T-SB-0061-13

May 2, 2013
T-SB-0061-13
Abnormal Power Door Lock Operation (Cycle)
Service
Category
Vehicle Interior
Section
Door Lock
Market
USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2009 – 2011
Corolla, Matrix
WMI(s): 2T1
Introduction
Some vehicles may exhibit a condition where the door locks cycle without any operator input of a
door lock switch or keyless remote assembly. In limited cases this condition may be caused by
grease contamination in the door lock switch. The following procedure is available to inspect and
diagnose this condition. Replacement instructions for the door wire harness and door lock actuator
are also provided in this bulletin.
Production Change Information
This bulletin applies to:
• All 2009 – 2010 model year Corolla and Matrix vehicles.
• All 2011 model year Corolla, Matrix produced BEFORE the Production Change Effective
VINs* shown below.
MODEL
PRODUCTION CHANGE EFFECTIVE VIN
Corolla
2T1BU4EE#BC653555
Matrix
2T1KU4EE#BC653562
* For detailed information on VINs, please reference the 2009 / 2010 / 2011 VIN Decoder Chart found on the Technical
Information System (TIS), under Reference Information: Technician Group.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
Plastic Pry Tool Set*
PART NUMBER
QTY
00002-06000-01
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Parts Information
PART NUMBER
PART NAME
QTY
82151-02J90
RH Front Door Wire
1
82152-02J90
LH Front Door Wire
1
69030-06200
FR Door Motor RH w/Lock Assy
1
69040-06180
FR Door Motor LH w/Lock Assy
1
82152-02G90
Wire, Front Door, LH
1
82152-02J00
Wire, Front Door, LH
1
82152-02J20
Wire, Front Door, LH
1
82152-02J30
Wire, Front Door, LH
1
82151-02J10
Wire, Front Door, RH
1
82151-02J20
Wire, Front Door, RH
1
82151-02J40
Wire, Front Door, RH
1
82151-02J50
Wire, Front Door, RH
1
82152-02J50
Wire, Front Door, LH
1
82152-02J60
Wire, Front Door, LH
1
82152-02J70
Wire, Front Door, LH
1
82152-02K00
Wire, Front Door, LH
1
82152-02K10
Wire, Front Door, LH
1
82152-02K20
Wire, Front Door, LH
1
82152-02K40
Wire, Front Door, LH
1
82152-02K60
Wire, Front Door, LH
1
82152-02N00
Wire, Front Door, LH
1
82151-02J70
Wire, Front Door, RH
1
82151-02J80
Wire, Front Door, RH
1
82151-02K10
Wire, Front Door, RH
1
82151-02K20
Wire, Front Door, RH
1
82151-02K30
Wire, Front Door, RH
1
82151-02K40
Wire, Front Door, RH
1
82151-02L20
Wire, Front Door, RH
1
82151-02L50
Wire, Front Door, RH
1
82151-02N90
Wire, Front Door, RH
1
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EL1221
Inspect Wire Harness (Both Sides)
0.8
Combo A
Wire Harness and Door Lock
Replacement (One Side)
1.2
69030-06200*
69040-06180*
82151-02J90
82152-02J90
82152-02G90
82152-02J00
82152-02J20
82152-02J30
82151-02J10
82151-02J20
82151-02J40
82151-02J50
82152-02J50
82152-02J60
82152-02J70
82152-02K00
82152-02K10
82152-02K20
82152-02K40
82152-02K60
82152-02N00
82151-02J70
82151-02J80
82151-02K10
82151-02K20
82151-02K30
82151-02K40
82151-02L20
82151-02L50
82151-02N90
87
17
Combo B
Opposite Side
1.2
* Represents door lock assemblies.
APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
• Warranty application is limited to occurrence of the specified condition described in this
bulletin.
© 2013 Toyota Motor Sales, USA
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T-SB-0061-13
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Abnormal Power Door Lock Operation (Cycle)
Overview
The procedures listed will be used to inspect the specified connectors for grease contamination and
will outline the replacement of the wire harnesses and door lock actuators if contamination is present.
Inspection Procedure
NOTE
• Inspect both the LH and RH side.
• The procedures listed are for inspecting the LH side.
• Use the same procedures to inspect the RH side.
1. Verify the door locks cycle without any operator input from a door lock switch or keyless remote
assembly.
• If YES — proceed to step 2.
• If NO — STOP! This bulletin does NOT apply.
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual for further diagnosis.
• 2009 / 2010 / 2011 Corolla:
Vehicle Interior – Door Lock – “Door Lock: Power Door Lock Control System: How To
Proceed with Troubleshooting”
• 2009 / 2010 / 2011 Matrix:
Vehicle Interior – Door Lock – “Door Lock: Power Door Lock Control System: How To
Proceed with Troubleshooting”
2. Using a plastic pry tool, disengage the 3 claws
and remove the driver door inside handle bezel.
Figure 1..
: 1
1
© 2013 Toyota Motor Sales, USA
Claw
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
3. Remove the front armrest upper base panel
(w/o power window).
Figure 2..
A. Using a plastic pry tool, disengage the 2 clips
and 6 claws, and remove the front armrest
upper base panel.
B. Disconnect the door lock switch connector.
: 1
: 2
4. Remove the front armrest upper base panel
(w/ power window).
1
Clip
2
Claw
Figure 3..
A. Using a plastic pry tool, disengage the 2 clips
and 6 claws.
B. Disconnect the master switch connector and
remove the front armrest upper base panel.
: 1
: 2
1
Clip
2
Claw
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
5. Remove the front door trim board sub-assembly.
A. Using a screwdriver with its tip wrapped
with protective tape, disengage the claw and
disconnect the door armrest cap.
Figure 4.
1
1
B. Remove the 2 screws.
Protective Tape
Figure 5.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
C. Using a clip remover, disengage the 10 clips around the door panel.
D. Disengage the 5 claws and separate the front
door trim board sub-assembly from the front
door inner glass weatherstrip.
Figure 6.
: 1
1
E. Disengage the 2 claws and disconnect the
front door inside handle sub-assembly.
Claw
Figure 7.
: 1
1
© 2013 Toyota Motor Sales, USA
Claw
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
6. Disengage the 8 claws and remove the front door
scuff plate LH.
Figure 8..
: 1
1
Claw
Door Wire Harness Inspection
1. Remove the front door lower frame bracket
garnish (w/ front No. 2 speaker).
Figure 9..
A. Disengage the clip and clamp.
B. Disconnect the speaker connector and remove
the front door lower frame bracket garnish.
: 1
: 2
1
Clip
2
Clamp
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
Door Wire Harness Inspection (Continued)
2. Remove the front door service hole cover.
A. Disconnect the door lock connector.
Figure 10.
B. Remove the front door service hole cover
(plastic sheet).
Figure 11.
NOTICE
Remove plastic cover carefully to prevent
tearing of plastic sheet.
HINT
Remove any remaining butyl tape from
the door.
C. Unclip door wire harness mounting clips using a clip remover or blade screwdriver.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
Door Wire Harness Inspection (Continued)
3. Inspect the following connectors for contamination.
Figure 12. Corolla ONLY
D
C
B
A
A
I5 – Front Door Lock Assembly LH
C
H6 – Front Door Lock Assembly RH
B
I8 – Front Door Lock Control Switch Assembly LH
D
H9 – Front Door Lock Control Switch Assembly
RH
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
Door Wire Harness Inspection (Continued)
Figure 13. Matrix ONLY
D
C
B
A
A
I5 – Front Door Lock Assembly LH
C
H6 – Front Door Lock Assembly RH
B
I3 – Power Window Regulator Master Switch
Assembly LH
D
H5 – Door Control Switch Assembly RH
A. If grease contamination is NOT found, STOP! This bulletin does NOT apply.
Refer to TIS, applicable model and model year Repair Manual for further diagnosis.
• 2009 / 2010 / 2011 Corolla:
Vehicle Interior – Door Lock – “Door Lock: Power Door Lock Control System: How To
Proceed with Troubleshooting”
• 2009 / 2010 / 2011 Matrix:
Vehicle Interior – Door Lock – “Door Lock: Power Door Lock Control System: How To
Proceed with Troubleshooting”
NOTE
Reassemble in reverse order of inspection.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Inspection Procedure (Continued)
Door Wire Harness Inspection (Continued)
B. If any of the above connectors are contaminated with grease, continue to Repair Procedure
to replace the wire harnesses and door lock actuators on the affected side.
Repair Procedure
Door Wire Harness Removal
HINT
• The procedures listed are for repairing the LH side if grease contamination is found.
• Use the same procedures to repair the RH side if grease contamination is found in the
specified connectors.
1. Remove the cowl side trim board LH.
A. Disengage the clip and guide, and remove the cowl side trim board LH.
Figure 14.
: 1
: 2
1
2
Guide
B. Disconnect harness connectors in kick panel.
© 2013 Toyota Motor Sales, USA
Clip
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Wire Harness Removal (Continued)
2. Loosen the rubber boot in door jamb (at bottom of
A pillar and leading edge of door).
Figure 15..
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Wire Harness Removal (Continued)
3. Pull door harness into door from kick panel and
door jamb to remove from the door.
Figure 16..
Door Lock Assembly Removal
1. Remove the bolt and the front door rear lower
frame sub-assembly.
Figure 17..
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Lock Assembly Removal (Continued)
2. Remove the front door lock assembly.
Figure 18..
A. Using a T30 Torx bit, remove the 3 screws.
B. Slide the front door lock assembly downward,
and remove the front door lock assembly and
cables as a unit.
C. Remove the door lock wiring harness seal
from the front door lock assembly.
3. Remove the front door lock remote control
cable assembly.
Figure 19..
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Lock Assembly Removal (Continued)
4. Remove the front door inside locking cable assembly.
A. Using a screwdriver, disengage the 3 claws.
Figure 20.
HINT
Tape the screwdriver tip before use.
B. Remove the front door inside locking cable
assembly.
Figure 21.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Lock Assembly Installation
1. Install the front door inside locking cable assembly.
A. Install the front door inside locking
cable assembly.
Figure 22.
B. Engage the 3 claws.
Figure 23.
C. Install the front door lock remote control
cable assembly.
Figure 24.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Lock Assembly Installation (Continued)
2. Install the front door lock assembly.
Figure 25..
NOTICE
Reusing the door lock wiring harness seal or
using a damaged door lock wiring harness seal
may cause water intrusion. This may result in
a malfunction of the front door lock assembly.
NOTE
• When reusing the removed front door lock
assembly, replace the door lock wiring
harness seal on the connector with a
new one.
• Do NOT allow grease or dust to adhere to
the door lock wiring harness seal surface
of the connector.
A. Apply MP grease to the sliding parts of the
front door lock assembly.
B. Install a NEW door lock wiring harness seal to
the front door lock assembly.
C. Insert the front door lock open rod to the front
door lock assembly.
D. Make sure that the front door lock open rod
is securely connected to the front door lock
assembly.
E. Using a T30 Torx bit, install the 3 screws.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Lock Assembly Installation (Continued)
3. Install the front door rear lower frame
sub-assembly.
Figure 26..
Torque: 6.2 N*m (63 kgf*cm, 55 in*lbf)
Door Wire Harness Installation
1. Install the NEW door wire harness by pulling the
leading edge connectors of the door harness from
inside door, through the hole in front of the door,
and into the hole to access the kick panel.
Figure 27..
NOTICE
Be careful NOT to chafe wires on metal edges
when pulling harness through the holes.
© 2013 Toyota Motor Sales, USA
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Abnormal Power Door Lock Operation (Cycle)
Repair Procedure (Continued)
Door Wire Harness Installation (Continued)
2. Secure the rubber boot on both sides of
door jamb.
Figure 28..
NOTE
Be sure both rubber boots are completely
seated in the door jamb and base of the A pillar.
Vehicle Assembly Procedure
1. Complete assembly in reverse order of inspection procedure.
2. Confirm repair by ensuring that the locks do NOT cycle without any operator input from a door
lock switch or keyless remote assembly.
© 2013 Toyota Motor Sales, USA