1988 – 1995 V6 Truck, 4Runner 3VZ CYLINDER HEAD INSTALLATION and REMOVAL

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Filed Under (Toyota Manuals) by admin on 06-12-2011

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Install cylinder head a. Place a new cylinder head gasket on the engine block and install cylinder head. b. Apply a light coat of engine oil on the threads and washer face of the cylinder head bolts. c. Install the plate washer to the cylinder head bolt. d. Using a 12-point socket, install and uniformly tighten the (8) 12-point bolts in several passes, in the sequence shown in the illustration. Torque: 33 ft.lbs. (44 N-m, 450 kg-cm) e. Repeat for the other head. 2. Proceed with final tightening sequences: a. Mark the front side of the top of the bolt with a drop of paint as shown in the illustration

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Honda / Acura Crank Shaft Seal Kit installation

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Filed Under (Toyota Manuals) by admin on 17-11-2011

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Due to the close proximity of transversely mounted engines to the shock tower, this essential tool is crucial for the
proper installation of Cam Shaft Oil Seals. Comes equipped with an exclusive expansion guide ensuring damage free installation. Applicable: Most Toyota 4 cylinder & some Mazda engines. This Special Bonus Kit was designed for the proper installation of Pulley Crank Shaft oil seals, situated within confined areas on most 4, 6 & 8 cylinder Toyota / Lexus, Nissan, Mitsubishi, Mazda and Infiniti engines. Application includes Cam Shaft oil seal installation of Toyota / Lexus 2.5L, 2.8L, 3.0L, 3.4L, 4.0L & 4.3L engines. The step bolts screw into the cam or crank shaft end. The press nut w/ washer allows for an even ressing force, seating the oil seal into the engine case every time

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2003 – 2008 4Runner AND 2007 – 2008 FJ Cruiser FRONT AND REAR DIFFERENTIAL GEAR OIL SPECIFICATION CHANGE

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Filed Under (Toyota Manuals) by admin on 14-11-2011

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75W-85 GL5 synthetic gear oil beginning with the 2008 model year. This new synthetic gear oil is compatible with 2003 – 2007 model year 4Runner and 2007 model year FJ Cruiser differentials. Please refer to the Parts Information section below for information about this gear oil and use this gear oil (or equivalent) when filling front or rear differentials with oil. 2003 – 2008 model year 4Runner vehicles. 2007 – 2008 model year FJ Cruiser vehicles. PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME TYPE QTY N/A 08885-02606 Toyota Genuine Differential Gear Oil LX 75W-85 API GL-5 SAE 75W-85 LSD As Needed N/A 08885-02506 Toyota Genuine Differential Gear Oil LT 75W-85 API GL-5 SAE 75W-85 w/o LSD As Needed Refer to the diagram below to identify if LSD or non-LSD gear oil is used on the vehicle. For applicable vehicles, there is a caution label above the filler plug, as shown below

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AVALON WINDSHIELD MOLDING WIND NOISE REPAIR

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Filed Under (Toyota Manuals) by admin on 01-11-2011

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TOYOTA MOTOR SALES U.S.A., INC. TMM has implemented a production process change to improve windshield sealing. EFFECTIVE DATE VIN REFERENCE 4/26/95 4T1GB11E5SU038470 To eliminate whistling noise from the windshield top outside molding, fill in the windshield channel with a urethane sealant such as 3M Window Weld Re-sealant or equivalent (refer to illustration below for proper application)

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TOYOTA TACOMA 2008 – INTERFACE KIT FOR IPOD REPAIR

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Filed Under (Toyota Manuals) by admin on 01-11-2011

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Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as: • Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Protection. (a) Place driver seat in mid position. (b) Set emergency brake. (c) Remove the negative battery cable. (Fig. 1-1) (1) Protect the fender before starting. CAUTION: Do not touch the positive terminal with any tool when removing cable. (d) Using protective blankets cover front seats, interior of vehicle and center console and front side of the shift lever. (e) Wait 90 seconds before proceeding to disassemble vehicle. 2. Disassembly of Vehicle. NOTE: Place all removed parts on a protected surface. NOTE: When disconnecting wiring connectors, do not pull on the wiring; pull on the connector only. (a) Remove air conditioning control assembly (L,R). (Fig. 2-1) (1) Apply protective tape. (2) Using a panel remover, disengage the four (4) clips and remove the air conditioning control assembly

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2007 Corolla & Matrix 1ZZ-FE ENGINE NO START CONDITION REPAIR

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Filed Under (Toyota Manuals) by admin on 01-11-2011

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Refer to TIS, 2007 model year Corolla or Matrix Repair Manual: Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: ECM: Removal” Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: ECM: Installation” 2. Register the VIN into the replacement ECM (PCM). Refer to TIS, 2007 model year Corolla or Matrix Repair Manual: Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: SFI System: Registration Some 2007 model year Corolla and Matrix vehicles equipped with a 1ZZ-FE engine may exhibit a “no start” condition. Improvements have been made to the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM) manufacturing process to reduce the possibility of this condition occurring. Please use the following procedure to repair the vehicle

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4X4 – TRUCK, 4RUNNER 4X4 FRONT AXLE BEARING REPLACEMENT

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Filed Under (Toyota Manuals) by admin on 31-10-2011

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To reduce front spindle bushing noise which may be experienced during severe cold ambient temperatures, a new needle roller bearing and thrust bushing have been made available for use in place of the original bushing. Note: This repair is applicable only to 4X4 vehicles produced after 8/89. INSTALLATION PROCEDURE: 1. Remove front axle bushings (refer to applicable service manual section). 2. Install needle roller bearing using SST #09620-30010, tool #5 or equivalent bearing driver. Reference: Bearing must be installed with flat side (I.D. number and part number) facing outward. Refer to illustration.

2005-2010 TACOMA RUNNING BOARD REPAIR

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Filed Under (Toyota Manuals) by admin on 31-10-2011

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Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- — Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). — Safety (eye protection, rechecking torque procedure, etc.). — Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). — Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Remove Running Board from Packaging. (a) Remove running board assembly from package and place on a clean protected surface. The boards are sided (Fig. 1-1) (b) Verify kit contents and inspect the running board for damage. 2. Running Board Preparation for Installation (LH/RH Side). (a) Verify hardware bag content by referring to the cover page of this instruction sheet. (b) Loosen the 1/4 – 20 flange nuts at each of the three (3) bracket locations on each running board. (Fig. 2-1) (c) With a small slotted screwdriver, remove the plastic plugs covering M8 weld nuts in body of vehicle at 6 points/side.

2003 – 2007 4Runner OIL LEAK FROM FRONT TIMING COVER

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Filed Under (Toyota Manuals) by admin on 31-10-2011

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evidence of a small oil leak located where the Bank 1 cylinder head, engine block, and timing cover meet. Use the following repair procedure to address this condition. 2003 – 2007 model year 4Runner vehicles equipped with the 1GR-FE engine and produced BEFORE the Production Change Effective VINs shown below. MODEL PLANT DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN 2WD JTEZU17R#68064608 Hino 2WD JTEZU14R#78076191 4Runner Hino 4WD JTEBU14R#78078323 4Runner 4WD JTEBU14R#78090468 Tahara 2WD JTEZU14R#70091230 Tahara 4WD JTEBU14R#70117349 OP CODE DESCRIPTION TIME OFP T1 T2 EG7036 Reseal FrontTiming Cover with FIPG 2WD7.6 113100P0306548 EG7036 Reseal Front Timing Cover with FIPG 4WD8.5 11310-0P030 65 48 Applicable Warranty*: This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date. *Warranty application is limited to correction of a problem based upon a customer’s specific complaint

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1989 – Current All Mode SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM REPAIR

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Filed Under (Toyota Manuals) by admin on 30-10-2011

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specifications. The inspection procedure for each type of sensor differs from the others. Select the appropriate inspection procedure from the table below according to vehicle specifications and perform the inspection. EQUIPPED WITH AUTOMATIC LIGHT CONTROL SYSTEM A/C SYSTEM WITH RIGHT/LEFT INDEPENDENT TEMPERATURE CONTROL INSPECTION PROCEDURE No No A No Yes B Yes Yes C Yes No D Procedure A: a. Disconnect the solar sensor connector. b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions: Cover the sensor with a cloth to avoid direct light. Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light. NOTE: Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, connect the positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor. HINT: If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light

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