do not connect the yellow SST connector to the airbag. If the LED comes on when the activation switch is not being pressed, SST is malfunctioning. Replace SST.

3. Disconnect SST from the battery. b. Refer to Precaution. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Remove the lower steering column cover. Refer to REMOVAL - Step 8 . d. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. e. Disconnect the yellow airbag connector from the spiral cable. 1. Slide the slider to release the lock, and then disconnect the connector.

Fig. 13: Disconnecting Yellow Airbag Connector From Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

f. Install SST. WARNING: Check that there is no looseness in the steering wheel assembly and horn button assembly. 1. Connect the SST connector to the airbag connector of the spiral cable.

Fig. 14: View Of Connected SST Connector To Airbag Connector Of Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00780

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 15: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:

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Before deployment, make sure that no one is near the vehicle. The horn button assembly becomes extremely hot when the airbag is deployed, so do not touch it for at

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least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF HORN BUTTON ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST.

Fig. 16: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700

WARNING: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool 1. Connect SST to the battery. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 17: Connecting SST To Battery Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 2. Check the function of SST. Press the SST activation switch and check that the LED of the SST activation switch comes on.

Fig. 18: Identifying SST Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING:

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Do not connect the yellow SST connector to the airbag. If the LED comes on when the activation switch is not being pressed, SST is malfunctioning. Replace SST.

3. Disconnect SST from the battery. b. Remove the horn button assembly. Refer to REMOVAL. WARNING:

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Before removing the horn button assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the horn button assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the horn button assembly to an unneeded wheel.

Fig. 19: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire harness is too thin or an alternative object is used to tie down the horn button assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. After connecting the following SST to each other, connect them to the horn button assembly.

Fig. 20: View Of SST Connected To Horn Button Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-30801 2. Wind 3 wires at least 2 times each around each of the snap pins. 

Fig. 21: Identifying Wires Wrapped Around Snap Pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 2

times *a or more WARNING:

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Tightly wind the wires around the snap pins without any slack. Make sure that the wires are tight. If there is slack in the wires, the horn button assembly may break loose when the airbag is deployed.

3. Face the airbag deployment side of the horn button assembly upward on top of an unneeded tire and wheel set. Separately tie the each sides of the horn button assembly to the wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole of the wheel.

Fig. 22: View Of SST Connector Positioned Downward Through Hub Hole Of Wheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Minimum tire size Width 185 mm (7.28 in.) Inner diameter

360 mm (1.18 ft.) WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the horn button assembly may break loose when the airbag is deployed. Always tie down the horn button assembly with the airbag deployment side facing upward.

The wheel will be damaged by the airbag deployment, so use an unneeded wheel.

d. Install SST.

Fig. 23: View Of Connected SST Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Place the wheel on level ground.

1. Connect the SST connector.  SST: 09082-00700 NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the wheel.

Fig. 24: Identifying SST & Airbag Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION 10 m (32.8 *a ft.) or more e. Cover the horn button assembly (using a cardboard box). 1. Cover the horn button assembly with a cardboard box.

Fig. 25: Covering Steering Pad With Cardboard Box Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Weight 2. Place weights on the cardboard box in 4 places totaling at least 190 N (19 kg, 42.7 lb). Minimum cardboard box size Must exceed the following dimensions X 460 mm (1.51 ft.) Y 650 mm (2.13 ft.) NOTE:



When dimension Y of the cardboard box exceeds the diameter of the wheel and tire to which the horn button assembly is tied, X should be the following size. X = 460 mm (1.51 ft.) + width of tire



If a cardboard box smaller than the specified size is used, it may be broken by the shock from the airbag deployment.

f. Cover the horn button assembly (using tires). 1. Place at least 3 tires without wheels onto the wheel and tire to which the horn button assembly is tied.

Fig. 26: Identifying Horn Button Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires (3 *1 or more) Inner *a Diameter

*b Width 2. Place a wheel and tire on top. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING: Do not use tires with wheels except for on the top and bottom. NOTE:





The tires may be damaged by the airbag deployment, so use unneeded tires. Do not place the SST connector under the tire because it could be damaged.

3. Tie the tires together with the 2 wires.

Fig. 27: Identifying Tires Tied Together With Wires

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

Fig. 28: View Of SST Deployment Examples Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Using a

Cardboard Box Using *B Tires *1 Battery Horn *2 Button Assembly 10 m *a (32.8 ft.) or more

*A

2. Check that no one is within a 10 m (32.8 ft.) radius of the wheel to which the horn button assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the horn button assembly. WARNING:









The horn button assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assembly with a deployed airbag. Do not apply water etc. to a horn button assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the horn button assembly from the wheel. 2. Place the horn button assembly in a plastic bag, tie it tightly and dispose of it according to local regulations.

SPIRAL CABLE COMPONENTS ILLUSTRATION

Fig. 29: Identifying Spiral Cable Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 30: Identifying Spiral Cable Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. REMOVE STEERING WHEEL ASSEMBLY  For 4 Spoke: Refer to REMOVAL .  For 3 Spoke: Refer to REMOVAL . 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. INSPECT SPIRAL CABLE SUB-ASSEMBLY a. Check the colored part as shown in the illustration.

Fig. 31: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part If the colored part shown in the illustration cannot be confirmed, it is possible that the spiral cable sub-assembly is broken. Replace the spiral cable with sensor sub-assembly with a new one. 4. REMOVE LOWER STEERING COLUMN COVER . Refer to REMOVAL - Step 8 . 5. REMOVE UPPER STEERING COLUMN COVER . Refer to REMOVAL - Step 9 . 6. REMOVE SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY NOTE:



Do not replace the spiral cable sub-assembly with the battery connected and the ignition switch on (IG).





a. b. c. d.

Do not rotate the spiral cable sub-assembly without the steering wheel with the battery connected and the ignition switch on (IG). Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.

Check that the ignition switch is off. Check that the cable is disconnected from the negative (-) battery terminal. Check that the front wheels are facing straight ahead. Slide the slider to release the lock, and then disconnect the yellow airbag connector from the spiral cable with sensor sub-assembly.

Fig. 32: Disconnecting Yellow Airbag Connector From Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Disconnect the other connector from the spiral cable with sensor sub-assembly. f. Disengage the 3 claws to remove the spiral cable with sensor sub-assembly.

Fig. 33: Locating Spiral Cable Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE SPIRAL CABLE SUB-ASSEMBLY

NOTE:







Remove the spiral cable sub-assembly from the steering sensor only when replacing it or the steering sensor. Removing the steering sensor from the spiral cable sub-assembly without using a lock pin may result in a misaligned center position of the steering sensor. Therefore, make sure to use the lock pin provided with a new spiral cable sub-assembly or steering sensor when removing the steering sensor from the spiral cable subassembly. When replacing the steering sensor: Refer to REMOVAL .

a. Install the lock pin to the steering sensor.

Fig. 34: Locating Steering Sensor Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

 

Use the lock pin provided with a new spiral cable sub-assembly. Do not remove the lock pin before the spiral cable subassembly is installed to the steering sensor.

b. Disengage the 6 claws and 2 pins to remove the spiral cable sub-assembly from the steering sensor.

Fig. 35: Locating Spiral Cable Sub-Assembly Lock Pin, Guides, Pins & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not damage the guide.

TEXT IN ILLUSTRATION *1 Guide INSPECTION INSPECTION

1. INSPECT SPIRAL CABLE SUB-ASSEMBLY NOTE:





Do not remove the steering sensor from the spiral cable subassembly. As the spiral cable sub-assembly may break, do not rotate the spiral cable sub-assembly more than the specified amount.

a. Remove the spiral cable with sensor sub-assembly from the vehicle See step 6. b. Visually check for defects with the spiral cable sub-assembly. 1. The defects are as follows:  Scratches  Small cracks  Dents

 

Chips Cracks or other damage to the connector OK No defects are found.

If any of the defects is found, replace the spiral cable sub-assembly with a new one. c. Check the spiral cable sub-assembly.

Fig. 36: Checking Spiral Cable Sub-Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION w/o w/ Steering Steering *A *B Pad Switch Pad Switch Component without Color: *a harness *b Orange connected (Spiral Cable Sub-

assembly) Color: *c Black Interlock NOTE:

- - When rotating the spiral cable, make sure to push on the interlock indicated in the illustration to release the interlock mechanism.

1. Set the spiral cable sub-assembly to the center position See step 1. 2. Measure the resistance between each terminal of the spiral cable sub-assembly according to the table below. Standard Resistance W/ STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-2 3 ohms or (ECC) - z3- Always less 7 I28-3 3 ohms or (EAU) - z3- Always less 8 I28-4 3 ohms or (AU3) - z3- Always less 9 I28-5 3 ohms or (AU2) - z3- Always less 10 I28-6 3 ohms or (AU1) - z3- Always less 11 I28-7 3 ohms or (SDN) - z3- Always less 12 I28-9 (HO) 3 ohms or Always - z3-1 less I28-10 Always (+DP) - z33 ohms or

2 I28-11 (DP) - z3-3 I28-13 (IL+2) - z35 I28-14 (SUP) - z36 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

less 3 ohms or Always less Always

3 ohms or less

Always

3 ohms or less

Always Always Always Always

Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms

W/O STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-9 (HO) 3 ohms or Always - z2-2 less I27-1 (D+) Below 1 Always - z4-2 (D+) ohms I27-2 (D-) Below 1 Always z4-1 (D-) ohms I27-3 (D2-) Below 1 Always - z5-1 (D2-) ohms I27-4 (D2+) Below 1 - z5-2 Always ohms (D2+) 3. After setting the spiral cable sub-assembly to the center position, rotate the spiral cable subassembly 2.5 times clockwise, and measure the resistance as shown in the table below. Then rotate the spiral cable sub-assembly 5 times counterclockwise, and measure the resistance as shown in the table below.

Standard Resistance W/ STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-2 3 ohms or (ECC) - z3- Always less 7 I28-3 3 ohms or (EAU) - z3- Always less 8 I28-4 3 ohms or (AU3) - z3- Always less 9 I28-5 3 ohms or (AU2) - z3- Always less 10 I28-6 3 ohms or (AU1) - z3- Always less 11 I28-7 3 ohms or (SDN) - z3- Always less 12 I28-9 (HO) 3 ohms or Always - z3-1 less I28-10 3 ohms or (+DP) - z3- Always less 2 I28-11 (3 ohms or Always DP) - z3-3 less I28-13 3 ohms or (IL+2) - z3- Always less 5 I28-14 3 ohms or (SUP) - z3- Always less 6 I27-1 (D+) Below 1 Always - z4-2 (D+) ohms I27-2 (D-) - Always

Below 1

z4-1 (D-) I27-3 (D2-) Always - z5-1 (D2-) I27-4 (D2+) - z5-2 Always (D2+)

ohms Below 1 ohms Below 1 ohms

W/O STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 I28-9 (HO) 3 ohms or Always - z2-2 less I27-1 (D+) Below 1 Always - z4-2 (D+) ohms I27-2 (D-) Below 1 Always z4-1 (D-) ohms I27-3 (D2-) Below 1 Always - z5-1 (D2-) ohms I27-4 (D2+) Below 1 - z5-2 Always ohms (D2+) 4. After setting the spiral cable sub-assembly to the center position, rotate the spiral cable subassembly 2.5 times clockwise. Then while rotating the spiral cable sub-assembly 5 times counterclockwise, measure the resistance as shown in the table below. Standard Resistance W/ STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3 I28-2 3 ohms or (ECC) - z2- Always less 4 3 ohms or I28-2 Always less (ECC) - z3-

7 I28-3 (EAU) - z38 I28-4 (AU3) - z39 I28-5 (AU2) - z310 I28-6 (AU1) - z311 I28-7 (SDN) - z312 I28-9 (HO) - z3-1 I28-10 (+DP) - z32 I28-11 (DP) - z3-3 I28-13 (IL+2) - z35 I28-14 (SUP) - z36 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always

3 ohms or less

Always Always Always Always

Below 1 ohms Below 1 ohms Below 1 ohms Below 1 ohms

W/O STEERING PAD SWITCH: Tester Specified Condition Connection Condition I28-1 3 ohms or (CCS) - z2- Always less 3

I28-2 (ECC) - z24 I28-9 (HO) - z2-2 I27-1 (D+) - z4-2 (D+) I27-2 (D-) z4-1 (D-) I27-3 (D2-) - z5-1 (D2-) I27-4 (D2+) - z5-2 (D2+)

Always

3 ohms or less

3 ohms or less Below 1 Always ohms Below 1 Always ohms Below 1 Always ohms Always

Always

Below 1 ohms

If the result is not as specified, replace the spiral cable with sensor sub-assembly. INSTALLATION INSTALLATION

1. INSPECT SPIRAL CABLE SUB-ASSEMBLY NOTE:

If the steering sensor is installed to a misaligned spiral cable subassembly, DTCs for an abnormal steering sensor value such as DTC B1801, C1231 and DTC C1433 are stored and it is impossible to repair them. If this happens, replace the spiral cable with sensor sub-assembly with a new one.

a. Check if the spiral cable sub-assembly is centered.

Fig. 37: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part HINT: When the spiral cable sub-assembly is centered, the part indicated by A is positioned at the top and the colored part shown in the illustration is visible. b. If the spiral cable sub-assembly is not centered, center it. If the cable cannot be centered, it is possible that the spiral cable sub-assembly is broken. Replace the spiral cable with sensor sub-assembly with a new one. 1. While pushing on the interlock indicated in the illustration, rotate the spiral cable subassembly counterclockwise slowly by hand until it stops.

Fig. 38: Rotating Spiral Cable Sub-Assembly Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





When rotating the spiral cable sub-assembly, make sure to push on the interlock indicated in the illustration to release the interlock mechanism. Do not turn the spiral cable sub-assembly using the airbag wire harness.

TEXT IN ILLUSTRATION Interlock 2. Rotate the spiral cable sub-assembly clockwise approximately 2.5 turns to the position where the colored part shown in the illustration is visible.

Fig. 39: Rotating Spiral Cable Sub-Assembly Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part Interlock HINT: The spiral cable sub-assembly will rotate approximately 2.5 turns to both the left and right from the center. 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY a. Align the 2 pins and 2 guides, and engage the 6 claws to install the spiral cable sub-assembly to the steering sensor.

Fig. 40: Locating Spiral Cable Sub-Assembly Lock Pin, Guides, Pins & Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lock *1 Pin *2 Guide *3 Pin NOTE:





The spiral cable sub-assembly can be rotate up to 30° even when the interlock is engaged. Therefore, make sure that both guides are aligned properly when installing the steering sensor to the spiral cable sub-assembly. Do not remove the lock pin before the spiral cable subassembly is installed to the steering sensor.

b. Remove the lock pin from the steering sensor. 3. ALIGN FRONT WHEELS TO FACE STRAIGHT AHEAD 4. INSTALL SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY NOTE:





Do not replace the spiral cable sub-assembly with the battery connected and the ignition switch on (IG). Do not rotate the spiral cable sub-assembly without the steering wheel with the battery connected and the ignition switch on (IG).



Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.

a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Check that the front wheels are facing straight ahead. d. Set the turn signal switch to the neutral position. NOTE:

If it is not in the neutral position, the turn signal switch pin may snap.

e. Engage the 3 claws to install the spiral cable with sensor sub-assembly. f. Connect the each connector. 5. INSTALL UPPER STEERING COLUMN COVER . Refer to INSTALLATION - Step 7 . 6. INSTALL LOWER STEERING COLUMN COVER . Refer to INSTALLATION - Step 8 . 7. INSPECT AND ADJUST SPIRAL CABLE WITH SENSOR SUB-ASSEMBLY NOTE:

Do not adjust the spiral cable sub-assembly with the battery connected and the ignition switch on (IG).

a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Check if the spiral cable sub-assembly is centered.

Fig. 41: Inspecting Spiral Cable Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part HINT: When the spiral cable sub-assembly is centered, the part indicated by A is positioned at the top and the colored part shown in the illustration is visible. d. If the spiral cable sub-assembly is not centered, center it. NOTE:





When rotating the spiral cable sub-assembly, make sure to push on the interlock indicated in the illustration to release the interlock mechanism. Do not turn the spiral cable sub-assembly using the airbag wire harness.

1. While pushing on the interlock indicated in the illustration, rotate the spiral cable subassembly counterclockwise slowly by hand until it stops.

Fig. 42: Rotating Spiral Cable Sub-Assembly Counterclockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Interlock 2. Rotate the spiral cable sub-assembly clockwise approximately 2.5 turns to the position where the colored part shown in the illustration is visible.

Fig. 43: Rotating Spiral Cable Sub-Assembly Clockwise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Colored Part Interlock HINT: The spiral cable sub-assembly will rotate approximately 2.5 turns to both the left and right from the center. 8. INSTALL STEERING WHEEL ASSEMBLY  For 4 Spoke: Refer to INSTALLATION - Step 9 .  For 3 Spoke: Refer to INSTALLATION - Step 11 . 9. ADJUST PARKING ASSIST MONITOR SYSTEM (w/ Parking Assist Monitor System) Refer to CALIBRATION .

KNEE AIRBAG ASSEMBLY (FOR DRIVER SIDE) COMPONENTS ILLUSTRATION

Fig. 44: Identifying Knee Airbag Assembly (For Driver Side) Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the

lower No. 1 instrument panel airbag assembly. 1. INSPECT LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the lower No. 1 instrument panel airbag assembly installed on the vehicle. HINT: The defects are as follows:   

Cuts Small cracks Significant discoloration

OK No defects are found. If any of the defects is found, replace the lower No. 1 instrument panel airbag assembly with a new one. 2. INSPECT LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the lower No. 1 instrument panel airbag assembly removed from the vehicle. HINT: The defects are as follows:  

Cuts Small cracks

  

Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the lower No. 1 instrument panel airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4 . 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Disconnect the front door opening trim weatherstrip LH to the extent that allows the removal of the

instrument side panel LH. 6. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 7. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 . 8. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 13 . 9. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY WARNING: When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward. a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Remove the 4 bolts.

Fig. 45: Locating Lower No. 1 Instrument Panel Airbag Assembly Bolts And DLC3 Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 2 claws to disconnect the DLC3. e. Disengage the 2 hooks to remove the lower No. 1 instrument panel airbag assembly.

Fig. 46: Locating Lower No. 1 Instrument Panel Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the lower No. 1 instrument panel airbag assembly, do not pull the airbag wire harness.

f. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock.

Fig. 47: Disconnecting Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock g. Disconnect the airbag connector to remove the lower No. 1 instrument panel airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage

the airbag wire harness. INSTALLATION INSTALLATION

1. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Connect the airbag connector to the lower No. 1 instrument panel airbag assembly.

Fig. 48: Connecting Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock NOTE:

d. e. f. g.

When connecting any airbag connector, take care not to damage the airbag wire harness.

Push in the lock to install the airbag connector. Temporarily install the lower No. 1 instrument panel airbag assembly with the 2 hooks. Engage the 2 claws to install the DLC3. Install the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Confirm that the lower No. 1 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 40 . 3. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 41 . 4. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . 5. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 6. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 43 . 7. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 . 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

9. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 10. INSPECT SRS WARNING LIGHT

For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a lower No. 1 instrument panel airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 1 instrument panel airbag assembly. The lower No. 1 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the lower No. 1 instrument panel airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES,

U.S.A., INC. 2. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the lower No. 1 instrument panel airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.

Fig. 49: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION .

c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Disconnect the lower No. 1 instrument panel airbag connector. 1. Using a screwdriver with the tip wrapped with protective tape, disconnect the airbag connector. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Install SST. WARNING: Check that there is no looseness in the lower No. 1 instrument panel airbag assembly. 1. Connect the SST connector to the lower No. 1 instrument panel airbag assembly.

Fig. 50: View Of Connected SST Connector To Lower No. 1 Instrument Panel Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802

09082-10801 09082-20801 NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 51: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag.

1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:











Before deployment, make sure that no one is near the vehicle. The lower No. 1 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.

Fig. 52: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the lower No. 1 instrument panel airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the lower No. 1 instrument panel airbag assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the lower No. 1 instrument panel airbag assembly to an unneeded tire.

Fig. 53: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the lower No. 1 instrument panel airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the lower No. 1 instrument panel airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 54: View Of Lower No. 1 Instrument Panel Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Inner *a Width *b Diameter WARNING:





NOTE:

d. Install SST.

Make sure that the wires are tight. If there is slack in the wires, the lower No. 1 instrument panel airbag assembly may break loose when the airbag is deployed. Always tie down the lower No. 1 instrument panel airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

1. After connecting the following SST to each other, connect them to the lower No. 1 instrument panel airbag assembly.

Fig. 55: View Of SST Connected To Lower No. 1 Instrument Panel Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-20801 e. Place the tires. 1. Place at least 2 tires under the tire to which the lower No. 1 instrument panel airbag assembly is tied. 

Fig. 56: Identifying Lower No. 1 Instrument Panel Airbag Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the lower No. 1 instrument panel airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 57: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 58: Identifying SST Distance From Lower No. 1 Instrument Panel Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lower No. 1 Instrument *1 Panel Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more



SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the lower No. 1 instrument panel airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the lower No. 1 instrument panel airbag assembly. WARNING:









The lower No. 1 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the lower No. 1 instrument panel airbag assembly from the tire. 2. Place the lower No. 1 instrument panel airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

KNEE AIRBAG ASSEMBLY (FOR FRONT PASSENGER SIDE) COMPONENTS ILLUSTRATION

Fig. 59: Identifying Knee Airbag Assembly (For Front Passenger Side) Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the lower No. 2 instrument panel airbag assembly. 1. INSPECT LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the lower No. 2 instrument panel airbag assembly installed on the vehicle. HINT: The defects are as follows:   

Cuts Small cracks Significant discoloration

OK No defects are found. If any of the defects is found, replace the lower No. 2 instrument panel airbag assembly with a new one. 2. INSPECT LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the lower No. 2 instrument panel airbag assembly removed from the vehicle. HINT: The defects are as follows:  

Cuts Small cracks

  

Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the lower No. 2 instrument panel airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 3 . 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT: Use the same procedure for the RH side and LH side. Refer to REMOVAL - Step 4 . 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH HINT: Disconnect the front door opening trim weatherstrip RH to the extent that allows the removal of the instrument side panel RH. 6. REMOVE INSTRUMENT SIDE PANEL RH . Refer to REMOVAL - Step 35 . 7. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 36 . 8. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY WARNING: When storing the lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward. a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Remove the 3 bolts.

Fig. 60: Locating Lower No. 2 Instrument Panel Airbag Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disengage the 3 claws to remove the lower No. 2 instrument panel airbag assembly.

Fig. 61: Locating Lower No. 2 Instrument Panel Airbag Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the lower No. 2 instrument panel airbag assembly, do not pull the airbag wire harness.

e. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock.

Fig. 62: Disconnecting No. 2 Instrument Panel Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock f. Disconnect the airbag connector to remove the lower No. 2 instrument panel airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage

the airbag wire harness. INSTALLATION INSTALLATION

1. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Connect the airbag connector to the lower No. 2 instrument panel airbag assembly.

Fig. 63: Connecting No. 2 Instrument Panel Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock d. Push in the lock to install the airbag connector. e. Temporarily install the lower No. 2 instrument panel airbag assembly with the 3 claws. f. Install the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE:

Confirm that the lower No. 2 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 17 . 3. INSTALL INSTRUMENT SIDE PANEL RH . Refer to INSTALLATION - Step 18 . 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 43 . 6. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. Refer to INSTALLATION - Step 44 . 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. PERFORM DIAGNOSTIC SYSTEM CHECK

For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 9. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a lower No. 2 instrument panel airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 2 instrument panel airbag assembly. The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the

operation. HINT: When scrapping a vehicle equipped with an SRS or disposing of the lower No. 2 instrument panel airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the lower No. 2 instrument panel airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.

Fig. 64: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SST: 09082-00700 b. Refer to Precaution. 

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Remove the No. 2 instrument panel under cover sub-assembly. Refer to REMOVAL - Step 36 . e. Disconnect the lower No. 2 instrument panel airbag connector. 1. Using a screwdriver with the tip wrapped with protective tape, disconnect the airbag connector. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

f. Install SST. WARNING: Check that there is no looseness in the lower No. 2 instrument panel airbag assembly. 1. Connect the SST connector to the lower No. 2 instrument panel airbag assembly.

Fig. 65: View Of SST Connected To No. 2 Instrument Panel Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 66: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed,







so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.

Fig. 67: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the lower No. 2 instrument panel airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the lower No. 2 instrument panel airbag assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the lower No. 2 instrument panel airbag assembly to an unneeded tire.

Fig. 68: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire

Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the lower No. 2 instrument panel airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4 1. Position the lower No. 2 instrument panel airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 69: View Of Lower No. 2 Instrument Panel Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a

Inner *b Width Diameter WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the lower No. 2 instrument panel airbag assembly may break loose when the airbag is deployed. Always tie down the lower No. 2 instrument panel airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

d. Install SST. 1. After connecting the following SST to each other, connect them to the lower No. 2 instrument panel airbag assembly.

Fig. 70: View Of SST Connected To Lower No. 2 Instrument Panel Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00802 09082-10801 09082-20801

e. Place the tires. 1. Place at least 2 tires under the tire to which the lower No. 2 instrument panel airbag assembly is tied.

Fig. 71: Identifying Lower No. 2 Instrument Panel Airbag Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the lower No. 2 instrument panel airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 72: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 73: Identifying SST Distance From Lower No. 2 Instrument Panel Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Lower No. 2 Instrument *1 Panel Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more



SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the lower No. 2 instrument panel airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the lower No. 2 instrument panel airbag assembly. WARNING:









The lower No. 2 instrument panel airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag assembly with a deployed airbag. Do not apply water etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the lower No. 2 instrument panel airbag assembly from the tire. 2. Place the lower No. 2 instrument panel airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 74: Identifying Front Passenger Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the instrument panel passenger airbag assembly. 1. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the instrument panel passenger airbag assembly installed on the vehicle.

HINT: The defects are as follows: 





Cuts on the instrument panel sub-assembly around the instrument panel passenger airbag assembly Small cracks on the instrument panel sub-assembly around the instrument panel passenger airbag assembly Significant discoloration on the instrument panel sub-assembly around the instrument panel passenger airbag assembly

OK No defects are found. If any of the defects is found, replace the instrument panel sub-assembly with a new one. 2. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the instrument panel passenger airbag assembly removed from the vehicle. HINT:     

Cuts Small cracks Significant discoloration Cracks or other damage to the connector Deformation or cracks on the instrument panel sub-assembly or instrument panel reinforcement

OK No defects are found. If any of the defects is found, replace the instrument panel passenger airbag assembly, instrument panel sub-assembly or instrument panel reinforcement with a new one. REMOVAL

REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY Refer to REMOVAL . 3. DISCONNECT NO. 2 INSTRUMENT PANEL WIRE a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Slide the slider to release the lock, and then disconnect the connector.

Fig. 75: Disconnecting Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

4. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY . Refer to REMOVAL - Step 52 . 5. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY WARNING: When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

a. Remove the 2 screws.

Fig. 76: Locating Instrument Panel Passenger Airbag Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lean the instrument panel safety pad assembly and disengage the 3 hooks.

Fig. 77: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the 3 hooks to remove the instrument panel passenger airbag assembly from the instrument panel safety pad assembly.

Fig. 78: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE NO. 2 INSTRUMENT PANEL WIRE a. Disengage the clamp.

Fig. 79: Disconnecting Airbag Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with the tip wrapped with protective tape, release the 2 airbag connector locks. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock c. Disconnect the 2 airbag connectors to remove the No. 2 instrument panel wire from the instrument panel passenger airbag assembly.

NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

INSTALLATION INSTALLATION

1. INSTALL NO. 2 INSTRUMENT PANEL WIRE a. Connect the 2 airbag connectors of the No. 2 instrument panel wire to the instrument panel passenger airbag assembly.

Fig. 80: Connecting Airbag Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

Airbag Connector Airbag *2 Connector Lock *1

NOTE:

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

When connecting any airbag connector, take care not to damage the airbag wire harness. Be sure to only connect the connectors to each corresponding color.

b. Push in the 2 locks to install the 2 airbag connectors to the instrument panel passenger airbag assembly. c. Engage the clamp. 2. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY NOTE:

If the hooks are not engaged in the correct order, the deployment part of the instrument panel passenger airbag assembly may be damaged.

a. Engage the 3 hooks as shown in the illustration.

Fig. 81: Locating Instrument Panel Passenger Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the instrument panel passenger airbag assembly to engage the 3 hooks.

c. Install the 2 screws to install the instrument panel passenger airbag assembly. 3. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY . Refer to INSTALLATION - Step 1. 4. CONNECT NO. 2 INSTRUMENT PANEL WIRE a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Connect the connector.

Fig. 82: Identifying Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

5. INSTALL NO. 1 INSTRUMENT PANEL GARNISH SUB-ASSEMBLY Refer to INSTALLATION - Step 3 . 6. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR .

For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. Never dispose of a instrument panel passenger airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the instrument panel passenger airbag assembly. The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the instrument panel passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC.

2. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the instrument panel passenger airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.

Fig. 83: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Disconnect the cable from the negative (-) battery terminal.

WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Remove the lower instrument panel sub-assembly. Refer to REMOVAL - Step 38 . e. Disconnect the No. 2 instrument panel wire. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the connector.

Fig. 84: Disconnecting Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION

*a Slider f. Install SST. WARNING: Check that there is no looseness in the instrument panel passenger airbag assembly and instrument panel safety pad. 1. Connect the SST connector to the No. 2 instrument panel wire.

Fig. 85: View Of SST Connected To The No. 2 Instrument Panel Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00780

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

Fig. 86: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed,







so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.

Fig. 87: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Remove the instrument panel passenger airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the instrument panel passenger airbag assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

c. Install SST. 1. After connecting the following SST to each other, connect them to the instrument panel passenger airbag assembly.

Fig. 88: View Of SST Connected To Instrument Panel Passenger Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-30801 d. Using braided wire, tie down the instrument panel passenger airbag assembly to an unneeded tire. 

Fig. 89: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the instrument panel passenger airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the instrument panel passenger airbag assembly inside the tire with the airbag deployment side facing inside. Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.)

Fig. 90: View Of Instrument Panel Passenger Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Inner *a *b Width Diameter WARNING:





NOTE:

e. Place the tires.

Make sure that the wires are tight. If there is slack in the wires, the instrument panel passenger airbag assembly may break loose when the airbag is deployed. Always tie down the instrument panel passenger airbag assembly with the airbag deployment side facing inside the tire as shown in the illustration.

The tires may be damaged by the airbag deployment, so use an unneeded tire.

1. Place at least 2 tires under the tire to which the instrument panel passenger airbag assembly is tied.

Fig. 91: Identifying Instrument Panel Passenger Airbag Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the instrument panel passenger airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 92: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 93: Identifying SST Distance From Instrument Panel Passenger Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Instrument Panel *1 Passenger Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more 

SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the instrument panel passenger airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the instrument panel passenger airbag assembly. WARNING:









The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a instrument panel passenger airbag assembly with a deployed airbag. Do not apply water etc. to a instrument panel passenger airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the instrument panel passenger airbag assembly from the tire. 2. Place the instrument panel passenger airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

CURTAIN SHIELD AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 94: Identifying Curtain Shield Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the curtain shield airbag assemblies. 1. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the curtain shield airbag assemblies installed on the vehicle. HINT: The defects are as follows: 

Cuts on each pillar garnish or the roof headlining assembly around the curtain shield airbag





assemblies Small cracks on each pillar garnish or the roof headlining assembly around the curtain shield airbag assemblies Significant discoloration on each pillar garnish or the roof headlining assembly around the curtain shield airbag assemblies

OK No defects are found. If any of the defects is found, replace each pillar garnish or the roof headlining assembly with a new one. 2. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the curtain shield airbag assemblies removed from the vehicle. HINT: The defects are as follows:    

Cuts Small cracks Significant discoloration Cracks or other damage to the connector

OK No defects are found. If any of the defects is found, replace the curtain shield airbag assembly with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. REMOVE ROOF HEADLINING ASSEMBLY Refer to REMOVAL . 3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY WARNING: When storing the curtain shield airbag assembly, keep the airbag deployment side facing upward. a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock and disconnect the curtain shield airbag connector.

Fig. 95: Disconnecting Curtain Shield Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Protective *1 Tape Airbag *2 Connector Airbag *3 Connector Lock NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

d. Using a clip remover, remove the pin.

Fig. 96: Removing Curtain Shield Airbag Assembly Connector Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Perform the same procedure for the other pins. e. Using 2 screw drivers, disengage the 2 claws and remove the clip from the body panel as shown in the illustration.

Fig. 97: Removing Clips From Body Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1

Body Curtain *2 Panel Shield Airbag

Assembly HINT: Perform the same procedure for the other clips. f. While holding the curtain shield airbag assembly, disengage the 5 claws.

Fig. 98: Locating Curtain Shield Airbag Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When removing the curtain shield airbag assembly, have assistants hold it to prevent it from bending.

g. Remove the 2 bolts.

Fig. 99: Locating Curtain Shield Airbag Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Disengage the 2 hooks to remove the curtain shield airbag assembly. i. Remove the 2 spacers from the curtain shield airbag assembly.

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Temporarily install the curtain shield airbag assembly with the 2 hooks.

Fig. 100: Locating Curtain Shield Airbag Assembly Bolts With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:





When installing the curtain shield airbag assembly, have assistants hold it to prevent it from bending. Do not twist the curtain shield airbag assembly when installing it.

d. Install 2 new bolts in the order shown in the illustration. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) e. Install the curtain shield airbag assembly to the body panel with 5 claws, 6 new clips and 2 new spacers in the order shown in the illustration.

Fig. 101: Locating Curtain Shield Airbag Assembly Fasteners With Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Pin *2 Clip Curtain Shield Body *3 *4 Airbag Panel Assembly *5 Spacer - f. Push in new pin to each clip.

Fig. 102: Installing Curtain Shield Airbag Assembly Connector Pin

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Make sure that the pins of the clips are pushed in firmly.

g. Connect the curtain shield airbag connector.

Fig. 103: Connect Curtain Shield Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Airbag *1 Connector Airbag *2 Connector Lock

NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

h. Push in the lock to install the curtain shield airbag connector. 2. INSTALL ROOF HEADLINING ASSEMBLY Refer to INSTALLATION . 3. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a curtain shield airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain shield airbag assembly. The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag.





Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





When disposing of the curtain shield airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.

Fig. 104: Checking Function Of SST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Remove the roof headlining assembly. Refer to REMOVAL . e. Install SST. WARNING: Check that there is no looseness in the curtain shield airbag assembly. 1. Disconnect the connector from the curtain shield airbag assembly. NOTE:

When disconnecting the airbag connector, take care not to damage the airbag wire harness.

2. After connecting the following SST to each other, connect them to the curtain shield airbag assembly.

Fig. 105: View Of SST Connected To Curtain Shield Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

3. Move SST at least 10 m (32.8 ft.) away from the rear side window.

Fig. 106: Identifying SST, Battery & Distance From Rear Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 4. Maintaining sufficient clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

5. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not







touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.

Fig. 107: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SST: 09082-00700 b. Remove the curtain shield airbag assembly. Refer to REMOVAL. 

WARNING:





Before removing the curtain shield airbag assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the curtain shield airbag assembly, keep the airbag deployment side facing upward.

c. Cut off the deployment section of the curtain shield airbag assembly.

Fig. 108: Identifying Cut Off Deployment Section Of Curtain Shield Airbag Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using braided wire, tie down the curtain shield airbag assembly to an unneeded tire.

Fig. 109: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more WARNING: If the wire is too thin or an alternative object is used to tie down the curtain shield airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4

1. Position the curtain shield airbag assembly inside the tire as shown in the illustration.

Fig. 110: View Of Curtain Shield Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING: Make sure that the wires are tight. If there is slack in the wires, the curtain shield airbag assembly may break loose when the airbag is deployed. NOTE:

The tire may be marked by the airbag deployment, so use an unneeded tire.

e. Install SST. 1. After connecting the following SST to each other, connect them to the curtain shield airbag assembly.

Fig. 111: View Of SST Connected To Curtain Shield Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00802 09082-10801 09082-20801 f. Place the tires. 

WARNING: Do not face the deployment side of the curtain shield airbag assembly toward the ground. 1. Place at least 2 tires under the tire to which the curtain shield airbag assembly is tied.

Fig. 112: Identifying Curtain Shield Airbag Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the curtain shield airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 113: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. g. Install SST. 1. Connect the SST connector.

Fig. 114: Identifying SST Distance From Curtain Shield Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Curtain Shield *1 Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more 

SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. h. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the curtain shield airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. i. Dispose of the curtain shield airbag assembly. WARNING:









The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. Do not apply water etc. to a curtain shield airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the curtain shield airbag assembly from the tire. 2. Place the curtain shield airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

FRONT SEAT SIDE AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 115: Identifying Front Seat Side Airbag Assembly Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front seat airbag assemblies. 1. INSPECT FRONT SEAT AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the front seat airbag assemblies installed on the vehicle. HINT: The defects are as follows:   

Cuts on the front seatback assembly around the front seat airbag assemblies Small cracks on the front seatback assembly around the front seat airbag assemblies Significant discoloration on the front seatback assembly around the front seat airbag assemblies

OK No defects are found. If any of the defects is found, replace the separate type front seatback pad or separate type front seatback cover with a new one. 2. INSPECT FRONT SEAT AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the front seat airbag assemblies removed from the vehicle. HINT: The defects are as follows: 



Make sure that there are no scratches, broken or frayed threads on the surface of the front seat airbag assemblies base fabric Marks from being dropped

 

Deformation on the installation part of the front seat airbag assemblies Cracks or other damage to the wire harness or connector

OK No defects are found. If any of the defects is found, replace the front seat airbag assembly with a new one. REMOVAL REMOVAL

WARNING:



Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION .





Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. If the side airbag was deployed, replace the front seat airbag assembly, front seatback frame sub-assembly or separate type front seatback spring assembly, separate type front seatback cover and separate type front seatback pad with the necessary parts in accordance with the extent of the collision damage. For TMMI Made Manual Seat: Refer to DISASSEMBLY . For SIA Made Manual Seat: Refer to DISASSEMBLY . For TMMI Made Power Seat: Refer to DISASSEMBLY . For SIA Made Power Seat: Refer to DISASSEMBLY .

HINT: Use the same procedure for the LH side and RH side. 1. REMOVE FRONT SEAT ASSEMBLY (for TMMK Made Manual Seat) Refer to REMOVAL . 2. REMOVE FRONT SEAT ASSEMBLY (for SIA Made Manual Seat) Refer to REMOVAL .

3. REMOVE FRONT SEAT ASSEMBLY (for TMMK Made Power Seat) Refer to REMOVAL . 4. REMOVE FRONT SEAT ASSEMBLY (for SIA Made Power Seat) Refer to REMOVAL . 5. DISCONNECT AIRBAG WIRE HARNESS (for TMMK Made Manual Seat) a. Disconnect the 2 rubber bands of the separate type front seatback cover with pad.

Fig. 116: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the claw and 3 clamps to disconnect the airbag wire harness.

Fig. 117: Identifying Front Seatback Cover Claw And Clamps (For TMMK Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. DISCONNECT AIRBAG WIRE HARNESS (for SIA Made Manual Seat) a. Disconnect the rubber band of the separate type front seatback cover with pad.

Fig. 118: Identifying Rubber Band Of Front Seatback Cover (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the fastener and separate the airbag wire harness.

Fig. 119: Identifying Front Seatback Cover Airbag Wire Harness (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the claw and 3 clamps to disconnect the airbag wire harness.

Fig. 120: Identifying Front Seatback Cover Claw And Clamps (For SIA Made Manual Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. DISCONNECT AIRBAG WIRE HARNESS (for TMMK Made Power Seat) a. Disconnect the 2 rubber bands of the separate type front seatback cover with pad.

Fig. 121: Identifying Rubber Bands Of Front Seatback Cover (For TMMK Made Power Seat)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector (A).

Fig. 122: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disengage the clamp (B). d. Disengage the claw (D) and 3 clamps (C) to disconnect the airbag wire harness. e. w/ Seat Heater System: 1. Disconnect the connector (E). 2. Disengage the clamp (F). 8. DISCONNECT AIRBAG WIRE HARNESS (for SIA Made Power Seat) a. Disconnect the rubber band of the separate type front seatback cover with pad.

Fig. 123: Identifying Rubber Band Of Front Seatback Cover (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the fastener and separate the airbag wire harness.

Fig. 124: Identifying Front Seatback Cover Airbag Wire Harness (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Disengage the claw and 3 clamps to disconnect the airbag wire harness.

Fig. 125: Identifying Front Seatback Cover Claw And Clamps (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. w/ Seat Heater System: 1. Disconnect the connector.

Fig. 126: Identifying Front Seatback Cover Connector And Clamp (For SIA Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. 10. 11. 12. 13.

2. Disengage the clamp. REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made Manual Seat) . Refer to DISASSEMBLY - Step 11 . REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made Manual Seat) . Refer to DISASSEMBLY - Step 13 . REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made Power Seat) . Refer to DISASSEMBLY - Step 14 . REMOVE SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made Power Seat) . Refer to DISASSEMBLY - Step 17 . REMOVE FRONT SEAT AIRBAG ASSEMBLY a. Disengage the 2 clamps.

Fig. 127: Locating Front Seat Airbag Assembly Clamps And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 nuts and the front seat airbag assembly. WARNING:

 

The nuts must not be reused. Make sure that the front seatback frame sub-assembly or separate type front seatback spring assembly is not deformed. If it is, replace it with a new one.

INSTALLATION INSTALLATION

1. INSTALL FRONT SEAT AIRBAG ASSEMBLY WARNING:

 

The nuts must not be reused. Make sure that the front seatback frame sub-assembly or separate type front seatback spring assembly is not deformed. If it is, replace it with a new one.

a. Install the front seat airbag assembly with 2 new nuts. for TMMK Made Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

for SIA Made Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)

2. 3. 4. 5. 6.

7.

8.

b. Engage the 2 clamps. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made Manual Seat) . Refer to REASSEMBLY - Step 18 . INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made Manual Seat) . Refer to REASSEMBLY - Step 15 . INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for TMMK Made Power Seat) . Refer to REASSEMBLY - Step 21 . INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (for SIA Made Power Seat) . Refer to REASSEMBLY - Step 18 . CONNECT AIRBAG WIRE HARNESS (for TMMK Made Manual Seat) a. Engage the claw and 3 clamps to connect the airbag wire harness. b. Connect the 2 rubber bands of the separate type front seatback cover with pad. CONNECT AIRBAG WIRE HARNESS (for SIA Made Manual Seat) a. Engage the claw and 3 clamps to connect the airbag wire harness. b. Engage the fastener to connect the airbag wire harness. c. Connect the rubber band of the separate type front seatback cover with pad. CONNECT AIRBAG WIRE HARNESS (for TMMK Made Power Seat) a. w/ Seat Heater System: 1. Connect the connector (E).

Fig. 128: Identifying Front Seatback Cover Connectors, Claw And Clamps (For TMMK Made Power Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Engage the clamp (F). b. Engage the claw (D) and 3 clamps (C) to Connect the airbag wire harness. c. Engage the clamp (B). d. Connect the connector (A). e. Connect the 2 rubber bands of the separate type front seatback cover with pad. 9. CONNECT AIRBAG WIRE HARNESS (for SIA Made Power Seat) a. w/ Seat Heater System: 1. Connect the connector. 2. Engage the clamp. b. Engage the claw and 3 clamps to Connect the airbag wire harness. c. Engage the fastener to connect the airbag wire harness. d. Connect the rubber band of the separate type front seatback cover with pad. 10. INSTALL FRONT SEAT ASSEMBLY (for TMMK Made Manual Seat) Refer to INSTALLATION . 11. INSTALL FRONT SEAT ASSEMBLY (for SIA Made Manual Seat) Refer to INSTALLATION . 12. INSTALL FRONT SEAT ASSEMBLY (for TMMK Made Power Seat) Refer to INSTALLATION . 13. INSTALL FRONT SEAT ASSEMBLY (for SIA Made Power Seat) Refer to INSTALLATION . 14. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material

regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a front seat airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the front seat airbag assembly. The front seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the front seat airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:





HINT:

When disposing of the front seat airbag assembly, never use the customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.

Fig. 129: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00700 b. Refer to Precaution. 

For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Disconnect the connector from the front seat airbag assembly under the front seat assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the yellow airbag connector as shown in the illustration.

Fig. 130: Identifying Harness Connector Lock Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Slider e. Install SST. WARNING: Check that there is no looseness in the front seat assembly.

1. Connect the SST connector to the front seat airbag assembly connector.

Fig. 131: View Of SST Connected To Front Seat Airbag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.  

SST: 09082-00700 SST: 09082-00820

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the front side window.

Fig. 132: Identifying SST Distance From Front Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. f. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The front seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it







for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.

Fig. 133: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09082-00700

b. Remove the front seat airbag assembly. Refer to REMOVAL. WARNING:





Before removing the front seat assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the front seat airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the front seat airbag assembly to an unneeded tire.

Fig. 134: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more

WARNING: If the wire is too thin or an alternative object is used to tie down the front seat airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4 1. Install the 2 nuts to the front seat airbag assembly.

Fig. 135: Identifying Front Seat Airbag Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Wind the wires around the stud bolts of the front seat airbag assembly as shown in the illustration.

Fig. 136: Identifying Wires Around Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Position the front seat airbag assembly inside the tire.

Fig. 137: View Of Front Seat Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the front seat airbag assembly may break loose when the airbag is deployed. Face the front seat airbag assembly deployment surface toward the inside the tire to evenly distribute the force of deployment.

The tire may be marked by the airbag deployment, so use an

unneeded tire. d. Install SST. 1. Connect the SST connector to the front seat airbag assembly connector.

Fig. 138: View Of SST Connected To Front Seat Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST: 09082-00820 e. Place the tires. 1. Place at least 2 tires under the tire to which the front seat airbag assembly is tied. 

Fig. 139: Identifying Front Seat Airbag Assembly Inside Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the front seat airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 140: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.

Fig. 141: Identifying SST Distance From Front Seat Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Front Seat *1 Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more 

SST: 09082-00700

NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the front seat airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the front seat airbag assembly. WARNING:









The front seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assembly with a deployed airbag. Do not apply water etc. to a front seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the front seat airbag assembly from the tire. 2. Place the front seat airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

REAR SEAT SIDE AIRBAG ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 142: Identifying Rear Seat Side Airbag Assembly Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 143: Identifying Rear Seat Side Airbag Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the rear seat airbag assemblies. 1. INSPECT REAR SEAT AIRBAG ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR .

For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the rear seat airbag assemblies installed on the vehicle. HINT: The defects are as follows:   

Cuts on the rear side seatback assembly around the rear seat airbag assemblies Small cracks on the rear side seatback assembly around the rear seat airbag assemblies Significant discoloration on the rear side seatback assembly around the rear seat airbag assemblies

OK No defects are found. If any of the defects is found, replace the rear side seatback pad or rear side seatback cover subassembly with a new one. 2. INSPECT REAR SEAT AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the rear seat airbag assemblies removed from the vehicle. HINT: The defects are as follows: 

  

Make sure that there are no scratches, broken or frayed threads on the surface of the rear seat airbag assemblies base fabric Marks from being dropped Deformation on the installation part of the rear seat airbag assemblies Cracks or other damage to the wire harness or connector

OK No defects are found. If any of the defects is found, replace the rear seat airbag assembly with a new one.

REMOVAL REMOVAL

WARNING: If the side airbag was deployed, replace the rear seat airbag assembly, rear side seatback frame sub-assembly, rear side seatback cover subassembly and rear side seatback pad with the necessary parts in accordance with the extent of the collision damage. HINT: Use the same procedure for the LH side and RH side. 1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6. 7.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 8 . REMOVE REAR SEAT SHOULDER BELT GUIDE . Refer to DISASSEMBLY - Step 3 . REMOVE REAR SEAT AIRBAG ASSEMBLY a. Disengage the 8 hooks.

Fig. 144: Locating Rear Seat Airbag Assembly Hooks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disengage the clamp and remove the 2 nuts.

Fig. 145: Locating Rear Seat Airbag Assembly Clamp And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the rear side seatback frame sub-assembly and rear seat airbag assembly from the rear side seatback cover with pad.

Fig. 146: Identifying Rear Side Seatback Frame Sub-Assembly, Rear Seat Airbag Assembly And Rear Side Seatback Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Side Seatback *1 Frame Subassembly Rear Seat *2 Airbag Assembly Rear Side *3 Seatback Cover

with Pad WARNING:

 

The nuts must not be reused. Make sure that the rear side seatback frame sub-assembly is not deformed. If it is, replace it with a new one.

INSTALLATION INSTALLATION

1. INSTALL REAR SEAT AIRBAG ASSEMBLY WARNING:

 

The nuts must not be reused. Make sure that the rear side seatback frame sub-assembly is not deformed. If it is, replace it with a new one.

a. Install the rear seat airbag assembly to the rear side seatback frame sub-assembly with 2 new nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

2. 3. 4. 5. 6.

b. Engage the clamp to connect the airbag wire harness. c. Engage the 8 hooks to install the rear side seatback cover with pad. INSTALL REAR SEAT SHOULDER BELT GUIDE . Refer to REASSEMBLY - Step 11 . INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 2 . INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

7. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 8. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

DISPOSAL DISPOSAL

WARNING: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment. 1. PRECAUTION WARNING:



















An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure. Never dispose of a rear seat airbag assembly with an undeployed airbag. The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the rear seat airbag assembly. The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: When scrapping a vehicle equipped with an SRS or disposing of the rear seat airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the Service Dept. of TOYOTA MOTOR SALES, U.S.A., INC. 2. DISPOSE OF REAR SEAT AIRBAG ASSEMBLY (When Installed in Vehicle) NOTE:



When disposing of the rear seat airbag assembly, never use the



customer's vehicle to deploy the airbag. Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 2.  SST: 09082-00700

Fig. 147: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Refer to Precaution. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . c. Disconnect the cable from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. d. Remove the rear seat cushion assembly. Refer to REMOVAL - Step 3 .

e. Disconnect the connector from the rear seat airbag assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Slide the slider to release the lock, and then disconnect the yellow airbag connector. f. Install SST. WARNING: Check that there is no looseness in the rear side seatback assembly. 1. Connect the SST connector to the rear seat airbag assembly connector.  SST: 09082-00700  SST: 09082-00820

Fig. 148: View Of SST Connected To Rear Seat Airbag Assembly Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

2. Move SST at least 10 m (32.8 ft.) away from the rear side window.

Fig. 149: Identifying SST, Battery & Distance From Rear Side Window Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Battery 10 m (32.8 *a ft.) or more 3. Maintaining sufficient clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTE:

Take care not to damage the SST wire harness.

4. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. g. Deploy the airbag. 1. Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. 2. Press the SST activation switch and deploy the airbag. WARNING:





Before deployment, make sure that no one is near the vehicle. The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it







for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

HINT: The airbag is deployed as the LED of the SST activation switch comes on. 3. DISPOSE OF REAR SEAT AIRBAG ASSEMBLY (When Not Installed in Vehicle) NOTE:

Be sure to observe the following procedure when deploying the airbag.

HINT: Prepare a battery as the power source to deploy the airbag. a. Check the function of SST. See step 3.  SST: 09082-00700

Fig. 150: Checking Function Of SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Remove the rear seat airbag assembly. Refer to REMOVAL. WARNING:





Before removing the rear side seatback assembly, wait at least 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal. When storing the rear seat airbag assembly, keep the airbag deployment side facing upward.

c. Using braided wire, tie down the rear seat airbag assembly to an unneeded tire.

Fig. 151: Identifying Stripped Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Stripped *1 Wire Section Wire *a Diameter Wire Stripped wire section 1.25 mm2 (0.0019 in.2 ) or more

WARNING: If the wire is too thin or an alternative object is used to tie down the rear seat airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2 ). HINT: To calculate the area of the stripped wire section: Area = 3.14 x (Diameter)2 / 4 1. Install the 2 nuts to the rear seat airbag assembly.

Fig. 152: Locating Rear Seat Airbag Assembly Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Wind the wires around the stud bolts of the rear seat airbag assembly as shown in the illustration.

Fig. 153: Identifying Wires Around Stud Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Position the rear seat airbag assembly inside the tire.

Fig. 154: View Of Rear Seat Airbag Assembly Positioned Inside The Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Width Inner *b Diameter Minimum tire size Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) WARNING:





NOTE:

Make sure that the wires are tight. If there is slack in the wires, the rear seat airbag assembly may break loose when the airbag is deployed. Face the rear seat airbag assembly deployment surface toward the inside the tire to evenly distribute the force of deployment.

The tire may be marked by the airbag deployment, so use an unneeded tire.

d. Install SST. 1. Connect the SST connector to the rear seat airbag assembly connector.  SST: 09082-00820

Fig. 155: View Of SST Connected To Rear Seat Airbag Assembly In Tire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Place the tires. 1. Place at least 2 tires under the tire to which the rear seat airbag assembly is tied.

Fig. 156: Identifying Rear Seat Airbag Assembly Inside Tires

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Tires *1 (2 or more) NOTE:

Do not place the SST connector under the tire because it could be damaged.

2. Place at least 2 tires onto the tire to which the rear seat airbag assembly is tied. The top tire should have a wheel installed. 3. Tie the tires together with the 2 wires.

Fig. 157: Identifying Tires Tied Together With Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Make sure that the wires are tight. Looseness in the wires results in the tires breaking loose when the airbag is deployed. f. Install SST. 1. Connect the SST connector.  SST: 09082-00700

Fig. 158: Identifying SST Distance From Rear Seat Airbag Assembly In Tires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Rear Seat *1 Airbag Assembly *2 Battery 10 m *a (32.8 ft.) or more NOTE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

2. Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire. g. Deploy the airbag. 1. Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. 2. Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the rear seat airbag assembly is tied. 3. Press the SST activation switch and deploy the airbag. WARNING: Before deployment, make sure that no one is near the airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. h. Dispose of the rear seat airbag assembly. WARNING:









The rear seat airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a rear seat airbag assembly with a deployed airbag. Do not apply water etc. to a rear seat airbag assembly with a deployed airbag. Always wash your hands with water after completing the operation.

1. Remove the rear seat airbag assembly from the tire. 2. Place the rear seat airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

CENTER AIRBAG SENSOR ASSEMBLY COMPONENTS ILLUSTRATION

Fig. 159: Identifying Center Airbag Sensor Assembly Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 160: Identifying Center Airbag Sensor Assembly Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the airbag sensor assembly. 1. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision)

a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 2. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check for defects with the airbag sensor assembly installed on the vehicle. 1. The defects are as follows:  Cracks on the sensor housing  Dents on the sensor housing  Chips on the sensor housing  Cracks or other damage to the connector  Peeling of the label OK No defects are found. If any of the defects is found, replace the airbag sensor assembly with a new one. 3. INSPECT AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. Replace the airbag sensor assembly. HINT: The airbag sensor assembly should be replaced after any of the airbags has deployed, as it has been subjected to an impact. REMOVAL REMOVAL

1. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to REMOVAL.

2. REMOVE REAR CONSOLE BOX ASSEMBLY Refer to REMOVAL . 3. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 . 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4 . 5. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Disconnect the front door opening trim weatherstrip LH to the extent that allows the removal of the instrument side panel LH. 6. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 . 7. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 . 8. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 13 . 9. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 38 . 10. REMOVE BOX BOTTOM MAT . Refer to REMOVAL - Step 25 . 11. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 26 . 12. REMOVE FRONT NO. 2 CONSOLE BOX INSERT . Refer to REMOVAL - Step 48 . 13. REMOVE CONSOLE BOX INSERT . Refer to REMOVAL - Step 49 . 14. REMOVE FLOOR CARPET BRACKET LH . Refer to REMOVAL - Step 31 . 15. REMOVE FLOOR CARPET BRACKET RH . Refer to REMOVAL - Step 34 . 16. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) . Refer to REMOVAL - Step 36 . 17. REMOVE AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Turn back the carpet. d. Disconnect the connectors from the airbag sensor assembly as shown in the illustration.

Fig. 161: Disconnecting Airbag Sensor Assembly Connectors And Fasteners Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

e. Remove the 3 bolts and airbag sensor assembly. INSTALLATION INSTALLATION

1. INSTALL AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal.

WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Using SST, install the airbag sensor assembly with the 3 bolts.

Fig. 162: Connecting Airbag Sensor Assembly Connectors And Fasteners Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 

SST: 09961-00950

TEXT IN ILLUSTRATION Waterproof *1 -Sheet Fulcrum *a -Length without SST Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) with SST Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE:

 





Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective when SST is parallel to a torque wrench. If the airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between



other parts. When the ignition switch is first turned on (IG) after the airbag sensor assembly has been replaced, make sure that no one is in the vehicle.

d. Connect the connectors to the airbag sensor assembly as shown in the illustration. NOTE:

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

When connecting any airbag connector, take care not to damage the airbag wire harness.

e. Check that the waterproof sheet is properly set. f. Check that there is no looseness in the installation parts of the airbag sensor assembly. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct) . Refer to INSTALLATION Step 8 . INSTALL FLOOR CARPET BRACKET LH . Refer to INSTALLATION - Step 10 . INSTALL FLOOR CARPET BRACKET RH . Refer to INSTALLATION - Step 14 . INSTALL FRONT NO. 2 CONSOLE BOX INSERT . Refer to INSTALLATION - Step 5 . INSTALL CONSOLE BOX INSERT . Refer to INSTALLATION - Step 4 . INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 27 . INSTALL BOX BOTTOM MAT . Refer to INSTALLATION - Step 28 . INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY . Refer to INSTALLATION - Step 15 . INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 40 . CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 41 . INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 . INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 43 . INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 . INSTALL REAR CONSOLE BOX ASSEMBLY Refer to INSTALLATION .

17. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY Refer to INSTALLATION.

FRONT AIRBAG SENSOR COMPONENTS

ILLUSTRATION

Fig. 163: Identifying Front Airbag Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the front airbag sensors. 1. INSPECT FRONT AIRBAG SENSOR (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 2. INSPECT FRONT AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check the front airbag sensors for defects if the front bumper of the vehicle or the area around the bumper is damaged.

HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the front airbag sensor with a new one. 3. INSPECT FRONT AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all front airbag sensors in the damaged areas (anywhere in need of repair). b. Visually check the front airbag sensors in undamaged areas for defects. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a front airbag sensor has detected a major collision, replace the front airbag sensor with a new one. REMOVAL REMOVAL

HINT: 

Use the same procedure for the RH side and LH side.



The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT AIRBAG SENSOR a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Disconnect the connector from the front airbag sensor. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 164: Sliding Yellow CPA Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connector *a Lock is - Released 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting.

d. Remove the bolt and front airbag sensor from the vehicle body.

Fig. 165: Identifying Front Airbag Sensor Clip And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Loosen the bolt while holding the front airbag sensor because the front airbag sensor pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 166: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct

INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL FRONT AIRBAG SENSOR a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 167: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct d. Insert the pin (stopper) into the body hole and install the front airbag sensor to the vehicle body with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:



If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.







When installing the front airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the front airbag sensor because the front airbag sensor pin (stopper) is easily damaged.

e. Connect the connector to the front airbag sensor. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

Fig. 168: Identifying Housing Lock, CPA & Completed Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connection *a is - Completed HINT:

When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit. f. Check that there is no looseness in the installation parts of the front airbag sensor. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 4. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

SIDE AIRBAG SENSOR (FOR FRONT SIDE) COMPONENTS ILLUSTRATION

Fig. 169: Identifying Side Airbag Sensor (For Front Side) Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the door side airbag sensors. 1. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 2. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check the door side airbag sensors for defects if a front door of the vehicle or the area around a front door is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the door side airbag sensor with a new one. 3. INSPECT DOOR SIDE AIRBAG SENSOR (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all door side airbag sensors in the damaged areas (anywhere in need of repair). b. Visually check the door side airbag sensors in undamaged areas for defects. HINT:

The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a door side airbag sensor has detected a major collision, replace the door side airbag sensor with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to DISASSEMBLY - Step 3 . 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to DISASSEMBLY Step 4 . 5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to DISASSEMBLY - Step 5 . 6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to DISASSEMBLY - Step 6 . 7. REMOVE FRONT DOOR ARMREST ASSEMBLY . Refer to DISASSEMBLY - Step 7 . 8. REMOVE COURTESY LIGHT ASSEMBLY . Refer to REMOVAL - Step 1 . 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to DISASSEMBLY - Step 9 . 10. REMOVE DOOR SIDE AIRBAG SENSOR a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Disconnect the connector from the door side airbag sensor. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 170: Sliding Yellow CPA Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connector *a Lock is - Released 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting.

d. Remove the bolt and door side airbag sensor from the front door panel.

Fig. 171: Identifying Door Side Airbag Sensor Clip And Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Loosen the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 172: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL DOOR SIDE AIRBAG SENSOR a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 173: Identifying Correct Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Incorrect *b Correct d. Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:









If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

e. Connect the connector to the door side airbag sensor. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

Fig. 174: Identifying Housing Lock, CPA & Completed Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock Connection *a is - Completed HINT: When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

2. 3. 4. 5. 6. 7. 8. 9.

f. Check that there is no looseness in the installation parts of the door side airbag sensor. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY . Refer to REASSEMBLY - Step 40 . INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION - Step 1 . INSTALL FRONT DOOR ARMREST ASSEMBLY . Refer to REASSEMBLY - Step 42 . INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) . Refer to REASSEMBLY - Step 43 . INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) . Refer to REASSEMBLY - Step 44 . INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH . Refer to REASSEMBLY Step 45 . INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG . Refer to REASSEMBLY - Step 46 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

10. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 11. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

SIDE AIRBAG SENSOR (FOR REAR SIDE) COMPONENTS ILLUSTRATION

Fig. 175: Identifying Side Airbag Sensor (For Rear Side) Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the side airbag sensor assemblies. 1. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 2. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check the side airbag sensor assemblies for defects if a center pillar of the vehicle or the area around a center pillar is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the side airbag sensor assembly with a new one. 3. INSPECT SIDE AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all side airbag sensor assemblies in the damaged areas (anywhere in need of repair). b. Visually check the side airbag sensor assemblies in undamaged areas for defects. HINT:

The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a side airbag sensor assembly has detected a major collision, replace the side airbag sensor assembly with a new one. REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR SCUFF PLATE . Refer to REMOVAL - Step 3 . 4. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP HINT: Disconnect the front door opening trim weatherstrip to the extent that allows the removal of the center pillar lower garnish. 5. REMOVE REAR DOOR SCUFF PLATE . Refer to REMOVAL - Step 18 . 6. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP HINT: Disconnect the rear door opening trim weatherstrip to the extent that allows the removal of the center pillar lower garnish. 7. REMOVE CENTER PILLAR LOWER GARNISH . Refer to REMOVAL - Step 22 . 8. REMOVE SIDE AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Disconnect the connector from the side airbag sensor assembly. NOTE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 176: Disconnecting Connector From Side Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock *a Slide *b Push 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting.

d. Remove the bolt and side airbag sensor assembly from the vehicle body. NOTE:

Loosen the bolt while holding the side airbag sensor assembly because the side airbag sensor assembly pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 177: Identifying Correct White Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect INSTALLATION INSTALLATION

HINT:

 

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL SIDE AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 178: Identifying Correct White Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect d. Insert the pin (stopper) into the body hole and install the side airbag sensor assembly to the vehicle body with the bolt.

Fig. 179: Connecting Connector From Side Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White *1 housing - lock *a Slide - Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:







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If the side airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the side airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the side airbag sensor assembly because the side airbag sensor assembly pin (stopper) is easily damaged.

e. Connect the connector to the side airbag sensor assembly. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard). HINT:

When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

2. 3. 4. 5. 6. 7.

f. Check that there is no looseness in the installation parts of the side airbag sensor assembly. INSTALL CENTER PILLAR LOWER GARNISH . Refer to INSTALLATION - Step 22 . INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP INSTALL REAR DOOR SCUFF PLATE . Refer to INSTALLATION - Step 26 . INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP INSTALL FRONT DOOR SCUFF PLATE . Refer to INSTALLATION - Step 44 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

8. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 9. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

REAR AIRBAG SENSOR COMPONENTS ILLUSTRATION

Fig. 180: Identifying Rear Airbag Sensor Replacement Components With Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the side No. 2 airbag sensor assemblies. 1. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 2. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check.

For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . b. Visually check the side No. 2 airbag sensor assemblies for defects if a quarter panel of the vehicle or the area around a quarter panel is damaged. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the side No. 2 airbag sensor assembly with a new one. 3. INSPECT SIDE NO. 2 AIRBAG SENSOR ASSEMBLY (for Vehicle Involved in Collision and Airbag is Deployed) a. When airbags have deployed as the result of a collision, be sure to replace all side No. 2 airbag sensor assemblies in the damaged areas (anywhere in need of repair). b. Visually check the side No. 2 airbag sensor assemblies in undamaged areas for defects. HINT: The defects are as follows:     

Cracks on the sensor housing Dents on the sensor housing Chips on the sensor housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found or a side No. 2 airbag sensor assembly has detected a major collision, replace the side No. 2 airbag sensor assembly with a new one.

REMOVAL REMOVAL

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. NOTE:

3. 4. 5. 6.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3 . REMOVE REAR SEAT CUSHION LOCK HOOK . Refer to REMOVAL - Step 4 . REMOVE REAR SIDE SEATBACK ASSEMBLY . Refer to REMOVAL - Step 8 . REMOVE SIDE NO. 2 AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Disconnect the connector from the side No. 2 airbag sensor assembly. NOTE:

When disconnecting any airbag connector, take care not to damage

the airbag wire harness. 1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

Fig. 181: Disconnecting Connector From Side No. 2 Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White Yellow *1 Housing *2 CPA Lock *a Slide *b Push 2. Push down the white housing lock again and disconnect the connector. NOTE:

Do not push down the part (A) shown in the illustration when disconnecting.

d. Remove the bolt and side No. 2 airbag sensor assembly from the vehicle body. NOTE:

Loosen the bolt while holding the side No. 2 airbag sensor assembly because the side No. 2 airbag sensor assembly pin (stopper) is easily damaged.

e. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 182: Identifying Correct White Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect INSTALLATION INSTALLATION

HINT:  

Use the same procedure for the RH side and LH side. The procedure listed below is for the LH side.

1. INSTALL SIDE NO. 2 AIRBAG SENSOR ASSEMBLY a. Check that the ignition switch is off. b. Check that the cable is disconnected from the negative (-) battery terminal. WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. c. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Fig. 183: Identifying Correct White Housing Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Correct *b Incorrect d. Insert the pin (stopper) into the body hole and install the side No. 2 airbag sensor assembly to the vehicle body with the bolt.

Fig. 184: Connecting Connector From Side No. 2 Airbag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION White *1 housing - lock *a Slide - Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTE:



If the side No. 2 airbag sensor assembly has been dropped, or

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

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there are any cracks, dents or other defects in the case or connector, replace it with a new one. When installing the side No. 2 airbag sensor assembly, be careful that the SRS wiring does not interfere with or is not pinched between other parts. Make sure that the pin (stopper) is securely inserted into the body hole. Tighten the bolt while holding the side No. 2 airbag sensor assembly because the side No. 2 airbag sensor assembly pin (stopper) is easily damaged.

e. Connect the connector to the side No. 2 airbag sensor assembly. NOTE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard). HINT: When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

2. 3. 4. 5.

f. Check that there is no looseness in the installation parts of the side No. 2 airbag sensor assembly. INSTALL REAR SIDE SEATBACK ASSEMBLY . Refer to INSTALLATION - Step 2 . INSTALL REAR SEAT CUSHION LOCK HOOK . Refer to INSTALLATION - Step 6 . INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 7 . CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

6. PERFORM DIAGNOSTIC SYSTEM CHECK For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 7. INSPECT SRS WARNING LIGHT For Separate Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM . For Built-In Type Yaw Rate Sensor: Refer to DIAGNOSIS SYSTEM .

OCCUPANT CLASSIFICATION ECU COMPONENTS ILLUSTRATION

Fig. 185: Identifying Occupant Classification ECU Replacement Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

WARNING: Be sure to correctly follow the removal and installation procedures for the occupant detection ECU. 1. INSPECT OCCUPANT DETECTION ECU (for Vehicle not Involved in Collision) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . 2. INSPECT OCCUPANT DETECTION ECU (for Vehicle Involved in Collision and Airbag not Deployed) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . b. Visually check for defects with the occupant detection ECU. 1. The defects are as follows:  Cracks on the ECU housing

   

Dents on the ECU housing Chips on the ECU housing Cracks or other damage to the connector Damage to the serial number

OK No defects are found. If any of the defects is found, replace the occupant detection ECU with a new one. 3. INSPECT OCCUPANT DETECTION ECU (for Vehicle Involved in Collision and Airbag is Deployed) a. Perform a diagnostic system check. Refer to DTC CHECK / CLEAR . b. Visually check for defects with the occupant detection ECU. 1. The defects are as follows:  Cracks on the ECU housing  Dents on the ECU housing  Chips on the ECU housing  Cracks or other damage to the connector  Damage to the serial number OK No defects are found. If any of the defects is found, replace the occupant detection ECU with a new one. REMOVAL REMOVAL

1. PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. For Separate Type Yaw Rate Sensor: Refer to PRECAUTION . For Built-In Type Yaw Rate Sensor: Refer to PRECAUTION . 2. REMOVE FRONT SEAT ASSEMBLY RH HINT:

Use the same procedure for the RH side and LH side. for TMMK Made Manual Seat: Refer to REMOVAL .  for SIA Made Manual Seat: Refer to REMOVAL .  for TMMK Made Power Seat: Refer to REMOVAL .  for SIA Made Power Seat: Refer to REMOVAL . 3. REMOVE OCCUPANT DETECTION ECU a. Disconnect the 2 connectors. 

Fig. 186: Removing Occupant Detection ECU Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the occupant detection ECU. TEXT IN ILLUSTRATION Protective *1 Tape INSTALLATION INSTALLATION

1. INSTALL OCCUPANT DETECTION ECU a. Engage the claw to install the occupant detection ECU.

Fig. 187: Identifying Occupant Detection ECU Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the occupant detection ECU has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the occupant detection ECU with a new one.

b. Connect the 2 connectors. NOTE:

When installing the occupant detection ECU, be careful that the SRS wiring does not interfere with or is pinched between other parts.

2. INSTALL FRONT SEAT ASSEMBLY RH HINT: Use the same procedure for the RH side and LH side. For TMMK Made Manual Seat: Refer to INSTALLATION .  For SIA Made Manual Seat: Refer to INSTALLATION .  For TMMK Made Power Seat: Refer to INSTALLATION .  For SIA Made Power Seat: Refer to INSTALLATION . 3. PERFORM DIAGNOSTIC SYSTEM CHECK 

For Separate Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR .

For Built-In Type Yaw Rate Sensor: Refer to DTC CHECK / CLEAR . 4. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK Refer to INITIALIZATION .

2012-2017 ENGINE Starting System (Service Information) - Camry (2AR-FE)

STARTER COMPONENTS ILLUSTRATION

Fig. 1: Identifying Starter Replacement Components With Torque Specifications (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 2: Identifying Starter Replacement Components With Torque Specifications (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

REMOVAL

1. PRECAUTION NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

3. 4. 5. 6. 7. 8. 9. 10.

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1 REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 18 REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 19 REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL - Step 7 REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL - Step 21 REMOVE BATTERY . Refer to REMOVAL - Step 23 REMOVE STARTER ASSEMBLY a. Disconnect the starter connector.

Fig. 3: Identifying Starter Connector

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Open the terminal cap, remove the nut and disconnect the starter wire. c. Remove the 2 bolts and starter.

Fig. 4: Identifying Starter Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY DISASSEMBLY

1. REMOVE REPAIR SERVICE STARTER KIT a. Remove the nut and disconnect the lead wire from the magnetic switch.

Fig. 5: Locating Magnetic Switch Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Holding the magnetic switch to the starter drive housing, remove the 2 screws.

Fig. 6: Locating Magnetic Switch Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the magnetic switch. d. Remove the return spring and plunger from the starter drive housing. 2. REMOVE STARTER YOKE ASSEMBLY a. Remove the 2 through-bolts, and pull out the starter yoke together with the commutator end frame.

Fig. 7: Locating Field Frame With Through Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the starter yoke from the commutator end frame.

Fig. 8: Identifying Starter Commutator End Frame Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE STARTER ARMATURE PLATE a. Remove the armature plate from the starter yoke.

Fig. 9: Identifying Starter Armature Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. REMOVE STARTER COMMUTATOR END FRAME COVER a. Using a screwdriver, pry out the commutator end frame cover.

Fig. 10: Prying Out Commutator End Frame Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE STARTER ARMATURE ASSEMBLY a. Using snap ring pliers, remove the snap ring and plate washer.

Fig. 11: Removing/Installing Snap Ring And Plate Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Do not drop the starter armature assembly.

TEXT IN ILLUSTRATION Snap *1 Ring Pliers b. Remove the armature from the commutator end frame. 6. REMOVE PLANETARY GEAR a. Remove the 3 planetary gears from the starter drive housing.

Fig. 12: Removing Planetary Gears From Starter Drive Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT STARTER ASSEMBLY WARNING: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may became hot and cause injury. NOTE:

These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

a. Perform a pull-in test. 1. Remove the nut and disconnect the lead wire from terminal C. 2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear extends.

Fig. 13: Checking Clutch Pinion Gear Extends Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Terminal *1 50 Terminal *2 C If the clutch pinion gear does not move, replace the magnetic switch assembly. b. Perform a hold-in test.

Fig. 14: Hold-In Test Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. TEXT IN ILLUSTRATION Terminal *1 C *a Disconnect If the clutch pinion gear returns inward, replace the magnetic switch assembly. c. Perform a clutch pinion gear return test.

Fig. 15: Clutch Pinion Gear Return Test Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch assembly. TEXT IN ILLUSTRATION *a Disconnect d. Perform a no-load performance test.

Fig. 16: Checking Starter Assembly No-Load Performance Test Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Terminal *1 30 Terminal *2 50 1. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 2. Clamp the starter in a vise. 3. Connect the battery and an ammeter to the starter as shown in the illustration. 4. Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current. Standard current 90 A or less at 11.5 V If the result is not as specified, repair or replace the starter assembly. 2. INSPECT REPAIR SERVICE STARTER KIT a. Check the plunger.

Fig. 17: Checking Plunger Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. b. Check if the pull-in coil has an open circuit.

Fig. 18: Checking Pull-In Coil Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Terminal *1 C Terminal *2 50 1. Measure the resistance between terminals 50 and C. Standard resistance Below 1 ohms If the result is not as specified, replace the repair service starter kit. c. Check if the hold-in coil has an open circuit.

Fig. 19: Checking Hold-In Coil Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Terminal *1 50 *2 Body

1. Measure the resistance between terminal 50 and the switch body. Standard resistance Below 2 ohms If the result is not as specified, replace the repair service starter kit. 3. INSPECT STARTER ARMATURE ASSEMBLY HINT: If these is no continuity between any segments, replace the starter armature assembly. a. Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. b. Check if the commutator has an open circuit.

Fig. 20: Checking Commutator (Open Circuit) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Segment 1. Measure the resistance between the segments of the commutator.

Standard resistance Below 1 ohms If the result is not as specified, replace the armature assembly. c. Check if the commutator is grounded.

Fig. 21: Checking Commutator (Grounded) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Commutator *2 Coil Core 1. Measure the resistance between the commutator and armature coil core. Standard resistance 10 kohms or higher If the result is not as specified, replace the armature assembly. d. Using a vernier caliper, measure the commutator length.

Fig. 22: Identifying Commutator Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Length Standard length 3.1 to 3.8 mm (0.122 to 0.149 in.) Maximum length 3.8 mm (0.149 in.) If the length is greater than the maximum, replace the starter armature assembly. 4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY a. Using a vernier caliper, measure the brush length.

Fig. 23: Identifying Brush Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *1 Length Standard length 4.0 to 9.0 mm (0.158 to 0.354 in.) Minimum length 4.0 mm (0.158 in.) If the length is less than the minimum, replace the end frame assembly. b. Check the brush insulation.

Fig. 24: Checking Brush Insulation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Measure the resistance between the positive (+) and negative (-) brushes. Standard resistance 10 kohms or higher If the result is not as specified, replace the end frame assembly. 5. INSPECT STARTER CLUTCH a. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.

Fig. 25: Checking Clutch Pinion Gear Turns Freely Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Lock *b Free If necessary, replace the starter drive housing assembly. REASSEMBLY REASSEMBLY

HINT: Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter. 1. INSTALL PLANETARY GEAR a. Apply grease to the planetary gears and pin parts of the planetary shaft.

Fig. 26: Applying Grease To Planetary Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hightemperature grease b. Install the 3 planetary gears. 2. INSTALL STARTER ARMATURE ASSEMBLY a. Apply grease to the armature shaft.

Fig. 27: Applying Grease To Armature Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hightemperature grease b. Apply high-temperature grease to the plate washer and bearing, as shown in the illustration.

Fig. 28: Identifying Plate Washer And Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hightemperature grease c. Install the starter armature to the starter commutator end frame. d. Using snap ring pliers, install the plate washer and a new snap ring.

Fig. 29: Installing Plate Washer And Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Snap *a Ring Pliers NOTE:

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

Be sure to install the snap ring in the armature shaft groove securely. Be sure to properly install the snap ring because it expands easily.

e. Using a vernier caliper, measure the length of the snap ring.

Fig. 30: Identifying Length Of Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Length Maximum length 5.0 mm (0.196 in.) If the length is greater than the maximum, replace it with a new snap ring. 3. INSTALL STARTER COMMUTATOR END FRAME COVER a. Install the end frame cover to the commutator end frame.

Fig. 31: Installing End Frame Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL STARTER ARMATURE PLATE a. Insert the starter armature plate to the starter yoke.

Fig. 32: Identifying Starter Armature Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TEXT IN ILLUSTRATION *a Keyway *b Key b. Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate. 5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY a. Align the rubber of the end frame with the cutout of the starter yoke.

Fig. 33: Aligning End Frame Rubber And Starter Yoke Cutout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout *b Rubber b. Install the end frame to the starter yoke. NOTE:

The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.

6. INSTALL STARTER YOKE ASSEMBLY a. Align the protrusion of the starter yoke with the cutout of the starter drive housing.

Fig. 34: Aligning Starter Yoke Protrusion And Starter Drive Housing Cutout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION *a Cutout *b Protrusion b. Install the starter yoke with the 2 through-bolts.

Fig. 35: Locating Field Frame With Through Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 7. INSTALL REPAIR SERVICE STARTER KIT a. Apply grease to the plunger and the hook.

Fig. 36: Applying Grease To Plunger And Hook Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Hightemperature grease b. Hang the plunger hook of the magnetic switch to the drive lever. c. Install the plunger and return spring. d. Install the magnetic switch with the 2 screws.

Fig. 37: Locating Magnetic Switch Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) e. Connect the lead wire to the magnetic switch with the nut.

Fig. 38: Locating Magnetic Switch Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) INSTALLATION INSTALLATION

1. INSTALL STARTER ASSEMBLY a. Install the starter with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) b. Connect the starter connector. c. Install the terminal nut and cover the nut with the cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 2. 3. 4. 5. 6. 7. 8.

INSTALL BATTERY . Refer to INSTALLATION - Step 49 INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to INSTALLATION - Step 50 INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to INSTALLATION - Step 2 INSTALL INLET AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 53 INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 68 INSTALL COOL AIR INTAKE DUCT SEAL . Refer to INSTALLATION - Step 4

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

ENGINE SWITCH COMPONENTS ILLUSTRATION

Fig. 39: Identifying Engine Switch Replacement Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 40: Identifying Engine Switch Replacement Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. PRECAUTION

NOTE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (w/o Navigation System) Refer to REMOVAL . 4. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (w/ Navigation System) Refer to REMOVAL . 5. REMOVE FRONT DOOR SCUFF PLATE LH . Refer to REMOVAL - Step 3 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4 7. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to REMOVAL Step 5 8. REMOVE INSTRUMENT SIDE PANEL LH . Refer to REMOVAL - Step 6 9. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to REMOVAL Step 7 10. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to REMOVAL - Step 8 11. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 9 12. REMOVE FRONT PANEL GARNISH LH . Refer to REMOVAL - Step 11 13. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to REMOVAL - Step 12 14. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL - Step 13 15. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to REMOVAL Step 47 16. REMOVE ENGINE SWITCH a. Disengage the 2 claws and remove the engine switch.

Fig. 41: Identifying Engine Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT ENGINE SWITCH

Fig. 42: Identifying Engine Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Switch Specified Connection Condition Condition 5 (SS1) - 6 (GND) Not 10 kohms or higher 1 (SS2) - 6 pushed (GND) 5 (SS1) - 6 (GND) Below 1 Pushed ohms 1 (SS2) - 6 (GND) If the result is not as specified, replace the engine switch. b. Apply battery voltage between the terminals of the switch, and check the illumination condition of the engine switch. HINT: 



If a positive (+) battery lead and a negative (-) battery lead are incorrectly connected, the engine switch indicator light will not illuminate. If the voltage is too low, the indicator light will not illuminate.

OK Measurement Specified Condition Condition Battery positive (+) -> Terminal 9 Illuminates (SWIL) Battery

negative (-) -> Terminal 6 (GND)

Fig. 43: Identifying Engine Switch Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Indicator *a Light If the result is not as specified, replace the engine switch. INSTALLATION INSTALLATION

1. INSTALL ENGINE SWITCH a. Engage the 2 claws to install the engine switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 6 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL ASSEMBLY . Refer to INSTALLATION - Step 40 4. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY . Refer to INSTALLATION Step 41 5. INSTALL FRONT PANEL GARNISH LH . Refer to INSTALLATION - Step 42 6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY . Refer to INSTALLATION Step 44 7. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY . Refer to INSTALLATION Step 45 8. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH . Refer to INSTALLATION - Step 46 9. INSTALL INSTRUMENT SIDE PANEL LH . Refer to INSTALLATION - Step 47 10. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH . Refer to INSTALLATION Step 42 11. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 43

12. INSTALL FRONT DOOR SCUFF PLATE LH . Refer to INSTALLATION - Step 44 13. INSTALL RADIO RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (w/o Navigation System) Refer to INSTALLATION . 14. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH AIR CONDITIONING CONTROL ASSEMBLY (w/ Navigation System) Refer to INSTALLATION . 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

IGNITION SWITCH COMPONENTS ILLUSTRATION

Fig. 44: Identifying Ignition Switch Replacement Components (With Wireless Door Lock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ILLUSTRATION

Fig. 45: Identifying Ignition Switch Replacement Components (Without Wireless Door Lock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL REMOVAL

1. REMOVE STEERING COLUMN ASSEMBLY Refer to REMOVAL . 2. REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY . Refer to DISASSEMBLY - Step 1 3. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY a. Disengage the 2 claws and remove the ignition or starter switch assembly.

Fig. 46: Identifying Ignition Or Starter Switch Assembly Claws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION INSPECTION

1. INSPECT IGNITION OR STARTER SWITCH ASSEMBLY a. Measure the switch resistance.

Fig. 47: Identifying Ignition Or Starter Switch Assembly Connector Terminal Identification Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEXT IN ILLUSTRATION Component

without harness connected *a (Ignition or Starter Switch Assembly) *b LOCK *c ACC *d ON *e START Standard Resistance Tester Switch Specified Connection Position Condition Between all 10 kohms LOCK terminals or higher 2 (ACC) - 4 ACC (AM1) 2 (ACC) - 4 (AM1) 1 (IG1) - 4 ON (AM1) 5 (AM2) - 6 (IG2) Below 1 ohms 3 (ST1) - 4 (AM1) 1 (IG1) - 4 (AM1) START 5 (AM2) - 6 (IG2) 5 (AM2) - 7 (ST2) If the result is not as specified, replace the ignition or starter switch assembly. INSTALLATION INSTALLATION

1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY a. Engage the 2 claws to install the ignition or starter switch assembly. 2. INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY . Refer to REASSEMBLY - Step 17

3. INSTALL STEERING COLUMN ASSEMBLY Refer to INSTALLATION .

RELAY ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION

1. INSPECT STARTER RELAY a. Measure the resistance according to the value(s) in the table below.

Fig. 48: Identifying Starter Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard Resistance Tester Specified Condition Connection Condition Battery voltage not 10 kohms 3-5 applied or higher betw