Fall 2007

In this issue:
Brake system service

Toyota’s hybrid
vehicle continuously
variable transmission

Power steering
service
 STAR Service News Issue 118
Toyota’s Support to Automotive Repair
Editor: Roberta Ritter, Toyota Motor Sales, U.S.A., Inc.
Content: Birchwood Automotive Group, Creston, Ohio
Source: Toyota Service Manuals
Design: Bobit Business Media, Uniontown, Ohio

STAR departments

Jerry Raskind letter — 3

Back issues ordering — 25

Dealer listings — 33

BRAKE SYSTEM
SERVICE
Taking a look at basic
brake system mechanical
service as well as brake
sysem-related sensor
circuits for vehicles TOYOTA’S HYBRID
equipped with ABS with VEHICLE CVT
TRAC & VSC sysems — 4 An in-depth look at the
Continuously Variable
Transmission (CVT)
technology featured in
the 2004 Prius and 2006
POWER STEERING
Highlander HV — 17
SERVICE
From problem symptoms to
inspection to servicing the
2004 4Runner power steering
rack assembly — 27
STAR Service News is a quarterly publication of Toyota Motor Sales, U.S.A., Inc. Editorial and circulation offices: Toyota Customer Services, STAR Program WC21, 19001 South Western Avenue,
Torrance, CA 90509. Fax (310) 468-0913.
STAR Service News is available through Toyota STAR Dealers and is also available by subscription. Toyota makes no warranty, expressed or implied, regarding the contents of this publication, nor should any be construed. All procedures, specifi-
cations and part numbers were in effect at the time of printing. Toyota reserves the right to change procedures and/or specifications at any time, without prior notice and without incurring any obligation. Articles and technical data contained in
this publication are based in whole or in part on prior communications by Toyota to its dealers. FOR COMPLETE SPECIFICATIONS AND PROCEDURAL INFORMATION, PLEASE REFER TO THE APPROPRIATE REPAIR MANUAL. For part number
changes, please contact your Toyota dealer.
Copyright 2007 Toyota Motor Sales, U.S.A., Inc. Contents of this publication may not be reprinted without written permission. The Toyota name and logo and Toyota STAR name and logo are registered trademarks of Toyota Motor Corporation and
may not be used in any manner without the prior written consent of Toyota Motor Sales, U.S.A., Inc.
Caution: Vehicle servicing performed by untrained persons could result in serious injury to those persons or others.

2 STAR Service News Fall 2007

Your success is our success!

I
’ve been on the run! I’ve recently been spotted dashing
through airport security and making last minute calls
before takeoff. In just two months my agenda was all
over the map — literally. My stops included Scottsdale, Ariz.;
Sacramento, Calif.; Las Vegas, Nev.; Pittsburg, Pa., and Japan.
The good news is that I’m earning all kinds of mileage — and
the better news is that a good portion of the travel is the
result of our growing Toyota STAR program.

Service drives are bustling, and there’s plenty of business

out there. How can you satisfy customers and make it con-
venient for them to come to your shop? For starters, making
quick and efficient repairs is paramount. You need informa-
tion! You need parts! That’s what the STAR program is for.
This is a program that gives you first-rate technical informa-
tion and helps you provide the best repairs possible by deliv-
ering Genuine Toyota Parts when and where you need them.

Our dealers have never been more enthusiastic or supportive of the Toyota
STAR program — that’s great news for every independent shop. More dealers
are participating with enrollment up to 485 dealers nationwide — which means
more convenience for you. We’ve dedicated our resources to make sure your
experience with the program is positive. We realize that timely vehicle and
parts information is critical, so visit Toyota’s Wholesale Web site www.toyota-
partsandservice.com and Technical Information System (TIS) Web site
www.techinfo.toyota.com often. These resources give you some of the most
up-to-date parts and technical information in the industry.

Your success is our success. If our resources help make your shop more effi-
cient and profitable, we’ve done our job. And we’re open to your ideas and sug-
gestions — after all, you’re out there every day. If there’s something you need,
let me know by sending an e-mail to jerry_raskind@toyota.com. We’re here to
help.

Best regards,

Jerry Raskind
Wholesale Development Manager, Toyota Motor Sales, U.S.A., Inc.

Fall 2007 STAR service news 3

 TOYOTA TECHNICAL
BRAKE SYSTEM SERVICE
Using the 2004 Sequoia as the
vehicle example, this article discuss-
es basic brake system mechanical
service (calipers, pads, discs), as
well as brake system-related sensor
circuits for vehicles equipped with
ABS with TRAC & VSC systems. Due
to space constraints, the ABS service
is not included in this article.
Sensors involving yaw rate, decelera-
tion, skid control and master cylin-
der pressure are discussed.
FRONT BRAKE CALIPERS
The 2004 Sequoia features four-pis-
ton front calipers and single-piston
rear calipers.
Since the front calipers feature
opposing pistons, the caliper bodies
4 STAR service news
are rigidly-mounted, and are secured
with two mounting bolts. The rear
calipers are the sliding type, located
on fixed-mounted torque plates.
FRONT CALIPER SERVICE
Using SST 09023-00100 (or equiva-
lent), disconnect the brake line.
Remove the two caliper mounting
bolts and remove the caliper.
Remove the clip, two pad pins and
anti-rattle spring, and remove the
two pads and all four anti-squeal
shims.
Remove the cylinder boot set rings
and boots using a flat-blade screw-
driver. In order to remove the pis-
tons, first fabricate a spacer plate
(wood or similar material) that is
6.70 inches wide by 1.97 inches
deep and 1.10 inches thick (170mm
x 50mm x 28mm), featuring angle-
cut corners on one side of the plate
depth as shown in the illustration.
Insert a brake pad on one side
(against one pair of pistons), and
insert the wood spacer between the
pad and the exposed opposite-side
pistons.
With the spacer plate positioned
with the angle-cut corners facing the
top of the caliper, use compressed
air (via the brake line inlet port) to
alternately push one pair of pistons
out of their bores. Remove the brake
pad and force the remaining two pis-
tons out of their bores, again using
compressed air, with the wood spac-
Fall 2007
 TOYOTA TECHNICAL

er in place. Once the pistons have

Bleeder plug been removed, use a flat-blade
screwdriver to remove the piston
seals.
Clean and inspect the caliper
bores. If the bores are in good con-
Piston seal
Piston dition (not rusted, pitted or scored),
Boot the caliper may be reassembled using
Set ring Brake caliper new pistons, seals, boots and boot
set rings. Always install new bleed
valves, and always use new brake
line fitting crush washers and bolts.

Inner pad
Clip

Outer pad

Anti-squeal shim

Anti-rattle
spring

Pin

Remove the piston set rings

Inner anti-squeal shim
and boots.
The 2004 Sequoia front brake calipers feature a four-piston design.
170 mm 50 mm
(6.70 in.) (1.97 in.)

28 mm
(1.10 in.)

Make a wood spacer plate with

angle-cut corners. This will pro-
vide a stopping surface for the
pistons as they are pushed out of
their bores with compressed air.

Measuring rotor thickness must be done with a quality, properly cal- With the wood spacer in place,
ibrated micrometer. When measuring a used rotor, measure about inject compressed air through
10mm or so inboard from the outer edge. the brake fluid inlet port.

Fall 2007 STAR service news 5

 TOYOTA TECHNICAL
With pistons removed, use a
screwdriver to remove the pis-
ton seals.
NOTE: Torque values are as follows:
a. Caliper mounting bolts 90 ft-lbf
(123 N-m)
b. Brake line fitting to caliper 11 ft-lbf
(15 N-m)
c. Wheel 83 ft-lbf (110 N-m)
INSPECT PADS
If the existing pads are being con-
sidered for re-use, inspect the pads for
cracks, signs of uneven wear and pad
thickness. Pad standard thickness is
0.453 in. (11.5mm). Minimum pad
thickness is 0.039 in. (1.0mm). If
thickness is less than the minimum, or
if the pad(s) show signs of uneven
wear, cracking, glazing or other dam-
age, replace the pads as a complete
set (never mix worn and new pads).
NOTE: Whenever pad replacement is
required, it is always advisable to
replace both right and left side pads as
a complete axle set.
Measure brake pad thickness,
in addition to inspecting for
uneven wear, cracking, glazing
or other damage.
6 STAR service news
BRAKE DISC INSPECTION
Temporarily fasten the brake disc
to the hub with three wheel nuts.
Using a micrometer, measure disc
thickness at a minimum of three
equidistant locations. Always meas-
ure at a spot about 0.39 in. (10mm)
inboard from the disc edge, to avoid
placing the micrometer on a buildup
of rust. Be sure to measure within
the area of pad contact. Standard
disc thickness is 1.102 in. (28.0mm).
A fixed-position caliper (as opposed to a sliding caliper that features
a single piston) captures the pads using locating pins. Make sure
that the pin holes in the caliper and pad backing plates are clean and
free of debris.
Minimum thickness is 1.024 in.
(26.0mm). If disc thickness is at the
minimum or less, the disc must be
replaced.
Using a dial indicator (on a stand
that is rigidly mounted to the sus-
pension upright), measure disc
runout. The indicator plunger should
be placed about 0.39 in. (10mm)
from the disc’s outer edge, and
should be positioned with about
0.050 in. preload. Then zero the
gauge and slowly rotate the disc a
full 360 degrees, while monitoring
the gauge. Maximum allowable
runout is 0.0028 in. (0.07mm). If
runout exceeds this minimum, either
replace the disc or re-surface the
disc only using an “on-car” brake
lathe. Once resurfaced, measure disc
thickness again to verify that it is
greater than the specified minimum
thickness.
Also, if disc runout is outside the
specified range, check the hub for
runout as well. A worn hub bearing
may be the cause of excessive
runout, so it’s important to isolate
the source of the runout problem
(this may involve the hub, the disc,
or both).
It is possible that very small
runout variances in the hub and disc
may result in a “stack-up” of toler-
ance, and may be corrected by repo-
sitioning the disc onto the hub in a
different clock position. First, mark
one hub stud and its corresponding
hole in the disc. Next, remove the
hub nuts and disc, and re-locate the
disc onto the hub by aligning the
marked bolt hole in the disc to the
Fall 2007
 TOYOTA TECHNICAL

runout check (repeat this process

until the disc has been checked in
all possible clock positions on the
hub.) It is possible that minimum
runout may be achieved in one of
these positions. If excessive runout
persists despite disc clock position,
replace the disc, hub or both,
depending on your findings.

REAR BRAKE CALIPERS

After disconnecting the flexible
brake hose from the caliper (union
bolt with crush washers), remove the
two sliding pins, remove the caliper
2004 Sequoia front brakes feature four-piston calipers, with two pis- from the torque plate, and remove
tons per side. This spreads the pad pressure over a wider contact area. the brake pads and the anti-squeal

next hub stud (turning the disc Pad support plate

clockwise). Repeat the dial indicator
Anti-squeal shim
Outer pad

Brake caliper Inner pad

Bleeder plug
Pad wear
indicator

Cap Pad support

plate

Piston seal Anti-squeal shim

Boot
Measure disc thickness using a Piston
quality micrometer. Be sure to
measure at a point inboard
from the disc edge, within the
pad contact area. Sliding pin
Washer
Boot

Torque plate

Plug

Union bolt
Bushing

Washer
Gasket

Measure disc runout using a

dial indicator. Be sure to place
the indicator plunger about
0.039 in. inboard from the disc’s
outer edge. The 2004 Sequoia rear brakes feature single-piston sliding calipers.

Fall 2007 STAR service news 7

 TOYOTA TECHNICAL
shim and the four pad tempered
sheet metal support plates.
Using a flat-blade screwdriver,
remove the cylinder boot from the
caliper. Place a bundled shop rag
between the piston and opposing
caliper body, and use compressed air
to push the piston from its bore.
Never place your fingers in the path
of the piston, as severe injury can
occur if the piston pops out unex-
Use a screwdriver to pry the
cylinder boot from the caliper.
Before placing a new or resurfaced rotor into service, take the time
to thoroughly clean the disc surfaces to remove any oils or machin-
ing residue. Hot soapy water and a nylon brush works well.
8 STAR service news
With a folded shop rag placed
between the piston and caliper
body, use compressed air (fed
through the hydraulic fluid inlet
port) to push the piston from its
bore.
pectedly. The folded-up shop rag will
absorb the energy of the moving pis-
ton.
Using a screwdriver, remove the
piston seal from the caliper. Remove
the pin bushings and boots. Always
use new bushings and boots before
reinstalling a caliper.
Use a screwdriver to remove
the piston seal.
REAR BRAKE PADS
Measure pad thickness using a ruler
or other straight-line measuring
device. Standard rear pad thickness
is 0.39 in. (10.0mm). Minimum pad
thickness is 0.039 in. (1.0mm). In
addition to thickness, check the pads
for uneven wear, cracking, glazing,
etc.
REAR BRAKE DISCS
Temporarily fasten a rear disc to its
hub using three wheel nuts. Using a
micrometer, measure disc thickness
at the area of pad contact. Standard
thickness is 0.709 in. (18.0mm).
Minimum allowable thickness is
0.611 in. (16.0mm). Replace the disc
if at or less than the minimum thick-
ness. Also inspect the disc for scor-
ing or uneven wear. The disc may be
saved by resurfacing on a quality
brake lathe. If the disc is resurfaced,
re-measure disc thickness.
Using a dial indicator, measure disc
runout, with the indicator plunger
located 0.39 in. (10mm) from the
disc outside edge. If disc runout is
greater than 0.0039 in. (0.1mm),
check the bearing play in the axial
direction. If the bearing play and
axle hub runout are not abnormal,
you may be able to adjust disc
runout using an on-car lathe. If nec-
essary, disc runout may be reduced
Fall 2007

or eliminated by checking runout
with the disc located at all possible
bolt locations (following the same
routine outlined for front discs).
Measure rear disc thickness
using a micrometer.
Inspect the disc for runout
using a dial indicator. Be sure to
place the indicator plunger at a
position 10mm from the out-
side disc edge.
BRAKE SYSTEM RELATED
SENSOR CIRCUITS
While not a direct part of the brake
hydraulic system, there are several
ABS/TRAC VSC-related circuits that
impact vehicle performance during
braking. It’s a good idea to become
familiar with these circuits.
VSC-RELATED ZERO POINT
CALIBRATION & SENSOR
CHECK
Zero point calibration must be per-
formed after replacing any of the fol-
lowing components on 2003 - 2006
model year Sequoia vehicles:
Fall 2007
• Vehicle skid control computer
• Steering angle sensor
• Master cylinder pressure sensor
• Yaw rate sensor
• Deceleration sensor
Zero point calibration of the above
components must also be performed
when replacing or repairing steering-
related parts and when changing the
vehicle’s straight-ahead condition via
toe adjustment.
REQUIRED SSTs
Toyota Diagnostic Tester Kit — P/N
TOY220036
All components in this kit are
required. 12 megabyte diagnostic
tester program card (P/N 01002593)
with version 13.3a software (or
later) is required.
CAN Interface Module Kit — P/N
01002744
CAUTION:
While performing zero point cali-
bration, do not tilt, move or shake
the vehicle. The vehicle must main-
tain a stationary position. Do not
start the engine. Be sure to perform
calibration on a level surface (within
an inclination of 1%).
Whenever replacing the skid control
ECU, registration of the new ECU
must first be performed.
Step 1
For 2WD Sequoia models, registra-
tion is already complete. Proceed to
Step 2.
For 4WD models with a transfer
lever, after turning the ignition
switch ON, with the shifter in the
“P” position, move the transfer lever
to the “L4” position. For vehicles
STAR service news
TOYOTA TECHNICAL
equipped with a push button selec-
tor, place the transmission in neu-
tral, press the “L4” button and then
place the transmission in the “P”
position. At this time, the VSC sys-
tem buzzer will sound for three sec-
onds indicating that registration is
complete. Now turn the ignition
switch OFF and proceed to Step 2.
Step 2
Perform master cylinder pressure,
yaw rate and deceleration sensor
zero point calibration.
a. Connect the Toyota Diagnostic
tester to the DLC3.
b. Move the shift lever to the “P”
position.
c. Turn the ignition switch to the
“ON” position.
d. Place the Diagnostic Tester into
Signal Check mode under the
ABS/VSC menu.
e. Keep the vehicle in a stationary
position on a level surface for four
seconds or more.
f. For 2WD models, press the TRAC
OFF switch three times within three
seconds without pressing the brake
pedal.
g. For 4WD models, press the cen-
ter differential lock (TRAC OFF)
switch three times within three sec-
onds without pressing the brake
pedal.
h. Check that the VSC buzzer
sounds for three seconds. If the VSC
buzzer does not sound, repeat the
zero point calibration procedures. If
the buzzer still does not sound,
check the VSC buzzer circuit.
i. Zero point of master cylinder
pressure, yaw rate and deceleration
sensor is complete. Proceed to Step
3.
9
 TOYOTA TECHNICAL

Step 3
Perform steering angle
sensor zero point cali-
bration.
a. Disconnect the
Diagnostic Tester.
b. Calibrate the steer-
ing angle sensor by driv-
ing the vehicle above 28
mph.

Step 4
a. Stop the vehicle.
b. Place the shifter
into the “P” position.
c. Connect the Toyota
Diagnostic Tester to the
DLC3.
d. View the ABS/VSC
Illustration of Diagnostic
Data List to confirm that
Tester screen during
Step 2, sub-steps A the steering angle value
through D. changes when the steer-
ing wheel is turned.

Disconnect the
Diagnostic Tester and
turn the ignition switch
OFF.

DELTA S SENSOR
CIRCUIT
The Delta S sensor is
also known as the pedal
stroke speed sensor.
When DTC C1247/47 is
output, this indicates
that output turns 4.7V
or more or 0.2V or less
per 100msec; or when
output does not return
to 2.5V even when
500msec or more elaps-
es, in spite of no change
in brake operation. The
Illustration of Diagnostic Tester screen during
Step 4, sub-steps A through D. problem lays with the
brake booster, the Delta

10 STAR service news Fall 2007

 TOYOTA TECHNICAL

S sensor circuit, the skid con- the yaw rate sensor and the output
Voltage (1) Brake pedal
trol ECU or any combination of depressed value calculated from the other sen-
these areas. (2) Brake pedal sors’ output continues to be large. In
released
In order to check the output either case, the trouble lies with the
value of the Delta S sensor, yaw rate sensor or its circuit.
connect the Toyota Diagnostic The first step in inspecting the yaw
Tester to the DLC3. Turn the rate/deceleration sensor is to check
ignition switch to the ON posi- its installation. The sensor should be
Time
tion, and run the engine until tight (bolt mounting torque value is
engine speed reaches 3,000 Delta S sensor value should change as 3.7 ft-lbf (5 N-m), and check to make
rpm, and then return engine the brake pedal is depressed and sure that the sensor is not tilted.
released. Voltage should not fall below
speed back to idle (HINT: Rev 0.2V when the pedal is depressed, nor Next, check the output value of the
the engine to ensure sufficient should it exceed 4.5V when the pedal yaw rate sensor. Remove the two
vacuum). is released. bolts and the yaw rate sensor assem-
Select the DATA LIST mode on bly, with the harness still connected.
the hand-held tester. The pedal fied, check for an open or short cir- Connect the hand-held tester to the
stroke sensor should show a mini- cuit in the harness and connector DLC3. Turn the ignition switch ON
mum of 0V and a maximum of 5.1V. between the Delta S sensor and the and turn the hand-held tester main
Normal condition is about 2.0V with- skid control ECU. If no open or short switch on. Select the DATA LIST
out the brake pedal depressed. is found, inspect the Delta S sensor mode on the hand-held tester and
NOTE: The result appears on the terminal voltage at the VCP terminal. check that the value of the YAW RATE
tester after a brief delay because a With the Delta S sensor disconnected,
time lag occurs during this measure- turn the ignition switch ON and Torque: 5 N-m (10 kgf-cm, 3.7 ft-lbs)

ment with the hand-held tester. If a
signal from the Delta S sensor is
being sent between sampling, the
result does not appear on the tester,
so be sure to perform this measure-
ment two or three times.
Check that the brake pedal acceler-
ation value of the Delta S sensor dis-
played on the hand-held tester
changes, alternatively increasing the
brake pedal stroke. The value should
change as the brake pedal is
depressed and released. With the
measure voltage between the VCP ter-
minal and body ground. Voltage
should read 5V. If not, replace the
skid control ECU. If this voltage check
is OK, replace the brake booster.
Delta S sensor
brake stroke
speed sensor Check the yaw rate sensor for
correct installation.
VCP

pedal depressed, voltage should be Read voltage at the Delta S har-

approximately 1.9V. When the pedal
is released, voltage should be about
4.5V. The value should return to
about 2.0V after the pedal is
released.
The maximum voltage depends on
pedal stroke speed, but should not
exceed 4.5V or fall below 0.2V.
If Delta S voltage is not as speci-
ness connector’s terminal VCP.
YAW RATE SENSOR
CIRCUIT
A DTC C1234/34 indicates that
either a) power output of 4.65V or
more or 0.25V or less continues for
0.1 second or more; or b) the differ-
ence between the actual output of
With the yaw rate sensor
detached but still connected to
its harness, hold the sensor ver-
tical to the ground and turn the
sensor to the right and left to
check for value changes.

Fall 2007 STAR service news 11

 TOYOTA TECHNICAL
displayed on the tester changes.
Place the yaw rate sensor vertically
and turn the sensor to the right and
left a minimum of -128 degrees and
a maximum of 128 degrees.
Check for an open or short circuit
in the harness and connector
between the yaw rate sensor and the
skid control ECU.
Check for voltage between termi-
nals VYS and GYAW of the yaw rate
sensor. Disconnect the yaw rate sen-
sor from its connector. Turn the igni-
tion switch ON. Measure voltage
between terminals VYS and GYAW of
the yaw rate sensor harness-side
connector. Voltage should be 10 to
14V. If voltage is not within this
range, replace the skid control ECU.
Yaw rate
(deceleration) sensor
VYS
GYAW
A voltage check between yaw
rate sensor connector terminals
VYS and GYAW should show 10
to 14V.
DECELERATION CIRCUIT
Yaw rate and deceleration is moni-
tored by the same sensor. In order to
check the deceleration circuit, verify
that the sensor is correctly mounted
(bolts tight to value and sensor not
tilted). Next, remove the two mount-
ing bolts and with the sensor still
connected to its harness, connect the
Toyota Diagnostic Tester to the DLC3.
Turn the ignition switch ON and turn
the hand-held tester main switch on.
Select the DATA LIST mode on the
hand-held tester. Check that the
12
value of the DECELERAT SENS dis- are still present, check and replace
played on the tester changes. Place the skid control ECU. If the sensor
the sensor vertical to the ground and value change is not correct, check
then tilt the sensor frontward and for an open or short circuit in the
rearward. Check that the value of the harness and connector between the
DECELERAT SENS2 displayed on the steering angle sensor, translate ECU
hand-held tester changes. Normal and the skid control ECU.
condition is approximately 0 +/- 0.13
G while stationary. INSPECTING THE BRAKE
INHIBIT RELAY
Check (a)
This will involve checking voltage
between terminal 1 and 3 of the
brake inhibit relay and body ground.
Remove the brake inhibit relay from
the connector. Turn the ignition
switch ON. Measure the voltage
Check (b)
between terminal 1 of the brake
inhibit relay harness side connector
and body ground. Voltage should be
10 - 14V. Next, measure the voltage
between terminal 3 of the brake
inhibit relay harness side connector
and body ground while the brake
When checking for value
pedal is depressed. Voltage should be
changes in the deceleration
sensor, tilt the sensor rearward 8 - 14V.
and forward (with sensor dis-
mounted but still connected to
ON
its harness).
STEERING ANGLE SENSOR
Check the output of the steering
angle sensor. Connect the Toyota
Diagnostic Tester to the vehicle’s
DLC3. Turn the ignition ON and turn
the tester’s main switch on. Select
the DATA LIST mode on the hand-
held tester and select STEERING ANG.
Check that the steering wheel turn-
ing angle value of the steering angle
sensor displayed on the hand-held
tester changes as the steering wheel
is turned. NOTE: Turning the steering
wheel to the left increases value; When checking voltage be-
turning the steering wheel to the tween body ground and termi-
nal 3 of the brake inhibit relay
right decreases value. harness side connector, the
If DTC codes C1231/31 or C1235/35 brake pedal must be depressed.
STAR service news Fall 2007

Check the brake inhibit relay for
continuity between terminals 1 and
2, and between terminals 3 and 4.
Continuity should be present in both
cases (a reference value for continu-
ity between terminal 1 and 2 should
be about 62 ohms).
Apply battery positive voltage
between terminals 1 and 2, and
check continuity between terminals 3
and 4. Continuity should be open.
Check the brake inhibit relay for
continuity between terminals 1
and 2, and between terminals 3
and 4.
INSPECTING THE ACTIVE
BRAKE BOOSTER
SOLENOID
Disconnect the connector from the
brake booster and check resistance
between terminals 3 and 4 of the
brake booster. Resistance should be
1.1 - 1.7 ohms. If not, replace the
brake booster. If OK, check for an
open or short in the harness and con-
nector between the skid control ECU
Fall 2007
and the brake booster. If OK, check
and replace the skid control ECU.
Check resistance between ter-
minals 3 and 4 of the brake
booster.
TROUBLESHOOTING
LOW OR SPONGY PEDAL
Fluid leaks
Air in brake system
Piston seals worn or damaged
Faulty master cylinder
BRAKE DRAG
Brake pedal freeplay under minimum
Parking brake pedal travel out of
adjustment
Parking brake cable sticking
Parking brake shoe clearance out of
adjustment
Pad(s) cracked or distorted
Piston stuck or frozen
Tension or return spring faulty
Vacuum leaks in booster system
Faulty master cylinder
BRAKE PULLS
Stuck piston
Cracked or distorted pad(s)
Brake disc scored
Vacuum leak in booster system
Faulty master cylinder
HARD PEDAL AND INEFFICIENT
BRAKING
Fluid leaks
Air in brake system
Worn pads
STAR service news
TOYOTA TECHNICAL
Pad(s) cracked or distorted
Pad(s) glazed
Disc scored
Vacuum leaks in booster system
NOISE FROM BRAKES
Cracked or distorted pad(s)
Loose installation bolts
Scored disc
Loose pad support plate
Worn caliper sliding pin
Pads glazed or dirty
Faulty tension or return spring
Damaged anti-squeal shim
Damaged shoe hold-down spring
PROBLEM SYMPTOMS
TABLE
ABS DOES NOT OPERATE
Check the DTC, reconfirming that the
normal code is output
IG power source circuit
Speed sensor circuit
Check hydraulic circuit for leaks
(When all of above are normal and
the problem still occurs, replace the
skid control ECU.)
ABS DOES NOT OPERATE EFFICIENTLY
Check DTCs to confirm that the nor-
mal code is output
Speed sensor circuit
Stop light switch control
Check hydraulic circuit for leaks
(When all of the above are normal
but the problem remains, replace the
skid control ECU.)
ABS WARNING LIGHT ABNORMAL
ABS warning light circuit
Skid control ECU
BRAKE WARNING LIGHT ABNORMAL
Brake warning light circuit
Skid control ECU
Translate ECU
13
 TOYOTA TECHNICAL

DIAGNOSTIC TROUBLE CODE CHART

NOTE: When removing a part, the ignition
switch must be OFF. When replacing mas-
ter cylinder pressure, yaw rate or deceler-
ation sensors and/or the ECU, you must
perform master cylinder pressure, yaw
rate and deceleration sensors zero point
calibration.
DTC C0200/31
Right front wheel speed sensor signal
malfunction
DTC C0205/32
Left front wheel speed sensor signal
malfunction
DTC C0210/33
Right rear wheel speed sensor signal
malfunction
DTC C0215/34
Left rear wheel speed sensor signal
malfunction
(For any or all of the above, check the
appropriate wheel sensor, speed sensor
circuit and the speed sensor rotor.)
DTC C0226/21
Malfunction in ABS & VSC solenoid valves
(Check ABS & VSC actuator and ABS &
VSC solenoid circuit.)
DTC C0278/11
Open or short circuit in ABS & VSC relay
circuit
(Delta S sensor, Delta S sensor circuit.)
DTC C1249/49
Open circuit in stop light switch circuit
(Stop light switch, stop light switch
circuit.)
DTC C1251/51
Pump motor is locked or open circuit in
pump motor circuit
(ABS & VSC pump motor.)
DTC C1337/37
Tire size variation
(Check all four tires for size difference.)
DTC ALWAYS ON
Malfunction in skid control ECU
(Battery, charging system, power source
circuit, ABS warning light circuit.)
DTC C1203/53
ECM communication circuit malfunction
(Brake fluid level, brake fluid level warning
switch circuit, TRC+ or TRC- circuit, ENG+
or ENG- circuit, SS1 or SS2 circuit, ECM,
translate ECU.)
DTC C1207/37
Reverse gear signal failure
(ECT.)
(Yaw rate sensor, yaw rate sensor circuit.)
DTC C1310/11
Open or short circuit of active brake
booster solenoid circuit
(Brake booster, active brake booster
solenoid circuit.)
DTC C1311/12
Open or short circuit in brake inhibit relay
circuit
(Brake inhibit relay, brake inhibit relay
circuit.)
DTC C1335/35
Malfunction in steering angle sensor
communication circuit
(Steering angle sensor, steering angle
sensor communication circuit to translate
ECU.)
DTC C1340/47
Center diff. Lock circuit malfunction
(Center diff. Lock position switch, center
diff. Lock position circuit, center diff. Lock
indicator light circuit, translate ECU.)
DTC C1360/61
Malfunction in master cylinder pressure
sensor
(Master cylinder pressure sensor, master
cylinder pressure sensor circuit.)

(ABS & VSC solenoid relay, ABS & VSC
solenoid relay circuit, ABS & VSC motor
relay, ABS & VSC motor relay circuit)
DTC C1241/41
Low battery positive voltage or abnormally
high battery positive voltage
(Battery, charging system, power source
circuit.)
DTC C1223/43 DTC C1361/62
Malfunction in ABS control system Abnormal battery voltage of VSC sensor
(ABS control system.) (Battery, charging system, power source
circuit, deceleration sensor, yaw rate
DTC C1231/31 sensor, master cylinder pressure sensor.)
Malfunction in steering angle sensor
DTC C1362/36
(Steering angle sensor, steering angle Malfunction in sensor set value (VSC
sensor circuit.) sensor system)

DTC C1244/44 DTC C1232/32 (Skid control ECU.)

Open or short circuit in deceleration Malfunction in deceleration sensor
sensor circuit DTC C1363/63
(Deceleration sensor, deceleration sensor Malfunction in booster pedal force switch
(Deceleration sensor, deceleration sensor circuit.)
circuit.) (Brake booster, booster pedal force switch
DTC C1234/34 circuit.)
DTC C1247/47 Malfunction in yaw rate sensor
Malfunction in Delta S sensor

14 STAR service news Fall 2007

 TOYOTA TECHNICAL

DTC CHECK CANNOT BE DONE

ABS warning light circuit
Tc terminal circuit
VSC TRAC warning light circuit
(When all above are normal but the
problem persists, replace the skid
control ECU.)

SPEED SENSOR SIGNAL CHECK

CANNOT BE DONE
Ts terminal circuit
Skid control ECU

TRAC DOES NOT OPERATE

Check the DTC to confirm that the
normal code is output
IG power source circuit
Check the hydraulic circuit for leaks
Speed sensor circuit
(When all above are normal but the
problem persists, replace the skid
control ECU.)
TRAC DOES NOT OPERATE
EFFICIENTLY
Check the DTC to confirm output of
normal code
Check for hydraulic system leaks
Speed sensor circuit
Whenever possible, if a rotor requires resurfacing, use an on-the-car
lathe. This eliminates any stacked runout variables and provides
true rotor surfaces.
Check DTCs for normal code output
Perform zero point calibration
Check for hydraulic system leaks TOYOTA
Speed sensor circuit Brake fluid:
Deceleration sensor circuit
Yaw rate sensor circuit
Steering angle sensor circuit
Master cylinder pressure sensor circuit
(When all above are normal, but the
problem persists, replace the skid
control ECU.)

VSC DOES NOT OPERATE VSC TRAC WARNING LIGHT

Check for normal code output
Perform zero point calibration
IG power source circuit
Check for hydraulic system leaks
Speed sensor circuit
Deceleration sensor circuit
Yaw rate sensor circuit
Steering angle sensor circuit
Master cylinder pressure sensor circuit
(When all above are normal, but the
problem persists, replace the skid
control ECU.)
VSC DOES NOT OPERATE
EFFICIENTLY
ABNORMAL
VSC TRAC warning light circuit
Skid control ECU
SLIP INDICATOR LIGHT ABNORMAL
SLIP indicator light circuit
Skid control ECU
VSC OFF (TRAC OFF) INDICATOR
ABNORMAL
VSC OFF (TRAC OFF) indicator light
circuit
VSC OFF (TRAC OFF) switch circuit
Skid control ECU ★
Specially formulated by
Toyota for reliability in
Toyota vehicles.
These Toyota Genuine Parts can
be exclusively sourced through
your Toyota STAR Dealer.
Looking for more technical infor-
mation? Please visit
http://techinfo.toyota.com
and see how easy it is to sub-
scribe and gain access to parts
and repair information for Toyota
vehicles.

Fall 2007 STAR service news 15


TOYOTA’S HYBRID VEHICLE
CONTINUOUSLY VARIABLE
TRANSMISSION
For informational purposes, this article dis-
cusses the CVT (Continuously Variable
Transmission) technology featured in two
specific Toyota vehicles. Here we use the
2004 Prius and 2006 Highlander HV as our
examples. The 2004 Prius features the P112
hybrid transaxle, while the 2006 Highlander
HV features the P310 hybrid transaxle.
NOTE: Due to the complexity and potential
hazards of servicing a high-voltage hybrid
Fall 2007
TOYOTA TECHNICAL
system, only Toyota-trained and certified
hybrid technicians are permitted to service
this engine/transmission system. This article
serves only to provide a technical overview
of the continuously variable transmission
that is featured in specific Toyota hybrid
vehicles. This article is not intended to pro-
vide service guidelines and is offered for
informational purposes only.
One very important aspect relates to cable
color. All high-voltage cables utilized on
STAR service news 17
 TOYOTA TECHNICAL
Toyota hybrid vehicles are orange in
color. Gauges will vary, but the criti-
cal point to remember is that if you
encounter an orange cable, do not
touch or tamper with it. Serious
injury can result when untrained per-
sonnel attempt to handle these
cables. If it’s orange, keep your
hands off!
The THS-II (Toyota Hybrid System
II) is a type of powertrain that fea-
tures a combination of two types of
motive forces, such as an internal
combustion engine and an electric
Motor Generator. This system is char-
acterized by skillful use of two types
of motive forces according to driving
conditions. It maximizes the
strengths of each of the motive
forces and complements their weak-
nesses. This provides a seamless
blend of acceleration and decelera-
tion without noticeable shift points.
As a result, it can achieve a highly
responsive level of performance as
well as a dramatic reduction in fuel
consumption and exhaust gas emis-
sions. The THS-II can be broadly
divided into two systems: the series
hybrid system and the parallel hybrid
system.
NOTE: MG1 is Motor Generator No.
1. This starts the engine and then is
driven by the engine, generating
electricity to drive the MG2, or
charge the HV battery, depending on
vehicle status.
MG2 is Motor Generator No. 2. This
uses electricity or generates electric-
ity by reversing the current through
the motor generators.
Series Parallel Hybrid System:
The Series Parallel Hybrid System
18
drives the wheels with the electric
motors and the gas/petrol engine,
yielding electricity via the generator
to self-charge the battery.
With the Series Parallel Hybrid
System, it is possible to drive the
wheels using the dual sources of
power (electric motors and/or
gas/petrol engine), as well as to
generate electricity while running on
the electric motors.
The system runs the car on power
from the electric motors only, or by
using both the gas/petrol engine and
the electric motors together, depend-
ing on driving conditions. Since the
generator is integrated into the sys-
tem, the battery can be charged
while the car is running.
This system takes advantage of the
energy-efficient electric motors when
the car runs in the low speed range,
and calls on the gas/petrol engine
Battery
Inverter
Engine
Generator Electric
motor
1: Direct current
2: Alternating current
Series Parallel Hybrid System
on the Highlander HV.
Battery
Inverter
Engine
Transmission Motor/
generator
1: Direct current
2: Alternating current
Parallel Hybrid System on the
2004 Prius.
STAR service news
when the car runs in the higher
speed range. In other words, the sys-
tem can control the dual sources of
power for optimum energy-efficient
operation under any driving condi-
tions.
THE HYBRID TRANSAXLE
Commonly referred to as a CVT
(Continuously Variable Transmission),
the Toyota hybrid transmission
essentially provides the driver with
the experience of smooth accelera-
tion and deceleration, without notic-
ing specific shift points.
While this system efficiently com-
bines and operates the two types of
motive forces (engine and MG2), the
basic motive force is provided by the
engine. The motive force of the
engine is divided into two areas: the
motive force applied to the wheels
by the planetary gear unit in the
hybrid transaxle, and the motive
force used to operate the MG1 as a
generator.
The hybrid transaxle, which con-
tains the MG1, MG2 and the plane-
tary gear unit, uses these compo-
nents to achieve a smooth drive real-
ized through seamless shifting.
A computer-controlled planetary
gear unit has been adopted to
mechanically link the front wheels
and MG2 via gears and a chain. To
disengage the motive force in the
neutral position, the shift position
sensor outputs an N position signal
to turn off all the power transistors
in the inverter (which connects the
MG1 and MG2). As a result, the oper-
ation of MG1 and MG2 shut down,
rendering the motive forces at the
wheels to zero. In this condition,
even if the MG1 is rotated by the
engine or MG2 is rotated by the
Fall 2007
 TOYOTA TECHNICAL

Planetary gear unit

the HV battery by means of MG2.
Chain drive
Carrier sprocket
Transaxle
The HV ECU controls hybrid opera-
Sun gear Ring gear damper tion according to driving conditions.
MG2 MG1
However, when the HV battery state
of charge (SOC) is low, the HV bat-
tery is then charged by the engine as
it turns MG1.
oil pump Engine As a result, the system achieves far
Silent chain Counter drive gear
greater fuel economy compared to
conventional-engine-equipped vehi-
Counter driven gear cles, and at a reduced level of
Final drive
pinion gear
exhaust gas emissions. In addition,
this revolutionary powertrain has
Final drive eliminated the constraints that are
ring gear
Differential
gear unit

MG1 Inverter
The 2004 Prius P112 Hybrid transaxle. The transaxle unit consists
primarily of a transaxle damper, MG1, MG2, planetary gear unit and Planetary HV battery
gear
a reduction unit (containing a silent chain, counter drive gear,
counter driven gear, final drive pinion gear and a final drive ring Engine MG2
gear). The planetary gear unit, MG1, MG2, transaxle damper and
the chain drive sprocket are located coaxially (in-line), and the force Wheel
is transmitted from the chain drive sprocket to the reduction unit
via a silent chain. Operating mode 1, where elec-
trical power from the HV bat-
tery to MG2 provides force to
drive wheels, no generation of elec- drive the wheels.
Flywheel
tricity occurs because both MG1 and portion

MG2 are inactive. As a result, the

Coil spring
state of charge of the HV battery MG1 Inverter

decreases as the shift position Driven force

Planetary HV battery
gear
remains in the N position. from the
engine Engine MG2

BASIC OPERATION Wheel

The THS-II system controls the fol-
lowing modes in order to achieve the Operating mode 2, where the
engine drives the wheels in
most efficient operations to match order to supply MG2 with elec-
The transaxle damper transmits
real-time driving conditions: the drive force of the engine tricity.
and minimizes vibration.
1. Supply of electrical power from
MG1 Inverter
the HV battery to MG2 provides the 3. MG1 is rotated by the engine via
Planetary HV battery
force to drive the wheels. the planetary gears in order to gear
2. While the wheels are being driv- charge the HV battery, or freewheels, Engine MG2
en by the engine via the planetary depending on operating status.
gears, MG1 is rotated by the engine 4. When the vehicle decelerates, Wheel

(via the planetary gears), in order to kinetic energy from the wheels is
Operating mode 3, where MG1
supply the generated electricity to recovered and converted into electri- is rotated by the engine in order
MG2 and the battery. cal energy, which is used to recharge to charge the HV battery.

Fall 2007 STAR service news 19

 MG1 Inverter

HV battery
Planetary
gear

Engine MG2

Wheel

Operating mode 4, where kinetic energy from

the wheels is recovered during deceleration,
resulting in HV battery recharging through MG2.
associated with electric-only vehicles, such as limited
cruising range or reliance on external charging units.

REGENERATIVE BRAKE
The regenerative brake function operates MG2 as a gen-
erator while the vehicle is decelerating or braking, and
stores this energy in the HV battery. At the same time, it
utilizes the operating resistance which the MG2 exerts
during the generation of electricity as a braking force.
As on the 2003 Prius, the 2004 Prius utilizes shift-by-
wire technology. This is a “link-less” type that does not
use a shift cable. Instead, a shift position sensor in the
transmission detects the shift position and sends a sig-
nal to the HV ECU. Upon receiving this signal, the HV
ECU produces the respective shift positions. When the
driver presses the parking switch (located on top of the
shifter), the “P” position control actuates the shift con-
trol actuator located in the hybrid transaxle in order to
mechanically lock the counter-driven gear, which
engages the parking lock.
The 2004 Prius also features a link-less accelerator
pedal system called ETCS-I (Electronic Throttle Control
System-Intelligent). This features an accelerator pedal
position sensor and a throttle position sensor to detect
Throttle control
motor

Throttle
HV ECU ECM valve

Accelerator
pedal position
sensor Throttle position sensor

The link-less accelerator systems uses a signal

sent by the accelerator pedal position sensor to
ultimately control the engine’s throttle valve
position.

Fall 2007
the accelerator pedal position and the throttle posi-
tion. The HV ECU calculates the target engine speed
and required engine motive force in accordance with
the signals provided by the accelerator pedal position
sensor, vehicle driving conditions and the SOC of the
battery, and sends a control signal to the ECM, which
optimally controls the throttle valve.
The 2006 Highlander HV also features shift-by-wire
and link-less accelerator pedal systems.

FUNCTION OF THS-II MAIN

COMPONENTS
(Concept is either Motor or Generator)

HYBRID TRANSAXLE MG1

Rotated by the engine, MG1 generates high-voltage
electricity in order to operate MG2 or to charge the HV
battery. MG1 also functions as a starter for the engine.

HYBRID TRANSAXLE MG2

Driven by electrical power from MG1 or the HV bat-
tery, MG2 provides motive force for the drive wheels.
During braking, or when the accelerator pedal is not
depressed, MG2 generates electricity to recharge the HV
battery.

HYBRID TRANSAXLE PLANETARY GEAR UNIT

The hybrid transaxle planetary gear unit distributes
the engine’s drive force as needed to directly drive the
wheels and the generator. See chart on page 22.

HV BATTERY
This special HV battery supplies electric power to the
MG2 during start-off, acceleration, and uphill driving.
The battery is recharged during braking or when the
accelerator pedal is not depressed.

INVERTER ASSEMBLY
The inverter assembly is a device that converts the
high-voltage DC HV battery power into AC (MG1 and
MG2) and vice versa (converts AC into DC).
A Boost Converter boosts or lowers the maximum
high-voltage of the HV battery.
A DC-DC Converter drops the maximum high-voltage
in order to supply electricity to body electrical compo-
nents, as well as to recharge the auxiliary battery.

Fall 2007
 TOYOTA TECHNICAL
SUMMARY OF THE TWO PLANETARY GEARSETS
Model Gearset General
2004 Prius Planetary
gear unit
2006 Highlander HV Compound Power split
gear unit planetary
gear
Motor speed
reduction
planetary
gear
An A/C Inverter converts the nomi-
nal DC high-voltage of the HV bat-
tery to AC and supplies power to
operate the electric inverter com-
pressor of the A/C (air conditioning)
system.
Both Toyota models (2004 Prius
and 2006 Highlander HV) feature air
conditioning compressors with inte-
gral high-voltage alternating current
motors. This allows powering the air
conditioning compressor with a high-
voltage electric motor for further
improvements in vehicle efficiency.
HV ECU
(The HV ECU is also known as the
THS-ECU on the Highlander HV).
The Hybrid Vehicle ECU receives
information from each sensor, as well
as from the ECM, battery ECU, skid
control ECU and EPS ECU. Based on
this information, the required torque
and output power is calculated. The
HV ECU sends the calculated result
to the ECM, inverter assembly, bat-
tery ECU and skid control ECU.
ECM
The ECM activates the ETCSi in
accordance with the target engine
22
into an electrical signal and outputs
this signal to the HV ECU.
Functions
Distributes the engine’s drive force as SHIFT POSITION SENSOR
appropriate to directly drive the vehicle as The shift position sensor converts
well as the generator.
the shift position into an electrical
signal and outputs this to the HV
Distributes the engine’s drive force as ECU.
appropriate to directly drive the vehicle as
well as the generator. On the 4WD-1 system (2006
Highlander HV, as an example), an
Located between the motor and the power
MGR (Motor Generator Rear) is provid-
split planetary gear, the motor speed
reduction planetary gear reduces the rota- ed in the rear drive unit. MGR, which
tional speed of the motor in accordance is powered by the electricity from
with the characteristics of the planetary
gear, in order to increase torque. MG1 or the HV battery, drives the rear
wheels in accordance with driving
speed and the required engine motive conditions. During deceleration, MGR
force received from the HV ECU. functions as a generator and charges
the HV battery as needed.
BATTERY ECU The MG1, MG2 and MGR are com-
The battery ECU monitors the pact, lightweight and highly efficient
charging condition of the HV battery alternating current permanent mag-
(slightly different on the Highlander net synchronous type motors.
HV, which features an analog-to-digi- An independent cooling system is
tal “smart unit”). featured for cooling the MG1, MG2
and the inverter. This cooling system
SKID CONTROL ECU activates when the power supply sta-
The skid control ECU controls the
regenerative brake that is affected
MG1
by the MG2 and the hydraulic brake MG2
Stator
so that the total braking force equals
that of a conventional vehicle that is
equipped with hydraulic brakes only.
Also, the skid control ECU performs
brake system control (ABS with EBD,
Brake Assist, and Enhanced VSC; or
VDIM on the Highlander HV). The
VDIM, or vehicle Dynamic Integrated
Management unit, bundles the logic
Rotor
for better control during acceleration
and deceleration to avoid any poten-
tial hesitation issues.
ACCELERATOR PEDAL POSITION
SENSOR
Front transaxle
The accelerator pedal position sen-
sor converts the accelerator angle Front transaxle cutaway view.
STAR service news Fall 2007
 TOYOTA TECHNICAL

tus is switched to READY ON state.
The radiator for this cooling system is
separate from the engine’s radiator.
NOTE: Toyota specifies special ATF
for these transmissions, as well as
special coolant for the inverter
assembly.
FEATURES OF
4WD-I SYSTEM
On a slippery road surface, the skid
control ECU calculates the required
total motive force and the torque
distribution between the front and
rear wheels, and transmits this signal
to the THS ECU. Upon receiving
these signals, the THS ECU appropri-
ately drives the front and rear wheels
in order to achieve traction perform-
ance while ensuring driving stability.
As a rule, the system deactivates the
driving of the rear wheels during nor-

MGR Rear wheel

speed sensors

Stator

Rotor
Inverter
assembly

3MZ-FE
engine

Rear drive
unit

RH front wheel
speed sensor

Shift position hybrid LH front wheel

sensor transaxle speed sensor
Rear drive unit
(with 4WD-1 systems model)

Cutaway view of the rear drive The 2006 Highlander HV 4Wdi system features the P310 transaxle
unit featured on 4WD-I systems. and an additional MGR (Motor Generator Rear).

Reseroir tank mal driving to ensure fuel economy. If

the vehicle is being driven on a slip-
pery road surface, accelerates or makes
a tight turn, the skid control ECU
detects the conditions of the vehicle
based on the signals provided by the
sensors. The skid control ECU calcu-
lates the total required motive force
and the torque distribution between
the front and rear wheels and trans-
mits the signals to the THS ECU. The
THS ECU then allows the front and rear
wheels to be driven. When the vehicle
Water pump
decelerates, the kinetic energy is
Dedicated recovered from the front and rear
radiator
wheels, is converted into electrical
An independent cooling system provides cooling for MG1, MG2 and energy, and is used for recharging the
the inverter. HV battery by means of MG2 and MGR.

Fall 2007 STAR service news 23

 TOYOTA TECHNICAL

HIGHLANDER HV P310 NOTE: The Prius gearset features speed reduction planetary gear unit
TRANSAXLE one planetary gearset, while the to the system.
This hybrid transaxle consists pri- Highlander HV features two planetary
marily of MG1, MG2, a compound gearsets (one for reducing speed and HV BATTERY
gear unit (which consists of a motor torque needed for MG2, allowing a The 2006 Highlander HV battery is
speed reduction planetary gear unit downsizing of the MG2). This com- a sealed nickel metal hydride (Ni-
MH) assembly. This HV battery has a
Compound gear high power density, is lightweight
Ring gear for Ring gear for
motor speed power split
and offers longevity to match the
reduction planetary gear
planetary gear characteristics of the THS-II system.
The HV battery consists of 240 cells
(eight cells x 30 modules) with a
nominal voltage of 288V (240 cells x
1.2V). The HV battery is mounted
under the rear seat and is split into
three sections, separated by the seat
rails.
As we mentioned earlier, this arti-
cle is intended to provide an infor-
Compound Parking gear mational overview of Toyota’s hybrid
gear unit
Counter drive gear system.
Toyota strongly emphasizes that
The compound gear unit consists of a motor speed reduction plan- only Toyota-trained and certified
etary gear and a power split planetary gear. Each planetary ring hybrid technicians should attempt
gear is integrated with the compound gear. The compound gear is
integrated with a counter drive gear and parking gear. service of this system.
NOTE: Proper recycling must be
and a power split planetary gear pound planetary gearset is a notable adhered to with regard to battery
unit), a counter gear unit and a dif- development, as this adds a motor disposal. ★
ferential gear unit.
The engine, MG1 and MG2 are
mechanically joined via the com- Rear seat
pound gear unit. The compound gear
unit contains a motor speed reduc-
tion planetary gear unit and a power
split planetary gear unit. The motor
speed reduction planetary gear unit, HV battery Floor board
module (seven-seat model)
whose purpose is to reduce motor
speed, is used to enable the high-
speed, high-output MG2 to adapt
optimally to the power split plane-
tary gear unit. The power split plane-
tary gear unit splits the motive force
of the engine in two ways: one to Seat rails
drive the wheels, and the other to
drive the MG1, allowing the MG1 to Citing the 2006 Highlander HV as an example, the HV battery is
act as a generator. located under the rear seat, split into three portions.

24 STAR service news Fall 2007

STAR Service News

Missed an issue? You’re in luck!

The following back issues of the Toyota STAR Service News are available
FREE in limited quantities. Use the form to request back issues.
Issue # Months Contents
25 Fall 1987 Toyota Computer Controlled System
27 Spring 1988 Emission Control Systems
28 Summer 1988 Air Conditioning
29 Fall 1988 Charging & Starting Systems
30 Winter 1988 The Variable Venturi Carburetor
31 Spring 1989 Toyota Publications Information — Repair Manuals, Collision Manuals,
Diagnosis Manuals
32 Summer 1989 The Fuel Systems
33 Fall 1989 Suspension — Toyota Electronically Modulated Suspension (TEMS)/
1986 Celica Front Brake System
34 Winter 1990 Special Service Tools for Toyota Vehicles/Toyota Engine & Transmission
Applications Chart (1981-1989)
35 Spring 1990 Free Wheeling Hubs (1984-1988 4WD)/MR2 Cooling System (1985-1989)/
“Y” Series Engines (1984-1989 Van)
36 Summer 1990 Security — Toyota Intrusion Monitoring System/Brakes — Toyota Anti-Lock
Brake System (ABS)/Engine (2S-E Engine)
38 Winter 1991 2WD & 4WD Wheel Alignment (1984-1988 Pickup Truck)/Rust Repair
42 Winter 1992 Body Repair — Outer Door Panel Replacement/Battery Testing for Winter
43 Spring 1992 Camry Timing Belt Inspection & Installation/Four Ways to Control Idle Speed
45 Fall 1992 1988 Camry Automatic Transaxle Description & Troubleshooting
48 Summer 1993 1990 Truck Engine Cooling Systems/22R & 22R-E Engine
(4-Cyclinder)/3VZ-E Engine (6-Cyclinder)
49 Fall 1993 Diagnosing & Troubleshooting the 1990 Camry Automatic Transmission
60 Summer 1996 1993 Truck Air Conditioning System
71 Jul./Aug. 1998 Engine Short Block Service/Truck Suspension Basics/Automatic Transaxles

Fall 2007 STAR Service News 25

Issue # Months Contents
76 May/Jun. 1999 Cylinder Head Inspection & Service/A/C Diagnostic & Service Tips/
CV Shaft Service
82 May/Jun. 2000 Engine Timing Belt/Ride Control/Automatic Transmission Service
83 Jul./Aug. 2000 Engine Knock Sensors/Power Rack & Pinion Steering System Service/
Wheel Bearing Service
86 Jan./Feb. 2001 Wheel Alignment/Cylinder Head Service/Four-Wheel Disc Brake Service
87 Mar./Apr. 2001 A/C Service/Fuel Injector Service/Piston & Ring Service
92 Jan./Feb. 2002 OHC Service/Clutch System Service/Fuel Pump & Fuel Delivery
93 Mar./Apr. 2002 Distributorless Ignition Systems/Lighting Systems/Common Codes
94 May/Jun. 2002 Stabilizer Bars/Cooling System Service/Brake Pulsation
95 Jul./Aug. 2002 Noise, Vibration, Harshness/Front Suspension Lower Control Arm Service
On FWD/Threaded Fasteners
96 Sep./Oct. 2002 Crankshaft Bearing Service/Temperature Sensors/Strut & Shock Service
103 Winter 2004 Wheel Alignment Basics/Automatic Transmission/Cooling System
104 Spring 2004 Fuel Injectors/Wheel/Tire Vibration & Balancing/Towing & Trailering
105 Summer 2004 Alloy Wheel Installation/Power Steering/Engine Short Block Service
106 Fall 2004 MAP, Knock & TPS/Stabilizer Bars/Traction Control Systems
107 Winter 2005 Truck Rear Axle Service/Temperature Sensors/Brake System Service
108 Spring 2005 Crankshaft & Camshaft Position Sensors/Electronic Fuel Injection/
DOHC Timing Belt Service
109 Summer 2005 Cooling System Service/ABS Theory & Service/Cylinder Head Service
110 Fall 2005 Connecting Rod Service/Toyota Tire Pressure Warning System/Airbag Service
112 Spring 2006 Torque Converter Operation & Diagnosis/Wheel Alignment/Cooling System Service
113 Summer 2006 Antilock Brake System/Fuel Injection System/Piston Ring Service
114 Fall 2006 Cylinder Head Service/Understanding & Measuring Ride Height/Engine
Immobiliser System
115 Winter 2007 Brake System Service/Fuel System Service/Oxygen Sensor Tech
116 Spring 2007 Vehicle Stability Control/A/C Service
117 Summer 2007 Air Suspension/Run-flat Tires/Tundra SFI

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26 STAR Service News Fall 2007


POWER STEERING SERVICE
PROBLEM SYMPTOMS
TABLE
HARD STEERING:
1. Tires improperly inflated
2. Power steering fluid level low
3. Front wheel alignment incorrect
4. Worn steering system joints
5. Worn suspension arm ball joints
6. Binding steering column
7. Power steering vane pump
8. Power steering gear
POOR RETURN:
1. Tires improperly inflated
2. Front wheel alignment incorrect
3. Binding steering column
4. Power steering gear
EXCESSIVE PLAY:
1. Worn steering system joints
2. Worn suspension arm ball joints
3. Worn intermediate shaft, sliding yoke
4. Worn front wheel bearings
5. Power steering gear
ABNORMAL NOISE:
1. Low power steering fluid level
2. Worn steering system joints
3. Power steering vane pump
4. Power steering gear
INSPECT DRIVE BELT:
Visually check the power steering drive belt
for signs of excessive wear, frayed cords,
etc. Cracks on the rib side of the belt are
considered acceptable. However, if missing
rib chunks are noticed, replace the belt.
Fall 2007
BLEEDING THE POWER
STEERING SYSTEM
Check the fluid level. Jack up the
front of the vehicle and support it
with jack stands. With the engine
off, turn the steering wheel slowly
from lock to lock several times. Lower
the vehicle and start the engine. Run
the engine at idle for a few minutes.
With the engine idling, turn the
wheel to the left or right to full lock,
and hold the wheel at full lock for
two to three seconds. Next, turn the
wheel to the opposite full lock posi-
tion and hold it there for two to
three seconds. Repeat this several
times. Stop the engine and check the
power steering reservoir for fluid
foaming or emulsification. If the sys-
tem must be bled twice because of
foaming or emulsification, check for
fluid leaks in the system.
When checking fluid level, keep the
vehicle on a level surface. With the
engine stopped, check the fluid level
in the oil reservoir. If necessary, add
fluid (ATF Dexron II or III). If the
fluid is cold, check that the level is
STAR service news
TOYOTA TECHNICAL
within the COLD LEVEL range. If it is
hot, check that it is within the HOT
LEVEL range. To check hot level, start
the engine and run it at idle. Turn
the steering wheel from lock to lock
several times to raise fluid tempera-
ture (in the hot level range, fluid
temperature should be 167 - 176
degrees Fahrenheit. With the engine
idling, measure the fluid level in the
oil reservoir. Stop the engine, wait a
few minutes and re-measure fluid
level. Maximum fluid level rise (from
engine idling to engine stopped)
should be 0.20 in. (5mm).
CHECKING STEERING
FLUID PRESSURE
Disconnect the pressure feed tube
assembly from the vane pump assem-
bly. Connect SST 09640-10010
(09641-01010, 09641-01030, 09641-
01060) or equivalent.
Check that the valve of the SST is
in the open position. Bleed the
power steering system. Start the
engine and run it at idle. Turn the
steering wheel from lock to lock sev-
27
 TOYOTA TECHNICAL

eral times. With the engine idling,

Attachment close the valve of the SST and
SST
observe the reading on the SST.
Minimum fluid pressure is 1,209 psi
(8,336 kPa).
Pressure IN OUT NOTE: Do not keep the valve closed
feed tube
assembly for more than 10 seconds. Do not
Attachment allow the fluid temperature to
become too high.
With the engine idling, open the
valve fully. Measure the fluid pres-
sure at engine speeds of 1,000 rpm
and 3,000 rpm. The difference in
Connect the SST as shown, with the SST out line connected to the
pressure feed tube assembly. fluid pressure should be 71 psi or

Oil
reservoir

PS
gear Closed

PS vane
pump
SST

With engine idling and the SST

valve closed, minimum fluid
pressure should be 1,209 psi.

Oil
reservoir
Vacuum hose
PS Air cleaner assembly
gear Open

PS vane Union bolt

pump
SST
Reservoir to Gasket Clip
With engine idling and the SST pump hose
valve fully open, measure fluid No. 1
Pressure
pressure at 1,000 rpm and at feed tube
3,000 rpm. The fluid pressure dif- Clip
ference should be 71 psi or less.
Stud bolt
Vane pump V belt
Oil
reservoir
Lock position
PS
gear Open
Vane pump assembly
PS vane
pump
SST
The vane pump assembly is located on
With engine idling and the valve the right (passenger) side of the engine.
fully open, turn the steering The pressure feed tube connects at the
wheel to full lock. At this point, top of the pump body.
fluid pressure should be 1,209 psi.

28 STAR service news Fall 2007

 TOYOTA TECHNICAL

less. NOTE: Do not turn the steering
wheel during this check.
With the engine idling and the
valve fully open, turn the steering
wheel to the full lock position (right
or left). At this point, minimum fluid
pressure should be 1,209 psi. Do not
maintain the lock position for more
than 10 seconds. Once fluid pressure
has been checked, disconnect the SST
and connect the pressure feed tube
assembly to the vane pump assembly,
and bleed the power steering system.
Next, check steering effort. Center
the steering wheel and remove the
steering wheel pad. Start the engine
and run it at idle. Measure the steer-
ing effort in both directions.
Steering effort should be 53 in.-lbf
or less. Torque the steering wheel set
the engine’s serpentine drive belt.
If pump service is required, remove
the vane pump following the service
manual procedures. With the vane
pump secured in a vise, check that
the pump rotates smoothly without
SST abnormal noise. Using a beam-type
torque wrench, check rotating
Use the SST to hold the pulley
in place while loosening the torque, which should be 2.4 in.-lbf
pulley retaining nut. (0.28 N-m) or less.
Pressure port union
O-ring
Flow control valve
Suction port union Spring Gasket
O-ring

nut to a value of 37 ft.-lbf and

Vane pump shaft
install the steering wheel pad.
NOTE: When checking steering
effort, be aware of tire type, tire
inflation pressure and tire contact Oil seal
Vane pump
surface, as these factors can influ- housing front
ence steering effort. Make sure that
tire pressure is correct and avoid
performing this check on rough sur- Vane pump pulley

faces such as gravel.

O-ring
POWER STEERING VANE Straight pin Wave washer
PUMP ASSEMBLY
The 2004 4Runner features a vane- Vane pump
Cam ring

type power steering pump, driven by rotor

Side plate Vane pump

housing rear
x 10
Straight pin
Snap ring
Vane plate

This exploded view shows the components of the vane pump

With the vane pump secured in
a vise, use a torque wrench to
check for pump rotating torque.
The pump should rotate at a
value of 2.4 in.-lbf or less.
assembly. Whenever vane pump repair is planned, always replace
the gasket, pressure port union O-ring, suction port O-ring, vane
pump shaft oil seal, vane pump housing O-rings, the cam ring
straight pins, the snap ring located between the vane pump rotor
and the side plate, and the retaining nut that secures the pump pul-
ley to the pump shaft.

Fall 2007 STAR service news 29

 TOYOTA TECHNICAL
Using SST 09960-10010 (09962-
01000, 09963-01000) to hold the
pulley stationary, remove the pulley
retaining nut. Remove the pulley
from the vane pump shaft.
VANE PUMP DISASSEMBLY
Remove the power steering suction
port union (along with its O-ring).
Remove the pressure port union, flow
control valve and spring, and O-ring.
Remove the four bolts that secure
the rear housing and remove the rear
housing. NOTE: If the wave washer
and side plate are stuck to the vane
pump rear housing, lightly tap the
vane pump rear housing with a plas-
tic hammer, and remove the wave
washer an side plate.
Remove the two O-rings from the
rear housing, and remove the vane
pump cam ring (remove the snap
ring from the vane pump shaft using
a screwdriver).
Remove the vane pump rotor and
its 10 vane plates. Remove the vane
pump shaft, and remove the two
straight pins from the vane pump
front housing.
Remove the vane pump housing oil
seal using a screwdriver with a vinyl
tape wrapped around its tip. Be care-
ful not to damage the vane pump
housing front.
Vane pump shaft
Vane pump
Bushing
housing front
Determine shaft oil clearance by
measuring the shaft O.D. and
the front housing’s bushing I.D.
30
Feeler gauge
Measure the clearance between
each vane pump rotor groove
and vane plate.
Using a micrometer, measure the
vane pump shaft diameter. Using a
caliper gauge or bore gauge, measure
the bushing inner diameter in the
front housing. Subtract the bushing
inside diameter from the shaft’s
outer diameter to determine oil
clearance. Standard clearance is
0.0012 - 0.0020 in. Maximum clear-
ance is 0.0028 in. If clearance is
greater than the allowable maximum,
replace the shaft and the front vane
pump housing.
Inscribed mark
If replacing the vane pump rotor
and/or plates, refer to the num-
ber stamped on the cam ring in
order to achieve proper clear-
ance.
Inspect the vane pump rotor and
vane pump plates. Using a microme-
ter, measure the height, thickness
and length of the 10 vane plates.
Minimum plate height is 0.33858 in.
(8.6mm). Minimum plate thickness is
0.05500 in. (1.397mm). Minimum
plate length is 0.59020 in.
(14.991mm). Replace any plates that
STAR service news
do not meet the minimum specifica-
tions. If one or more plates require
replacement, it is suggested that all
10 plates be replaced.
Using a feeler gauge, measure the
clearance between the vane pump
rotor groove and the vane plate in
all 10 locations. Maximum clearance
is 0.00130 in. (0.033mm). If clear-
ance is greater, replace the plate(s)
and/or rotor. NOTE: Be sure to
replace the plate(s) and rotor with
units that feature the same mark
that is stamped on the cam ring.
ROTOR VANE VANE
AND CAM PLATE PLATE
RING MARK P/N LENGTH
None 44345- 0.59051 - 0.59059 in.
26010 (14.999 - 15.001mm)
1 44345- 0.59043 - 0.59051 in.
26020 (14.997 - 14.999mm)
2 44345- 0.59035 - 0.59043 in.
26030 (14.995 - 14.997mm)
3 44345- 0.59027 - 0.59035 in.
26040 (14.993 - 14.995mm)
4 44345- 0.59020 - 0.59027 in.
26050 (14.991 - 14.993mm)
FLOW CONTROL VALVE
Coat the flow control valve with
clean power steering fluid and check
that it falls smoothly into the flow
control valve bore by its own weight.
Next, check the flow control valve
for leakage. Close one of the holes
and apply 57 - 71 psi of compressed
air into the opposite-side hole, and
confirm that air does not exit the
end holes. If it is necessary to
replace the flow control valve,
replace with a valve that features
the same reference letter that is
marked on the front housing (mark
A, B, C, D, E or F).
Inspect the flow control valve com-
Fall 2007

pression spring using outside
calipers. Free length (uncompressed)
minimum is 1.307 in. (33.2mm). If
the spring measures less than this
minimum, replace the spring.
Compressed air
With one side hole blocked and
compressed air injected into the
op p o s i t e s i d e h o l e , n o a i r
should escape from either end
of the flow control valve.
Inscribed mark
When replacing the flow control
valve, be sure to select a valve
that features an alpha letter mark
that corresponds to the letter
mark on the front housing.
Vernier calipers
Measure free length of the flow
control valve spring (uncom-
pressed length).
VANE PUMP REASSEMBLY
Coat a new vane pump housing oil
seal’s lip with power steering fluid
and press-install the seal using SST
09950-60010-01 (09951-00320),
09950-70010-01 (09951-07100).
Fall 2007
Make sure that the oil seal is
installed correctly, with the lips fac-
ing inboard into the housing.
Install the vane pump shaft. Using
a plastic hammer, tap the two new
pins to the vane pump housing front.
Be careful not to damage the pins.
Install the vane pump cam ring
with the reference mark facing out-
ward. Align the holes of the cam ring
with the straight pins.
Install the vane pump rotor (without
its plates) into the cam ring. The rotor
must be installed with the reference
mark facing outward. Install a new
snap ring to the vane pump shaft.
Next, install all 10 plates into the
rotor grooves, with the round end of
the plates facing outward toward the
outer circumference of the rotor.
Install a new gasket and install the
rear side plate, aligning the plate
holes with the straight pins.
Install the wave washer so that its
protrusions fit into the slots in the
side plate. Coat two new O-rings
with power steering fluid and install
then to the rear housing.
Install the rear housing with four
bolts, and tighten the bolts to a
value of 17 ft.-lbf (24 N-m).
Install the pressure spring to the
vane pump front housing at the pres-
sure port, and install the flow control
valve (coat the valve with fresh power
steering fluid). Coat the new O-ring
with power steering fluid and install it
to the pressure port union. Install the
pressure port union and tighten to a
value of 61 ft.-lbf (83 N-m).
Install the suction port union (fit-
ted with a new O-ring coated with
power steering fluid). Install the
suction port union and bolt, tighten-
ing to 9 ft.-lbf (13 N-m).
Finally, install the pump pulley and
STAR service news
TOYOTA TECHNICAL
Using the SST driver, press the
new oil seal into the housing,
making sure the seal is oriented
correctly.
new retaining nut to the pump shaft.
Using the SST pulley-holding tool,
tighten the nut to 32 ft.-lbf (44 N-
m). Using a torque wrench, verify
the pump’s rotation torque. A force
of 2.4 in.-lbf or less should be
required to rotate the pump.
Round end
Once the rotor is in place, install
the vane plates with the round-
ed end facing outward toward
th e r o t o r o u t e r e d g e s ( t h e
round ends of the vane plates
should face the inside wall of
the cam ring).
SERVICING THE POWER
STEERING RACK
ASSEMBLY
For purposes of this article, we’ll
focus only on the servicing/rebuild-
ing of the power rack’s control valve
system. For removal and installation
of the rack assembly, refer to the
vehicle’s Service Manual.
With the rack & pinion unit’s tie
rods removed, use SST 09922-10010-
01 to remove the rack guide lock nut.
Using a 24mm hex wrench, remove the
31
 TOYOTA TECHNICAL
Turn pressure tube
Oil seal
O-ring
Bearing guide nut
Lock nut
Rack guide
spring cap
Rack guide spring
Rack guide
rack guide spring cap, and remove the
spring and rack guide.
Remove the two bolts that secure
the power steering control valve and
pull out the control valve assembly
with the control valve housing. Re-
move the O-ring. Carefully mount the
control valve assembly in a soft-jaw
vise.
Using SST 09631-20060-01, remove
the bearing guide nut. Be careful not
to damage the oil seal lip. Remove
the O-ring and dust cover.
Using SST 09950-60010-01 (09951-
00300), 09950-70010-01 (09951-
32
shaft to protect the shaft
Control valve housing from nicks and scratches).
Using a plastic hammer,
tap out the valve assembly
Dust cover
with the bearing guide nut
from the control valve
housing.
Using a screwdriver,
remove the four Teflon
O-ring Union rings from the control valve
seat
Control valve assembly. Be careful not to
upper oil seal
damage the ring grooves.
Bearing Using a screw extractor,
Control valve
remove the union seat from
Teflon ring the control valve housing.
Next, remove the power
steering control valve upper
seal using a press and SST
09950-70010-01 (09951-
07150), 09950-60010-01
(09951-00250).
Using SST 09631-20120,
remove the stopper and
remove the O-ring from the
Rack housing stopper.
Using SST 09950-70010-
01 (09951-07200-01) and a
This exploded view shows the 2004 press, remove the steering
Toyota 4Runner power rack & pinion rack and oil seal. Be careful
internal components. to avoid allowing the rack
to fall to the floor.
07100) and a hammer, drive out the
oil seal from the bearing guide nut INSPECTION
(wind vinyl tape to the control valve Insert a wire into the vent hole of
the steering rack by 1.18 in.
(30mm), and make sure that the
vent hole is not clogged with grease.
If the hole is clogged, the pressure
inside the boot will change after
assembly and when the steering
wheel is turned.
Inspect the rack teeth and the pin-
ion gear teeth for damage. Replace if
Use specified Toyota SSTs to necessary. Carefully scrape any burrs
remove the bearing guide nut
and to drive out the oil seal off of the rack teeth and burnish any
from the bearing guide nut. sharp edges. ★
STAR service news Fall 2007
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Fall 2007 STAR Service News 33

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Alameda CA Tracy CA Bradenton FL
510-522-6400; 800-986-9727 860-278-5411 941-756-5511;
209-834-1111
800-282-3964 (FL only)
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619-440-0225 714-832-3111 305-364-9800; 800-779-8696
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Riverside CA Orlando FL 954-966-2150
951-687-1622 Liberty Toyota-Scion 407-846-1600; 800-432-8090
Colorado Springs CO Toyota of Melbourne
Toyota of San Bernardino 719-598-2222; 800-289-0401 Clearwater Toyota Melbourne FL
San Bernardino CA Clearwater FL 321-254-8888
909-381-4444 Mountain States Toyota/Scion 727-799-1234
Denver CO Toyota of Orlando
Toyota of Santa Barbara 303-302-8888 Courtesy Toyota Orlando FL
Goleta CA Tampa FL 407-298-4500; 800-842-4699
805-967-5611 Pedersen Toyota-Scion-Volvo 813-621-7747; 800-444-4983
Fort Collins CO Georgia
Toyota of Santa Maria Courtesy Toyota
970-223-3100; 800-800-0788 Winter Park FL Atlanta Toyota
Santa Maria CA Duluth GA
805-928-3881 407-678-1234; 800-942-7926
Stevinson Toyota East & Scion 770-476-8282; 800-334-5149
Aurora CO David Maus Toyota
Toyota of the Desert Butler Toyota
Cathedral City CA 303-340-2170; 800-332-5877 Sanford FL
407-302-8800; 800-864-8023 Macon GA
760-328-0871; 800-479-5744 478-784-0600; 800-858-7240
Stevinson Toyota West & Scion
Toyota of Vallejo Lakewood CO Daytona Toyota
303-277-0550; 800-525-8858 Daytona Beach FL Cobb County Toyota
Vallejo CA 386-255-7475 Kennesaw GA
707-552-4545; 800-537-5151 770-422-8555; 800-238-6968
Western Slope Auto Co.
Grand Junction CO Earl Stewart Toyota
Toyota of Walnut Creek of North Palm Beach Conyers Toyota
Walnut Creek CA 970-243-0843; 800-525-7072 Conyers GA
Lake Park FL
925-933-7440 561-844-3461 770-922-5500
Connecticut
Toyota Santa Monica A-1 Toyota Ed Morse Delray Toyota Heyward Allen Toyota
Santa Monica CA New Haven CT Delray Beach FL Athens GA
310-394-6744 203-389-1521; 800-428-8678 561-276-5000; 800-940-0390 706-549-7002; 800-260-0228

34 STAR service news Fall 2007

 STAR dealer listings
Jay Toyota Schaumburg Toyota Bohn Brothers Toyota Jim Coleman Toyota Inc.
Columbus GA Schaumburg IL Harvey LA Bethesda MD
706-322-8891; 800-367-4760 847-882-1800; 800-882-7228 504-341-3300; 800-348-8180 301-469-7100
LaGrange Toyota Toyota of Naperville Greg LeBlanc Toyota Koons Toyota
LaGrange GA Naperville IL Houma LA Annapolis MD
706-882-2963; 800-882-2963 630-357-1578 985-876-7210; 800-764-6422 410-268-6480; 800-262-3330
Lowe Toyota/Warner Robins Toyota on Western Hampton Toyota R&H Toyota
Warner Robins GA Chicago IL Lafayette LA Owings Mills MD
478-929-7900 773-776-4016 337-984-5010; 800-633-5010 410-363-2000
Sandy Springs Toyota Indiana John Harvey Toyota Russel Toyota
Atlanta GA Beck Toyota Baltimore MD
404-256-3392 Bossier City LA
Indianapolis IN 318-741-1337 410-788-8400; 800-638-8401
317-882-2600; 800-541-7635
Savannah Toyota Toyota of Glen Burnie
Savannah GA Lakeside Toyota
Evans Toyota Metairie LA Glen Burnie MD
912-927-1234; 800-633-8805 Ft. Wayne IN 410-761-9000; 800-848-4451
504-833-3311; 800-833-2128
260-482-3730; 800-218-1046
Stone Mountain Toyota Toyota of Waldorf
Stone Mountain GA Richmond Toyota Northshore Toyota Waldorf MD
770-736-0030; 800-210-9391 Richmond IN Covington LA 301-843-3700; 800-243-3949
765-935-8057; 888-820-4569 985-893-7778
Team Toyota Massachusetts
Lithia Springs GA
770-941-1200
Iowa Price LeBlanc Toyota
Acton Toyota
Dan Deery Toyota Baton Rouge LA
225-408-1100; 800-960-1157 Acton MA
Toyota Mall of Georgia Waterloo IA 978-263-1500
Buford GA 319-233-5000; 800-383-4348
Ray Brandt Toyota Balise Toyota
678-546-1212 Kenner LA
Toyota of Des Moines West Springfield MA
Des Moines IA 504-464-4500 413-734-8795
Toyota of Roswell
Roswell GA 515-276-4911; 800-342-7045
Team Toyota Bernardi Toyota
770-594-8696; 888-594-8696 Baton Rouge LA
Wilson Toyota Framingham MA
Toyota South Ames IA 225-273-5880; 800-696-5895 508-879-1520; 800-248-3035
Morrow GA 515-232-4081; 800-232-4081
770-961-0225; 800-24-LEXUS Toyota of New Orleans Boch Toyota Inc.
Kansas New Orleans LA Norwood MA
Idaho Lewis Toyota 504-940-0000; 800-980-6252 781-769-8100; 800-532-9622
Parker Toyota Inc. Topeka KS
Coeur D’Alene ID 785-273-2220 Toyota of Slidell Boch Toyota South
208-765-8228; 800-733-8170 Slidell LA North Attleboro MA
Olathe Toyota 985-643-0005; 800-521-8101 508-699-7551
Peterson Toyota Olathe KS
Boise ID 913-780-9919 Yokem Toyota Clair Toyota Inc.
208-378-9000; 800-584-7751 Shreveport LA Boston MA
Superior Toyota 318-798-3773; 800-456-0501 617-469-1024; 800-354-5100
Illinois Merriam KS
Anderson Toyota
913-831-0800; 800-798-8267 Maine Copeland Toyota
Charlie’s Toyota Brockton MA
Rockford IL Kentucky 508-584-2440
815-397-8995 Augusta ME
Green’s Toyota of Lexington 207-622-4748
Arlington Toyota Lexington KY Expressway Toyota
Buffalo Grove IL 859-254-5751 Dorchester MA
Down East Toyota 617-265-4321
847-394-5100; 800-426-1854 Brewer ME
Kerry Toyota 207-989-6400; 800-869-6827
Chicago Northside Toyota Florence KY Falmouth Toyota Inc.
Chicago IL 859-371-3939 Bourne MA
Prime Toyota 508-759-1900; 800-442-1330
773-728-5000 Saco ME
Mike Smith Toyota
Paducah KY 207-282-6161 Harr Toyota Inc.
Elmhurst Toyota
Elmhurst IL 270-415-0474; 866-423-0474 Worcester MA
630-279-2160; 800-266-3000 Toyota of Portland 508-852-5511
Oxmoor Toyota Portland ME
Grossinger Toyota North Louisville KY 207-321-3477 Herb Chambers Mid-State Toyota
Lincolnwood IL 502-426-1200; 800-880-3381 Auburn MA
847-675-7100 Maryland 508-832-8000; 800-767-1898
Toyota of Louisville
Libertyville Toyota Louisville KY 355 Toyota Ira Toyota
Libertyville IL 502-935-1433 Rockville MD Danvers MA
847-362-1500; 888-771-9997 301-340-0900 978-777-2330; 800-774-8411
Toyota on Nicholasville
Oakbrook Toyota in Westmont Nicholasville KY Beltway Toyota Ira Toyota II
Westmont IL 859-887-4200 Marlow Heights MD Tewksbury MA
630-789-9600 301-899-6000; 800-543-7093 978-863-9009
Toyota South Inc.
Orland Toyota Richmond KY DarCars Toyota Ira Toyota III
Tinley Park IL 859-624-1313; 800-688-6968 Silver Spring MD Milford MA
708-429-3900; 800-755-3987 301-622-0300; 800-298-6900 508-478-0500; 800-698-5711
Louisiana
Peoria Toyota All Star Toyota/Baton Rouge Fitzgerald’s Lakeforest Toyota Jaffarian Volvo Toyota
Peoria IL Baton Rouge LA Gaithersburg MD Haverhill MA
309-693-7000; 800-949-6351 225-925-2525; 800-225-2769 301-921-0300 978-372-8551

Fall 2007 STAR service news 35

 STAR dealer listings
Lexington Toyota Minnesota New Jersey Toyota World of Lakewood
Lexington MA Autoland Toyota Lakewood NJ
781-861-7400 Burnsville Toyota 732-364-9000
Burnsville MN Springfield NJ
800-521-3101 (local) 973-467-6137; 800-752-0086
952-435-8200; 800-448-5912 New Mexico
McGee Toyota Crestmont Toyota Beaver Toyota
Hanover MA Maplewood Toyota Santa Fe NM
Maplewood MN Pompton Plains NJ
781-826-8333; 800-642-3000 973-839-2500; 800-839-6444 505-992-1535; 866-845-1799
651-482-1322; 877-574-0667
Norm Wagner Toyota Crystal Toyota Karl Malone Toyota
Lancaster MA Rudy Luther Toyota Green Brook NJ Albuquerque NM
978-342-1330 Golden Valley MN 732-968-1000 505-294-8800; 800-444-6702
763-544-1313; 800-742-5690
Route 44 Toyota
Dayton Toyota New York
Raynham MA Toyota City Advantage Toyota
508-824-4044; 877-ROUTE-44 Dayton NJ
Brooklyn Park MN 732-329-9191 Lynbrook NY
763-566-0060 516-887-8600
Sullivan Brothers Toyota
Kingston MA DCH Brunswick Toyota
Walser Toyota North Brunswick NJ Bay Ridge Toyota
781-585-1300 Bloomington MN Brooklyn NY
732-418-8888; 800-368-0097
952-888-5581 718-439-7888
Toyota of Dartmouth
North Dartmouth MA DCH Freehold Toyota
508-993-2616 Mississippi Freehold NJ Fordham Toyota
Gray-Daniels Toyota 732-431-1300; 800-221-0032 Bronx NY
Brandon MS 718-367-0400; 866-932-2111
Toyota of Watertown
Watertown MA 601-948-0576; 800-530-7955 East Coast Toyota
Wood Ridge NJ Fucillo Toyota
617-926-5200 Grand Island NY
Herrin-Gear Toyota 201-939-9400
716-773-7505
Toyota of Wellesley Jackson MS
Wellesley MA 601-956-9696; 800-748-9921 Gateway Toyota
Toms River NJ Huntington Toyota
781-237-2970; 800-734-0006 Huntington Station NY
732-240-2000
Missouri 631-423-6644
Toyota of Weymouth
North Weymouth MA Adams Toyota Lee’s Summit Glen Motors Inc.
Lee’s Summit MO Fairlawn NJ Interstate Toyota
781-337-2000; 800-371-2001 Monsey NY
816-358-7600; 800-800-7291 201-791-3800; 800-444-1959
845-352-6200; 800-942-6449
Tri-State Toyota
Dudley MA Jay Wolfe Toyota of West County Hudson Toyota
Ballwin MO Jersey City NJ Jack Sherman Toyota
508-943-7474; 800-339-2321 Binghamton NY
636-207-3900; 800-603-2146 201-433-0009; 800-342-3300
607-724-1334; 800-572-4561
Woburn Toyota
Woburn MA Jerry Ackerman Toyota James Toyota
Flemington NJ Johnstons Toyota
781-933-1100; 800-624-8000 (MA only) St. Louis MO New Hampton NY
314-351-3000; 800-871-3433 908-788-5700
845-374-8600
Michigan
Crown Toyota John Weiss Toyota of South County Lawrence Toyota
Lawrenceville NJ Lee’s Toyota
Holland MI St. Louis MO Jamaica NY
616-393-0400 314-849-3700; 800-221-4021 609-883-4200 718-657-2220
Dunning Toyota Ann Arbor Nevada Parkway Toyota Lia Toyota of Colonie
Ann Arbor MI Englewood Cliffs NJ Schenectady NY
Desert Toyota of Las Vegas 201-944-3300
734-997-7600 Las Vegas NV 518-374-3700
702-871-4111 Prestige Toyota
Grand Blanc Motor Cars Northtown Toyota
Grand Blanc MI Ramsey NJ Amherst NY
810-579-2107; 800-968-6968 Findlay Toyota & Scion 201-825-2700
Henderson NV 716-836-4600
LaFontaine Toyota 702-566-2000 Route 1 Toyota Penn Toyota
Dearborn MI Avenel NJ Greenvale NY
313-561-6600; 800-989-2886 Fletcher Jones Toyota/Scion 732-815-2324; 800-545-5850 516-621-8600; 866-5-TOYOTA
Las Vegas NV
Metro Toyota 702-457-2000 Route 22 Toyota Plaza Toyota
Kalamazoo MI Hillside NJ Brooklyn NY
269-375-1000 New Hampshire 973-705-9400 718-253-8400
Grappone Toyota
Page Toyota Concord NH Shore Toyota Queensboro Toyota
Southfield MI 603-224-9912 Mays Landing NJ Jackson Heights NY
248-352-8580; 800-325-8578 609-645-2770 718-335-8600
Ira Toyota of Manchester Toyota of Hackensack
Spartan Toyota Manchester NH Rockland Toyota
Lansing MI Hackensack NJ Blauvelt NY
603-624-1800 201-488-7777
517-394-6000; 800-998-7557 845-358-2220; 800-844-9976
Suburban Toyota-Volvo Rockingham Toyota Toyota of Morristown Romano Toyota
Troy MI Salem NH Morristown NJ East Syracuse NY
248-643-8500; 800-875-3300 603-893-3525 973-540-1111; 800-541-1127 315-445-1071
Toyota of Grand Rapids Toyota of Nashua Toyota of Turnersville Smithtown Toyota
Grand Rapids MI Nashua NH Turnersville NJ Smithtown NY
616-942-5290; 800-354-7037 603-888-3555; 800-231-0688 856-728-5000 631-724-3300
Toyota of Muskegon Toyota of Portsmouth Toyota of Vineland Star Toyota of Bayside
Muskegon MI Portsmouth NH Vineland NJ Flushing NY
231-799-2886 603-431-6100; 888-888-9070 856-696-5900; 800-566-3225 718-359-7454

36 STAR service news Fall 2007

 STAR dealer listings
Sunrise Toyota Toyota of Gastonia Sunnyside Toyota Team Toyota
Oakdale NY Gastonia NC North Olmsted OH Langhorne PA
631-589-9000 704-824-7777; 800-849-8696 440-777-9911 215-741-4200
Toyota of Manhattan Toyota of Goldsboro Tansky Sawmill Toyota Thompson Toyota Inc.
New York City NY Goldsboro NC Dublin OH Doylestown PA
212-582-5767 919-778-3232 614-766-4800 215-345-9460; 800-THOMPSON
Toyota of Newburgh Toyota of Lake Norman Toyota of Cincinnati Co. Rhode Island
New Windsor NY Huntersville NC Cincinnati OH Balise Toyota of Rhode Island
845-561-0340 704-875-9199 513-385-1800 Chepachet RI
401-780-3661
Toyota of the Bronx Toyota West Oklahoma
Bronx NY Statesville NC Bristol Toyota
718-655-1800 Dub Richardson Toyota
704-872-2771; 800-326-4455 Oklahoma City OK Bristol RI
405-721-1911 401-253-2100; 800-284-2916
Vanderstyne Toyota Victory Toyota
Rochester NY North Wilkesboro NC
585-225-6600; 800-950-4827 Fowler Toyota-AMC-Jeep Colonial Toyota
336-667-1185; 800-588-0215 Norman OK Smithfield RI
800-375-9550 401-723-0972; 800-631-0199
West Herr Toyota North Dakota
Orchard Park NY Tim Corwin Toyota
716-648-4141 Jim Norton Toyota Tarbox Toyota
Fargo ND Tulsa OK North Kingstown RI
Westbury Toyota 701-282-8425 918-250-6888; 800-888-3555 401-884-5438; 888-982-7269
Westbury NY
516-333-3100 Ohio Riverside Toyota South Carolina
Beechmont Toyota Inc. Tulsa OK Dave Edwards Toyota Inc.
Westchester Toyota Cincinnati OH 918-836-2769; 800-225-2769 Spartanburg SC
Yonkers NY 513-388-3800 864-595-2300; 800-636-3283
914-779-8700; 800-831-8360 Oregon
Brunswick Toyota Beaverton Toyota-Scion Florence Toyota
North Carolina Brunswick OH Beaverton OR Florence SC
Cloninger Toyota 330-273-3300; 888-468-6226 503-626-7200 843-669-1676; 800-922-7598
Salisbury NC
704-637-5353; 888-617-1147 Cain Toyota-BMW Inc. Kendall Toyota-Scion Gene Reed Toyota Inc.
North Canton OH Eugene OR North Charleston SC
Fred Anderson Toyota 330-494-8855 541-344-5566; 800-231-2909 843-797-8000; 800-922-1353
Raleigh NC
919-787-0099; 800-727-8101 Classic Toyota
Mentor OH
Pennsylvania Harrelson Toyota
Ardmore Toyota Rock Hill SC
Greenville Toyota 440-953-0910; 800-942-1980 803-328-2886; 800-242-4274
Ardmore PA
Greenville NC 610-645-5000; 800-473-1203
252-321-3000; 800-788-2440 Don Joseph Toyota Taylor Toyota Inc.
Kent OH North Augusta SC
330-673-2200; 800-714-6635 Baierl Toyota
Jim Barkley Toyota Mars PA 803-279-8400; 800-763-8696
Asheville NC 724-772-1600; 888-772-3412
828-667-8888; 800-951-0672 Ganley Toyota
Toyota Center
Akron OH
Carousel Toyota West Columbia SC
Leith Toyota 330-733-7511; 800-686-4355
Glen Mills PA 803-796-6650; 800-635-8213
Raleigh NC 610-558-6800; 800-403-4048
919-876-5900; 800-394-5008 Germain Toyota of Columbus
Columbus OH Toyota of Easley Inc.
614-868-0300; 800-686-2277 Conicelli Toyota Easley SC
Mark Jacobson Toyota 864-855-2233; 800-922-2307
Durham NC Conshohocken PA
919-493-5599 Glockner Toyota 610-825-7128; 800-825-7128 x5
Portsmouth OH West Ashley Toyota
740-354-3255; 800-837-1072 Conicelli Toyota of Springfield Charleston SC
Mike Johnson’s Hickory Toyota 843-556-9110; 800-316-3017
Hickory NC Springfield PA
828-328-5586; 800-627-0321 Jim White Toyota 610-690-6035; 800-737-6300
Toledo OH Tennessee
Modern Toyota 419-841-6681 Faulkner Toyota Capital Toyota Inc.
Winston-Salem NC Trevose PA Chattanooga TN
336-785-3100; 800-642-0808 Joseph Airport Toyota 215-244-9300; 800-341-1717 423-892-0661
Vandalia OH
Patterson Toyota 937-898-8060 Halterman’s Toyota Fox Toyota
Mount Airy NC 800-451-6511 (local) East Stroudsburg PA Clinton TN
336-786-2118 570-421-6930; 800-922-8867 865-457-1773
Kings Toyota Inc.
Rice Toyota Cincinnati OH Lancaster Toyota Jay Johnson Toyota
Greensboro NC 513-683-5440 East Petersburg PA Bristol TN
336-288-1190 717-569-7371; 800-322-1639 423-764-3155
Metro Toyota
Scott Clark’s Toyota City Cleveland OH New Holland Toyota Performance Toyota
Charlotte NC 216-267-7000; 800-441-3441 New Holland PA Memphis TN
704-535-1972; 800-849-1972 717-354-4907; 800-367-3232 901-758-4040
Motorcars Toyota
Town & Country Toyota-Scion in Cleveland Heights Sloane Toyota Phil Bachman Toyota
Charlotte NC Cleveland Heights OH Glenside PA Johnson City TN
704-552-7600; 888-704-7278 216-321-9100 215-885-5400; 800-235-7444 423-282-2241

Toyota of Concord Performance Toyota Sloane Toyota of Devon Rivergate Toyota

Concord NC Fairfield OH Devon PA Madison TN
704-979-7700 513-874-8797 610-647-2300; 800-672-7870 615-868-4480; 800-251-3011

Fall 2007 STAR service news 37

 STAR dealer listings
Rusty Wallace Toyota Hoy-Fox Toyota Toyota of Richardson Mechanicsville Toyota
Morristown TN El Paso TX Richardson TX Mechanicsville VA
423-587-1972 915-598-0399; 800-285-7278 972-238-4400; 800-527-2781 804-417-1121; 800-338-5538
Toyota Knoxville Joe Myers Toyota Universal Toyota Miller Toyota
Knoxville TN Houston TX San Antonio TX Manassas VA
865-218-3300 281-890-8700; 800-749-9632 210-654-1515; 800-489-7575 703-369-3040
Toyota of Cleveland John Eagle Sport City Toyota Vandergriff Toyota Ourisman Fairfax Toyota
Cleveland TN Dallas TX Arlington TX Fairfax VA
423-339-1138 972-681-8361; 800-876-1843 817-468-8696 703-359-1010; 800-626-2236
Texas Kinsel Toyota Inc.
Beaumont TX Utah Priority Toyota
Alamo Toyota Inc. 409-899-4000; 800-323-4090 Karl Malone Toyota Chesapeake VA
San Antonio TX Sandy UT 757-366-5000
210-657-6100 Loving Toyota 801-553-5800; 888-281-3185
Lufkin TX Priority Toyota Richmond
Atkinson Toyota 936-699-1028 Larry H. Miller Toyota Chester VA
Bryan TX Murray UT 804-526-2811
979-776-0404; 800-922-5030 Metroplex Toyota 801-264-3800; 800-453-6456
Duncanville TX Springfield Toyota
Cavender Toyota 972-780-1166; 800-877-6672 Menlove Toyota Springfield VA
San Antonio TX Bountiful UT 703-451-0300; 800-TOYOTA-0
210-681-6031; 800-292-5899 Mike Calvert Toyota 801-295-3554; 800-574-9100
Houston TX Washington
Champion Toyota 713-558-8100; 800-527-5368
Austin TX
Vermont Appleway Toyota
Red McCombs Toyota Heritage Toyota Spokane WA
512-440-4500; 800-856-4527
San Antonio TX South Burlington VT 509-924-1150; 800-876-4412
Champion Toyota Gulf Freeway 210-530-3000; 800-292-7810 802-865-8200; 800-439-8856
Houston TX Foothills Toyota
713-943-9900; 800-327-2087 Rene Isip Toyota/Lewisville White River Toyota Burlington WA
Lewisville TX White River Junction VT 360-757-7575; 800-962-7384
Charles Maund Toyota 469-671-5500 802-299-2800; 800-639-1101
Austin TX Magic Toyota
512-458-2222 Round Rock Toyota
Round Rock TX
Virginia Edmonds WA
425-775-4422
512-244-6900 Alexandria Toyota
Cowboy Toyota Alexandria VA
Dallas TX Michael’s Toyota of Bellevue
San Marcos Toyota 703-684-0700; 800-766-9767 Bellevue WA
214-324-0411; 800-266-0752 San Marcos TX 425-455-9500
512-805-6546; 866-213-1999 Berglund Oak Ridge Toyota
Dick Poe Toyota Lynchburg VA
El Paso TX Rodland Toyota
Star Toyota 434-528-3202; 888-287-0333 Everett WA
915-775-2000; 800-395-9331 League City TX
281-338-9700 425-353-2929; 800-562-1805
Bill Page Toyota
Don McGill Toyota Inc. Falls Church VA
Houston TX Sterling McCall Toyota Toyota of Lake City
703-532-8800 Seattle WA
281-496-2000 Houston TX
713-270-3900 206-367-0080; 800-426-2300
Checkered Flag Toyota
Don McGill Toyota of Katy Virginia Beach VA
Katy TX Street Toyota Inc. Toyota of Seattle
757-490-1111; 800-277-2122 Seattle WA
832-772-1000 Amarillo TX
806-355-9846 206-382-4300
Durant Toyota David R. McGeorge Toyota
Weatherford TX Tejas Toyota Inc. Richmond VA Toyota of Tri-Cities
817-597-5000; 877-538-7268 Humble TX 804-755-9200; 800-888-9753 Kennewick WA
281-446-0271 509-547-9888; 888-616-3648
Fort Bend Toyota First Team Toyota
Richmond TX Texas Toyota of Grapevine Chesapeake VA West Virginia
281-341-5900; 800-856-5956 Grapevine TX 757-673-2345
817-329-5949; 888-866-8577 Bert Wolfe Toyota
Haley Toyota Charleston WV
Frank Smith Toyota 304-344-1601; 800-989-8520
McAllan TX Toyota of Dallas Roanoke VA
956-686-3767; 800-347-2360 Dallas TX 540-345-1666; 800-294-2539
972-241-6655; 800-442-4349 Wisconsin
Fred Haas Toyota Country Haley Toyota of Richmond Don Jacobs Toyota
Houston TX Toyota of Fort Worth Midlothian VA Milwaukee WI
281-357-4000 Fort Worth TX 804-545-7401; 800-328-7121 414-281-3100; 800-572-6490
817-560-1500; 866-295-8384
Fred Haas Toyota World Koons Arlington Toyota Jack Safro Toyota
Toyota of Irving Inc. Arlington VA Brookfield WI
Spring TX Irving TX
281-297-7000; 800-231-2064 703-522-6000 262-781-2626; 800-242-2086
972-258-1200; 800-527-5874
Freeman Toyota Toyota of Killeen Koons Tysons Toyota Kolosso Toyota
Hurst TX Killeen TX Vienna VA Appleton WI
817-287-5200 254-690-7273; 888-437-2514 703-790-5920; 800-299-8310 920-738-3666; 800-236-4333

Gene Messer Toyota Toyota of Longview Leesburg Toyota Rhinelander Toyota

Lubbock TX Longview TX Leesburg VA Rhinelander WI
806-748-4802; 800-682-4300 903-295-9300 703-771-8990; 800-545-6925 715-365-8120; 800-560-7701
Gullo Toyota of Conroe Toyota of Plano Lustine Toyota/Dodge Wilde Toyota Inc
Conroe TX Plano TX Woodbridge VA West Allis WI
936-441-4141; 800-47-GULLO 972-248-7777; 800-925-8009 703-494-9154; 800-537-1746 414-545-8010; 800-452-4255

38 STAR service news Fall 2007