H0P_TI_Yaris MT_

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN H0P
YARIS INSTRUMENT PANEL WIRE HARNESS
CERTAIN 2017 MY YARIS M/T (With Immobilizer)
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this recall are required to successfully complete the most current version of the E-Learning course “Safety
Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly;
technicians performing this recall repair are required to currently hold at least one of the following
certification levels:
• Certified Technician (Electrical)
• Expert Technician (Any Specialty)
• Master Technician
• Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this recall repair. Carefully review your resources, the technician skill level, and ability
before assigning technicians to this repair. It is important to consider technician days off and
vacation schedules to ensure there are properly trained technicians available to perform this repair at
all times.
I.
OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry
Not Involved
No further action required
A/T
Please refer to A/T technical
instructions for repair procedure
No
Please refer to the M/T without
immobilizer technical instructions for
repair procedure
System
Involved
Check the type of transmission in the
vehicle
M/T
Check if vehicle has engine
immobilizer
Yes
Replace instrument panel wire
harness
Campaign completed, return the
vehicle to the customer
II. IDENTIFICATION OF AFFECTED VEHICLES
•
•
Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the
Campaign has not already been competed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were
completed by another dealer.
ONLY THE TWO VINs SHOWN IN THE TABLE BELOW ARE APPLICABLE TO THIS REPAIR PROCEDURE
VINs
VNKKTUD34HA072893
VNKKTUD3XHA073367
2
III. PREPARATION
A. PARTS
Part Number
Part Description
04007-5910U
90099-14119
90099-14121
WIRE KIT, INSTRUMENT PANEL
Quantity
1
1
1
A/C O-Ring
B. TOOLS & EQUIPTMENT
•
•
Techstream
Protective Gloves
•
•
Standard Hand Tools
Refrigerant Recovery Unit
•
Torque Wrench
SST – These Special Service Tools required for this repair:
Part Number
Tool Name
09950-50013
UNIVERSAL PULLER SET "C"
Quantity
1
*The set above includes the following tools needed for the repair:
09951-05010
09952-05010
09953-05020
09954-05021
C.
HANGER 150
SLIDE ARM
CENTER BOLT 100
CENTER BOLT 150
1
2
1
1
MATERIALS
•
•
Protective Tape
Marker Pen
3
IV. BACKGROUND
In the subject vehicles, an incorrect instrument panel wire harness may have been installed during the vehicle
assembly process. The incorrect instrument panel wire harness may not be compatible with the Pre-Collision
system front sensor. As a result, the Automatic High Beam and Pre-Collision system may be inoperative
4
V.
WORK PROCEDURE
A. COMPONENTS
5
6
7
8
9
10
VI.
REMOVE INSTRUMENT PANEL WIRE HARNESS
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. CHECK FOR DTC’s
a. If a DTC(s) is displayed, record the DTC(s) and the freeze frame data and perform the
repairs as necessary
3. RECORD AUDIO AND AIR CONDITIONING SETTINGS
a. When the battery cable is disconnected, the settings for the audio, air conditioning, etc. may
be reset. Therefore, make a note of the settings before disconnecting the cable from the
negative (-) battery terminal
4. RECOVER REFRIDGERANT FROM THE REFRIGERATION SYSTEM
Refer to TIS for instructions on Vehicle Interior / HEATING/AIR CONDITIONING /
REFRIGERANT (for Hatchback) / REPLACEMENT
5. DRAIN ENGINE COOLANT
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
For models with a navigation system, wait at least 6 minutes before
disconnecting the battery. It takes approximately 6 minutes for the system
to save information and settings after the ignition switch is turned off.
7. WEAR PROTECTIVE GLOVES
Be sure to wear protective gloves. Sharp
edges on components such as burrs
may injure your hands.
11
8. REMOVE FRONT WIPER ARM HEAD CAP
a. Use a screwdriver with its tip wrapped in tape to disengage the 3 claws and remove the front
wiper arm head cap
9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY
a. Disconnect the washer hose
b. Remove the nut and the front wiper main arm
*1
Front wiper main arm
c. Apply protective tape to the areas shown in the illustration
*a
Protective Tape
12
d. Twist a rope around the front wiper sub arm and pull the
rope upward to disengage and remove the front wiper arm
blade assembly
*a
*b
Head of the front wiper sub arm
Rope
-If you forcibly remove the wiper arm it could be
damaged
-If you forcibly pry off the wiper arm or the joint
it could be damaged
10. DISENGAGE THE END OF THE FRONT FENDER TO
COWL SIDE SEAL RH / LH
a. Disengage the clip and claw at the bottom of the front
fender to cowl side seal
*a
Double-sided tape
Do NOT separate the double sided tape the
upper portion of the front fender to cowl side
seal. If removed it will require replacement.
11. REMOVE THE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY
a. Remove the 2 bolts
b. Disengage the grommet as shown in the illustration
c. Disconnect the connector to remove the windshield wiper
motor and link assembly
12. REMOVE THE FRONT NO.1 VENTILATOR SEAL
a. Disengage the clamp and to remove the No.1 ventilator
seal
13. REMOVE THE FRONT AIR SHUTTER SEAL RH
a. Disengage the clamp and remove the air shutter seal RH
13
14. REMOVE THE INNER COWL TOP TO COWL BRACE
a. Remove the 2 bolts and the inner cowl top to cowl brace
15. REMOVE THE OUTER COWL TOP PANEL
a. Disengage the 2 clamps and separate the wire harness
b. Remove the 8 bolts and the outer cowl top panel
16. DISCONNECT AIR CONDITIONER TUBE AND
ACCESSORY ASSEMBLY
a. Remove the bolt
b. Turn the hook connector clockwise and disconnect the air
conditioner tube and liquid tube
c. Remove the O-ring from the air conditioner tube and liquid
tube
NOTE: Seal the openings of the disconnected parts
using vinyl tape to prevent the entry of moisture and
foreign matter
14
17. DISCONNECT THE HEATER WATER OUTLET HOSE A
a. Slide the clip and disconnect the heater water outlet hose
from the air conditioning unit
18. DISCONNECT THE HEATER WATER INLET HOSE A
a. Slide the clip and disconnect the heater water inlet hose
from the air conditioning unit
19. REMOVE LOWER NO.2 STEERING WHEEL COVER
a. Using a screwdriver with its tip wrapped with protective
tape, disengage the 2 claws and remove the lower No.2
steering wheel cover
*1
Protective Tape
20. REMOVE THE STEERING PAD
a. Check that the ignition switch is off
b. Check that the cable is disconnected from the negative (-)
battery terminal
Wait at least 90 seconds after disconnecting
the cable from the negative (-) battery terminal
to disable the SRS system
c. Using a “TORX” driver, push in the 3 snap rings to
disengage it from the 3 pins
d. Pull the steering pad towards the rear
15
e. Using a screwdriver with its tip wrapped with protective
tape, release the 2 locking buttons.
f. Disconnect the 2 airbag connectors
*1
*2
Protective Tape
Locking button
g. Disconnect the horn terminal
21. REMOVE STEERING WHEEL ASSEMBLY
a. Remove the steering wheel assembly set nut.
b. Put matchmarks on the steering wheel assembly and the
top of the steering main shaft
*a
Matchmark
c. Disconnect the connectors from the spiral cable subassembly
d. Using SST: 09950-50013, remove the steering wheel
assembly
NOTE: Apply a small amount of grease to the threads and
tip of the SST (center bolt) before use
*a
*b
•
•
•
•
Hold
Turn
NOTE: You will need the following tools from SST kit number
09950-50013
09951-05010
09952-05010
09953-05020
09954-05021
22. REMOVE THE LOWER STEERING COLUMN COVER
a. Remove the 3 screws
16
b. Disengage the 4 claws and remove the lower steering
column cover
23. REMOVE UPPER STEERING COLUM COVER
a. Disengage the claw and remove the upper steering
column cover.
24. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH AND LH
25. REMOVE FRONT PILLAR GARNISH RH
a. Disengage the front pillar garnish clips
NOTE: The front pillar garnish clip should remain
between the front pillar garnish and the pillar
*1
Front Pillar Garnish Clip
17
b. Using needle nose pliers with its tip wrapped in tape, turn
the front pillar garnish clip 90° and disengage it from the
front pillar garnish
*a
Protective Tape
NOTE: Do NOT remove the front pillar garnish clip from
the vehicle as long as it is not damaged. If removed,
the front pillar garnish clip will require replacement.
c. Disengage the 2 guides to remove the front pillar garnish
d. Disconnect the connector for the speaker (w / 6 speakers)
e. Protect the curtain shield airbag assembly by covering it
with a cloth or piece of nylon and secure the ends of the
cover with tape as shown in the illustration.
*1
*a
*b
Curtain Shield Airbag Assembly
Adhesive Tape
Protective Cover
26. REMOVE THE FRONT PILLAR GARNISH LH
a. Use the same procedure as the RH side
27. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL
a. Disengage the 7 clips to remove the No.1 instrument
cluster finish panel
28. REMOVE THE COMBINATION METER ASSEMBLY
a. Remove the 2 screws
b. Disengage the 2 clips and 2 guides
c. Disconnect the 2 connectors to remove the combination
meter assembly
18
29. REMOVE THE INSTRUMENT CLUSTER FINISH PANEL
GARNISH ASSEMBLY
a. Disengage the 13 clips and 4 guides to remove the
instrument cluster finish panel garnish assembly
30. REMOVE INSTRUMENT CLUSTER FINISH CENTER
PANEL SUB-ASSEMBLY
a. Disengage the 7 clips
b. Disconnect the connector to remove the instrument cluster
finish center panel sub-assembly
31. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
a. Slide the slider and disconnect the front passenger airbag
connector
b. Slide the slider and disconnect the vent hole connector
*1
*2
*3
Slider
Airbag Connector
Vent Hole Connector
c. Remove the  bolt
19
d.
e.
f.
g.
h.
Disengage the clamps
Disconnect the connectors
Remove the 2 clips
Disengage the 8 clips while lifting the rear instrument panel up
While lifting the instrument panel, slide it toward the rear of the vehicle. Disengage the 5
guides of the front side of the instrument panel to remove the upper instrument panel
32. REMOVE FRONT DOOR SCUFF PLATE RH
a. Disengage the 8 claws to remove the front door scuff plate
RH
20
33. REMOVE COWL SIDE TRIM BOARD RH
a. Remove the clip
b. Disengage the clip to remove the cowl side trim board RH
34. REMOVE FRONT DOOR SCUFF PLATE LH
a. Use same procedure as RH side
35. REMOVE COWL SIDE TRIM BOARD LH
a. Use the same procedure as RH side
36. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
a. Disengage the claw to separate the glove compartment
door stopper from the glove compartment door
b. Slightly flex the upper part of the glove compartment door
to release the 2 stoppers and open the glove compartment
door until it is horizontal
c. Pull the glove compartment door out horizontally to
disengage the 2 hinges and 3 guides to remove the glove
compartment door
*a
*b
Hold
Turn
21
37. REMOVE NO.2 INSTRUMENT PANEL UNDER COVER
SUB-ASSEMBLY
a. Disengage the 3 claws and guide to remove the No. 2
instrument panel under cover
b. (w/ Footwell Light) Disconnect the connector
38. REMOVE THE NO.1 INSTRUMENT PANEL UNDER
COVER SUB-ASSEMBLY
a. Remove the 2  screws
b. Disengage the 2 claws and guide to remove the No. 1
instrument panel under cover sub-assembly
c. (w/ Footwell Light) Disconnect the connector
39. REMOVE THE LOWER NO.2 INSTRUMENT PANEL FINISH
PANEL
a. Disengage the 5 clips, 2 claws and guide to remove the
No.2 instrument panel finish panel
NOTE: The number of clips varies depending on vehicle
options
40. REMOVE THE LOWER NO.1 INSTRUMENT PANEL
AIRBAG ASSEMBLY
a. Remove the 4 bolts
b. Disengage the 6 claws to separate the lower No.1
instrument panel airbag assembly
c. Using a screwdriver with its tip wrapped in protective tape,
release the locking button
d. Disconnect the airbag connector to remove the lower No.1
instrument panel airbag assembly
22
41. REMOVE THE STEREO
a. Remove the 4 screws and stereo
b. Disconnect the connectors behind the stereo
NOTE: Depending on the vehicle options there will be a
various number of connectors located behind the stereo
42. SEPARATE THE AIR CONDITIONING PANEL ASSEMBLY
a. Disengage the 8 clips
b. Disconnect the connector to separate the air conditioning
panel assembly
c. Disconnect the connector to separate the air conditioning
panel assembly
43. DISCONNECT THE DEFROSTER DAMPER CONTROL
CABLE SUB-ASSEMBLY
a. Disengage the 2 claws to disconnect the defroster damper
control cable sub-assembly
23
44. DISCONNECT THE AIR MIX DAMPER CONTROL CABLE
SUB-ASSEMBLY
a. Disengage the 2 claws to disconnect the air mix damper
control cable sub-assembly
45. REMOVE NO.1 STEREO JACK ADAPTER ASSEMBLY
a. Disconnect the connector
b. Disengage the 2 claws to remove the No.1 Stereo jack
adapter assembly
46. REMOVE NO.1 POWER OUTLET SOCKET ASSEMBLY
a. Disconnect the connector
b. Using a screwdriver wrapped in protective tape, disengage
the claw, then turn the No.1 power outlet socket clockwise
and pull the power outlet socket half way out.
*a
Protective Tape
24
c. Align the protrusion of the No.1 power outlet socket cover
with the cutout of the No.1 power outlet socket cover and
then pull the No.1 power outlet socket assembly out
*b
*a
Protrusion
Cutout
47. REMOVE NO.1 POWER OUTLET SOCKET COVER
a. Disengage the 2 claws to remove the No. 1 power outlet
socket cover
48. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
a. Turn the shift lever knob sub-assembly counterclockwise
and remove the shift lever knob sub-assembly
49. REMOVE THE SHIFTING HOLE COVER SUB-ASSEMBLY
a. Disengage the 6 claws to remove the shifting hole cover
sub-assembly
NOTE: Do not remove the cover. It is not necessary for
repair
25
50. REMOVE THE REAR CONSOLE BOX COVER
a. Disengage the 5 claws and clip
b. Disengage the guide and pull out the rear console box
cover as shown in the illustration
c. Disconnect the connectors to remove the rear console box
cover
51. REMOVE CONSOLE BOX CARPET
52. REMOVE REAR CONSOLE BOX ASSEMBLY
a. Remove the bolt
b. Disengage the 2 clips and guide to remove the rear
console box assembly
53. SEPARATE HOOD LOCK CONTROL LEVER SUBASSEMBLY
a. Disengage the claw and 2 guides to separate the hood
lock control lever
26
54. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY
a. Disengage the 2 claws to disconnect the DLC3 connector
b. Disengage the clamps
c. Disconnect the connectors
d. Remove the 6  or  bolts,  or  screw, and 2  bolts from the lower
instrument panel sub-assembly
27
e. Disengage the 10 guides to remove the lower instrument panel sub-assembly
28
55. REMOVE INSTRUMENT PANEL WIRE
a. Disconnect the connectors, disengage the clamps, and remove the screws, bolts etc. shown
in the illustration
NOTE:
•
Print this page as a check sheet, and put a mark after each disconnection or removal.
•
DO NOT dispose of the check sheet but use it also when installing a NEW instrument
panel wire.
•
See the following pages for detailed information on sections 1) to 4) in the illustration
below.
29
1) Instrument panel relay box
i. Disconnect the 6 engine room main wire connectors from the instrument panel relay
box
ii. Disengage the 3 clamps
iii. Remove the 2 screws and disengage the clamp to separate the relay box
30
iv. Remove the 3 relays from the detached instrument panel relay box, and then install
them to the relay box of the NEW instrument panel wire as shown
DO NOT install the small relays in opposite positions. One is a 4 pole relay
and the other is a 5 pole relay.
31
2) Instrument panel junction block
i. Disengage the clamps
ii. Disconnect the connectors on the front side
iii. Remove the bolt and separate the junction block
iv. Disconnect the back-side connectors and remove the
junction block as shown in the illustration
32
3) Disconnect steering column lower section connectors and clamps
i. Disconnect the connectors
ii. Disengage the 3 clamps and separate the instrument panel wire
33
4) Disconnect the connectors on the RH cowl side section
i. Disconnect the floor wire connectors from the connector
holder on the LH cowl side
ii. Disengage the 2 clamps
iii. Remove the ground bolt and separate the connector
holder
34
a. Disconnect the connectors, disengage the clamps, and remove the bolts shown in the
illustration
•
•
•
•
NOTE:
Print this page as a check sheet, and put a mark after each disconnection or removal.
DO NOT dispose of the check sheet but use it also when installing the NEW
instrument panel wire.
See the following pages for detailed information on sections 1) and 2) in the
illustration below.
For Section 1) go to the Transponder ECU section
35
2) Airbag sensor assembly connector
i. Disconnect the connector from the airbag sensor assembly
ii. Using a thin-bladed screwdriver, lift up the retainer to unlock the connector
iii. Insert a thin-bladed screwdriver to the location shown in the illustration below and lift up the
claw inside the connector housing
iv. While lifting up the claw, push the airbag sensor assembly connector shown in the illustration
out from the connector housing
36
c.
Disconnect the connectors, disengage the clamps and remove the bolt shown in the
illustration
NOTE:
•
Print this page as a check sheet, and put a mark after each disconnection or removal.
•
DO NOT dispose of the check sheet but use it also when installing the NEW
instrument panel wire.
•
See the next page for detailed information on section 1) in the illustration below.
37
1) Disconnect the connectors on the RH cowl side section
i. Disconnect the 5 floor wire connectors from the
connector holder on the RH cowl side
ii. Disengage the 2 clamps
iii. Remove the ground bolt and separate the connector
holder
56. REMOVE STOP LIGHT SWITCH ASSEMBLY
a. Disconnect the connector from the stop light switch
assembly
b. Disengage the harness from the brake pedal support
c. Turn the stop light switch counterclockwise and remove
the stop light switch assembly
38
57. SEPARATE BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
a. Remove the brake pedal return spring
b. Remove the clip and push rod pin and separate the push
rod clevis from the brake pedal
58. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a. Remove the 4 nuts, bolt and the brake pedal support
59. REMOVE COLUMN HOLE COVER SILENCER SHEET
a. Remove the 2 clips and the column hole cover silencer
sheet.
39
60. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY
a. Place matchmarks on the No.2 steering intermediate shaft
assembly and steering column assembly
*1
*2
*a
No.2 Steering Intermediate Shaft Assembly
Steering Sliding Yoke Sub-Assembly
Matchmark
b. Place matchmarks on the steering sliding yoke subassembly and steering gear assembly
c. Loosen bolt A
d. Loosen bolt C
e. Remove bolt B and detach the steering sliding yoke subassembly from the steering gear assembly
61. REMOVE STEERING COLUMN ASSEMBLY
a. Separate the wire harness clamp form the power steering
ECU assembly.
b. Disconnect the 2 steering column connectors from the
power steering ECU assembly
c. Disconnect all the remaining connectors and disengage all
wire harness clamps from the steering column assembly
d. Remove the bolt, 2 nuts and steering column assembly
from the instrument panel reinforcement assembly
40
62. REMOVE HEATER TO REGISTER DUCT ASSEMBLY
a. Disengage the 3 claws and remove the heater to register
duct
63. REMOVE DEFROSTER NOZZLE ASSEMBLY
a. Disconnect the connectors and disengage the clamps,
then disconnect the wire harness
b. Disengage the 2 claws and 3 guides and remove the
defroster nozzle
64. REMOVE REAR NO.2 AIR DUCT (for Cold Area Spec.
Vehicles)
a. Peel back the carpet so that air duct can be removed and
installed from the vehicle
41
b. Disengage the 2 claws and remove the air duct
65. REMOVE REAR NO.3 AIR DUCT (for Cold Area Spec.
Vehicles)
a. Disengage the 2 claws and remove the air duct
66. SEPARATE THE DRAIN COOLER HOSE
42
67. REMOVE NO.1 INSTRUMENT PANEL BRACE SUBASSEMBLY (Except Cold Area Spec Vehicles)
a. Disengage the 2 clamps
b. Remove the 2 bolts, nut, and screw, then remove the
instrument panel brace.
c. Remove the knee airbag mounting bolt
68. REMOVE NO.1 INSTRUMENT PANEL BRACE SUBASSEMBLY (for Cold Area Spec Vehicles)
a. Disengage the 2 clamps
b. Remove the bolt and disconnect the ground wire
c. Remove the 2 bolts, nut, and screw, then remove the
instrument panel brace.
d. Remove the knee airbag mounting bolt A
69. REMOVE REAR NO.1 AIR DUCT (for Cold Area Spec
Vehicles)
a. Disengage the 2 claws and remove the air duct
43
70. REMOVE INSTRUMENT PANEL REINFORCEMENT
a. Remove the 8 bolts and 3 screws, then remove the instrument panel reinforcement
71. REMOVE AIR CONDITIONER UNIT ASSEMBLY
a. Remove the 3 bolts and nut, then remove the air
conditioner unit
72. REMOVE TRANSPONDER KEY ECU ASSEMBLY
a. Move the transponder key ECU in the direction of the
arrow in the illustration to disengage the guide.
44
b. Move the transponder key ECU in the direction of the
arrow to disengage the 2 guides and remove the
transponder key ECU
c. Disconnect the connector
73. REMOVE INSTRUMENT PANEL WIRE HARNESS
a. Remove the Instrument panel wire harness from the vehicle
45
VII.
REMOVE INSTRUMENT PANEL WIRE HARNESS
1. INSTALL TRANSPONDER KEY ECU ASSEMBLY
a. Connect the transponder key ECU connector
b. Engage the 2 guides and move the transponder key ECU
in the direction of the arrow
c. Move the transponder key ECU in the direction of the
arrow to engage the guide and install the transponder key
ECU
2. TEMPORARILY TIGHTEN THE AIR CONDITIONER UNIT ASSEMBLY
a. Temporarily tighten the air conditioner unit with the 3 bolts and nuts
Be sure to support the air conditioning unit to prevent damage to the
installation bracket
3. INSTALL THE INSTRUMENT PANEL REINFORCEMENT
a. Install the instrument panel reinforcement with the 8 bolts
46
4. INSTALL REAR NO.1 AIR DUCT (for Cold Area Spec
Vehicles)
a. Engage the 2 claws and install the rear No.1 air duct
5. INSTALL NO.1 INSTRUMENT PANEL BRACE SUBASSEMBLY (for Cold Area Spec Vehicles)
a. Engage the 2 clamps
b. Install the bolt and connect the ground wire
c. Install the 2 bolts, nut, and screw, then install the
instrument panel brace.
d. Install the knee airbag mounting bolt A
6. INSTALL NO.1 INSTRUMENT PANEL BRACE SUBASSEMBLY (Except Cold Area Spec Vehicles)
b. Engage the 2 clamps
c. Install the 2 bolts, nut, and screw, then install the
instrument panel brace.
d. Install the knee airbag mounting bolt
47
7. INSTALL AIR CONDITIONER UNIT ASSEMBLY
a. Install the air duct with the 2 bolts
Torque:
87 in-lbf {9.8 N.m, 100 kgf-cm} for bolt
Torque:
35 in-lbf {4.0 N.m, 41 kgf-cm} for nut
Torque:
35 in-lbf {4.0 N.m, 41 kgf-cm} for screw 1, 2, 3
48
8. CONNECT COOLER DRAIN HOSE
a. Install the drain cooler hose as shown in the illustration
*a
UP Mark
9. INSTALL THE REAR NO.3 AIR DUCT (for Cold Area Spec
Vehicles)
a. Install the 2 claws and install the air duct
10. INSTALL REAR NO.2 AIR DUCT (for Cold Area Spec
Vehicles)
a. Install the 2 claws and install the air duct
49
b. Return the floor carpet
11. INSTALL THE DEFROSTER NOZZLE ASSEMBLY
a. Engage the 2 claws and 3 guides, then install the defroster
nozzle
b. Engage the clamps and connect the connectors, then
connect the wire harness
12. INSTALL HEATER TO REGISTER DUCT ASSEMBLY
a. Engage the 3 claws and install the heater to register duct
50
13. INSTALL STEERING COLUMN ASSEMBLY
a. Install the steering column assembly to the instrument
panel reinforcement assembly with the 2 nuts and bolt
Torque (Bolt) :
27 ft·lbf {36 N·m. 367 kgf·cm}
Torque (Nut) :
18 ft·lbf {25 N·m, 255 kgf·cm}
Be sure there is no interference around the wire
harness
b. Connect all the connectors and engage all the wire
harness clamps to the steering column assembly bracket
c. Install the wire harness clamp to the power steering ECU
assembly
d. Connect the 2 steering column assembly connectors to the
power steering ECU assembly
51
14. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
a. Tighten the bolt C while aligning the No.2 steering
intermediate shaft assembly with the position D as shown
in the illustration
b. Align the matchmarks on the steering sliding yoke sub
assembly and the steering gear assembly
*1
*2
*a
Steering Sliding Yoke Sub-assembly
No.2 Steering Intermediate Shaft Assembly
UP Mark
Front of Vehicle
Standard D:
18.5 to 19.7mm (0.728 to 0.776 in)
Torque:
26 ft-lbf {35 N.m, 360 kgf.cm}
c. Install bolt B
Torque:
26 ft-lbf {35 N.m, 360 kgf.cm}
d. Tighten bolt A
Torque:
26 ft-lbf {35 N.m, 360 kgf.cm}
15. INSTALL COLUMN HOLE COVER SILENCER SHEET
a. Install the column hole cover silencer sheet with the 2 clips
16. INSTALL BRAKE PEDAL SUPPOERT SUB-ASSEMBLY
a. Temporarily install the pedal support with the bolt and 4
nuts
b. Tighten the 4 nuts in the order shown in the illustration
Torque:
80 in-lbf {9.0 N.m, 92 kgf.cm}
c. Tighten the bolt
Torque:
17 ft-lbf {24 N.m, 241 kgf.cm}
52
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
a. Apply lithium soap base glycol grease to the push rod pin
b. Install the push rod clevis with the push rod pin and a new
clip
Apply Lithium Soap Base Glycol Grease
18. INSTALL STOP LIGHT SWITCH ASSEMBLY
a. Insert the stop light switch into the adjuster until it just
touches the brake pedal
*1
*2
*3
Adjuster
Stop Light Switch Assembly
Brake Pedal
Do NOT depress the brake pedal
b. Make a quarter turn clockwise to install the stop light
switch
*1
*a
Stop Light Switch Assembly
Stop Light Switch Clearance
c. Check the stop light switch clearance:
0.5 to 2.6 mm (0.020 to 0.102 in.)
d. Engage the harness clamp to the pedal support
e. Connect the connector to the stop light switch
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19. INSTALL NEW INSTRUMENT PANEL WIRE
a. Connect the connectors, engage the clamps and install the screws, bolt etc. shown in the
illustration
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
NOTE:
• Put a mark on the check sheet after each connection or installation, to ensure that
all parts are connected.
• See the following pages for detailed information on sections 1) to 4) in the
illustration below.
54
Confirm that the 3 relays are installed to the relay box of the NEW
instrument panel wire.
55
1) Instrument panel relay box
i. Install the 2 screws and engage the clamp
Torque:
27 in-lbf {3.0 N.m, 31 kgf.cm}
ii. Engage the 3 clamps
iii. Connect the 6 engine room main wire connectors to the instrument panel relay box of the
NEW instrument panel wire.
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2) Instrument panel junction block
i. Connect the back-side connectors and install the
instrument panel junction block as shown in the
illustration
ii. Install the instrument panel junction block with the bolt
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
iii. Connect the front side connectors as shown in the
illustration
iv. Engage the clamps
57
3) Steering column lower section
i. Engage the 3 clamps
ii. Connect the connectors
58
4) LH cowl side section
i. Engage the 2 clamps and install the ground bolt
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
ii. Connect the floor wire connectors to the connector holder
of the NEW instrument panel wire on the LH cowl side
59
a. Connect the connectors, engage the clamps and install the bolt shown in the illustration.
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
NOTE:
• Put a mark on the check sheet after each connection or installation, to ensure that
all parts are connected.
• See the following pages for detailed information on section 2) in the illustration
below.
60
2) Airbag sensor assembly connector section
i. Push the airbag sensor assembly connector into the connector housing until it clicks
ii. Reinstall the retainer to lock the connector
61
b. Connect the connectors, engage the clamps, and install the bolt shown in the illustration
NOTE:
• Put a mark on the check sheet after each connection or installation, to ensure that
all parts are connected.
• See the following pages for detailed information on sections 1) in the illustration
below.
62
5) RH cowl side section
i. Engage the 2 clamps and install the ground bolt
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
ii. Connect the 5 floor wire connectors to the connector
holder of the NEW instrument panel wire on the RH cowl
side
20. REINSTALL THE LOWER INSTRUMENT PANEL SUB-ASSEMBLY
2017 Yaris Lower Instrument Panel
21. REINSTALL THE UPPER INSTRUMENT PANEL SUB-ASSEMBLY
2017 Yaris Upper Instrument Panel
22. REINSTALL THE STEERING WHEEL ASSEMBLY
2017 Yaris Steering Wheel
23. REINSTALL THE STEERING PAD
2017 Yaris Steering Pad
24. REINSTALL THE COWL TOP OUTER PANEL
2017 Yaris Cowl Top Outer Panel
25. REINSTALL THE COWL TOP TO COWL INNER BRACE
2017 Yaris Cowl Top to Cowl Inner Brace
26. REINSTALL THE FRONT AIR SHUTTER SEAL RH
2017 Yaris Front Air Shutter Seal RH
27. REINSTALL THE FRONT NO.1 VENTILATOR SEAL
2017 Yaris Front No.1 Ventilator Seal
28. REINSTALL THE WINDSHIELD WIPER MOTOR AND LINK
2017 Yaris Windshield Wiper Motor and Link
29. RECONNECT THE CABLE TO THE NEGATIVE BATTERY TERMINAL
63
30. ADD ENGINE COLLANT
31. CHARGE REFRIGERANT
2017 Yaris Charge Refrigerant
32. INSPECT FOR COOLANT LEAK
2017 Yaris Coolant Leak Inspection
33. INSPECT FOR REFRIGERANT LEAK
2017 Yaris Refrigerant Leak Inspection
34. PERFORM HEALTH CHECK USING TECHSTREAM
35. INSPECT SRS WARNING LIGHT
36. RESTORE SETTINGS AFTER RECONNECTING CABLE TO NEGATIVE BATTERY
TERMINAL
2017 Yaris Initialization
64
◄ VERIFY REPAIR QUALITY ►
Check for proper HVAC Operation
Check for proper operation of headlights and turn signals
Check for proper operation of the radio
Check for proper operation of the horn
If you have any questions regarding this update, please contact your regional representative.
VIII. APPENDIX
A. 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.
B. CAMPAIGN DESIGNATION DECORDER
E
0
A
Year Campaign is Launched
Repair Phase
Current Campaign Letter
for this year
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
G = 2016
Etc...
0 = Remedy
1 = Interim (Remedy not yet
available) “1” will change to “0”
when the Remedy is available
(May use other characters in
unique cases)
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
27th Campaign = 1
28th Campaign = 2
Etc...
Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5th Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012
65