for special service campaign 30i throttle body …

TECHNICAL INSTRUCTIONS

FOR

SPECIAL SERVICE CAMPAIGN 30 I

THROTTLE BODY REPLACEMENTFOR THE FOLLOWING VEHICLES

2003 MY 4RUNNER V82003 MY CAMRY 4CYL. (JAPAN BUILT)

2003 MY CELICA GTS 2ZZ–GE2003 MY LAND CRUISER

2003 MY PRIUS

7

Table of ContentsVehicle Page

4Runner V8 2UZ–FE 3

Camry 4 Cyl. 2AZ–FE (Japan Built) 11

Celica 2ZZ–GE 17

Land Cruiser 27

Prius 34

Completion Label Installation 41

8

2003 4Runner V8 2UZ–FEThrottle Body Replacement

9

VI.OPERATION FLOW CHART

Verify Vehicle Eligibility1. Check VIN range.2. Check for SSC Completion Label.3. Check TIS/Dealer Daily.

No further action required.

Applicable

Affix an SSC Completion Label(from the owner notification) on

the specified location.

Not Eligible

Inspect throttle body lot number.

OK

Replace throttle body.NG

VII. IDENTIFICATION OF AFFECTED VEHICLES

B. AFFECTED VIN RANGE

Model Year VIN RangeVDS Ranges

4Runner V8 2003 ZT14RZT17R

0012713 – 0013088

8002126 – 8002496BT14RBT17R

0023270 – 0024468

8005248 – 8006467NOTE: Not all vehicles in the VIN range are affected by this SSC. Always consult Dealer

Daily or TIS to confirm VIN eligibility and to assure the SSC is applicable. This willverify the vehicle is involved and has not already been completed by another deal-er. TMS warranty will not reimburse dealers for repairs conducted on vehiclesthat are not affected.

VIII. PREPARATION

D. PARTS

Part No. Parts Name Q’ty/ Vehicle04003–18550 Throttle Body Kit 1

E. TOOLS• Standard Hand Tools• Toyota Scantool

10

F. COMPONENTS

11

IX. WORK PROCEDUREC. THROTTLE BODY INSPECTION

1. REMOVE THE THROTTLE BODY COVERSUB–ASSEMBLY(a) Remove the 2 nuts holding the throttle

body cover sub–assembly.

4E02

proceed to throttle body replacement,SECTION B.

2. If the throttle body lot number is not inthe list above proceed to step 2 .

4E06 4E10 4E14 4E18 4E224E03 4E07 4E11 4E15 4E19 4E234E04 4E08 4E12 4E16 4E20 4E244E05 4E09 4E13 4E17 4E21 4E25

2. REINSTALL THE THROTTLE BODY COV-ER SUB–ASSEMBLY

3. PROCEED TO PAGE 41, SSC COMPLE-TION LABEL INSTALLATION

12

D. THROTTLE BODY REPLACEMENT1. RECORD AUDIO STATION PRESETS2. DISCONNECT THE NEGATIVE BAT-

TERY CABLE

3. REMOVE THE AIR CLEANER INLETHOSE ASSEMBLY(a) Disconnect the following from the air

cleaner inlet hose assembly:Power steering idle–up vacuumhose.Fuel pressure regulator vacuumhose.Ventilation hose.

(b) Remove the air cleaner hose assem-bly.

4. REMOVE THE THROTTLE BODY AS-SEMBLY(a) Disconnect the following coolant

hoses:Water by–pass hose.Water by–pass hose No. 7.

(b) Disconnect the TPS connector.(c) Remove the 2 nuts and 2 bolts from

the throttle body.(d) Disconnect the throttle body from the

intake manifold.(e) Remove the throttle body gasket.(f) Disconnect the No. 8 water by–pass

hose.

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5. INSTALL THE NEW THROTTLE BODYASSEMBLY(a) Reinstall by–pass hose No. 8(b) Install the new throttle body gasket.(c) Install the new throttle body.(d) Reinstall the 2 nuts and 2 bolts.

Torque:18 N m (185 kgf cm, 13 ft lbf)

(e) Reconnect the following coolanthoses:Water by–pass hose.Water by–pass hose No. 7.

(f) Reconnect the TPS connector.

6. REINSTALL THE AIR CLEANER INLETHOSE ASSEMBLY(a) Reinstall the air cleaner hose assem-

bly.(b) Reconnect the following from the air

cleaner inlet hose assembly:Ventilation hose.Power steering idle–up vacuumhose.Fuel pressure regulator vacuumhose.

7. RECONNECT THE NEGATIVE BAT-TERY CABLE

8. CHECK FOR COOLANT LEAKS9. REINSTALL THE THROTTLE BODY

COVER SUB–ASSEMBLY

10. INSPECT THE FUNCTION OF THETHROTTLE BODY(a) Connect the scantool to the DLC3

connector.

14

(b) Turn the ignition switch to the “ON”position.

(c) Press down on the accelerator pedal,and ensure that the throttle motor isoperating properly and does not bindor make any friction noises.

(d) Inspect the TPS.1. Check that the MIL is “OFF”.2. Using the throttle linkage fully the

throttle.3. Check that the “THROTTLE POS”

on the CURRENT DATE screenshows the standard value.Standard Value:60% or greater

NOTE:If the Standard Value is out ofspecifications, refer to the ap-propriate repair manual.

(e) Start the engine and allow it to reachnormal operating temperature.

(f) Turn the A/C switch to the “ON” posi-tion.1. Check idle speed.

(g) Turn the A/C to the “OFF” position.1. Check idle speed.

NOTE:Refer to the appropriate repairmanual for idle speed specifica-tions.

(h) Disconnect the scantool.

15

11. RESET AUDIO STATION PRESETS12. REINITIALIZE THE FOLLOWING COM-

PONENTS IF EQUIPPED:CompassPower windowsMoon roof


16

2003 CAMRY 4 Cyl. 2AZ–FEThrottle Body Replacement

17

I. OPERATION FLOW CHART



Applicable



Not Eligible


OK


II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE


Camry4 Cyl.

2AZ–FEJapan built

2003 BE30KBE32K 0214345 – 0221165

NOTE: Not all vehicles in the VIN range are affected by this SSC. Always consult DealerDaily or TIS to confirm VIN eligibility and to assure the SSC is applicable. This willverify the vehicle is involved and has not already been completed by another deal-er. TMS warranty will not reimburse dealers for repairs conducted on vehiclesthat are not affected.

III. PREPARATION

A. PARTS


B. TOOLS• Standard Hand Tools• Toyota Scantool

18

C. COMPONENTS

19

IV. WORK PROCEDUREA. THROTTLE BODY INSPECTION

3D02 3D06 3D10 3D14 3D18 3D223D03 3D07 3D11 3D15 3D19 3D233D04 3D08 3D12 3D16 3D20 3D243D05 3D09 3D13 3D17 3D21 3D25

proceed to throttle body replacement,SECTION B.

2. If the throttle body lot number is not inthe list above proceed to step 2.


B. THROTTLE BODY REPLACEMENT1. RECORD AUDIO STATION PRESETSA. DISCONNECT THE NEGATIVE BAT-

TERY CABLE3. REMOVE THE AIR CLEANER CAP

AND AIR CLEANER HOSE(a) Disconnect the following from the air

cleaner inlet hose assembly:2 vacuum hoses.PCV hose.

c. Disconnect the VSV connector.1. Remove the air cleaner cap and

hose.

4. REMOVE THE THROTTLE BODY AS-SEMBLY(a) Disconnect the throttle body assem-

bly connector.(b) Disconnect the vacuum hose from

the throttle body.(c) Remove the bolt and the bracket.(d) Move the bracket to gain access to

the coolant by pass hoses.(e) Disconnect the 2 coolant by pass

hoses.(f) Remove the remaining 3 bolts from

the throttle body.(g) Remove the throttle body.(h) Remove the throttle body gasket.

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5. INSTALL THE NEW THROTTLE BODYASSEMBLY(a) Install the new throttle body gasket

as shown.

(b) Reconnect the 2 coolant by passhoses.

(c) Install the new throttle body.(d) Reinstall the 4 bolts and the bracket.


(e) Reconnect the TPS connector.(f) Reconnect the throttle body connec-

tor.(g) Reconnect the vacuum hose to the

throttle body.

6. REINSTALL THE AIR CLEANER CAPAND AIR CLEANER HOSE(a) Reinstall the air cleaner hose.(b) Reconnect the 2 vacuum hoses.(c) Reconnect the PCV hose.(d) Reconnect the VSV connector.


8. CHECK FOR COOLANT LEAKS9. INSPECT THE FUNCTION OF THE

THROTTLE BODY(a) Connect the scantool to the DLC3

connector.

21


a. Press down on the accelerator pedal,and ensure that the throttle motor isoperating properly and does not bindor make any friction noises.

(c) Inspect the TPS.1. Check that the MIL is “OFF”.2. Using the throttle linkage fully open

the throttle.3. Check that the “THROTTLE POS”


NOTE:If the Standard Value is out ofspecifications refer to the ap-propriate repair manual







PONENTS IF EQUIPPED:CompassMoon roof


22

2003 CELICA GTS 2ZZ–GEThrottle Body Replacement

23




Applicable



Not Eligible


OK





Celica GTS2ZZ–GE

2003 DY32TDY38T

0067966 – 0068726


III. PREPARATION

A. PARTS

Part No. Parts Name Q’ty/ Vehicle22030–22030 Throttle Body 1

Note: The throttle body gasket is reusable.


24

C. COMPONENTS

25



proceed to throttle body replacementSECTION B



B. THROTTLE BODY REPLACEMENT1. RECORD AUDIO STATION PRESETS2. REMOVE THE BATTERY

(a) Remove the negative battery cable.(b) Remove the positive battery cable.(c) Remove the battery hold down.(d) Remove battery.

3. REMOVE THE No. 2 CYLINDER HEADCOVER

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4. REMOVE THE AIR CLEANER HOSE(a) Remove the VSV for the EVAP.(b) Secure the VSV out of the way.(c) Remove the ECM cover by loosening

the 2 bolts.

(d) Remove the ECM outlet duct.(e) Disconnect the ECM connectors.(f) Remove the rubber boot for the ECM

connectors.(g) Remove the 3 bolts for the ECM.(h) Remove the ECM.

NOTE:Cover the ECM connectors with a plasticbag. Store the ECM in a plastic bag.

(i) Remove the support clamp from the aircleaner hose.

(j) Remove the air cleaner hose.

5. DISCONNECT THE THROTTLE BODYCONNECTOR

27

6. DISCONNECT THE THROTTLE BODYHARNESS CLAMP(a) Remove the bolt for the throttle body

harness clamp.(b) Disconnect the harness clamp from the

throttle body.7. REMOVE THE THROTTLE BRACKET

(a) Remove the bolt and disconnect thethrottle body wire harness clamp fromthe throttle body.

8. DISCONNECT THE PCV HOSE9. DISCONNECT THE 2 COOLANT

BY–PASS HOSES

NOTE:Mark the position of the hoses for cor-rect installation upon reassembly .

10.REMOVE THE THROTTLE BODY(a) Remove the 4 nuts.(b) Remove the throttle body.

28

11.INSTALL THE NEW THROTTLE BODYASSEMBLY(a) Install the new throttle body.


12. RECONNECT THE 2 WATER BY–PASSHOSES

NOTE:Ensure that the coolant hoses are re-installed in the correct position.

13. RECONNECT THE PCV HOSES14. REINSTALL THE THROTTLE BRACK-

ET(a) Reinstall the throttle bracket using the

2 bolts.

15. RECONNECT THE THROTTLE BODYWIRE HARNESS CLAMP(a) Reconnect the throttle body harness

clamp to the throttle body using thebolt.

Torque:5.0 N m (51 kgf cm, 44 in lbf)

16. RECONNECT THE THROTTLE BODYCONNECTOR

29

17. REINSTALL THE AIR CLEANER HOSE(a) Reinstall the air cleaner hose.(b) Reconnect the radiator hose support

to the air cleaner hose.(c) Tighten the air cleaner hose clamps.(d) Reinstall the ECM and tighten the 3

bolts.(e) Reinstall the rubber boots for the ECM

harness.

NOTE:To prevent damage do not use anytools while installing the ECM harnessboots

(f) Reconnect the ECM connectors.(g) Reinstall the ECM cover.(h) Tighten the 2 bolts for the ECM cover.(i) Reinstall the ECM outlet duct.

18. REINSTALL THE No. 2 CYLINDERHEAD COVER

19. REINSTALL THE BATTERY(a) Reinstall the battery.(b) Reinstall the battery hold down.(c) Reinstall the positive battery cable.(d) Reinstall the negative battery cable.

20. CHECK FOR COOLANT LEAKS

30

21. INSPECT THE FUNCTION OF THETHROTTLE BODY(a) Connect the scantool to the DLC3

connector.



(d) Inspect the TPS.1. Check that the MIL is “OFF”.2. Using the throttle linkage fully open



NOTE:If the Standard Value is out ofspecifications, refer to the ap-propriate repair manual

31






21. RESET AUDIO STATION PRESETS22. PROCEED TO PAGE 41, SSC COMPLE-

TION LABEL INSTALLATION

32

2003 Land Cruiser V8 2UZ–FEThrottle Body Replacement

33




Applicable



Not Eligible


OK





Land Cruiser 2003 HT05J 2044918 – 2046234NOTE: Not all vehicles in the VIN range are affected by this SSC. Always consult Dealer

Daily or TIS to confirm VIN eligibility and to assure the SSC is applicable. This willverify the vehicle is involved and has not already been completed by another deal-er. TMS warranty will not reimburse dealers for repairs conducted on vehiclesthat are not affected.

III. PREPARATION

A. PARTS



34

C. COMPONENTS

35


1. REMOVE THE V–BANK COVER(a) Remove the 2 nuts and 2 bolts holding

the V–Bank cover.(b) Unclip the fuel return line from the V–

Bank cover.

4E02 4E06 4E10 4E14 4E18 4E224E03 4E07 4E11 4E15 4E19 4E234E04 4E08 4E12 4E16 4E20 4E244E05 4E09 4E13 4E17 4E21 4E25

proceed to throttle body replacementSECTION B.


3. REINSTALL THE V–BANK COVER(a) Reinstall the V–Bank cover using the 2

nuts and the 2 bolts.(b) Reinstall the clip for the fuel return hose

onto the V–Bank cover.4. PROCEED TO PAGE 41, SSC COMPLE-


B. THROTTLE BODY REPLACEMENT

36

1. RECORD AUDIO STATION PRESETS2. DISCONNECT THE NEGATIVE BATTERY

CABLE.3. REMOVE THE AIR CLEANER INLET

HOSE ASSEMBLY(a) Disconnect the following from the air

cleaner inlet hose assembly:Power steering idle–up vacuumhose.Fuel pressure regulator vacuumhose.Ventilation hose.

(b) Remove the air cleaner hose assembly.4. REMOVE THE THROTTLE BODY AS-

SEMBLY(a) Disconnect the following coolant hoses:

Water by pass hose.Water by pass hose No. 7.

(b) Disconnect the TPS connector.(c) Remove the 2 nuts and 2 bolts from the

throttle body.(d) Disconnect the throttle body from the in-

take manifold.(e) Remove the throttle body gasket.(f) Disconnect the No. 8 water by–pass

hose.

5. INSTALL THE NEW THROTTLE BODYASSEMBLY(a) Reinstall by pass hose No. 8(b) Install the new throttle body gasket.(c) Install the new throttle body.(d) Reinstall the 2 nuts and 2 bolts.


(e) Reconnect the following coolant hoses:Water by–pass hose.Water by–pass hose No. 7.

(f) Reconnect the TPS connector.

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6. REINSTALL THE AIR CLEANER INLETHOSE ASSEMBLY(a) Reinstall the air cleaner hose assembly.(b) Reconnect the following from the air

cleaner inlet hose assembly:Ventilation hose.Power steering idle–up vacuumhose.Fuel pressure regulator vacuumhose.

38


8. CHECK FOR COOLANT LEAKS9. REINSTALL THE THROTTLE BODY

COVER SUB–ASSEMBLY10. REINSTALL THE V–BANK COVER11. INSPECT THE FUNCTION OF THE

THROTTLE BODY

12. INSPECT THE FUNCTION OF THETHROTTLE BODY

(a) Connect the scantool to the DLC3connector.



(d) Inspect the TPS.1. Check that the MIL is “OFF”.2. Using the throttle linkage fully open



NOTE:If the Standard Value is out ofspecifications, refer to the ap-propriate repair manual

39







PONENTS IF EQUIPPED:Compass


40

2003 PRIUSThrottle Body Replacement

41




Applicable



Not Eligible


OK





Prius 2003 BK12UBK18U

0087157 – 0088010


III. PREPARATION

A. PARTS



42

C. COMPONENTS

43



proceed to throttle body replacementSECTION B.



B. THROTTLE BODY REPLACEMENT1. RECORD AUDIO STATION PRESETS2. DISCONNECT THE NEGATIVE BATTERY

CABLE3. REMOVE THE AIR CLEANER ASSEMBLY

(a) Disconnect air cleaner inlet No. 1 fromthe air cleaner assembly.

(b) Disconnect the MAF connector.(c) Remove the 2 air cleaner assembly

bolts.(d) Loosen the air cleaner hose clamp at the

throttle body neck.(e) Remove the air cleaner assembly.

4. REMOVE THE THROTTLE BODY AS-SEMBLY(a) Disconnect the TPS.(b) Disconnect the throttle motor connector.(c) Disconnect the 2 PCV hoses from the

throttle body.

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44

(d) Disconnect the 2 coolant by pass hoses.

(e) Remove the bolt and the 2 nuts.(f) Remove the throttle body.(g) Remove the throttle body gasket.

5. INSTALL THE NEW THROTTLE BODY(a) Install the new throttle body gasket.(b) Install the new throttle body using the bolt

and 2 nuts.


(c) Reconnect the 2 coolant by pass hoses.

45

(d) Reconnect the 2 PCV hoses to the throttlebody.

(e) Reconnect the throttle motor connector.(f) Reconnect the TPS connector.

6. REINSTALL THE AIR CLEANER AS-SEMBLY(a) Reinstall the intake air assembly.(b) Reinstall and tighten the 2 bolts.(c) Tighten the hose clamp at the neck of the

throttle body.

7. RECONNECT THE NEGATIVE BATTERYCABLE

8. CHECK FOR COOLANT LEAKS9. RESET AUDIO STATION PRESETS

10. INSPECT THE FUNCTION OF THETHROTTLE BODY(a) Connect the scantool to the DCL3 con-

nector.(b) Disconnect the throttle control motor con-

nector.

(c) Turn the ignition switch to the “ON” posi-tion.

(d) Inspect TPS function.1. Using the throttle linkage fully open the

throttle.2. Check that the “THROTTLE POS” on

the CURRENT DATE screen showsthe standard value.Standard Value:60% or grater

NOTE:If the Standard Value is out of speci-fications, refer to the appropriate re-pair manual

46

(e) Reconnect the throttle control motor.(f) Select INSPECTION mode on the

scan tool.(g) Start the engine and allow it to reach

normal operating temperature.(h) Check the charging rate of the HV

battery.1. Set parking brake.2. Depress brake pedal.3. Shift gear selector into “D” the en-

gine should stop.

NOTE:If the engine does not stop, theHV battery is not fully charged.Allow the engine to run (in Park)until the HV battery is charged.

(i) Start the engine.(j) Place the gear selector in neutral.(k) Turn the A/C switch to the “ON” posi-

tion.1. Check idle speed.

IDLE SPEED:1,150 to 1,250 RPM (A/C on)

(l) Turn the A/C to the “OFF” position.1. Check idle speed.

IDLE SPEED:950 to 1,050 RPM (A/C off)

NOTE:Check idle speed while the cool-ing fans are “OFF”

(m) Stop the engine.(n) Disconnect the scantool.

10. RESET AUDIO STATION PRESETS11. PROCEED TO PAGE 41, SSC COMPLE-


47

SSC COMPLETION LABEL INSTALLATIONAfter completing the repair and before returning the vehicle to the owner, an SSC comple-tion label, which is enclosed in the owner’s notification, must be affixed to the left front doorhinge post, near the check strap.

(c) The label is to be filled out as follows:

• Write in SSC 30I.• Write in date of repair.• Write in your dealer code.

(d) Additional SSC completion labels, in sheets of 50 (P/N 00410–01917), may beordered through the non–parts system on a 1450 order form or through the TDNsystem.

for special service campaign 30i throttle body …

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