T-SB-0031-16

T-SB-0031-16
April 13, 2016
Cruise Control Stalk Illumination Intermittent Operation
Service
Category
Vehicle Interior
Section
Meter/Gauge/Display
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2014 - 2016
Highlander, Highlander HV,
RAV4
Introduction
Some 2014 – 2016 model year Highlander, Highlander HV and RAV4 vehicles may exhibit an
intermittent cruise control stalk illumination flicker condition. Please follow the Repair Procedure
below to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
EL1601
Install cruise stalk
Illumination wire harness
assembly
0.7
MODEL
OFP
RAV4
4520A-42100
Highlander/HV
4520A-0E020
T1
T2
87
41
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.
Parts Information
PART NUMBER
PART NAME
QTY
Bolt, Flange
1
94611-10800
Washer, Plate
2
82998-0E010
82998-0E020
Terminal, Repair w/Wire
1
PREVIOUS
NEW
91551-80810
91551-80810
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QTY
Cable Tie
2
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite
1
TSLITEPDLR01
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Set*
00002-06000-01
1
Plastic Emblem Removal Tool*
00002-06002-01
1
Plastic Panel Clip Removal Tool*
00002-06001-01
1
* Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 11.00.017 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Precaution
Refer to the Technical Information System (TIS), applicable model and model year Repair Manual:

2014 / 2015 / 2016 Highlander/HV:
Steering – Steering Column – “Steering Column: Steering System: Precaution”

2014 / 2015 / 2016 RAV4:
Steering – Steering Column – “Steering Column: Steering System: Precaution”
NOTE
The precaution section provides details on procedures to ensure vehicle SRS System is safe to
work on and should be read prior to repairs.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure
1. Rotate steering wheel for clearance and
remove 2 bolts out of lower steering
column cover.
Figure 1.
NOTE
The steering wheel should NOT be
removed. Merely rotate it for
appropriate clearance.
2. Disconnect the negative ( – ) battery cable.
CAUTION
Wait at least 90 seconds after battery is
disconnected to disable the SRS system.
NOTICE
Before disconnecting the battery, please refer to the initialization section below. You will
need to follow the procedures necessary when battery terminal is
disconnected/reconnected.
Refer to TIS and the applicable model and model year Repair Manual:

2014 / 2015 / 2016 Highlander/HV:
General – Introduction – “Introduction: Repair Instruction: Initialization”

2014 / 2015 / 2016 RAV4:
General – Introduction – “Introduction: Repair Instruction: Initialization”
3. Align front wheels facing straight ahead.
4. Remove horn button assembly.
Refer to TIS and the applicable model and model year Repair Manual:

2014 / 2015 / 2016 Highlander/HV:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Steering Pad: Removal”

2014 / 2015 / 2016 RAV4:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Steering Pad: Removal”
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
5. Disengage the 2 claws.
Figure 2.
6. Disengage the claw and remove the lower
steering column cover.
Figure 3.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
7. Disconnect switch harness connector z4 for
Highlander/HV (connector z1 for RAV4)
from the spiral cable at the steering wheel
near the steering column shaft nut and
cruise control stalk.
Figure 4. z4/z1
8. Carefully lift connector lock tab and gently
pry on indentations on top of locking tab.
Figure 5.
NOTE
The tab does NOT come out of
the connector.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
9. Insert part number 82998-0E010 pin terminal into cavity 12 of connector z4 for Highlander/HV
(or connector z1 for RAV4).
Figure 6. Connector z1
View A
Figure 7. Connector z4
View A
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
10. Press lock tab down.
Figure 8.
11. Connect Highlander/HV connector z4 (connector z1 for RAV4) to spiral cable.
12. Route repair wire part number 82998-0E010
under existing harnesses as shown.
Figure 9.
NOTE
Do NOT attach ring terminal at this time.
(Ring terminal is attached in picture to
show routing.)
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
13. Disconnect IP connector F61 on
Highlander/HV (G8 on RAV4) from spiral
cable rear of steering wheel.
Figure 10.
Figure 11.
14. Lift connector lock tab using same guidelines
in step 8.
Figure 12.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
15. Insert repair wire part number 82998-0E020 pin terminal into cavity 7 of Instrument Panel
Connector F61 for Highlander/HV (or connector G8 on RAV4).
Figure 13. Connector F61
View A
Figure 14. Connector G8
View A
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
16. Press lock tab down.
Figure 15.
17. Connect IP Highlander/HV harness connector F61 (connector G8 on RAV4) to spiral cable.
18. Check resistance between the ring terminals
of both harnesses.
Figure 16.
NOTE
Both harness ring terminals should
NOT be attached to the vehicle.
The standard resistance should be less than
1 ohm. If resistance is not as specified,
check installation of both harnesses.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
19. Secure repair wire part number 82998-0E010
ring terminal to cruise control switch ground.
Figure 17.
A. Remove screw from cruise control switch.
B. Place repair wire ring terminal over screw.
C. Install screw.
Torque: 2.4 N*m (24 kgf*cm, 21 in*lbf)
20. Route repair wire part number 82998-0E020
to steering column.
Figure 18.
A. Insert bolt part number 91551-80801 and
2 washers onto ring terminal.
B. Insert bolt into steering column as shown
in figure.
Torque: 5 N*m (50 kgf*cm, 44 in*lbf)
21. Secure repair wires using cable ties in the
indicated locations.
Figure 19.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
22. Engage the 3 claws to install the lower steering column cover.
A. Install the 2 screws in the steering column cover (except for smart key).
B. Smart key vehicles, install 2 screws after battery is reconnected.
23. Check that the ignition switch is off.
A. Check that the cable is disconnected from
the negative (–) battery terminal.
Figure 20.
CAUTION
Wait at least 90 seconds after
disconnecting the cable from the
negative (–) battery terminal to disable
the SRS system.
B. Connect the 2 airbag connectors to the
horn assembly.
NOTICE
When connecting any airbag
connector, take care not to damage
the airbag wire harness.
Be sure to only connect the
connectors to each corresponding
color.
1
Airbag Connector
2
Horn Connector
3
Airbag Connector Lock
C. Push in the 2 airbag connector locks to install the 2 airbag connectors.
D. Connect the horn connector to the horn button assembly.
E. Push the horn button assembly to engage the 3 pins carefully.
NOTICE
Make sure that the pins are securely inserted into the steering wheel
assembly holes.
Make sure to engage the 2 uppers pins first.
Make sure that the horn button assembly is securely installed.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
24. Insert the guide and engage the claw to install
the lower No. 3 steering wheel cover.
Figure 21.
25. Insert the guide and engage the claw to install
the lower No. 2 steering wheel cover.
Figure 22.
26. Connect cable to negative (–) battery terminal and initialize all necessary systems.
NOTICE
After the battery is reconnected, please initialize all necessary components. Step 1
contains links to the initialization sections.
© 2016 Toyota Motor Sales, USA
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Cruise Control Stalk Illumination Intermittent Operation
Repair Procedure (Continued)
27. Make sure that the horn sounds. If the horn does NOT sound, inspect the horn system.
Refer to TIS, applicable model and model year Repair Manual:
 2014 / 2015 / 2016 Highlander/HV:
Vehicle Exterior – Horn – “Horn: Horn System: Problem Symptoms Table”
 2014 / 2015 / 2016 RAV4:
Vehicle Exterior – Horn – “Horn: Horn System: Problem Symptoms Table”
28. Perform Techstream Health Check and confirm no DTCs present.
Refer to TIS, applicable model and model year Repair Manual:
 2014 / 2015 / 2016 Highlander/HV:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Airbag System: DTC Check/Clear”
 2014 / 2015 / 2016 RAV4:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Airbag System: DTC Check/Clear”
29. Inspect warning lamp operation.
Refer to TIS, applicable model and model year Repair Manual:
 2014 / 2015 / 2016 Highlander/HV:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Airbag System: Diagnosis System”
 2014 / 2015 / 2016 RAV4:
Vehicle Interior – Supplemental Restraint Systems – “Supplemental Restraint Systems:
Airbag System: Diagnosis System”
© 2016 Toyota Motor Sales, USA