SET-TSB-16-006Re

ATTENTION: This Technical Service
Bulletin was issued by Southeast Toyota
Distributors, LLC.
For Toyota Dealers located within the Southeast
Region: Please refer to SET Dealer Daily to obtain
instructions on how to order parts and submit a warranty
claim (If applicable).
For Lexus Dealers or Toyota Dealers NOT located in
Florida, Georgia, Alabama, South Carolina or North
Carolina: For Repair Authorization, Parts Ordering, and
Warranty Claims please contact Southeast Toyota
Distributors Warranty Claims Department:
(888)851-2722
Press 5, then Press 4 for Out of Region SET Repairs
[email protected]
Thank you for your continued support.
REVISED: 12/09/2016
SET -TSB-16-006
Category:
Vehicle Exterior
Section:
Door/Latch
Highlander water intrusion
grommet damaged during accessory installation
REVISION NOTICE
12/09/2016
Added 2015 model year to applicable vehicles.
Any previous printed versions of this bulletin should be discarded.
Applicability
INSTALLED ACCESSORY INFORMATION
ACCESSORY
DESCRIPTION
CODE
KIT PART NUMBER
YEAR(S)
MODEL(S)
2015-16
Highlander
Onboard Vacuum
SV1000
2015-16
Highlander
LED Fog Light & DRL 2n1
LD4000 or
LD4010
00016-48017-01
00016-48017-02
00016-48017-04
00016-00081
00016-48011
**This Publication does not apply to Vehicles Equipped with an accessory from the factory or Systems added by
other manufacturers.
Introduction
Southeast Toyota (SET) offers onboard vacuum and LED fog & DRL 2n1 Light
accessories as port or dealer installed options. The hood release cable grommet may be
damaged during the installation of onboard vacuum cleaner or LED fog & DRL 2n1 light
on 2016 Highlander vehicles. Should the hood release cable grommet be damaged
water intrusion may occur during heavy rains. This Bulletin addresses the inspection
and repair procedures for water intrusion concerns on vehicles equipped with SET
accessories: onboard vacuum and/or LED fog & DLR light.
Work Flow Overview
Determine Installed Accessories
LED Fog Light / DRL 2n1
LD4000 or LD4010 ONLY
Inspect for water leak or
damaged hood release
cable grommet
OK
NG
1.
2.
Replace Hood Release
Cable
Reroute 2n1 light harness
Onboard Vacuum
SV1000 ONLY
1.
2.
Replace Hood Release
Cable
Reroute Onboard Vacuum
harness
BOTH Onboard Vacuum and LED
Fog Light / DRL 2n1
LD4010 and SV1000
1.
2.
3.
Replace Hood Release
Cable
Reroute Onboard Vacuum
Harness
Reroute 2n1 light harness
Repair Complete
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SET Accessory Highlander water intrusion (Cont.)
Warranty Information
For Dealers located in the Southeast Region, Florida, Georgia, Alabama, South Carolina, or
North Carolina, Submit Warranty claim utilizing the information below.
Accessory
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
LD4000 or
INSGRO
Inspect Grommet
1.2
00016-SPECL 99 99
LD4010
LD4000 or
RRHRC1
R&R Hood Release Cable with 2n1 harness
1.4
00016-SPECL 99 99
LD4010
SV1000
RRHRC2
R&R Hood Release Cable with Vacuum harness
2.4
00016-SPECL 99 99
LD4010 and
R&R Hood Release Cable with 2n1 and Vacuum
RRHRC3
2.6
00016-SPECL 99 99
SV1000
harness
Port Installed Option (PIO) - is in effect for 36 months or 36,000 miles from the vehicle’s in-service date, whichever occurs first.
Unless otherwise specified in vehicle VIN inquiry.
Dealer Installed Option (DIO) - is in effect for 12 months, regardless of mileage, from the date the part(s) was installed on the
vehicle or the remainder of any applicable New Vehicle Limited Warranty, whichever provides greater coverage.
Over the Counter Sale (OCS) - is in effect for 12 months, regardless of mileage, from the date the part(s) were sold. Labor is not
warranted for over-the counter service part replacements.
If you are a dealer located outside of the Southeast Region, please contact the SET Accessory Warranty Department
at (888) 851-2722, press 5 then 4 or email [email protected] for claim payment instructions.
Parts Information
PART NUMBER
DISCRIPTION
53630-0E050
Cable Assembly, Hood Lock Control (as needed)
Southeast Toyota Distributors, LLC
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SET Accessory Highlander water intrusion (Cont.)
SECTION A: Inspection
Verify Vehicle is equipped with SET accessory.
•
Port installed Onboard Vacuum
(Fig. 1) can be identified by
“SV1000” option code appearing
in TIS VIN inquiry vehicle
accessory codes.
•
Port installed LED Fog Light & DRL
2n1 (Fig.2) can be identified by
“LD4000” or “LD4010” option code
appearing in TIS VIN inquiry vehicle
accessory codes.
•
Dealer installed units can be
identified by reviewing service
history for 00016-48017-0X.
•
Dealer installed units can be
identified by reviewing service
history for 00016-00081 or
00016-48011
Fig. 1
Fig. 2
•
Vehicle equipped with LED Fog Light & DRL 2n1 LD4000 or LD4010 ONLY.
 Proceed to step 1 starting on page 4.
•
Vehicle equipped with Onboard Vacuum SV1000 ONLY.
 Perform repairs as listed in Section C starting on page 12.
•
Vehicle equipped with BOTH LED Fog Light & DRL 2n1 LD4000 or LD4010
AND Onboard Vacuum SV1000.
 Perform repairs as listed in Section B starting on page 6 and Section C
starting on page 12.
•
Vehicle is not equipped with SET accessories listed
 This TSB does not apply
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SET Accessory Highlander water intrusion (Cont.)
Inspect for water intrusion and grommet condition.
1. Remove front door scuff plate
LH and cowl side trim subassembly.
Fig. 3
Fig. 3
2. Pull carpeting away from floor
board in area behind parking
brake pedal.
Fig. 4
Fig. 4
3. Check Driver’s floor board for dampness.
A. Feel insulation
under carpet
Fig. 5a
B. Feel insulation under
foam pad.
Fig. 5b
C. Check insulation on
bulkhead
Fig. 5c
Note: If uncertain of water intrusion, perform water leak test while monitoring the area
behind the parking brake in the area of the hood release cable grommet.
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SET Accessory Highlander water intrusion (Cont.)
4. Remove left front tire.
Fig. 6
5. Remove front fender wheel
opening molding sub-assembly
LH.
6. Remove front fender liner LH.
Fig. 6
7. Inspect the hood release cable
grommet. Grommet should be:
Fig. 7
Fig. 7
•
Correctly positioned in
fender well.
•
Not ripped or torn.
•
Sealed with silicon.
 If water intrusion is detected or Grommet is damaged proceed to Section B
starting on page 6 for repair instructions.
 If Water intrusion is not found and the grommet is not damaged, inspection
is complete. No repairs required.
Southeast Toyota Distributors, LLC
December 9, 2016
SET Accessory Highlander water intrusion (Cont.)
SECTION B: LD4000 or LD4010 LED Fog Light & DRL 2n1
A.
LED FOG LIGHT & DRL 2N1 HARNESS REMOVAL.
1. Disconnect negative battery terminal.
2. Remove left front tire.
Fig. 5
3. Remove front fender wheel
opening molding sub-assembly
LH.
4. Remove front fender liner LH.
TIS INFO
Fig. 5
5. Remove front door scuff plate LH.
6. Remove cowl side trim subassembly LH.
TIS INFO
7. Remove no. 1 instrument panel
under cover sub-assembly.
8. Remove lower instrument panel
finish panel sub-assembly.
TIS INFO
Fig. 6
9. Locate DRL module behind left
side of lower instrument panel
finish panel sub-assembly.
Fig. 6
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SET Accessory Highlander water intrusion (Cont.)
10. Disconnect DRL harness from
module.
Fig. 7
Fig 7
11. Disassemble harness connectors.
a. Locate the plastic terminal
locking tab in the connector
housing.
Fig. 8
Fig 8
b. Using a terminal release tool,
disengage locking tab from
terminal to release from
connector body.
Fig. 9
Fig. 9
c. With locking tab disengaged,
lightly pull wire with terminal
from rear of connector body.
Fig. 10
Fig. 10
12. Cut all cable ties retaining excess accessory harness under dash.
13. Remove accessory harness through hood release cable grommet.
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SET Accessory Highlander water intrusion (Cont.)
Note: If this vehicle is also equipped with onboard Vacuum. Remove Onboard Vacuum
harness as outlined in Section C starting on page 13, step 10, before continuing.
B.
HOOD RELEASE CABLE REPLACEMENT
14. Per TIS instructions remove Hood release cable with grommet.
TIS INFO
15. Per TIS instructions install new Hood release cable with grommet.
TIS INFO
Note: See next steps before completely installing the Hood Release cable grommet.
C.
LED FOG LIGHT & DRL 2N1 HARNESS REVISED INSTALLATION PRIOR TO
INSTALLING HOOD RELEASE CABLE GROMMET INTO BODY.
16. Make a ¼ inch long incision in the
hood release cable grommet in the
area shown.
Fig. 11
Fig. 11
17. Route accessory wiring harness
through grommet. One Terminal at a
time.
Fig. 12
Fig 12
Note: Do not damage new hood release
cable grommet.
18. Pull harness through grommet. Do
not let existing electrical tape or
harness conduit to pass through
grommet.
Fig. 13
STOP
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SET Accessory Highlander water intrusion (Cont.)
19. Make a small loop in accessory wire
harness and wire tie to hood release
cable.
Fig. 14
Fig. 14
20. Push Hood Release cable into
position. Ensure grommet is flush
against bulkhead.
Fig. 15
Fig. 15
21. Extra harness can be pulled to the
front of the wheel well and secured
near left front fog light housing.
Fig. 16
Fig. 16
22. Reassemble connectors under dash.
Note: Connectors have polarity
markings. Push terminals into
connector as shown. Fig. 17
•
•
Red wire goes to “+”
connector cavity.
Black wire goes to “-”
connector cavity.
Southeast Toyota Distributors, LLC
Fig. 17
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SET Accessory Highlander water intrusion (Cont.)
23. Connect accessory harness to DRL
module. Fig. 18
Fig. 18
24. Seal Grommet with 3M silicone or
equivalent. Fig. 19
D.
•
Apply silicone between
harness and release cable.
•
Ensure incision made to
grommet is completely
sealed.
•
Apply silicone around
edges of grommet
Fig. 19
Note: If vehicle is also equipped with SV1000 onboard vacuum, proceed to Section C
prior to Reassembly.
VEHICLE REASSEMBLY (FOR 2N1 FOG DRL LIGHT)
25. Install lower instrument panel finish
panel sub-assembly.
Fig. 20
26. Install no. 1 instrument panel under
cover sub-assembly.
27. Install cowl side trim sub-assembly
LH.
28. Install front door scuff plate LH.
Fig. 20
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SET Accessory Highlander water intrusion (Cont.)
29. Install front fender liner LH.
Fig. 21
30. Install front fender wheel opening
molding sub-assembly LH.
TIS INFO
Fig. 21
31. Install left front tire.
32. Reconnect negative battery terminal.
Repair complete for vehicles with LD4000/LD4010 Fog and DRL light vehicles.
Proceed to next section if vehicle is also equipped with SV1000 onboard
vacuum.
Southeast Toyota Distributors, LLC
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SET Accessory Highlander water intrusion (Cont.)
SECTION C: SV1000 Onboard Vacuum
A.
ONBOARD VACUUM HARNESS REMOVAL
1. Disconnect negative battery terminal.
2. Remove left front tire.
Fig. 22
3. Remove front fender wheel
opening molding sub-assembly
LH.
4. Remove front fender liner LH.
TIS INFO
Fig. 22
5. Remove front door scuff plate LH.
6. Remove cowl side trim subassembly LH.
TIS INFO
7. Remove no. 1 instrument panel
under cover sub-assembly.
8. Remove lower instrument panel
finish panel sub-assembly.
TIS INFO
Fig. 23
9. Locate DRL module behind left
side of lower instrument panel
finish panel sub-assembly.
Fig. 23
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SET Accessory Highlander water intrusion (Cont.)
10. Remove vacuum hose panel.
11. Remove hose assembly by
unthreading nut on hose end onto
hose attachment point inside hose
storage cavity.
Vacuum hose panel
12. Remove vacuum canister panel and
canister assembly.
Fig. 24
Fig. 24
Canister
panel
13. Remove 8mm screw in the hose
storage compartment (Fig. 25) and 3
10mm bolts in the vacuum canister
compartment (Fig. 26) holding on
board vacuum to quarter panel trim
panel as shown in illustration.
Fig. 25
Fig. 26
14. Tilt vacuum inward and disconnect
the electrical connector.
Fig. 27
Fig. 27
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SET Accessory Highlander water intrusion (Cont.)
15. Tilt vacuum inward and disconnect
secondary fuel door release cable
from fuel door solenoid.
Fig. 28
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction.
Fig. 28
16. Remove the wire retainer on the back
of the harness power connector by
prying clips away from housing body
and sliding back.
Fig. 29
Fig. 29
17. Insert narrow flat blade screwdriver
into mating end of connector, just
under the top terminal. Apply
pressure down and pull back on the
top wire from the back of the housing.
Fig. 30
Fig. 30
18. Fully remove the top wire from the
connector housing.
Fig.31
19. Use Electrical tape to protect terminal
during procedure.
Fig. 31
Note: Onboard vacuum power wire is connected to B+ and has 12V at all times. Battery
cable must be disconnected to prevent damage.
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SET Accessory Highlander water intrusion (Cont.)
20. Remove LH rear quarter panel trim.
Fig. 32
TIS INFO
Fig. 32
21. Locate vacuum power harness
behind left rear quarter panel interior
trim routed along factory harness. Cut
all cable ties securing harness.
Fig. 33
Fig. 33
22. Remove Vacumm power harness by pulling through the hood release cable
grommet.
B.
HOOD RELEASE CABLE REPLACEMENT
23. Per TIS instructions remove Hood release cable with grommet.
TIS INFO
24. Per TIS instructions install new Hood release cable with grommet.
TIS INFO
Note: If vehicle is also equipped with LD4010 fog and DRL 2m1 light, refer to section B
before completely installing the Hood Release cable grommet.
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SET Accessory Highlander water intrusion (Cont.)
C.
REVISED VACUUM POWER HARNESS ROUTING
•
OVERVIEW- The harness will run
down the back of the wheel well.
Then routed on to the inside of the
body seam to a body plug in the
driver’s side floor board. Once
inside the vehicle the harness is to
be routed the driver’s side of the
vehicle to its original location.
Vacuum harness is not to be
routed through hood release cable
grommet. Fig. 34
Fig. 34
25. Loosen underbody splash shields
behind left front tire.
Fig. 35
Fig. 35
26. Route harness down back of wheel
well and to the inside of the body
seam.
Fig. 36
Seam
Fig. 36
Harness
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SET Accessory Highlander water intrusion (Cont.)
27. Route harness above frame support.
Fig. 37
Fig. 37
Support
28. Locate and temporarily remove floor
pan plug above support.
Fig. 38
Fig. 38
29. Make a cut in the center of body plug
by folding and using side cuts or
equivalent to make an incision in
center of plug.
Fig. 39
Fig. 39
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SET Accessory Highlander water intrusion (Cont.)
30. Route Harness through body plug as
shown. Pull harness through body
plug.
Fig. 40
Fig. 40
31. Push Harness into body through body
plug hole.
Fig. 41
Fig. 41
TIP: Mechanics wire or fish tool may be
helpful in routing wire under floor
insulation.
32. Locate the harness in the driver’s
floor pan under carpet. Pull harness
into vehicle.
Fig. 42
Harness
Fig. 42
33. Route Harness with factory harness
along left side of vehicle to rear
quarter on board vacuum location.
Fig. 43
Fig. 43
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SET Accessory Highlander water intrusion (Cont.)
D.
VEHICLE REASSEMBLY (FOR ONBOARD VACUUM)
34. Route the harness up through the
inner structure of the driver's side
quarter panel, using 2 cable ties to
secure to the existing harness.
Continue routing the harness up over
the wheel well, following the path of
the existing harness. There will be
extra harness length, so from the
point marked by the red arrow, keep 3
feet of harness length for finishing the
run. Attach a cable tie at the locations
of the red and white arrows and
tighten. The length of harness left
over should be bunched up and
secured between the areas marked
by the two yellow arrows, which will
be the two cable ties used to secure
each end of the bunched harness to
the existing harness. Fig 44
Fig. 44
35. Remove electrical tape from routed
wire terminal. Connect positive wire
back into wiring harness connector terminal is polarized and will only
latch in when inserted correctly. Pull
back on wire once inserted to test
connection. Replace wire retainer on
back of connector
Fig. 45
Fig. 45
36. Install Left rear quarter panel trim.
TIS INFO
Fig. 46
Fig. 46
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SET Accessory Highlander water intrusion (Cont.)
TIP: Before proceeding with assembly,
locate the manual fuel door release and
electrical connector in the left rear interior
trim panel. Fig. 47 Locate cable tab on
manual release where cable is to be
attached.
Fig. 47
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction
prior to assembly.
37. Position vacuum in rear of vehicle as
pictured. Reconnect electrical
connector.
Fig. 48
Fig. 48
38. Slide vacuum towards panel and forward (Fig. 49) allowing access to route cable
from rear of unit to manual release (Fig. 50).
Fig. 49
Fig. 50
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SET Accessory Highlander water intrusion (Cont.)
39. Affix cable loop to tab on manual fuel
door release lever.
Fig. 51
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction
prior to assembly.
Fig. 51
40. Properly position on board vacuum in
it’s mounting position.
Fig. 52
•
Verify operation of fuel door
release by pulling release cable
•
Temporarily connect negative
battery terminal and verify
operation of vacuum by pressing
the power button.
Fig. 52
41. Install vacuum assembly with 10mm
socket and ratchet using hardware
provided to mounting holes on
bracket.
Fig. 53
Fig. 53
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SET Accessory Highlander water intrusion (Cont.)
42. Install self tapping screw in hole
inside hose storage cavity. Tighten
with 8mm socket.
Fig. 54
Fig. 54
43. Install hose assembly by threading nut on hose end onto hose attachment point
inside hose storage cavity. Press power button again to test vacuum air path
connections - suction should be felt at end of hose assembly. Turn vacuum off
using power button.
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SET Accessory Highlander water intrusion (Cont.)
44. Insert hose assembly into hose
storage cavity following steps shown.
Fig. 55
Fig. 55
45. Install hose storage and vacuum canister compartment panels.
46. Install lower instrument panel finish
panel sub-assembly.
Fig. 56
47. Install no. 1 instrument panel under
cover sub-assembly.
48. Install cowl side trim sub-assembly
LH.
49. Install front door scuff plate LH.
Fig. 56
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SET Accessory Highlander water intrusion (Cont.)
50. Seat body plug in floor panel and seal
with 3M silicone or equivalent.
•
Apply silicone between
harness and body plug.
•
Ensure incision made to
body plug is completely
sealed.
Fig. 57
Apply
Sealant
Fig. 57
51. Install and secure underbody splash
shields.
Fig. 58
Fig. 58
52. Install front fender liner LH.
Fig. 59
53. Install front fender wheel opening
molding sub-assembly LH.
TIS INFO
Fig. 59
54. Install left front tire.
55. Reconnect negative battery terminal.
Southeast Toyota Distributors, LLC