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Repair Instruction: Precaution: Precaution

  1. SERVICE CAUTIONS 
    1. Injury/damage Prevention Precautions
      1. Depending on the vehicle, the cooling fan may operate suddenly even when the ignition is switched off (LOCK). Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing the cooling fan or parts near the cooling fan.
    2. Protection of the Vehicle
      Fig 1: Protection Of Vehicle
      GTY492895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Always be sure to cover fenders, seats and floor areas before starting work.
    3. Preparation of Tools and Measuring Equipment
      Fig 2: Preparing Tools And Measuring Equipment
      GTY492894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Be sure that all necessary tools and measuring equipment are available before starting any work.
    4. Special Service Tools
      Fig 3: Identifying Special Service Tools (SST)
      GTY495085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Use special service tools or the equivalent when they are required.
        • SST: 49SE01310 
    5. Malfunction Diagnosis System
      1. Use the Techstream for malfunction diagnosis.
    6. Connection to malfunction diagnosis system
      1. With the ignition switched off, connect the malfunction diagnosis system to the DLC-2 connector shown in the figure.
      Fig 4: Locating DLC2 Connector
      GTY485784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a DLC2
    7. Oil Leakage Inspection
      1. Use either of the following procedures to identify the type of oil that is leaking:
    8. Using UV light (black light)
      1. Remove any oil on the engine or transmission/transaxle.

        HINT: 

        Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or transmission/transaxle oil.

      2. Pour the fluorescent dye into the engine oil or transmission/transaxle oil.
      3. Allow the engine to run for 30 min.
      4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
      5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
      6. Find where the oil is leaking from, then make necessary repairs.

        HINT: 

        To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual.

    9. Not using UV light (black light)
      1. Gather sample of the leaking oil using an absorbent white tissue.
      2. Then, gather some samples of engine and transmission/transaxle oil onto a white cloth or piece of paper.
        • MT vehicles: Transmission/transaxle oil
        • AT vehicles: ATF
        • CVT vehicles: CVT fluid
      3. Compare the appearance and smell, and identify the type of oil that is leaking.
      4. Remove any oil on the engine or transmission/transaxle.
      5. Allow the engine to run for 30 min.
      6. Check the area where the oil is leaking, then make necessary repairs.
      Fig 5: Locating Fluid Leaks
      GTY485673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Transmission/Transaxle Oil
      *b Leaked Oil
      *c Engine Oil
    10. Switch The Power Supply Using The Push Button Start And Start The Engine
      1. The power supply switches according to the vehicle conditions such as the shift lever (MTX)/selector lever (ATX) position and the pedal depression/release.
        Fig 6: Power Supply Switching Chart
        GTY485168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        () *1 : To switch the ignition ACC or OFF from ON (engine on), the vehicle speed must be 5 km/h {3 mph} or less.

    11. Removal of Parts
      Fig 7: Identifying Parts And Sub-Components To Be Removed
      GTY492912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and sub-components must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.
    12. Control module configuration (initialization setting)
      NOTE:

      If the configuration procedure is not completed correctly after replacing a control module in which configuration is required, the system will not operate normally. Therefore, perform the work in accordance with the replacement procedure in the workshop information.

      1. If the control module is replaced, and depending on the control module, it may be necessary to write the vehicle specification data to the new control module using the Techstream. This procedure is for performing the configuration (initial setting).
      2. There are the following three methods of the configuration procedure for the control module:
        • Automatic configuration
          • The main control module (built into Combination Meter) performs configuration of the new control module itself and automatically using the vehicle specification data sent via CAN lines.
        • Configuration based on vehicle information read/write data
          • Reads the vehicle information from the control module prior to replacement, and writes the vehicle information to a new control module.
        • Configuration by As-Built data:
          • Obtains the vehicle specification data when the vehicle is shipped from the factory, and writes the data to a new control module.
          • The configuration using As-Built data is used if the vehicle information cannot be read due to a damaged control module which is to be replaced, or if a DTC such as a configuration malfunction is detected.
          • If a control module having personalization features is configured using As-Built data, the settings personalized by the customer are initialized (to factory settings). In this case, verify the setting values made by the customer and change the personalized setting values using the "Programmable Parameters " from the Techstream menu.
      3. If the module programming menu of the Techstream (Programmable Module Installation, As-Built, Programmable Parameters) is performed, perform the procedure while the battery monitor icon of the Techstream is green or gray.
    13. Disassembly
      Fig 8: Locating Alignment Marks
      GTY492909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance, and identified so that reassembly can be performed easily and efficiently.
    14. Inspection During Removal, Disassembly
      Fig 9: Part Inspection During Removal
      GTY495266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.
    15. Arrangement of Parts
      Fig 10: Arranging Parts For Reassembly
      GTY492911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. All disassembled parts should be carefully arranged for reassembly.
      2. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
    16. Cleaning of Parts
      1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
        WARNING:

        Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

        Fig 11: Cleaning Parts
        GTY492910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Reassembly
      Fig 12: Reassembly Of Parts
      GTY495265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
      2. If removed, these parts should be replaced with new ones:
        Oil seals Cotter pins
        Gaskets Locknuts (Nylon nuts)
        O-rings Spring pins
        Lock washers -
      3. Depending on location:
        • Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.
        • Oil should be applied to the moving components of parts.
          Fig 13: Application Of Sealants
          GTY492900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
    18. Adjustment
      Fig 14: Using Suitable Gauges And Testers When Making Adjustments
      GTY492905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Use suitable gauges and testers when making adjustments.
    19. Rubber Parts and Tubing
      Fig 15: Protecting Rubber Parts and Tubing
      GTY492275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Good
      1. Prevent gasoline or oil from getting on rubber parts or tubing.
    20. Hose Clamps
      Fig 16: Reinstalling Hose Clamp In Original Location
      GTY492925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

        HINT: 

        Follow the description in each article because the clamps which are used with the fuel-related system differ from the one indicated above.

    21. Torque Formulas
      Fig 17: Recalculating Torque Values
      GTY492260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. When using a torque wrench-SST or equivalent combination, the specified torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.
        Torque Unit Formula
        N*m N*m x (L/[L+A])
        kgf*m kgf*m x (L/[L+A])
        kgf*cm kgf*cm x (L/[L+A])
        ft.*lbf ft.*lbf x (L/[L+A])
        in.*lbf in.*lbf x (L/[L+A])

        () A : The length of the SST past the torque wrench drive.L : The length of the torque wrench.

    22. Vise
      Fig 18: Using Protective Plates In Vise
      GTY488023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Plates
      1. When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
    23. Dynamometer
      1. Cautions on chassis dynamometer use
        • When inspecting and servicing the powertrain on the dynamometer or speedometer tester, pay attention to the following:

          HINT: 

          If the engine cannot be stopped using the push button start, perform an emergency engine stop operation.

        • Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
        • Make sure the vehicle is in a facility with an exhaust gas ventilation system.
        • Keep the rear bumper cool by placing a cooling fan near the exhaust pipe so that the rear bumper does not get deformed by the heat from the exhaust.
        • Keep the area around the vehicle uncluttered so that heat does not build up.
        • Watch the water temperature gauge and do not overheat the engine.
        • Avoid added load to the engine and maintain normal driving conditions as much as possible.
      2. Servicing on vehicles with ABS/VSC
        • If only the front or rear wheels are rotated using a chassis dynamometer, the VSC HU/CM determines that the ABS/VSC is malfunctioning, detects a DTC, and turns on the related warning light at the same time.
        • If the light is turned on, remove the vehicle from the chassis dynamometer and switch the ignition OFF (LOCK). Then switch the ignition ON (engine on) and drive the vehicle at 20 km/h {12 mph} or more, and verify that the warning light turns off. The DTC is stored in the memory, therefore erase it by following the ON-BOARD DIAGNOSIS SYSTEM, Memory Clearing Procedure [ABS]/[VSC].

          for ABS: Refer to DTC CHECK / CLEAR

          for VSC: Refer to DTC CHECK / CLEAR

          HINT: 

          If the engine cannot be stopped using the push button start, perform an emergency engine stop operation.

      3. Cautions for vehicles with Pre-Collision System (PCS)
        NOTE:
        • If a vehicle with the following systems is inspected using a chassis dynamometer, always turn off the system before performing the inspection.
          • Pre-Collision System (PCS)
        • If a chassis dynamometer is used without turning off each system, automatic braking will operate and the inspection cannot be performed correctly.
        • In the event that a chassis dynamometer is used without turning off each system, take appropriate measures referring to the following as each of the system's warning lights may be illuminated/flashed and DTCs stored in the memory.
      4. Rotating only front or rear wheels
        • If only the front or rear wheels are rotated, the VSC HU/CM will determine that the VSC is malfunctioning. It will also determine that the laser sensor is malfunctioning and the following warning light will be illuminated or flashed.
          • Pre-Collision System (PCS) warning light (amber) is illuminated
            1. If the warning light is illuminated, remove the vehicle from the chassis dynamometer and switch the ignition OFF (LOCK).
            2. Switch the ignition ON (engine on) again and drive the vehicle at 20 km/h {12 mph} or more, and verify that the warning light turns off.
            3. Because DTCs are stored, clear the DTCs according to the memory clearing procedure.
    24. Emergency Engine Stop Operation
      1. While performing an inspection by rotating the wheels using a dynamometer, if the ABS (with ABS system) or VSC (with VSC system) detects a vehicle speed signal error, the engine cannot be stopped using the push button start. If the engine cannot be stopped using the push button start, perform an emergency stop using the following procedure.
        1. Press and hold the push button start for approx. 3 s or more, or press it three times or more successively within approx. 1.5 s.
        2. The engine stops (position is ACC).
        3. Press the push button start to switch the ignition OFF.
  2. INSTALLATION OF RADIO SYSTEM 
    1. The control modules and control unit have been designed with sufficient attention to radio wave disturbances from the outside. However, observe the following precautions when installing the radio set to the vehicle to prevent adverse effects on the control modules and control unit.
      • Install the radio set and its antenna as far away as possible from the control modules and control unit.
      • The antenna feeder and power cable generate radio waves, therefore, keep them 100 mm {3.94 in} or more from the control modules, control unit, and wiring harness. If the antenna feeder and power cable cross over the wiring harness, place them perpendicular to the wiring harness.
      • Do not install a high output radio set.
      • Do not use the control modules and control unit power source for the radio set. In addition, do not use the cigar lighter and accessory socket power source.
      • Do not attach the antenna feeder or wiring harness of the radio set to the wiring harness, fuel pipe, or brake tube of the vehicle.
      • Do not install any radio set-related devices in the area where the air bag module deploys to prevent a secondary accident if the air bag were to deploy.
      Fig 19: Locating Airbag And Restraint Components
      GTY490814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steering Pad *b Center Airbag Sensor Assembly
      *c Front Passenger Side Airbag Assembly *d Curtain Shield Airbag Assembly
      *e Pretensioner Seat Belt *f Front Seat Side Airbag Assembly
      *g Lap Pretensioner Seat Belt *h Driver Seat
      *i Passenger Seat - -

      () After installing the radio set, perform a test transmission with the engine idling to verify that it does not affect engine control.

  3. TOWING 
    1. Towing Description
      • Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
      • A towed vehicle usually should have its drive wheels (front wheels) off the ground. If excessive damage or other conditions prevent this, use wheel dollies.
      • When towing with the rear wheels on the ground, release the parking brake.
        Fig 20: Proper Towing Techniques
        GTY485018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Wheel Dollies
      NOTE:

      Do not tow the vehicle pointed backward with driving wheels on the ground. This may cause internal damage to the transaxle.

      Fig 21: Improper Towing Technique (1 Of 2)
      GTY485413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Good
      NOTE:

      Do not tow with sling-type equipment. This could damage vehicle. Use wheel-lift or flatbed equipment.

      Fig 22: Improper Towing Technique (2 Of 2)
      GTY484193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Good
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