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Accelerator Pedal Modification (T-CP-90L)

WARNING: This page is about the Tacoma Base, 2D Pickup, 4WD, which is a different variant/trim than selected.
Publication date: 2010-08-25
Reference number: T-CP-90L

ACCELERATOR PEDAL MODIFICATION

ACCELERATOR PEDAL MODIFICATION

SERVICE CAMPAIGN BULLETIN

Reference Number(s): T-CP-90L, Date of Issue:  August 25, 2010
TOYOTA: 2005 - 2010 MODEL YEAR TACOMA
COPYRIGHT: © 2018 Toyota, USA License Agreement TMS1002

TECHNICAL INSTRUCTIONS

FOR 

SAFETY RECALL 90L 

ACCELERATOR PEDAL MODIFICATION 

2005 - 2010 MODEL YEAR TACOMA 

REVISED AUGUST 25, 2010 

TECHNICAL INSTRUCTION REVISION NOTICE: 

I. OPERATION FLOW CHART

G07689054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE
AFFECTED VIN RANGE

Model WMI Year VIN Range
VDS Range
TACOMA 3TM 2005 JU62N M001038 - M008091
KU72N M001035 - M004841
LU42N M001025 - M002890
MU52N M001026 - M001900
2006 JU62N M007884 - M028771
KU72N M004775 - M010145
LU42N M002891 - M008847
MU52N M001878 - M003617
2007 JU62N M028772 - M049700
KU72N M010029 - M013697
LU42N M008667 - M013600
MU52N M003618 - M005093
2008 JU62N M049701 - M070800
KU72N M013698 - M017962
LU42N M013601 - M020109
MU52N M005056 - M007830
2009 JU62N M070182 - M091906
KU72N M017780 - M023467
LU42N M020024 - M038092
MU52N M007784 - M015694
2010 JU4GN M091570 - M106294
KU4HN M023403 - M026364
LU4EN M037788 - M051927
MU4FN M015695 - M021776
5TE 2005 JU62N Z001028 - Z144893
KU72N Z001077 - Z144860
LU42N Z001003 - Z144901
MU52N Z001010 - Z144879
NX22N Z001023 - Z144884
NX62N Z001659 - Z144755
PX42N Z001187 - Z144724
TU22N Z001007 - Z144886
TU62N Z001020 - Z144895
TX22N Z001048 - Z144900
TX62N Z001181 - Z144873
UU42N Z001009 - Z144899
UX42N Z001302 - Z144707
2006 JU62N Z144959 - Z320618
KU72N Z145137 - Z320543
LU42N Z145030 - Z320397
MU52N Z145150 - Z320296
NX22N Z145177 - Z320613
NX62N Z145547 - Z320176
PX42N Z145459 - Z320265
TU22N Z144903 - Z320205
TU62N Z144902 - Z320213
TX22N Z145349 - Z320497
TX62N Z145234 - Z320203
UU42N Z144920 - Z320427
UX42N Z145491 - Z320247
2007 JU62N Z320673 - Z469819
KU72N Z320671 - Z469635
LU42N Z320621 - Z469698
MU52N Z320868 - Z469726
NX22N Z320620 - Z469653
NX62N Z321207 - Z469255
PX42N Z320860 - Z469732
TU22N Z320619 - Z469759
TU62N Z320771 - Z469786
TX22N Z321110 - Z469654
TX62N Z321199 - Z469583
UU42N Z320622 - Z469869
UX42N Z320841 - Z469743
2008 JU62N Z470196 - Z592508
KU72N Z470201 - Z592453
LU42N Z469991 - Z592675
MU52N Z470099 - Z592635
NX22N Z469871 - Z592426
NX62N Z469873 - Z592203
PX42N Z470165 - Z592599
TU22N Z470218 - Z592582
TU62N Z470195 - Z592581
TX22N Z469874 - Z592319
TX62N Z469875 - Z592204
UU42N Z469911 - Z592689
UX42N Z470171 - Z592595
2009 JU62N Z592695 - Z671264
KU72N Z592696 - Z668993
LU42N Z592756 - Z671368
MU52N Z592693 - Z668540
NX22N Z592697 - Z671320
NX62N Z592974 - Z670223
PX42N Z592698 - Z671254
TU22N Z592690 - Z671370
TU62N Z592694 - Z671356
TX22N Z593018 - Z671260
TX62N Z592970 - Z671185
UU42N Z592691 - Z671420
UX42N Z592992 - Z671203
2010 JU4GN Z671670 - Z749018
KU4HN Z671655 - Z748760
LU4EN Z671445 - Z749000
MU4FN Z671727 - Z749004
NX4CN Z671597 - Z749058
NX4GN Z671782 - Z748524
PX4EN Z671812 - Z749106
TU4CN Z671426 - Z735120
TU4GN Z671422 - Z749014
TX4CN Z671424 - Z749091
TX4GN Z671425 - Z749126
UU4EN Z671428 - Z749134
UX4EN Z671780 - Z749122
NOTE:
  • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the campaign has not already been completed prior to dealer shipment or by another dealer.
  • TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer.

III. PREPARATION

A. PARTS
  • No parts are required for this activity.
B. TOOLS & EQUIPMENT
  • Dust mask
  • Hack saw
  • Hand file
  • Orbital sander *
  • Protective eyewear
  • Protective work gloves
  • Reciprocating Saw *
  • Scribe
  • Standard hand tools
  • Techstream
  • Torque wrench
  • Workbench with vise

* One orbital sander and one reciprocating saw were provided to each dealership during Phase 1 of this Safety Recall. 

C. ACCELERATOR PEDAL TEMPLATE & GAUGE
G07689055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
G07689056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

** One cutting template and one shape gauge will be provided to each dealership. 

D. MATERIALS
  • Bubble wrap
  • Masking tape
  • Sandpaper 400 grit
  • Shop cloth

IV. BACKGROUND

In early October, Toyota announced it will initiate a Safety Recall Campaign (Special Service Campaign) for potential floor mat interference with the accelerator pedal. The condition involves the potential for an unsecured or incompatible driver's floor mat to interfere with the accelerator pedal and cause it to get stuck in the wide open position.

  • The accelerator pedal will be modified to reduce the risk of an unsecured or incompatible floor mat from interfering with the accelerator pedal.
  • Vehicles equipped with the optional genuine Toyota All Weather Floor Mats (AWFM) will be inspected to determine if the AWFM set is of an older design. If it is, the older design AWFM for the driver and the front passenger will be replaced with newly designed ones.
  • Finally, the ECM will be reflashed with newly designed software to provide customers an extra measure of confidence. This reflash will allow the system to cut engine power in case of simultaneous application of both the accelerator and brake pedals during certain driving speeds.

V. WORK PROCEDURE

A. PRELIMINARY INSPECTION FOR 2010 MODELS ONLY
G00376249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 The following inspection procedure is to determine if some 2010 models produced in April 2010 may have had a remedy applied to the accelerator pedal by the factory.
  1. INSPECT THE ACCELERATOR PEDAL ASSEMBLY 

    - FOR 2010 MODELS PRODUCED IN APRIL 2010 - 

    1. Inspect the accelerator pedal length, is it approximately 1.89 in. (48 mm)?

      YES 

      • The accelerator pedal remedy has been applied by the factory, NO modification is required.
      • Confirm the vehicle has the correct floor mat following the Work Procedure.

      NO 

      • The accelerator pedal requires modification. Make sure to perform the modification process in the Work Procedure.
        G07689057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT THE ECM CALIBRATION ID (CID) 
    1. Verify if the ECM has the NEW  CID using the table below.
      ECM CALIBRATION ID (CID) INFORMATION

      Model Year Engine Drivetrain Current CID New CID
      2005 2TR MT / 2WD 30423000 30423200
      30423100
      MT / 4WD & PreRunner 30424000 30424200
      30424100
      AT / 2WD 30425000 30425300
      30425100
      30425200
      1GR AT / 4WD & PreRunner 30426000 30426300
      30426100
      30426200
      MT / 2WD 30429000 30429300
      30429100
      30429200
      MT / 4WD & PreRunner 30430000 30430300
      30430100
      30430200
      30441100
      2006 2TR MT / 2WD 30414000 30414100
      MT / 4WD & PreRunner 30415000 30415100
      AT / 2WD 30416000 30416200
      30416100
      1GR AT / 4WD & PreRunner 30433000 30433200
      30433100
      MT / 2WD 30434000 30434200
      30434100
      MT / 4WD & PreRunner 30435000 30435200
      30435100
      2007 2TR MT / 2WD 30436000 30436100
      MT / 4WD & PreRunner 30437000 30437100
      AT / 2WD 30438000 30448200
      30448000
      30448100
      1GR AT / 4WD & PreRunner 30439000 30439300
      30439100
      30439200
      MT / 2WD 30440000 30440200
      30440100
      MT / 4WD & PreRunner 30441000 30441200
      30441100
      2008 2TR MT / 2WD 30446000 30446100
      MT / 4WD & PreRunner 30447000 30447100
      AT / 2WD 30438000 30448200
      30448000
      30448100
      1GR AT / 4WD & PreRunner 30442000 30442200
      30442100
      MT / 2WD 30443000 30443100
      MT / 4WD & PreRunner 30444000 30444100
      2009 2TR MT / 2WD 30446000 30446100
      MT / 4WD & PreRunner 30447000 30447100
      AT / 2WD 30438000 30448200
      30448000
      30448100
      1GR AT / 4WD & PreRunner 30449000 30449300
      30449100
      30449200
      MT / 2WD 30450000 30450200
      30450100
      MT / 4WD & PreRunner 30451000 30451200
      30451100
      2010 2TR MT / 2WD 30460000 30460100
      MT / 4WD & PreRunner 30461000 30461100
      AT / 2WD 30462000 30462100
      1GR AT / 4WD & PreRunner 30457000 30445000
      30457100
      MT / 2WD 30458000 30453000
      MT / 4WD & PreRunner 30459000 30454000

      With NEW ECM CID: 

      • The ECM CID has been applied by the factory, NO modification is required.

      With Current ECM CID: 

      • The ECM CID requires updating. Make sure to perform the updating process in the Work Procedure.
B. ACCELERATOR PEDAL MODIFICATION
G00376249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
 ACCELERATOR PEDAL HANDLING NOTES: 
  • DO NOT drop 
  • DO NOT reuse an accelerator pedal that has been dropped 
  • Avoid vibration and shock 
  • DO NOT place sensor in vise 
  • Cover and uncover the sensor while in the vehicle to prevent damage and debris from entering 

Videos described in this procedure are not available at this time 

CLICK HERE TO WATCH THE VIDEO BEFORE BEGINNING THE WORK PROCEDURE 

  1. REMOVE THE ACCELERATOR PEDAL ASSEMBLY 

    Videos described in this procedure are not available at this time 

    Click here to watch the video to supplement this step 

    1. Record the radio station preset.
    2. Disconnect the negative battery cable and wait 90 seconds.
    3. Disconnect the accelerator pedal connector.
    4. Remove the 2 bolts.
    5. While still inside the vehicle, use bubble wrap and masking tape to cover and protect the sensor.
      NOTE:
      • For additional information on accelerator pedal removal, please refer to TIS.
      • Be sure to use bubble wrap to protect the sensor.
      • Be sure to seal the bubble wrap with masking tape to prevent damage to the sensor, and cutting debris from entering the pedal's movable lock.
      • DO NOT reuse the bubble wrap.
        G07689058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. MARK THE AREA TO BE CUT 

    Videos described in this procedure are not available at this time 

    Click here to watch the video to supplement steps 2-3 

    1. Firmly set the template to the pedal and scribe guide lines to outline the area to be cut.

      Cutting Template:

      • Color: Red
      • Stamping: TACOMA
        G07689059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • DO NOT  mark the area beyond the template.
      • Use a flat tip screwdriver if a scribe is not available.
      • Make sure to use the correct cutting template by verifying the color and stamping.
      • Never cut or sand the pedal while the template is on the pedal.
  3. SECURE THE ACCELERATOR PEDAL ASSEMBLY 
    1. Set the pedal in the vise at a right angle using a shop cloth while avoiding the sensor.
      NOTE:
      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT  over tighten the vise.
        G07689060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CUT THE LOWER SECTION OF THE ACCELERATOR PEDAL ASSEMBLY 

    Videos described in this procedure are not available at this time 

    Click here to watch the video to supplement steps 4-8 

    1. The cut line is slightly outside from the scribed line and its positioned 90 degrees from the pedal foot pad as illustrated.
      G07689061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hack-saw, cut the pedal 0.2 in (5 mm) to create a guide cut for the reciprocating-saw.
      NOTE:
      • Always wear protective eyewear, gloves, and dusk mask when cutting.
      • Guide cut must be straight and clean.
        G07689062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the reciprocating-saw, cut off the lower section of the pedal as illustrated.
      NOTE:
      • Always wear protective eyewear, gloves and dust mask when cutting.
      • The cut must be straight and clean.
      • Apply consistent pressure during cutting.
      • Do not stop while cutting.
        G07689063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CUT THE CORNERS OF THE ACCELERATOR PEDAL ASSEMBLY 
    1. Using the reciprocating-saw, cut off the pedal corners as illustrated.
      NOTE:
      • Always wear protective eyewear, gloves, and dusk mask when cutting.
      • Guide cut must be straight and clean.
      • Apply consistent pressure during cutting.
      • Do not stop while cutting.
        G07689064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. SAND THE RADIUS LINE 
    1. Using an orbital sander, sand the radius line which was scribed and remove the sharp edges and burrs.
      NOTE:
      • Always wear protective eyewear, gloves, and dust mask when sanding.
      • DO NOT  sand the back of the pedal arm as illustrated.
        G07689065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE ALL BURRS FROM THE CUTTING SURFACE 
    1. Remove the pedal from the vise.
    2. Turn the pedal over and set it the vise using a shop cloth while avoiding the sensor.
      NOTE:
      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT over tighten the vise.
        G07689066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using an orbital sander and file, remove all burrs from the cutting surface. The cut edges along the foot pad should be rounded and not square.
    4. Finish the cut surface and all edges with 400 grit sandpaper.
      NOTE:
      • Always wear protective eyewear, gloves, and dust mask when sanding or filing.
        G07689067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        G07689068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CHECK THE SHAPE OF THE PEDAL 
    1. Using the correct cutting template and shape gauge, check the shape of the pedal.

      Cutting Template Shape Gauge

      Color: Red Color: Red

      Stamping: TACOMA Stamping: TACOMA

    2. If the shape does NOT match the template and/or gauge, continue filing.
    3. If the shape matches the template and gauge, touch the cut surface with your hand to verify it is smooth and free of burrs.
      NOTE:
      • Always wear protective eyewear, gloves and dusk mask when sanding or filing.
      • A tolerance of -1.0 mm is permissible between the final cut surface and the template.
        G07689069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check for any pin holes, chips, nicks or sharp edges on the finished surface edge. If there are any chips, nicks or sharp edges file them to make them smooth.
      NOTE:
      • The key point of judgment is a "smooth pedal surface".
    5. If a "smooth pedal surface" cannot be achieved due to a pinhole / cavity, repair the pedal utilizing the steps below.

      Materials Needed:

      • KBS Coatings - NuMetal® Epoxy Putty (Black)

        Contact: 1-888-531-4527

        Website: www.kbs-coatings.com/KBS-NuMetal-Epoxy-Putty_p_9-19.html 

        OR 

      • Milliput® Black Epoxy Putty

        Website: www.milliput.com/home.htm 

      Repair Instructions:

      • Make sure to follow all manufacturer directions and cautions when using the Epoxy Putty. 
      • Fill in the pin hole/cavity with the Epoxy Putty, and then smooth it out with a wet finger as outlined in the instructions included with the putty.
        NOTE:
        • Make sure to use black Epoxy Putty, both brands listed above are offered in that color.
        • Milliput® Black Epoxy Putty is from a UK supplier, and may be difficult to locate in the US. If you should encounter this, please utilize KBS Coatings - NuMetal® Epoxy Putty (Black) that is locally supplied and easier to locate.
  9. REINSTALL THE ACCELERATOR PEDAL ASSEMBLY 
    1. Remove and discard the masking tape and bubble wrap from the accelerator pedal assembly, while it is inside the vehicle.
    2. Reinstall the pedal with the 2 bolts and torque to specification.

      Torque Specification: 5.0 Nm (51 kgf cm, 44 in. lbf) 

    3. Reconnect the accelerator pedal connector.
    4. Reconnect the negative battery cable.
    5. Set the clock and radio station presets.
    6. Reinitialize the vehicle system(s) as outlined in the repair manual on TIS for the vehicle you are working on.
      NOTE:
      • DO NOT  reuse the bubble wrap.
      • For additional information on accelerator pedal installation, please refer to TIS.
  10. INSPECT THE FLOOR MAT 
    1. Inspect the carpet and floor mat and clean them as appropriate.
    2. Confirm the correct floor mat for this model is secured with the retaining hooks (clips).
      • If the grommets in the floor for the vehicle are in poor condition, refer to the appropriate TSB and repair the grommets.
      NOTE:
      • If a Recalled All Weather Floor Mat (AWFM) has been identified, remove the AWFM from the vehicle and CUT THE RECALLED AWFM SO THAT IT CANNOT BE REUSED.
      • You may remove the semi-permanent installation plastic straps for the carpeted floor mat once the repair is completed. 

      Locate the ten digit floor mat part number on the bottom of the back side of the mat as illustrated below.

      PLEASE NOTE, the floor mat part numbers are 12 digits but only the first ten are shown.

      G07689070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      For Carpeted Floor Mats: 

      Utilizing the ten digit part number and the chart below, confirm the vehicle has the correct carpeted floor mat.

      PARTS INFORMATION FOR CARPETED FLOOR MATS

      Part Number Model Type '05 '06 '07 '08 '09 '10 Color
      PT206-35050-11 Tacoma - Regular Cab Carpeted x x x       Lt Charcoal
      PT206-35050-14 Tacoma - Regular Cab Carpeted x x x       Oak
      PT206-35051-11 Tacoma - Access Cab Carpeted x x x       Lt Charcoal
      PT206-35051-14 Tacoma - Access Cab Carpeted x x x       Oak
      PT206-35052-11 Tacoma - Double Cab Carpeted x x x       Lt Charcoal
      PT206-35052-14 Tacoma - Double Cab Carpeted x x x       Oak
      PT206-35055-11 Tacoma - Access Cab TRD Carpeted x x x       Charcoal
      PT206-35056-11 Tacoma - Double Cab TRD Carpeted x x x       Charcoal
      PT206-35080-11 Tacoma - Regular Cab Carpeted       x x x Lt Charcoal
      PT206-35080-14 Tacoma - Regular Cab Carpeted       x x   Oak
      PT206-35081-11 Tacoma - Access Cab Carpeted       x x x Lt Charcoal
      PT206-35081-14 Tacoma - Access Cab Carpeted       x x   Oak
      PT206-35082-11 Tacoma - Double Cab Carpeted       x x x Lt Charcoal
      PT206-35082-14 Tacoma - Double Cab Carpeted       x x   Oak
      PT206-35085-11 Tacoma - Acc Cab TRD Carpeted       x x x Charcoal
      PT206-35086-11 Tacoma - Double Cab TRD Carpeted       x x x Charcoal
      PT206-35090-43 Tacoma - Regular Cab Carpeted         x x Sand Beige
      PT206-35091-43 Tacoma - Access Cab Carpeted         x x Sand Beige
      PT206-35092-43 Tacoma - Double Cab Carpeted         x x Sand Beige
      PT206-35100-13 Tacoma - Regular Cab Carpeted           x Lt Charcoal
      PT206-35100-15 Tacoma - Regular Cab Carpeted           x Dk Charcoal
      PT206-35101-13 Tacoma - Access Cab Carpeted           x Lt Charcoal
      PT206-35101-15 Tacoma - Access Cab Carpeted           x Dk Charcoal
      PT206-35102-13 Tacoma - Double Cab Carpeted           x Lt Charcoal
      PT206-35102-15 Tacoma - Double Cab Carpeted           x Dk Charcoal
      PT206-35105-13 Tacoma - Access Cab TRD Carpeted           x Lt Charcoal
      PT206-35106-13 Tacoma - Double Cab TRD Carpeted           x Lt Charcoal

      For All Weather Floor Mats (AWFM): 

      Utilizing the ten digit part number and the chart below, confirm the vehicle has the newly designed AWFM.

      PARTS INFORMATION FOR ALL WEATHER FLOOR MATS

      Part Number Model Type '05 '06 '07 '08 '09 '10 Color
      PT908-3500W-02 Tacoma All Weather x x x       Black
      PT908-350RW-02 Tacoma - TRD All Weather       x     Black
      PT908-3510W-02 Tacoma All Weather       x x x Black
      NOTE: The part numbers listed above are for the 2 piece (driver & front passenger) campaign set ONLY.

      DO NOT  use the recalled AWFM listed below. These AWFM must be removed from the vehicle and recovered by the dealer.

      PARTS INFORMATION

      Part Number Model Type '05 '06 '07 '08 '09 '10 Color
      PT908-3505B-02 Tacoma - Regular Cab All Weather x x x x     Black
      PT908-3505C-02 Tacoma - Access Cab All Weather x x x x     Black
      PT908-3505D-02 Tacoma - Double Cab All Weather x x x x     Black
      PT908-3507B-02 Tacoma - Regular Cab All Weather       x x x Black
      PT908-3507C-02 Tacoma - Access Cab All Weather       x x x Black
      PT908-3507D-02 Tacoma - Double Cab All Weather       x x x Black
      PT908-35S8C-02 Tacoma - SE Access Cab All Weather       x     Black
      PT908-35S8D-02 Tacoma - SE Double Cab All Weather       x     Black

      All recalled AWFM will be placed on Warranty Parts Recovery, and dealers will be required to return them to TMS. AWFM that are not returned will result in the claim being debited.

    3. Confirm the pedal does not get caught on the floor or floor mat during operation.
    4. Confirm the pedal operates properly.
      G07689071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT THE ACCELERATOR PEDAL ASSEMBLY OPERATION 
    1. Connect Techstream to the DLC3.
    2. Enter the following menus: Powertrain / Engine and ECT / Data List.
    3. Check the values by referring to the table below.
      ACCELERATOR PEDAL ASSEMBLY INSPECTION CHART

      Tester Display Measurement: Range (Display) Normal Condition Diagnostic Note
      Accel Sensor Out No. 1 APP sensor No. 1 voltage Accelerator Pedal Released: 0.5 to 1.1 V Read value with ignition switch to ON (Do not start engine)
      Accelerator Pedal Fully Depressed: 2.6 to 4.5 V
      Accel Sensor Out No. 2 APP sensor No. 2 voltage Accelerator Pedal Released: 1.2 to 2.0 V Read value with ignition switch to ON (Do not start engine)
      Accelerator Pedal Fully Depressed: 3.4 to 5.0 V
      NOTE: There are two sets of Accel Sensor Out No. 1 & No. 2 parameters. Select ALL DATA (A to Z) on the pull down menu at the bottom of the screen when searching for the correct parameter set.
  12. REFLASH THE ECU 
    1. Reflash the ECU with the NEW  Override System software following T-SB-0064-10 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE .
    2. For Calibration ID, please refer to the table below and on the next page.
      ECU CALIBRATION ID INFORMATION

      Model Year Engine Drivetrain Current CID New CID
      2005 2TR MT / 2WD 30423000 30423200 
      30423100
      MT / 4WD & PreRunner 30424000 30424200 
      30424100
      AT / 2WD 30425000 30425300 
      30425100
      30425200
      1GR AT / 4WD & PreRunner 30426000 30426300 
      30426100
      30426200
      MT / 2WD 30429000 30429300 
      30429100
      30429200
      MT / 4WD & PreRunner 30430000 30430300 
      30430100
      30430200
      2006 2TR MT / 2WD 30414000 30414100 
      MT / 4WD & PreRunner 30415000 30415100 
      AT / 2WD 30416000 30416200 
      30416100
      1GR AT / 4WD & PreRunner 30433000 30433200 
      30433100
      MT / 2WD 30434000 30434200 
      30434100
      MT / 4WD & PreRunner 30435000 30435200 
      30435100
      2007 2TR MT / 2WD 30436000 30436100 
      MT / 4WD & PreRunner 30437000 30437100 
      AT / 2WD 30438000 30448200 
      30448000
      30448100
      1GR AT / 4WD & PreRunner 30439000 30439300 
      30439100
      30439200
      MT / 2WD 30440000 30440200 
      30440100
      MT / 4WD & PreRunner 30441000 30441200 
      30441100
      2008 2TR MT / 2WD 30446000 30446100 
      MT / 4WD & PreRunner 30447000 30447100 
      AT / 2WD 30438000 30448200 
      30448000
      30448100
      1GR AT / 4WD & PreRunner 30442000 30442200 
      30442100
      MT / 2WD 30443000 30443100 
      MT / 4WD & PreRunner 304446000 30444100
      2009 2TR MT / 2WD 30446000 30446100 
      MT / 4WD & PreRunner 30447000 30447100 
      AT / 2WD 30438000 30448200 
      30438000
      30448100
      1GR AT / 4WD & PreRunner 30449000 30449300 
      30449100
      30449200
      MT / 2WD 30450000 30450200 
      30450100
      MT / 4WD & PreRunner 30451000 30451200 
      30451100
      2010 2TR MT / 2WD 30460000 30460100 
      MT / 4WD & PreRunner 30461000 30461100 
      AT / 2WD 30462000 30462100 
      1GR AT / 4WD & PreRunner 30457000 30445000 
      30457100
      MT / 2WD 30458000 30453000 
      MT / 4WD & PreRunner 30459000 30454000 
  13. CHECK FOR DTC CODES 
    1. Connect the Techstream to the DLC3.
    2. Check for DTC codes.
      NOTE:
      • A U0101 DTC may set during reprogramming. This is normal and should be cleared.
      • For 2010 MY, a U0101 Permanent DTC may remain after DTCs are cleared. This is normal. A Permanent DTC does not illuminate the MIL and will not be cleared by a scantool. If the DTCs are cleared using Techstream but a U0101 Permanent DTC remains, there is no need to troubleshoot. The permanent DTC will clear during customer driving after completing the Universal Trip Drive Pattern.
      • If any Pending, Current, and/or History DTCs are set, troubleshoot according to the repair manual.
  14. PRINT CUSTOMER HEALTH CHECK REPORT 
    1. From the Health Check Results screen select the Customer Health Check Report button (TIS will launch when button is pressed).
      G07689072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      G07689073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Log in to TIS.
    3. Input Vehicle Mileage and Repair Order number.
    4. Check the "Performed" radio button for the 90L campaign and any other campaigns completed during this service event.
    5. Select the Report button.
      G07689074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Confirm Customer Health Check Report information is correct.
      G07689075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Print Customer Health Check Report from TIS.
    8. Sign and provide to the customer.
  15. TEST DRIVE THE VEHICLE AND INSPECT FOR ANY PROBLEMS 
  16. AFFIX THE AUTHORIZED MODIFICATIONS LABEL 
    G07689076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a permanent marker or ball point pen, complete the Authorized Modifications Label and attach it to the underside of the hood in front of the driver as shown.
      • Replacement ECU Part Number & Calibration ID(s) 
        ECU PART NUMBER & CALIBRATION ID INFORMATION

        Model Year Engine Drivetrain Replacement ECU P/N New CID
        2005 2TR MT / 2WD 89661-04A02 30423200
        MT / 4WD & PreRunner 89661-04A12 30424200
        AT / 2WD 89661-04A23 30425300
        1GR AT / 4WD & PreRunner 89661-04A33 30426300
        MT / 2WD 89661-04A63 30429300
        MT / 4WD & PreRunner 89661-04A73 30430300
        2006 2TR MT / 2WD 89661-04B51 30414100
        MT / 4WD & PreRunner 89661-04B61 30415100
        AT / 2WD 89661-04B72 30416200
        1GR AT / 4WD & PreRunner 89661-04B82 30433200
        MT / 2WD 89661-04B92 30434200
        MT / 4WD & PreRunner 89661-04C02 30435200
        2007 2TR MT / 2WD 89661-04C11 30436100
        MT / 4WD & PreRunner 89661-04C21 30437100
        AT / 2WD 89661-04D32 30448200
        1GR AT / 4WD & PreRunner 89661-04C43 30439300
        MT / 2WD 89661-04C52 30440200
        MT / 4WD & PreRunner 89661-04C62 30441200
        2008 2TR MT / 2WD 89661-04D11 30446100
        MT / 4WD & PreRunner 89661-04D21 30447100
        AT / 2WD 89661-04D32 30448200
        1GR AT / 4WD & PreRunner 89661-04C72 30442200
        MT / 2WD 89661-04C81 30443100
        MT / 4WD & PreRunner 89661-04C91 30444100
        2009 2TR MT / 2WD 89661-04D11 30446100
        MT / 4WD & PreRunner 89661-04D21 30447100
        AT / 2WD 89661-04D32 30448200
        1GR AT / 4WD & PreRunner 89661-04D43 30449300
        MT / 2WD 89661-04D52 30450200
        MT / 4WD & PreRunner 89661-04D62 30451200
        2010 2TR MT / 2WD 89661-04E71 30460100
        MT / 4WD & PreRunner 89661-04E81 30461100
        AT / 2WD 89661-04E91 30462100
        1GR AT / 4WD & PreRunner 89661-04D00 30445000
        MT / 2WD 89661-04D80 30453000
        MT / 4WD & PreRunner 89661-04D90 30454000
      • Dealer Code 
      • Date Completed 
      • Campaign Number 
      NOTE: Authorized Modifications Label (in packages of 25) can be ordered through the Material Distribution Center (MDC), P/N 00451-00001-LBL.

VI. APPENDIX

A. RECALLED PARTS DISPOSAL

As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. 

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