Part 2

INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION - Continued

9. ADJUSTMENT FOR BREAK PEDAL

(a) CHECK BRAKE PEDAL HEIGHT

(1) Check the brake pedal height.

Standard Pedal Height from No. 2 Dash Panel Insulator Pad:

147.1 to 157.1 mm (5.80 to 6.18 in.)

NOTICE:
Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio.

If the pedal height is incorrect, adjust the rod operating adapter length.

(2) Adjust the rod operating adapter length.

1 Remove the clip and clevis pin.

2 Loosen the clevis lock nut.

3 Adjust the rod operating adapter length by turning the pedal push rod clevis.

Standard Rod Operating Adapter Length "A":

201.7 to 202.7 mm (7.94 to 7.98 in.)

4 Tighten the clevis lock nut.

5 Set the master cylinder push rod clevis in place, insert the push rod pin from the outside of the vehicle and then install a new clip.

If the pedal height is incorrect even if the rod operating adapter is adjusted, check that there is no damage in the brake pedal, brake pedal lever, brake pedal support and dash panel.

* Even if there is damage, there is no problem if the reserve distance is within the standard value.

* If necessary, replace any damaged parts.

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

(b) CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY

HINT
If the pedal height is incorrect, check and adjust the stop light switch clearance.

(1) Disconnect the stop light switch assembly connector from the stop light switch assembly.

(2) Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly.

(3) Insert the stop light switch assembly until the body hits the brake pedal bracket.

NOTICE:
When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

(4) Turn the stop light switch assembly a quarter turn clockwise to install it.

HINT
Turning the stop light switch assembly counterclockwise loosens the switch.

(5) Connect the stop light switch connector to the stop light switch assembly.

(6) Check the protrusion of the rod.

Standard Rod Protrusion:

1.5 to 2.5 mm (0.0591 to 0.0984 in.)

(7) After adjusting the pedal height, check the pedal free play.

(c) CHECK PEDAL FREE PLAY

(1) Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown in the illustration.

Standard Pedal Free Play:

1 to 6 mm (0.0394 to 0.236 in.)

(d) CHECK PEDAL RESERVE DISTANCE

(1) Release the parking brake lever.

With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.

Standard Pedal Reserve Distance from No. 2 Dash Panel Insulator Pad at 490 N (50 kgf, 110.2 lbf):

More than 67 mm (2.64 in.)

If incorrect, troubleshoot the brake system.

10. ADJUSTMENT FOR PARKING BREAK SYSTEM

(a) INSPECT PARKING BRAKE LEVER TRAVEL

(1) Fully pull the parking brake lever to engage the parking brake.

(2) Release the lever to disengage the parking brake.

(3) Slowly pull the parking brake lever all the way, and count the number of clicks

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):

5 to 7 clicks

If the parking brake lever travel is not as specified, adjust the parking brake shoe clearance and parking brake lever travel.

(b) REMOVE REAR WHEEL

(c) ADJUST PARKING BRAKE LEVER TRAVEL

(1) Remove the console cup holder box sub-assembly.

(2) Completely release the parking brake lever.

(3) Loosen the adjusting nut to completely release the parking brake cable.

(4) Temporarily install the hub nuts.

(5) Remove the hole plug.

(6) Insert an adjustment tool into the adjustment hole of the disc. Rotate the adjustment wheel in the "X" direction until the shoes are locked. Then rotate the adjustment wheel in the "Y" direction 8 notches.

(7) Check that the disc can be rotated lightly. If not, rotate the adjustment wheel in the "Y" direction and check again.

(8) Install the hole plug.

(9) Remove the hub nuts.

(10) Turn the adjusting nut until the parking brake lever travel becomes correct.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):

5 to 7 clicks

(11) Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):

5 to 7 clicks

(12) Check whether the parking brake drags or not.

(13) When operating the parking brake lever, check that the brake warning light comes on.

Standard Condition:

The brake warning light always illuminates at the first click.

(14) Install the console cup holder box sub-assembly.

(d) INSTALL REAR WHEEL

Torque : 131 Nm (1,336 kgf-cm, 97 ft-lbf)

11. ADJUSTMENT FOR STEERING SYSTEM

(a) STEERING OFF CENTER ADJUSTMENT PROCEDURE

HINT
This is the adjustment procedure for when the steering is off center.

(1) Check if the steering wheel is off center.

1 Apply masking tape to the top center of the steering wheel and steering column upper cover.

2 Drive the vehicle in a straight line for 100 m (328 ft.) at a constant speed of 56 km/h (35 mph), and hold the steering wheel to maintain the course.

3 Draw a line on the masking tape as shown in the illustration.

4 Turn the steering wheel to the center position.

HINT
Look at the upper surface of the steering wheel, steering spoke and SRS airbag line to find the center position.

5 Draw a new line on the masking tape on the steering wheel as shown in the illustration.

6 Measure the distance between the 2 lines on the masking tape on the steering wheel.

7 Convert the measured distance to steering angle.

HINT
* Measured distance of 1 mm (0.0394 in.) = Steering angle of approximately 1°.
* Make a note of the steering angle.

(2) Adjust the steering angle.

1 Put matchmarks on the RH and LH tie rod ends and rack ends where it can be easily seen.

2 Using a paper gauge, measure the distance from the RH and LH tie rod ends to the rack end screws.

HINT
* Measure both the RH and LH sides.
* Make a note of the measured values.

3 Remove the RH and LH boot clips from the rack boots.

4 Loosen the RH and LH lock nuts.

5 Turn the RH and LH rack ends by the same amount (but in different directions) according to the steering angle.

HINT
One 360° turn of the rack end (1.5 mm (0.0591 in.) horizontal movement) equals 11° of steering angle.

6 Tighten the RH and LH lock nuts to the specified torque.

NOTICE:
Make sure that the difference in length between the RH and LH tie rod ends and rack end screws is within 1.5 mm (0.0591 in.).

7 Install the RH and LH boot clips.

Torque : 82 Nm (836 kgf-cm, 60 ft-lbf)

12. REGISTRATION RELATED TO GARAGE DOOR OPENER SYSTEM

(a) REGISTER TRANSMITTER CODE

HINT
* The vehicle garage door opener records transmitter codes for systems such as garage doors, gates, entry gates, door locks, home lighting systems, security systems or other transmitter code based systems.
* The garage door opener is built into the map light assembly. If replacing the map light assembly transmitter, codes for any systems previously registered in the garage door opener must be reregistered.

(1) Register systems in the garage door opener registration mode.

CAUTION:
Do not perform transmitter code registration for a system if people or objects are near the system. When registering transmitter codes for a system, injury or damage can occur because the system may open, close, unlock or otherwise operate.

NOTICE:
* Before transmitter code registration, confirm that all the electrical systems (headlight, blower motor, rear defogger, etc.) are turned off and that no key is in the vehicle.
* The garage door opener cannot be used with systems that: 1) were manufactured before April 1, 1982, or 2) do not meet Federal Standards (for example, garage doors without a jam protection function).

HINT
* 3 transmitter codes can be registered with the garage door opener, one transmitter code for each of the 3 garage door opener switches.
* Disconnecting the battery will not clear the transmitter codes registered with the garage door opener.

1 Select a garage door opener switch for transmitter code registration.

2 Press and hold the selected switch. The garage door opener will enter registration mode after a brief pause.

Text in Illustration

HINT
After entering registration mode, the LED flashes at a frequency of 1 Hz.

3 After the garage door opener has entered registration mode, continue holding the selected garage door opener switch and bring the original transmitter of the system to be registered within 1 inch of the garage door opener switches. Then, without releasing the selected garage door opener switch, press and hold the original transmitter switch.

Text in Illustration

4 If the transmitter code registration was successful, the LED of the garage door opener flashes at a frequency of 5.6 Hz, and the registration completes. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch.

(2) Overwrite previously registered systems in the garage door opener registration mode.

1 Select a garage door opener switch that will be overwritten with a new transmitter code.

2 Press and hold the selected switch. After approximately 20 seconds, the garage door opener will enter registration mode.

Text in Illustration

HINT
Before entering registration mode, the LED is on. After entering registration mode, the LED flashes at a frequency of 1 Hz.

3 After the garage door opener has entered registration mode, continue holding the selected garage door opener switch and bring the original transmitter of the system to be registered within 1 inch of the garage door opener switches. Then, without releasing the selected garage door opener switch, press and hold the original transmitter switch.

Text in Illustration

4 If the transmitter code registration was successful, the LED of the garage door opener flashes at a frequency of 5.6 Hz, and the overwriting completes. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch.

HINT
* If transmitter code registration fails: 1) the original transmitter battery may be low or need to be replaced, or 2) the system you are trying to register may not be compatible with the garage door opener.
* The signals of some transmitters stop after 1 to 2 seconds. For these types of transmitters: 1) press and hold one of the garage door opener switches, and 2) press and release (cycle) the transmitter switch every 2 seconds. Check if the transmitter code was successfully registered.
* After entering the garage door opener registration mode, transmitter code registration must be completed within 55 seconds. If 55 seconds elapse, the garage door opener will enter low power mode (refer to the "low power mode" below).

(3) Clear transmitter codes in the garage door opener clear mode.

HINT
All 3 registered transmitter codes will be cleared. No option exists for only erasing one transmitter code.

1 Press and hold the left and right switches at both ends of the garage door opener for 10 seconds. The LED will flash at a frequency of 5.6 Hz, and clearing is completed. Releasing the switches will end clear mode.

Text in Illustration

HINT
* If the switches are released within 10 seconds after the transmitter codes have been cleared, the garage door opener will enter registration mode.
* If the switches are held for 10 seconds or more after the transmitter codes have been cleared, default codes will be set to the switches of the garage door opener. Using these default codes, operation of the garage door opener can be checked using a tester.

(4) Low power mode:

1 If the garage door opener switch is held for 75 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off.

13. DCM ACTIVATION

This function should be used to activate the DCM (Telematics Transceiver) after a new DCM (Telematics Transceiver) has been installed. During the DCM Activation process, Techstream automatically provides the telematics service provider with the new DCM (Telematics Transceiver) information and deletes the old DCM (Telematics Transceiver) information associated with the vehicle. The DCM (Telematics Transceiver) that was replaced should be returned to the parts department.

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Choose "Telematics" from the System Selection Menu, and then click "Utility".

(e) Click "DCM Service" on the Utility Selection Menu.

(f) Choose "Activate DCM" and then click "Next" on the DCM Service Utility.

(g) Follow the instructions on the Techstream.

HINT
* If PRL is not latest version, utility will report that a PRL update must be performed before DCM Activation can be completed.
* If a fault occurs during DCM Activation, a specific fault message will be displayed with procedure guidelines.
* The manual (SOS) switch green indicator will turn on if activation is successful.

HINT
If the one these fault code is present, follow the procedure indicated in the following list.

* Fault 20: Try DCM Activation again.
* Fault 61: Replace the DCM (Telematics Transceiver) with a new service part and perform DCM Activation.
* Fault 62*: Verify VIN is correct in ECM. Run Vehicle Inquiry and verify VIN.
* Fault 63: Replace the DCM (Telematics Transceiver) with a new service part and perform DCM Activation.
* Fault 64*: Verify that the DCM (Telematics Transceiver) is a new service part.
* Fault 66*: Replace the DCM (Telematics Transceiver) with a new service part and perform DCM Activation.
* Fault 67: Try DCM Activation again. If the fault occurs again, wait and try again later.
* *: As the fault could also be caused by a problem in communicating with the call center, before replacing the DCM, check with the call center to determine it there is a database or communication problem.
(Call Center number for TOYOTA vehicle: 800-331-4331)

(h) Push the manual (SOS) switch to call an operator and confirm that the DCM (Telematics Transceiver) is activated.

14. REGISTRATION RELATED TO ENTRY AND START

(a) DESCRIPTION OF CODE REGISTRATION

HINT
* The engine immobiliser function ID code is the same as the recognition code for the smart key system and wireless transmitter. Registering an ID code enables the smart key system, wireless door lock control function and engine immobiliser function to be operated.
* Code registration is needed when the certification ECU (smart key ECU assembly), ID code box (immobiliser code ECU), steering lock ECU, ECM or key is replaced with a new one.
*

This vehicle does not have a key slot. Therefore, touch the logo of the key to the engine switch to register the key, as shown in the illustration.

(b) KEY REGISTRATION PROCEDURES WHEN ADDING OR REPLACING KEY OR WHEN KEY IS LOST

HINT
* The following procedures require the use of the Techstream:
* - New key ID registration
* - Additional key ID registration
* - Key ID erasure
* A maximum of 7 keys can be registered.

(c) PART REPLACEMENT AND KEY REGISTRATION PROCEDURES

(1) If a malfunctioning ECU is discovered through troubleshooting of the smart key system, use the ECU replacement and key registration procedures in the table below.

HINT
* The following procedures require the use of the Techstream:
* - New key ID registration
* - Additional key ID registration
* - Key ID erasure
* - ECU code registration
* A maximum of 7 keys can be registered.

(d) KEY REGISTRATION PROCEDURES

(1) PROCEDURE "A"

New key ID registration (when replacing certification ECU (smart key ECU assembly) and ID code box (immobiliser code ECU), or certification ECU (smart key ECU assembly), ID code box (immobiliser code ECU) and steering lock ECU), or when performing all keys ID erasure (key code reset):

HINT
*: Repeat this process for each key which is to be registered to the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform the registration from process 1 again. Make sure that only 1 key is in the cabin during registration. If 2 or more keys are in the cabin simultaneously, the electric waves will interfere with each other, preventing normal registration.

(2) PROCEDURE "B"

New key ID registration (when replacing certification ECU (smart key ECU assembly)):

HINT
* *1: Repeat this process for each key registered to the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform the registration from process 1 again. When performing the key confirmation procedure for a key, the security indicator light comes on and remains on until all the keys are confirmed.
* *2: Repeat this process for each key which is to be registered to the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform the registration from process 1 again. Make sure that only 1 key is in the cabin during registration. If 2 or more keys are in the cabin simultaneously, the electric waves will interfere with each other, preventing normal registration.

(3) PROCEDURE "C"

Additional key ID registration:

HINT
* *1: Perform this process for one of the keys registered to the vehicle. Finish the procedure within 30 seconds. If the procedure has not been finished within the specified time, perform the registration from process 1 again.
* *2: Repeat this process for each key which is to be registered to the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform the registration from process 1 again. Make sure that only 1 key is in the cabin during registration. If 2 or more keys are in the cabin simultaneously, the electric waves will interfere with each other, preventing normal registration.

(4) PROCEDURE "D"

Key ID erasure (clear all registered key codes except one):

(6) PROCEDURE "F"

ECU code registration:

HINT
*: Perform this process for one of the keys registered to the vehicle. Finish the procedure within 30 seconds. If the procedure has not been finished within the specified time, perform the registration from process 1 again.

(7) PROCEDURE "G"

ECU communication ID registration:

NOTICE:
* The ECU communication ID should be registered when the ID code box (immobiliser code ECU), steering lock ECU or ECM is replaced in order to match the ECU communication ID.
* The engine cannot be started unless ECU communication ID is registered.
* After the registration, pressing the engine switch may not start the engine on the first try. If so, press the engine switch again.
* After the engine is started, clear DTC B2799 (code for ECM immobiliser communication error) using either of the following methods:
- Use the Techstream.
- Disconnect the cable from the negative (-) battery terminal for 30 seconds.

SST : 09843-18040

1 Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

2 Turn the engine switch on (IG) (do not start the engine) and leave it as is for 30 minutes.

3 Turn the engine switch off and disconnect terminals 13 (TC) and 4 (CG).

4 Check that the engine starts and stays on for more than 3 seconds.

(8) PROCEDURE "H"

ECU communication ID reregistration:

NOTICE:
The ECU communication ID should be registered when the ECM is replaced in order to match the ECU communication ID.