Toyota All Toyota Models Inspection Standards Manual
Vehicle
Eligibility
Inspection
Check Sheet
Mechanical Detailing
Appearance
Repair
Records Display Inspections
Inspection Standards Manual
The TCUV Inspection Standards Manual
incorporates interactive features allowing
direct access to information by simply clicking
a hyperlink. The hyperlinks are located on the
major section tabs (along the edge of the page)
and the table of contents.
For off-line reference, you can save the guide
to your local hard drive. If desired, you can also
print a copy of the guide. The standard PDF file
format makes it easy to download, save, and
subsequently print the guide at a local printer.
INTRODUCTION
As the TCUV Program evolves and changes,
the manual will also change. Note the version
number and date on the bottom of each page
of the guide, as it will change each time the guide
is modified. Since the version online at the
TCUV Hub will always have the most up-to-date
content, you should use Dealer Daily’s TCUV Hub
whenever possible to find information regarding
the TCUV Program.
TABLE OF CONTENTS
Vehicle Eligibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inspection Check Sheet
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mechanical Standards and Process Notes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 – 19
• Explanation of Structural (Frame/Unibody) Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21
• Explanation of Excessive Body Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TCUV Detailing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 – 32
Detailing and Appearance Repair Standards and Process Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 – 38
• Paint and Body Repair Zones A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Records Standards
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Display Standards
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inspection Process
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1 Vehicle Eligibility 10/10
VEHICLE ELIGIBILITY
Make Toyota and Scion only.
Model All Toyota Models, including Scion for authorized dealers.
Year Current model year through and including six (6)-year-old models.
Mileage Less than 85,000 miles.
Vehicle History
• No frame/unibody or structural damage (see Mechanical Standards and Process Notes).
• Carfax® vehicle history report with no ineligible results.
• No excessive repaired or unrepaired body damage (any evidence that three
[3]
or more outer body panels have
been repaired, replaced and/or repainted; see Mechanical Standards and Process Notes).
• No evidence of rust perforation or “excessive rust.”
• No evidence of flood damage or excessive hail damage.
• No vehicles with evidence of abuse (e.g., oil gelling). No “True Mileage Unknown” units.
• No branded titles (lemon law, buy backs, salvage, rebuilt, dismantle, junk, flood, etc.).
• No power train component modifications (TRD modifications are acceptable).
• No body modifications (special flarings and/or ground effects are not acceptable; TRD modifications are acceptable).
• No suspension modifications (lowered, raised, altered 4WD, etc.). TRD, OEM and “factory installed” modifications
are acceptable. Wheels must be the same size, load rating and offset as OEM. Aftermarket wheels meeting these
criteria are acceptable if size does not exceed the largest TRD factory accessory wheel for that specific model. If
not OEM equipped, spare tire circumference must match OEM.
• No vehicles failing to meet the intent/spirit of the TCUV Process (if in doubt, do not certify).
Reconditioning Must pass Toyota Certified Used Vehicle 160-point quality assurance inspection (174 for hybrids).
Acquisition Any source, including trade-ins and purchases from private individuals, other dealers, wholesalers and auctions.
To be eligible for certification, vehicle must have been previously sold by Toyota Motor Sales, U.S.A., Inc.
Vehicles sold by Servco Toyota Hawaii, Toyota de Puerto Rico and Toyota Canada Inc. do not qualify for certification.
Sale Type Sale or lease to retail individuals, fleet accounts and commercial users are permitted. Leasing companies and brokers
are ineligible for certification benefits.
For questions on sales eligibility, call your Regional TCUV Manager.
This Inspection Check Sheet must be 1
)
completed with all items checked, 2
)
signed by responsible persons as
indicated, and 3
)
retained along with repair orders and Vehicle History Report in the vehicle’s service history file.
Dealership Name:
Dealer Code:
Y
ear/Make/Model: Stock Number:
E
xt. Color: Int. Color: VIN:
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Date Acquired:
Date Inspected: R.O. Number: Mileage:
160-Point Quality Assurance
Inspection Check Sheet
WHITE CO PY: DEALERSH IP YELLOW COPY: CUSTO MER HARD C OPY: SERVICE ( USED-CAR DEPARTM ENT)
DO NOT TE AR APART AT PERFORATIO N.
Mechanical Certification
(
See Mechanical Standards and Process Notes For Additional Details
)
VIN & Dealer Code Check
Meets
Stds
Adjust/
Repair N/A
1 Ru n and print Vehicle Histor y Repor t and at tach
■ ■
Run a Techstream Health Check and retain the diagnostic
report in dealer file
■ ■
Check for and perform outstanding Recalls and applicable SSCs
■ ■
Road Test
2
Cold engine oper ation performs pro perly
■ ■
3
Throttle operates prop erly during cold start
■ ■
4
Vehicle operates proper ly during warm-up co nditions
■ ■
5
Engine perform s properly during operating temperature
■ ■
6
Engine reaches nor mal operating temper ature
■ ■
7
Engine fan(s) operate proper ly
■ ■
8
Brake pedal free pl ay and travel within spec ifications
■ ■
9
No abnormal vibr ations and noises dur ing brake application s
■ ■
10
ABS operates proper ly (via Techstream Health Chec k)
■ ■ ■
11
Parking brake operates properly and withi n specification
■ ■
12
Seat belt material c ondition
■ ■
13
Seat belts operate properly with full extension and smooth operation
■ ■
14
Transmission/clutch operates smoothly
■ ■
15
Automatic transmission operates prop erly during cold temperature
■ ■ ■
16
Automatic transmission operates properly during operating temperature
■ ■ ■
17
Steering has normal feel in lock-to-lock turning
■ ■
18
Steering wheel c entered in straight-line driv ing
■ ■
19
Vehicle tracks and drives straight on level surface
■ ■
20
Tilt and telescopi c steering mechan ism operates properl y
■ ■ ■
21
Front windshield wipe r operates properly in all modes
■ ■
22
Rear windshield wiper operates prope rly in all modes
■ ■ ■
23
Windshield washe r fluid sprays proper ly
■ ■
24
Wiper blades cle ar glass properl y
■ ■
25
Wipers return to corre ct position when of f
■ ■
26
Speedometer functi ons properly
■ ■
27
Odometer application registers mileage in every mode
■ ■
28
Cruise control oper ates properly
■ ■ ■
29
Heater operates proper ly
■ ■
30
A/C operates proper ly
■ ■ ■
31
No abnormal nois e or vibration from eng ine
■ ■
32
No excessive wind or road noise
■ ■
33
No abnormal tire vi bration/steering wheel s himmy during road test
■
■
34
No abnormal sque aks/rattles within the interior of the vehicle
■ ■
Frame, Structure & Underbody
35
Frame/ Unibody condition
■ ■
36
Panel alignment an d fit
■ ■
37
Lower body and under body condition
■ ■
38
Suspension-related i tems for wear/leaks and prope r performanc e
■ ■
39
Inspect struts/shocks fo r leaks and wear
■ ■
Frame, Structure & Underbody (cont.)
Meets
Stds
Adjust/
Repair N/A
40
Power steering system operates properly with no le aks
■ ■
41 Wheel cover s secure and reason ably free of damage
■ ■ ■
42 Tires are inflated to specification and free of defects and damage
■ ■
43
Minimum of 5/32" tread depth rema ining across tread wid th
■ ■
44 A ll four tires must be of s ame brand, model, size, tread design,
speed and load ratin g
■ ■
45 Brake calipers and lines operate properly with no signs of damage
■ ■
46 T he brake system contains al l needed equipm ent (shim kit,
pins, rattle clips, etc.)
■ ■
47
Brake pad/shoe linings have a minimum thicknes s of 50% remaining
■ ■
48 B rake rotors/drums within specif ications with no abn ormal
grooving and discolo ration
■ ■
49 E xhaust system is properly secured with no leaks
■ ■
50
Engine/transmissio n mounts operate proper ly with no signs of wear
■ ■
51 Drive/axle s hafts operate proper ly with no damage
■ ■
52 CV joints /boots operate proper ly with no signs of wear
■ ■ ■
53 In spect engine for f uel, oil, coolant or other fluid leaks
■ ■
54 In spect transmissio n case and pan for le aks
■ ■
55 D ifferential flu id level correct with no leaks
■ ■ ■
Emissions & State Inspection
56 Per form emissions test and/or state inspection, if re quired
■ ■ ■
Under Hood
57 Dri ve belts and hoses f ree of cracks and damag e
■ ■
58 Co nfirm under-hood label s and decals
■ ■
59 Ai r filter in good cond ition
■ ■
60 Battery has no v isible damage
■ ■
61 Per form battery che ck with Midtronics G R8
■ ■
62 Bat tery posts and c ables free of corros ion and damage
■ ■
63 B attery properl y sized and secure
■ ■
64 C harging system operating properly and withi n specification
■ ■
65 En gine coolant level w ithin specificati on
■ ■
66 C oolant specifi c gravity to -31° Fahrenheit
■ ■
67 Chan ge engine oil and f ilter
■ ■
68 C heck for evidence of oil gel
■ ■
69
Oil, brake, clutch, transmissio n, transfer case, power steer ing
and washer fluid a t proper levels
■ ■
70 Under-hood f luids clear and u ncontaminated
■ ■
Functional & Walkaround
71 Owner’s Manual a nd TCUV Warranty Suppl ement in
dealer’s possession
■ ■
72 Fuel gau ge operational
■ ■
73 Batter y voltage gauge operational
■ ■ ■
74 Engine temperature ga uge operational
■ ■ ■
75 Horn op erates properly
■ ■
76 Airba g(s) present with no eviden ce of deployment
■ ■
77 He adlights are properly aligned
■ ■
78 High a nd low beams operate pro perly
■ ■
)
completed with all items checked, 2
)
signed by responsible persons as
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Inspection Check Sheet number:
10-TCV-04520 ©2010 Toyota Motor Sales, U.S.A ., Inc. 00310-00104 R ev. 9/10
Inspection Check Sheet
DO NOT TE AR APART AT PERFORATIO N.
Required Technician Signature
I certify that all mechanical items have been inspected.
Toyota Trained Technician
Date
Required Manager Signature
I certify that all mechanical repair standards have been met.
Service Manager
Date
I certify that all detailing and appearance standards have been met.
Used Car Manager
Date
Customer Signature
I acknowledge that I have received a copy of the 160-Point Inspection Check Sheet,
the Vehicle History Report and the Used Vehicle Warranty Supplement Manual.
Customer
Date
)
Meets
Stds
Adjust/
Repair N/A
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■ ■
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■
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Frame, Structure & Underbody (cont.)
Meets
Stds
Adjust/
Repair N/A
40
Power steering system operates properly with no le aks
■ ■
41 Wheel cover s secure and reason ably free of damage
■ ■ ■
42 Tires are inflated to specification and free of defects and damage
■ ■
43
Minimum of 5/32" tread depth rema ining across tread wid th
■ ■
44 A ll four tires must be of s ame brand, model, size, tread design,
speed and load ratin g
■ ■
45 Brake calipers and lines operate properly with no signs of damage
■ ■
46 T he brake system contains al l needed equipm ent (shim kit,
pins, rattle clips, etc.)
■ ■
47
Brake pad/shoe linings have a minimum thicknes s of 50% remaining
■ ■
48 B rake rotors/drums within specif ications with no abn ormal
grooving and discolo ration
■ ■
49 E xhaust system is properly secured with no leaks
■ ■
50
Engine/transmissio n mounts operate proper ly with no signs of wear
■ ■
51 Drive/axle s hafts operate proper ly with no damage
■ ■
52 CV joints /boots operate proper ly with no signs of wear
■ ■ ■
53 In spect engine for f uel, oil, coolant or other fluid leaks
■ ■
54 In spect transmissio n case and pan for le aks
■ ■
55 D ifferential flu id level correct with no leaks
■ ■ ■
Emissions & State Inspection
56 Per form emissions test and/or state inspection, if re quired
■ ■ ■
Under Hood
57 Dri ve belts and hoses f ree of cracks and damag e
■ ■
58 Co nfirm under-hood label s and decals
■ ■
59 Ai r filter in good cond ition
■ ■
60 Battery has no v isible damage
■ ■
61 Per form battery che ck with Midtronics G R8
■ ■
62 Bat tery posts and c ables free of corros ion and damage
■ ■
63 B attery properl y sized and secure
■ ■
64 C harging system operating properly and withi n specification
■ ■
65 En gine coolant level w ithin specificati on
■ ■
66 C oolant specifi c gravity to -31° Fahrenheit
■ ■
67 Chan ge engine oil and f ilter
■ ■
68 C heck for evidence of oil gel
■ ■
69
Oil, brake, clutch, transmissio n, transfer case, power steer ing
and washer fluid a t proper levels
■ ■
70 Under-hood f luids clear and u ncontaminated
■ ■
Functional & Walkaround
71 Owner’s Manual a nd TCUV Warranty Suppl ement in
dealer’s possession
■ ■
72 Fuel gau ge operational
■ ■
73 Batter y voltage gauge operational
■ ■ ■
74 Engine temperature ga uge operational
■ ■ ■
75 Horn op erates properly
■ ■
76 Airba g(s) present with no eviden ce of deployment
■ ■
77 He adlights are properly aligned
■ ■
78 High a nd low beams operate pro perly
■ ■
Functional & Walkaround (cont.)
Meets
Stds
Adjust/
Repair N/A
79
Tail lights operate properly
■ ■
80 B rake lights operate proper ly
■ ■
81 Side ma rker lights operate prope rly
■ ■
82 Bac kup lights operate prope rly
■ ■
83 L icense plate lights ope rate properly
■ ■
84 N o cracked or broken lens es of exterior lights
■ ■
85 In strument panel/war ning lights operate prop erly
■ ■
86 H VAC panel/lights operate prope rly
■ ■
87 Instru ment panel light dim mer operates proper ly
■ ■
88 Turn signal s operate properly an d self-cancel
■ ■
89 H azard flashe rs operate properly
■ ■
90 Rear-view interior mirror ope rates properly
■ ■
91 Ex terior mir rors’ operation and cond ition
■ ■
92 Re mote mirror control operates p roperly
■ ■ ■
93 G lass free of cracks, sta rs and large chips
■ ■
94 W indow tinting clear an d conforms to local requ irements
■ ■ ■
95 D ome/courtesy lights op erate with door cycles
■ ■
96 Windows operate proper ly
■ ■
97 Window locks operate properl y
■ ■ ■
98 Power windows operate from master switch and all door switches
■ ■ ■
99 Au dio/Cassette/CD/Aux system working properl y; CD cartridge
present (if equip ped)
■ ■ ■
100 Audio speakers do not rattle at high volume and function properly
■ ■ ■
101 Antenna is pres ent and functional
■ ■ ■
102 Clock op erates properly
■ ■ ■
103 12v ACC power outlet oper ates properly
■ ■ ■
104 Ashtrays (if equipped) are pre sent and operate prope rly
■ ■ ■
105 Headline r, sun visors, dash pad, upholstery, console,
cup holders, trim panels and carpet are in place, in good
condition and op erate properly
■
■
106 Driver floor mat (if equipped) is appropriate floor mat for the vehicle,
properly secured and not stacked on top of another floor mat
■ ■ ■
107 Doors open and close properl y
■ ■
108 Door lo cks, including child s afety locks, operate prop erly
■ ■
109
Remote keyless entry system and smart key system operate properly
■
■ ■
110 Master key is present
■ ■
111 Th eft deterrent system op erates properly
■ ■ ■
112 Seat adjustments a nd seat heater(s) operate proper ly
■ ■ ■
113 Memory se at control operates prope rly
■ ■ ■
114 Headrests functio n properly
■ ■ ■
115 Defogger indic ator light operates proper ly
■ ■ ■
116 Rear defogge r operates properly
■ ■ ■
117 Luggage compar tment light operatio n and trim appeara nce
■ ■ ■
118 Luggage compa rtment is clea n, free of debris, no stai ns
■ ■ ■
119 Hood and lugg age compartment latches operate properl y
■ ■ ■
120
Interior remote luggage compartm ent release operates properly
■ ■ ■
121 Emergency trunk release operates prop erly
■ ■ ■
122 Fuel door rel ease operates proper ly
■ ■ ■
123 Spare tire’s cover appearanc e and condition
■ ■ ■
124 Spare tire present
■ ■ ■
125 Spare tire has cor rect air pressure a nd a minimum of 5/32"
tread remaining
■ ■ ■
126 No signs of dam age to spare tire
■ ■ ■
127 Spare tire and storage areas are clean
■ ■ ■
128 Spare tire is secu rely fastened
■ ■ ■
129 Jack and tools a re correct, present an d secured
■ ■ ■
130 Acceptab le aftermarket items c hecked
■ ■ ■
131 Removal of unacce ptable aftermarket i tems
■ ■ ■
Detailing and Appearance Repair Certification
(
See Detailing Standards and Process Notes For Additional Details
)
Exterior Appearance
132 Body sur face condition
■ ■
133 Exter ior is washed, clea n and free of water spots
■ ■
134 Paint is fre e of swirl marks and ha s an even, high luster
■ ■
135 Paint is free of removable scratches
■ ■
136 Paint is fre e of wax residue
■ ■
137 Wheels/wh eel covers are clea n
■ ■
138 Wheel wells are clean
■ ■
139 Tires are clean and properly dressed
■ ■
Engine Compartment
140 Compartment is clean
■ ■
141 Unde r-hood heat insulator pad is clea n
■ ■ ■
142 Engine and compa rtment are proper ly dressed
■ ■
Interior Appearance
Meets
Stds
Adjust/
Repair N/A
143 Interior is free of de bris
■ ■
144 Dash and vents a re clean and prope rly dressed
■ ■
145 All crev ices are clean
■ ■
146 Ashtrays and lig hter are clean (if eq uipped)
■ ■ ■
147 Door jambs are cle an
■ ■
148 Glove box and con sole compartme nts are clean
■ ■
149 Cabin air fi lter condition
■ ■ ■
150
Seats, carpets, floor mats (if equipped) and headliner are free of stains
■ ■ ■
151 Free of odor, including heavy fra grance
■ ■
152 Glass is cle an and free of streak s
■ ■
Exterior Repairs
153 Body is f ree of all dents
■ ■
154 Body is re asonably free of din gs
■ ■
155 Paint is reaso nably free of scratche s and chips
■ ■
156 Vehicle is free of improper paint repa irs or mismatched colo r
■ ■
157 Glass is free of improper re pairs
■ ■
158 Bumpers are free of cuts, gouge s and mismatched paint
■ ■
Interior Repairs
159 Interior leath er, vinyl, plastic, carpet and fabr ic surfaces are free
of holes, rips, tears, exces sive wear or fading
■ ■
160 No evide nce of previous improp er interior repairs
■ ■
Additional Inspection Items
(
Where Applicable
)
1 “Fade -away” dome light operates properly
■ ■ ■
2
Sunroof/convertible top operates properly through full range of positions
■ ■ ■
3 Co nvertible top lockout f unction operates prope rly
■ ■ ■
4 Rad io security co des cleared
■ ■ ■
5 Navigation system operates properly and memory system cleared
■ ■ ■
6 Transfer case smoothly switches from 2WD to 4WD and back
from 4WD to 2WD
■ ■ ■
7 Truck bed is in good condition
■ ■ ■
8 Truck bed-lin er is in good condi tion and secured
■ ■ ■
9 Tailgate operates p roperly
■ ■ ■
10 Backup c amera operates prope rly
■ ■ ■
11 Bluetooth
®
searches for sig nal
■ ■ ■
12 SOS (Safety Con nect) light illuminates g reen
■ ■ ■
13 Lane Kee p Assist operates prop erly
■ ■ ■
14
Dynamic Radar Cr uise Control/Pre-C ollision Systems ope rate properly
■ ■ ■
15 Intelligent Par king Assist ope rates properly
■ ■ ■
Hybrid Components
1 Hy brid battery
■ ■ ■
2 Bat tery co ntrol module (batter y voltage s ensor)
■ ■ ■
3 Hy brid power managem ent control module
■ ■ ■
4 Ele ctric motor/generator operates properly
■ ■ ■
5 ECV T operates smoothly and proper ly
■ ■ ■
6 Power inve rter operates prope rly
■ ■ ■
7 Inver ter coolant level
■ ■ ■
8 E V/Eco/Power modes operate proper ly
■ ■ ■
9 Ch eck transaxle “park” mechanis m
■ ■ ■
10 Multi-information d isplay operates proper ly
■ ■ ■
11 Touch Tracer display operates properl y
■ ■ ■
12 Hill Start As sist Control operates pro perly
■ ■ ■
13 Remote air condition ing system (if equippe d) operates properl y
■ ■ ■
14
Solar-powered ventilation system (if e quipped) operates p roperly
■ ■ ■
4
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
MECHANICAL STANDARDS
AND PROCESS NOTES
*
I. VIN and Dealer Code Check
Item Criteria Comments
1 Run and print Vehicle History Report and attach.
Run a Techstream Health Check and retain the diagnostic
report in the dealer file.
Check for and perform outstanding Recalls and the
applicable SSCs.
Negative results placing the vehicle outside program eligibility
parameters make the vehicle ineligible for certification.
Carfax
®
reports stating “Accident Indicator or Vehicle has been to
a repair/collision facility,” require special inspection by the dealership
technician to confirm the vehicle meets Toyota certification standards.
If all TCUV standards are met, the vehicle is certifiable.
A Technical Information System (TIS) inquiry must be performed on
the service history of the vehicle. Any Special Service Campaigns
(SSCs) that have NOT been completed must be completed prior to
release of the vehicle from the service department.
Check original dealer code to confirm original sale by a Toyota
Motor Sales, U.S.A., Inc., dealership. First two (2) digits of selling
dealer code must be 01 – 50 to be eligible for certification. Dealer
codes beginning with 51 are Hawaiian, and dealer codes beginning
with 52 and above are Canadian. Hawaiian and Canadian vehicles
are not eligible for certification.
Tip: Toyota Certified Used Vehicles are eligible for any applicable
remaining New Vehicle Limited Warranty coverages. Goodwill
and claims for repairs associated with reconditioning may not be
submitted on in-stock pre-owned Toyota vehicles.
Technical Service Bulletings (TSBs) are designed to provide technical
assistance for repair procedures for specific vehicle conditions
based upon a customer’s specific complaint, and are not to
be performed as part of the used vehicle reconditioning.
*Mechanical inspection items must be completed by a Toyota-trained technician.
5
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
MECHANICAL STANDARDS
AND PROCESS NOTES
II. Road Test
2 Cold engine operation performs properly.
3 Throttle operates properly during cold start. Depending on prior maintenance, throttle body cleaning may be
needed to ensure proper throttle feel following cold start.
4 Vehicle operates properly during warm-up conditions. Hesitation or backfire may indicate dirty or clogged fuel injectors.
Clean with Toyota Pressurized Fuel Injector Cleaner.
5 Engine performs properly during operating temperature.
6 Engine reaches normal operating temperature. Failure to reach normal operating temperature generally indicates
a thermostat problem and can result in delayed O/D operation
on ECT AT. If engine shows symptoms of compression problems,
a cylinder compression balance test should be performed.
7 Engine fan(s) operate properly.
8 Brake pedal free play and travel within specifications.
9 No abnormal vibrations and noises during brake applications.
10 ABS operates properly (via Techstream Health Check). Properly functioning ABS and brake system operation should be
verified via Techstream Health Check. Excessive vehicle speeds
should not be used to test ABS operation.
11 Parking brake operates properly and within specification.
12 Seat belt material condition. Seat belts are intact with no tears or broken stitching.
13 Seat belts operate properly with full extension and smooth operation. Ensure all seat belts are functioning properly.
14 Transmission/clutch operates smoothly. No abnormal noise or vibration.
15 Automatic transmission operates properly during cold temperature.
6
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
II. Road Test (Continued)
Item Criteria Comments
16 Automatic transmission operates properly during operating
temperature.
Test both forward and reverse operation to ensure gear ranges
engage promptly (1 – 2 seconds) when shifting from N to D or R
when warmed up.
Delayed or “mushy” engagement may indicate internal transmission
pressure or clutch problems.
17 Steering has normal feel in lock-to-lock turning. Tight spots or sticking in lock-to-lock steering wheel rotation can
indicate damaged rack.
18 Steering wheel centered in straight-line driving.
19 Vehicle tracks and drives straight on level surface. Hands-off steering pull can be affected by alignment, tire
condition or type.
20 Tilt and telescopic steering mechanism operates properly.
21 Front windshield wiper operates properly in all modes. Check both front and rear wipers, and check for correct
“park” position.
22 Rear windshield wiper operates properly in all modes. Example: 4Runner rear window will not open if wiper does not
return to park position due to incorrect arm position on shaft.
Adjust as necessary.
23 Windshield washer fluid sprays properly.
24 Wiper blades clear glass properly. Consider replacing with Toyota genuine wiper inserts.
25 Wipers return to correct position when off.
26 Speedometer functions properly.
27 Odometer application registers mileage in every mode. Check each trip odometer.
28 Cruise control operates properly. Test all modes and functions.
7
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
II. Road Test (Continued)
Item Criteria Comments
29 Heater operates properly. A/C or heater noise can be result of bent or incorrectly positioned
piping due to accident damage or incorrect installation.
30 A/C operates properly. A/C and heater performance should be checked during engine
warm-up and hot idle tests. If in doubt, use refrigerant recycling
machine and recharge per specification.
31 No abnormal noise or vibration from engine. Excessive engine drone may be result of bent or warped exhaust
system. Can also be caused by “jumped” motor mounts or engine
bay distortion due to accident damage.
32 No excessive wind or road noise.
33 No abnormal tire vibration/steering wheel shimmy during road test. A pulsation (beating) may indicate a tire balance issue.
34 No abnormal squeaks or rattles within the interior of the vehicle.
III. Frame, Structure and Underbody
Item Criteria Comments
35 Frame/Unibody condition. Check frame/unibody for evidence of damage; no non-factory
welds; no cracks; not bent; no evidence of flood damage. See
“Explanation of Structural (Frame/Unibody) Damage” following
Mechanical Standards and Process Notes.
36 Panel alignment and fit. Panels should fit flush with no uneven gaps. Check for any high
or low panel alignment.
37 Lower body and underbody condition.
38 Suspension-related items for wear/leaks and proper performance. Inspect steering rack, linkage, bushings, control arms and dust boots.
8
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
III. Frame, Structure and Underbody (Continued)
Item Criteria Comments
39 Inspect struts/shocks for leaks and wear. If any leakage found on shocks, they must be replaced.
Shocks and struts should be replaced in axle pairs using
Toyota genuine parts.
Do not use solvents in the area of the strut seal when cleaning
up these components to avoid damaging seals.
40 Power steering system operates properly with no leaks. Drive belts and hoses free of cracks or damage, and at
proper tension.
41 Wheel covers secure and reasonably free of damage. No cracks or broken mount tabs. Remove all locking lug nuts
unless the proper key is present. Aftermarket wheels (of good
quality and same size) and offset are satisfactory. No reversed
wheels; wheels are not bent.
42 Tires are inflated to specification and free of defects and damage. No excessive damage, bulges or cupping. If condition exists,
check wheel alignment.
43 Minimum of 5/32" tread depth remaining across tread width.
44 All four tires must be of the same brand, model, size, tread design,
speed and load rating.
Wheels must be the same size and offset as OEM. Aftermarket
wheels meeting these criteria are acceptable if size does not
exceed the largest TRD factory accessory wheel for that specific
model. If not OEM equipped, the spare tire circumference must be
the same.
All valve stems must have caps.
If originally equipped with a full-size spare, a full-size spare must
be present, properly inflated and of the same size, speed and load
rating as OEM equipped. Spare must meet same standards as
OEM-equipped tires, but it does not have to be the same brand
as four tires on ground.
45 Brake calipers and lines operate properly with no signs of damage. If brake pads are to be replaced, use of Toyota genuine parts
is recommended.
9
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
III. Frame, Structure and Underbody (Continued)
Item Criteria Comments
46 The brake system contains all needed equipment (shim kit, pins,
rattle clips, etc.).
47 Brake pad/shoe linings have a minimum thickness of 50% remaining. Many brake pads can be measured without removing wheels.
48 Brake rotors/drums within specifications with no abnormal
grooving and discoloration.
49 Exhaust system is properly secured with no leaks. Check for excessive damage, such as dents or pulled seams that
expose unplated metal, extreme rust or exhaust leaks.
50 Engine/transmission mounts operate properly with no signs of wear.
51 Drive/axle shafts operate properly with no damage.
52 CV joints/boots operate properly with no signs of wear. Inspect for oil leaks from CV joint boots.
53 Inspect engine for fuel, oil, coolant or other fluid leaks. Let engine idle and check for oil leaks. Inspect all brake fittings
and hoses for brake fluid leaks.
54 Inspect transmission case and pan for leaks.
55 Differential fluid level correct with no leaks. Some vehicles use hypoid gear oil while others may use ATF.
Check for signs of moisture.
IV. Emissions and State Inspection
Item Criteria Comments
56 Perform emissions test and/or state inspection, if required. Remain versed on your state and local laws.
10
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
V. Under Hood
Item Criteria Comments
57 Drive belts and hoses free of cracks and damage.
58 Confirm under-hood labels and decals. All required under-hood labels and decals are present and readable.
59 Air filter in good condition. Air filter is clean and functioning properly. Use of genuine Toyota
filter is required if air filter must be replaced.
60 Battery has no visible damage.
61 Perform battery check with Midtronics GR8 or NVS-8150. If battery must be replaced, use of Toyota Genuine TrueStart
™
replacement battery is recommended.
Use of the Midtronics GR8 diagnostic device is recommended
for use in determining battery condition. The Midtronics GR8 is
a required Toyota Special Service Tool.
The Midtronics Battery Analyzer is designed to minimize customerwaiting time and improve work flow. In most cases, this tester will
allow you to quickly determine if a battery is GOOD or BAD without
charging the battery first.
62 Battery posts and cables free of corrosion and damage.
63 Battery properly sized and secure. Fits properly in harness.
64 Charging system operating properly and within specification.
65 Engine coolant level within specification. Check for oil residue in coolant recovery bottle.
66 Coolant specific gravity to -31º Fahrenheit. This check must be performed in the radiator, not the coolant
recovery bottle.
67 Change engine oil and filter. Use of genuine Toyota filter is required.
11
MECHANICAL STANDARDS
AND PROCESS NOTES
Mechanical Notes 10/10
V. Under Hood (Continued)
Item Criteria Comments
68 Check for evidence of oil gel. Closely examine oil pan drain plug, filler cap, oil filter and old
oil for signs of sludge and/or abuse. If symptoms exist, further
examination such as removal of oil pan and/or valve covers may
be required to confirm problem. Oil gel renders vehicle ineligible
for the TCUV program.
69 Oil, brake, clutch, transmission, transfer case, power steering
and washer fluid at proper levels.
Do not add brake fluid now if the brake pads will be replaced. When
the caliper pistons are pushed back (to make room for new pads),
the excess fluid will damage under-hood painted surfaces. Check
ATF level with engine idling and hot, and transmission in neutral.
70 Under-hood fluids are clear and uncontaminated.
VI. Functional and Walkaround
Item Criteria Comments
71 Owner’s Manual and TCUV Warranty Supplement in
dealer’s possession.
72 Fuel gauge operational.
73 Battery voltage gauge operational.
74 Engine temperature gauge operational.
75 Horn operates properly.
76 Airbag(s) present with no evidence of deployment. Airbag deployment or any signs that airbag covers have been
painted renders the vehicle permanently ineligible for certification.
77 Headlights are properly aligned.
78 High and low beams operate properly.
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