TOYOTA URETHANE ADHESIVE SEALANT FOR FIXED GLASS INSTALLATION

Short Description
In order to comply with FMVSS 212 – Windshield Retention and FMVSS 216 – Roof Crush Resistance, the factory uses a urethane adhesive sealant with bonded strength of not less than 40 kilograms per square centimeter or 569 pounds per square inch for certain bonded windshields and rear windows on Toyota vehicles. A Urethane adhesive sealant of at least equivalent strength must be used to maintain these retention and roof crush standards when windshield glass replacements are performed by either the dealer or an outside glass shop.

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Since the adhesive kits listed in Toyota Repair Manuals are not available in the U.S.A., a listing of some locally available equivalent materials is provided below. Be sure to follow the sealant manufacturer’s instructions for best results.
- CVS Urethane Auto Glass Sealer by American Sure Seal Bonding strength = 600 pounds per square in. (approximate)
- Super Fast Urethane by 3M Bonding strength = 1000 pounds per square in. (approximate)
- Unrest 212 by Kent Industries Bonding strength = 600 pounds per square in. (approximate)
- Urethane E Auto Glass Sealer by Protective Treatment Inc. Bonding strength = 600 pounds per square in. (approximate)
For more detailed application information, see the attached “Urethane Adhesive Sealant Application for Toyota Models”.
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Toyota How to Replace a Bulb

Short Description
SINGLE ENDED BULBS – These are used for exterior lights and are generally accessible by removing a lens cover. On some models, the rear light bulbs can be accessed by removing the cover inside the trunk or cargo compartment. There are two types of single ended bulbs: single filament and double filament.
DOUBLE ENDED BULBS – These are primarily for interior dome lights. WEDGE BASE BULBS – These are used in the glove box, trunk and as side marker lights. On newer vehicles, these are used for exterior lights including turn signals and brake lights.

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1. REMOVE THE KEYS FROM THE IGNITION WHEN WORKING ON THE VEHICLE. TURN THE HEADLAMP SWITCH OFF. SEE CAUTION ON BACK PANEL.
2. REMOVE THE BULB LENS COVER OR DISCONNECT THE LIGHT ASSEMBLY FROM THE VEHICLE INTERIOR AS APPLICABLE – Remove the screws and pull off the lens cover or pull off the cover by hand if applicable.
3. REMOVE THE BURNED-OUT BULB – For double-ended bulbs, carefully pull back one of the spring clips to release tension
on the bulb. For wedge-base bulbs, just pull straight out.
4. INSPECT THE SOCKET FOR DIRT AND CORROSION – Clean off any dirt with a rag or paper towel. If corroded, the light socket(s), wire connector, and/or light assembly may require replacement.
Consult your Toyota Dealer Service and/or Parts Departments for details and parts. Use bulbs with wattage ratings given in your owner’s manual.
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Toyota How to Replace Thermostat

Short Description
RECHECK COOLANT LEVEL – Shut the engine off, allow it to cool and check the coolant level. Coolant level should also be checked at the coolant reservoir (as per Owner’s Manual). Fill the radiator as required. Refer to the Owner’s Manual for exact fill level specifications.

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Engine runs hot or overheats: Check the coolant level in the radiator when the engine is cold. Check the radiator hoses and drain cock for leaks. Check the radiator, radiator cap, coolant reservoir, heater hoses and all hose connections for leaks. The radiator should also be inspected to ensure it’s free and clear of leaves, debris, etc. Remove the radiator cap when the engine is cold; run the engine for 5-10 minutes with the radiator cap removed to release air bubbles from the cooling system (this procedure may need to be repeated). With the engine off and the coolant still warm, touch the upper and lower radiator hoses. They should both be warm. If one is cold, the thermostat could be stuck in the closed position, or, the thermostat may have been installed backwards. If the problem persists, visit your Toyota Dealer Service Department for diagnosis and repair. DO NOT DRIVE THE VEHICLE if the engine overheats.
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Technical Bulletin FRONT SEAT SQUEAK NOISE 04 07 Toyota & Scion

Short Description
Some customers may experience a squeak noise due to contact between the seat track locating pin(s) and the floor pan location hole(s). The following procedure describes the repair method to correct this condition.

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CAUTION:
- Wear safety gloves to prevent injury to your hands.
- Work must be started more than 90 seconds after the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a backup power source. If work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may deploy.)
- The yaw rate sensor is installed under the front RH seat. Be careful NOT to step on the yaw rate sensor after the seat has been removed.
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HINT:
- The installation is the reverse order of removal. However, when there is a special point concerning installation, it is indicated.
- Use the same procedure on the RH side as on the LH side.
- When removing/installing and performing repairs on the passenger seat, perform the Occupant Classification System Zero Point Calibration as outlined in the Diagnostics section of the applicable model year Repair Manual for each model.
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Toyota Prius Chassis Rail Repair Manuals

Short Description
In 2004 Industry Research focused its Low Speed Crash Test Program on Hybrid vehicles, the two crashed were the Toyota Prius and Honda Civic Hybrid. Information has come to light with regards to repairs to the Prius. As a result of the test, the right hand front chassis was damaged. Normally the creasing would not be enough to require replacement. A substantial repair allowance was thought to be the correct method of repair.

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During repairs it was discovered that the chassis rail is constructed from high strength steel and whilst being realigned the rail easily tore away at the creases. A check of the Prius’s body Repair manual confirms the use of ‘Hot Stamped’ high strength steel. The following paragraph is an extract from the Prius NHW20 series repair manual, Precautions For Repairing Body Structure, IN –16 section 2, Structure Panel Kinks.
“A sharp deformation angle of the panel that cannot be returned to shape by pulling or hammering is called a kink. Since the structure parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred.”
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COLLISION REPAIR MANUAL INFORMATION FOR THE TOYOTA DEALER

Short Description
In today’s body shop environment high strength steel (H.S.S.) body parts are frequently welded during collision damage repairs. Typical uses for H.S.S. are the front cross member, front body outer pillar, floor side member and door side impact protection beam. Because H.S.S. is used in these areas of potential high stress, repairs must be done properly to maintain the structural integrity of the vehicle.

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Two types of H.S.S. are used. Solution hardened H.S.S. is used for door panels, hood outer panel, etc., while precipitation hardened H.S.S. is used for door impact beams and bumper reinforcements. It is not necessary to distinguish solid solution hardened steel from ordinary steels for repair purposes.
REPAIR GUIDELINES
H.S.S. and ordinary steel parts in Toyota vehicles are welded using the same methods. The following precautions apply:
- Use either spot welding or MIG/MAG (shield gas) welding. MIG/MAG (shield gas) welding should only be done by an experienced body shop person.
- Only braze body components previously brazed at the factory and as indicated in the Toyota Repair Manual for Collision Damage.
- Do not use an oxy–acetylene torch for fusion welding auto bodies. The large heat affected zone may destroy galvanized coatings and cause excessive panel distortions. In addition, an oxy–acetylene torch will reduce the strength and increase the brittleness of H.S.S.
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Toyota Service Bulletin - Shock Absorber Replacement Criteria

Short Description
The purpose of this TSB is to provide a quick reference to assist in making easy judgements regarding shock absorber and strut replacements.

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Applicable Vehicles: 2006 – 2007 model year Toyota vehicles.
Condition: Slight oil seepage from oil seal case
Action: Normal oil evaporation — NOT necessary to replace the shock absorber

Condition: Moderate oil seepage from oil seal case
Action: Normal oil evaporation — NOT necessary to replace the shock absorber
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1990 TOYOTA SUPRA REPAIR MANUAL

This chiral contains aliment and adjustment procedures for the

1990 TOYOTA SUPRA.

Applicable model: MA70 series

The chiral is disconnected into 24 sections and 4 appendixes with

a deride basis for anniversary area at the bend of the pages.

Please agenda that the publications beneath accept aswell been prepared

as accordant account manuals to the apparatus and systems in

this vehicle

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Toyota and Lexus Hybrid Brake Integration Information

Explanation about Hybrid vehicle, with picture and example, suitable for automotive learner. Contain information about: 1967 S800 GAS TURBINE HYBRID Gas Turbine Electricity Control Unit (Chopper) Electricity Control Unit (Chopper). TOYOTA & LEXUS HYBRID DRIVE Rear-Mounted Motor Generator (MGR). Internal Combustion Engine. Hybrid Electronic Control Unit (Hybrid ECU). Conventional brakes use mechanical friction to slow the vehicle. Kinetic energy is lost as heat. Toyota Hybrid System. HYBRID SYSTEM BRAKE CONTROL.

Supercharger Kit Installation Instructions – Toyota Land Cruiser 1995 – 1997

To help you later, we suggest you draw diagrams of your engine’s cable routing before disconnecting anything. You can do the same for the vacuum lines. However, some vacuum lines will be rerouted. To ensure proper hose connections, refer to the illustration in the back of this manual.

Special Tools Toyota Land Cruiser Repair Manual (available from Toyota, 1-800-622-2033). Remove the two throttle cable brackets and the Vehicle Identification Number (VIN) label attached to the cylinder head (if installed)

Owners Manual – Body Electrical Troubleshooting for 2003 Toyota Tacoma

Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine. It is stored when 180 sec. has passed after the power supply connector is pulled out after engine start. It may be stored when the engine key is turned 1 min. again after engine start. It may be stored when the engine key is turned again after engine start.

Manual Guide – Fuel Pump Control Circuit for 2002 Toyota Tacoma

When the STA signal and NE signal are input to the ECM, Tr is turned on, current flows to the coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr on (circuit opening relay on) and the fuel pump also keeps operating. WIRING DIAGRAM DIAGNOSTICS ENGINE (5VZ–FE). INSPECTION PROCEDURE.

Installation Manual TWM Performance Short Shifter 2009 Toyota Corolla

Please Note: It is preferable to park on a flat surface, as you will have to engage and
disengage the hand brake and shift from gears to neutral. If you cannot do so and are obliged
to install the short shifter on a slightly inclined surface, place wooden blocks in front and
behind the wheels to prevent the car from moving while you’re working. Please read this
manual completely before beginning to work on your car.
Estimated Installation Time: 60 minutes shifter only, 75 minutes with base bushings
Tools required:
• Flat head screw drivers (small and large)
• Philips head screw driver
• Hammer
• Flash light or shop light **Recommended
• Needle nose pliers
• Rotary cutting tool (Dremel Tool) **Recommended
• Safety glasses
• Shop towels or rags
• Metric socket set (with 10mm, 12mm, and 14mm sockets) and a ratchet with extension
• Punch set (screwdrivers may be substituted)
• Bench Vise
• All purpose automotive grease (white Lithium based grease preferred)

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Toyota Tacoma Technical Service Bulletin - Front Cowl Water Leak Repair Procedure

Short Description
Use the following field–fix procedure if water is present on the floor carpeting and it can be confirmed that the leak is from the front cowl seam.

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Toyota Glass Cleaner has been added to Required Tools & Materials. Steps 2 and step 3 have been updated in the confirmation procedures for the front cowl seam leak and the lower front cowl seam leak (step 2: Toyota Glass Cleaner added, step 3: air intake selector should be set to Fresh instead of Recirculate).
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1. Remove wiper arms and plastic cowl cover. For further removal instructions, refer to the Technical Information System (TIS): 2005 model year Tacoma Repair Manual: Wiper & Washer: Windshield Wiper Motor Assy: Replacement.
2. Locate the left and right front cowl seam and wet area with Toyota Glass Cleaner. Refer to Figure 1 for the location of the left front cowl seam.
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TOYOTA TACOMA FRONT HITCH INSTALLATION

TOYOTA TACOMA

Short Description
1. Remove 2 bolts, one from each end of front bumper beam. Pull out end caps and return to customer.
2. Place 4″ carriage bolt through spacer(CM-SP4) and into existing holes from the inside of the frame (both sides).

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3. Where the end cap was removed in step 1, place a 1/2″ x 1 1/4″ carriage bolt through spacer(CM-SP3) into the existing hole in the front bumper beam.
4. Hang side plates from carriage bolts installed in step 2 on the outside of the frames and finger tight with 1/2″ flange nuts.
5. Lift main body into place between side plates and loosely attach using 7/16″ carriage bolts and flange nuts as shown.
6. Attach straps of main body to 1/2″ carriage bolts placed in step 3. Finger tight with 1/2″ flange nuts.
7. Torque all 1/2″ fasteners to 75 ft.-lbs. and 7/16″ fasteners to 50 ft.-lbs. in the following order:
First: Fasten main body to side plates.
Second: Fasten strap to front bumper beam.
Third: Fasten side plates to frame.
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2005 TOYOTA TACOMA REPAIR MANUAL - LIGHTING - LH HEADLAMP ASSY

Short Description
ADJUSTMENT
1. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT
(a) Prepare the vehicle:
- Ensure that there is no damage or deformation to the body around the headlamps.
- 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.
- Place the spare tire, tools, and jack in their original positions.
- Unload the trunk.
- Sit a person of average weight (68 kg, 150 lb) in the driver’s seat.

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2. PREPARATION FOR HEADLAMP AIMING (Using a tester)
(a) Prepare the vehicle for headlamp aim check.
(b) Perform adjustment in accordance with the headlamp tester instructions.
3. PREPARATION FOR HEADLAMP AIMING (Using a screen)
(a) Prepare the vehicle according to the following conditions:
- 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 headlamps can be observed and above which it cannot.
- Place the vehicle at a 90 angle to the wall.
- Keep a 7.62 m (25 ft) distance between the center of the headlamp bulb and the wall.
- Place the vehicle on a level surface.
- Bounce the vehicle up and down to settle the suspension.
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TOYOTA TACOMA - Idle Control System Malfunction

Short Description
The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way, the intake air volume bypassing the throttle valve is regulated, controlling the engine speed.

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The ECM operates only the IAC valve to perform idle–up and provide feedback for the target idling speed.

INSPECTION PROCEDURE
HINT:
Read freeze frame data using hand–held tester or OBD II scan tool, as freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.

PREPARATION:
(a) Warm up the engine to normal operating temperature.
(b) Switch off all the accessories.
(c) Switch off the A/C.
(d) Shift the transmission into the N or neutral position.
(e) Connect the hand–held tester or OBD II scan tool to the DLC3 on the vehicle.
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TOYOTA TACOMA - Evaporative Emission Control System Leak Detected

Short Description
The vapor pressure sensor, VSV for EVAP, VSV for canister closed valve (CCV) and VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal.

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DTC P0442 or P0456 is recorded by the ECM when evaporative emissions leak from the components within the dotted line in Fig. 1 below, or when the vapor pressure sensor malfunctions.

After purge operation, the VSV for EVAP is turned off sealing the vacuum in the system and the ECM begins to monitor the pressure increase. It is a normal if the increase in pressure is lower than the predict level. A very rapid, sharp increase in pressure indicates a leak in the EVAP system and sets the DTC P0442. A pressure rise just above normal indicates a very small hole and will set the DTC P0456.
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Toyota - Oil Filter Cap Assembly Precautions

Short Description
The information contained in this TSB supersedes TSB No. T-SB-0332-08.
• Applicability has been updated to include 2009 – 2010 model year Highlander, 2010 model year Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles.
• The SST table has been updated with an illustration.
• The Notice in the Repair Procedure has been updated with a Figure and torque specification ranges to clarify SST usage.
TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding.

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To prevent damage to the oil filter cap assembly, this procedure must be closely followed during oil filter replacement to avoid immediate and future oil filter serviceability concerns. The following engines are equipped with a plastic oil filter cap assembly:
• 1UR-FE (Tundra, Sequoia)
• 3UR-FE (Tundra, Sequoia, Land Cruiser)
• 2ZR-FE (Corolla, Matrix)
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Repair Procedure
During oil filter replacement:
• Ensure that SST 09228-06500-02 or 09228-06501 is used to remove and install the oil filter cap — or damage to the cap may occur.
• Inspect the SST for any damage or distortion before use.
• Confirm that the SST is fully seated on the oil filter cap when removing/installing (see Figure 1).
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Toyota Service Bulletin - Shock Absorber Replacement Criteria

Short Description
The purpose of this TSB is to provide a quick reference to assist in making easy judgements regarding shock absorber and strut replacements.

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Content
Applicable Vehicles: 2006 – 2007 model year Toyota vehicles.
Condition: Slight oil seepage from oil seal case
Action: Normal oil evaporation — NOT necessary to replace the shock absorber

Condition: Moderate oil seepage from oil seal case
Action: Normal oil evaporation — NOT necessary to replace the shock absorber
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