H0P-TI-Yaris MT-

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN H0P
YARIS INSTRUMENT PANEL WIRE HARNESS
CERTAIN 2017 MY YARIS M/T (Without 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
Yes
Please refer to the M/T with
immobilizer technical instructions for
repair procedure
System
Involved
Check the type of transmission in the
vehicle
M/T
Check if vehicle has engine
immobilizer
No
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.
2
III. PREPARATION
A. PARTS
Applicable P/N
(Instrument Panel Wire
Harness)
VIN
VNKJTUD36HA072244
VNKJTUD37HA072270
VNKJTUD38HA072195
VNKJTUD33HA072234
VNKJTUD30HA072255
VNKJTUD33HA072315
VNKJTUD32HA072404
VNKJTUD38HA072469
VNKJTUD32HA072497
VNKJTUD36HA074088
VNKJTUD34HA074302
VNKJTUD32HA074329
VNKJTUD35HA074518
VNKJTUD3XHA074580
VNKJTUD34HA072159
VNKJTUD39HA072206
VNKKTUD38HA072332
VNKJTUD36HA072454
VNKJTUD32HA072466
VNKKTUD3XHA072607
VNKKTUD33HA072691
VNKKTUD35HA072725
VNKKTUD31HA072771
VNKKTUD33HA074439
VNKKTUD36HA072815
VNKKTUD31HA072852
VNKKTUD39HA072999
VNKJTUD39HA073050
VNKKTUD33HA073100
VNKJTUD38HA073136
VNKJTUD38HA073234
VNKJTUD38HA073279
VNKJTUD38HA073301
VNKKTUD35HA074376
Quantity
04007-5910D
1pc per
VIN
04007-5920D
B. TOOLS & EQUIPTMENT
•
•
C.
Techstream
Protective Gloves
•
Standard Hand Tools
•
Torque Wrench
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
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V.
WORK PROCEDURE
A. COMPONENTS
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6
7
VI.
REMOVE INSTURMENT PANEL WIRE HARNESS
1. 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
2. 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
3. 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.
4. WEAR PROTECTIVE GLOVES
Be sure to wear protective gloves. Sharp
edges on components such as burrs
may injure your hands.
5. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH AND LH
6. 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
8
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
7. REMOVE THE FRONT PILLAR GARNISH LH
a. Use the same procedure as the RH side
8. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL
a. Disengage the 7 clips to remove the No.1 instrument
cluster finish panel
9. 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
9
10. 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
11. 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
12. 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
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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
i. Detach the lower steering column cover
13. REMOVE FRONT DOOR SCUFF PLATE RH
a. Disengage the 8 claws to remove the front door scuff plate
RH
11
14. REMOVE COWL SIDE TRIM BOARD RH
a. Remove the clip
b. Disengage the clip to remove the cowl side trim board RH
15. REMOVE FRONT DOOR SCUFF PLATE LH
a. Use same procedure as RH side
16. REMOVE COWL SIDE TRIM BOARD LH
a. Use the same procedure as RH side
17. 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
12
18. 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
19. 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
20. 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
21. 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
13
22. 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
23. 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
24. DISCONNECT THE DEFROSTER DAMPER CONTROL
CABLE SUB-ASSEMBLY
a. Disengage the 2 claws to disconnect the defroster damper
control cable sub-assembly
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25. DISCONNECT THE AIR MIX DAMPER CONTROL CABLE
SUB-ASSEMBLY
a. Disengage the 2 claws to disconnect the air mix damper
control cable sub-assembly
26. 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
27. 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
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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
28. REMOVE NO.1 POWER OUTLET SOCKET COVER
a. Disengage the 2 claws to remove the No. 1 power outlet
socket cover
29. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
a. Turn the shift lever knob sub-assembly counterclockwise
and remove the shift lever knob sub-assembly
30. 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
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31. 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
32. REMOVE CONSOLE BOX CARPET
33. REMOVE REAR CONSOLE BOX ASSEMBLY
a. Remove the bolt
b. Disengage the 2 clips and guide to remove the rear
console box assembly
34. SEPARATE HOOD LOCK CONTROL LEVER SUBASSEMBLY
a. Disengage the claw and 2 guides to separate the hood
lock control lever
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35. 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
18
e. Disengage the 10 guides to remove the lower instrument panel sub-assembly
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36. 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.
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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
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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.
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2)
i.
ii.
iii.
Instrument panel junction block
Disengage the clamps
Disconnect the connectors on the front side
Remove the bolt and separate the junction block
iv.
Disconnect the back-side connectors and remove the
junction block as shown in the illustration
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3) Disconnect steering column lower section connectors and clamps
i. Disconnect the connectors
ii. Disengage the 3 clamps and separate the instrument panel wire
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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.
iii.
Disengage the 2 clamps
Remove the ground bolt and separate the connector
holder
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b. 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
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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
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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.
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3) 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
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VII.
INSTALL INSTURMENT PANEL WIRE HARNESS
1. 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.
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Confirm that the 3 relays are installed to the relay box of the NEW
instrument panel wire.
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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
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3) Steering column lower section
i. Engage the 3 clamps
ii. Connect the connectors
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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
35
b. 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.
36
1) 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
37
c. 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.
38
1) RH cowl side section
iii. Engage the 2 clamps and install the ground bolt
Torque:
74 in-lbf {8.4 N.m, 86 kgf.cm}
iv. Connect the 5 floor wire connectors to the connector
holder of the NEW instrument panel wire on the RH cowl
side
2. REINSTALL THE LOWER INSTRUMENT PANEL SUB-ASSEMBLY
2017 Yaris Lower Instrument Panel
3. REINSTALL THE UPPER INSTRUMENT PANEL SUB-ASSEMBLY
2017 Yaris Upper Instrument Panel
4. RECONNECT THE CABLE TO THE NEGATIVE BATTERY TERMINAL
5. PERFORM HEALTH CHECK USING TECHSTREAM
6. INSPECT SRS WARNING LIGHT
7. RESTORE SETTINGS AFTER RECONNECTING CABLE TO NEGATIVE BATTERY
TERMINAL
2017 Yaris Initialization
39
◄ 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
40