Post on 25-Jun-2018
transcript
1
IMV INNOVA, FORTUNER, HILUX
SPIRAL CABLE SUB-ASSEMBLY REPLACEMENT
1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 7
TECHNICAL INSTRUCTIONS
2
Safety Precautions
Be sure to observe the following precautions to prevent accidents and injuries.
- Park the vehicle and chock the wheels.
- If it is necessary to start the engine, perform the operation in a well ventilated area.
- Before removing and reinstalling heavy parts such as the engine, transmission and differential using specified tools, check that there are no problems with the tools.
- When working in a group of 2 or more, each person must work to ensure the safety of all team
members.
- To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts.
- When lifting the vehicle using a jack, support it in the specified location using a safety stand.
- When lifting the vehicle using a lift, lock the lift for safety.
Also perform the following operation with care.
Use of auto lift
- Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as “Raising the lift!” and “Lowering the lift!”) to alert other workers.
- When raising or lowering the lift, pay attention to the positions of your arms, legs, and other
body parts, and be extremely careful to prevent them from being caught in the lift.
Use of brake cleaner
- Use brake cleaner for appropriate purposes in accordance with instructions in the manual.
- Do not use brake cleaner to remove dirt or stains from the engineer clothes and so forth, as it can catch on fire and cause serious burns.
< Precautions >
- Do not use brake cleaner near flames or fire.
- Do not use large amounts of brake cleaner in a room where a fire is burning.
- Do not keep brake cleaner in a place subject to high temperatures exceeding 40°C, such as a place subject to direct sunlight or near fire.
- Do not put brake cleaner in fire.
Edges
- When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers.
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1. OPERATION FLOW CHART
Check Lot Number of Spiral Cable
Check spiral cable connector
Check if vehicle has equipped with SRS AIRBAG.
Check if vehicle has affected VIN and Frame Number
Work is completed
Receiving Vehicle
Replace Spiral Cable
Final Inspection
NOT ZERO
NO
YES
YES
NO
ONE CONNECTOR
TWO CONNECTORS
“0”(ZERO)
Reinstall everything
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2. IDENTIFICATION OF AFFECTED VEHICLES
2.1. COVERED VIN RANGE
Model
Name
VIN Range
Production Period WMI VDS VIS
Fortuner
PN1
11JV5* *0001001~*2000039 20050307~20100127
Innova 11NV4* *0000001~*8999993 20050307~20100127
Fortuner 11NV5* *7999991~*7999993 20050307~20100127
Hilux 33JV2* *8000000~*9006229 20050307~20100127
Hilux
8AJ
ER32G* *4008359~*4036036 20050601~20101231
EX32G* *4016172~*4031532 20050601~20101231
EZ32G* *1001465~*1008471 20050601~20101231
EZ39G* *2501547~*2517793 20050601~20101231
FR22G* *4509765~*4548384 20050601~20101231
FX22G* *6004283~*6004419 20050601~20101231
FZ22G* *5002716~*5015754 20050601~20101231
FZ29G* *6005097~*6068656 20050601~20101231
Fortuner
YZ59G* *3000007~*3031334 20050601~20101231
ZX62G* *5000003~*5001022 20050601~20101231
ZZ62G* *0001002~*0001583 20050601~20101231
Fortuner
8XA
11ZV5* *6000000~*6005328 20050615~20100630
11ZV6* *3000001~*6000006 20050615~20100630
Hilux
31NV2* *9000000~*9000011 20050615~20100630
31NV3* *9000000~*9005449 20050615~20100630
33JV2* *9000140~*9002329 20050615~20100630
33JV3* *9000080~*9002029 20050615~20100630
33NV2* *9000000~*9008109 20050615~20100630
33NV3* *9000000~*9005469 20050615~20100630
33ZV2* *9000000~*9009417 20050615~20100630
Innova MBJ 11JV4* *7000013~*7160078 20050207~20081229
11NV4* *6000011~*6004804 20050207~20081229
Innova MHF
XS42G* *2500514~*2515753 20041102~20100430
XW42G* *2097659~*2160697 20041102~20100430
XX42G* *5000002~*5008636 20041102~20100430
5
XX43G* *0001376~*0026603 20041102~20100430
Fortuner
YU59G* *7000004~*7010903 20041102~20100430
YX59G* *8000034~*8018192 20041102~20100430
ZX69G* *7001643~*7015437 20041102~20100430
Innova
RL4
XW43G* *9200001~*9399999 20060107~20100119
Fortuner YX59G* *4000067~*4000067 20060107~20100119
ZR69G* *4000003~*4002536 20060107~20100119
Hilux
AHT
CK12G* *0032448~*0032582 20050204~20100412
CK32G* *0001001~*0001666 20050204~20100412
CR12G* *8600000~*8604425 20050204~20100412
CR32G* *8006520~*8009507 20050204~20100412
CS12G* *7500004~*7535558 20050204~20100412
CW12G* *4023553~*4031558 20050204~20100412
CX12G* *9002076~*9002280 20050204~20100412
CX39G* *5000000~*5008298 20050204~20100412
CZ39G* *5000002~*5011459 20050204~20100412
DK22G* *0005546~*0006246 20050204~20100412
DR22G* *5500195~*5514814 20050204~20100412
DZ29G* *9300001~*9302060 20050204~20100412
EK12G* *7000009~*7005604 20050204~20100412
ER12G* *9100003~*9102364 20050204~20100412
ER19G* *8500000~*8500578 20050204~20100412
ER32G* *8500420~*8500630 20050204~20100412
ES12G* *9000001~*9002621 20050204~20100412
EX12G* *9503708~*9504229 20050204~20100412
EX39G* *7000001~*7010740 20050204~20100412
EZ39G* *7000001~*7018253 20050204~20100412
FK22G* *3000007~*3045855 20050204~20100412
FR22G* *6000000~*6029862 20050204~20100412
FR29G* *7000003~*7021728 20050204~20100412
FU29G* *7000005~*7004377 20050204~20100412
FX22G* *8000003~*8009070 20050204~20100412
FZ29G* *9000001~*9045890 20050204~20100412
Fortuner
YK59G* *0001007~*0004639 20050204~20100412
YU59G* *4000000~*4003371 20050204~20100412
YX59G* *6000004~*6000527 20050204~20100412
YZ59G* *8000000~*8007877 20050204~20100412
6
ZU69G* *0001001~*0002423 20050204~20100412
ZZ69G* *5000002~*5008683 20050204~20100412
Hilux MR0
AS12G* *0001008~*0003839 20040426~20091208
AW12G* *0001001~*0003373 20040426~20091208
AX12G* *0001003~*0011096 20040426~20091208
CR12G* *2500000~*2501227 20040426~20091208
CS12G* *0000101~*0081825 20040426~20091208
CU12G* *0001001~*0008755 20040426~20091208
CW12G* *0001001~*0017702 20040426~20091208
CX12G* *0001001~*0052216 20040426~20091208
CX19G* *2600004~*2604341 20040426~20091208
CZ12G* *0000100~*0023440 20040426~20091208
DR22G* *0001001~*0007319 20040426~20091208
DU22G* *0001001~*0002125 20040426~20091208
DX22G* *0001001~*0006140 20040426~20091208
DZ22G* *0001001~*0016082 20040426~20091208
ER12G* *3550000~*5501250 20040426~20091208
ER19G* *0450001~*4861227 20040426~20091208
ER32G* *6003402~*6004548 20040426~20091208
ES12G* *0300000~*3307009 20040426~20091208
ES19G* *4000000~*4350470 20040426~20091208
EU12G* *4000000~*4502007 20040426~20091208
EU19G* *6000000~*6300746 20040426~20091208
EW12G* *2000001~*3013338 20040426~20091208
EX12G* *2000000~*2316709 20040426~20091208
EX19G* *3000001~*3427713 20040426~20091208
EX39G* *0001001~*0250127 20040426~20091208
EZ12G* *4000000~*4154049 20040426~20091208
EZ19G* *0500037~*5303400 20040426~20091208
FR22G* *0500001~*0664475 20040426~20091208
FR29G* *0100002~*1151369 20040426~20091208
FU22G* *2000001~*2301336 20040426~20091208
FU29G* *4000000~*4302451 20040426~20091208
FX22G* *1000000~*1321083 20040426~20091208
FX29G* *2500000~*3101113 20040426~20091208
FZ22G* *1000000~*1172340 20040426~20091208
FZ29G* *0150043~*2513940 20040426~20091208
GR12G* *6500000~*6500801 20040426~20091208
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GR19G* *7000000~*7110350 20040426~20091208
GS12G* *0500018~*5029225 20040426~20091208
GS19G* *0600073~*6098342 20040426~20091208
GU12G* *8000000~*8003438 20040426~20091208
GU19G* *9000000~*9001245 20040426~20091208
GX12G* *5000001~*5001958 20040426~20091208
GX19G* *8000000~*8003004 20040426~20091208
GZ19G* *0600060~*6035036 20040426~20091208
HR22G* *1500000~*1512511 20040426~20091208
HR29G* *0200006~*2029853 20040426~20091208
HU29G* *6000000~*6001000 20040426~20091208
HX29G* *4000000~*4000506 20040426~20091208
HZ22G* *3500000~*3507481 20040426~20091208
HZ29G* *0400035~*4018632 20040426~20091208
Fortuner
YU59G* *8000000~*8004274 20040426~20091208
YZ59G* *0001002~*0092992 20040426~20091208
ZR69G* *0001002~*0016372 20040426~20091208
ZX69G* *0001001~*0017561 20040426~20091208
Fortuner MR1
YU59G* *0001001~*0008164 20040426~20091208
YX59G* *3000000~*3013628 20040426~20091208
ZX69G* *8000000~*8006067 20040426~20091208
Innova
KUN40 NO VIN DATA 5000000~5034144 20041018~20091222
TGN40 NO VIN DATA 5000000~5019875 20041018~20091222
Note:
· # indicates that various characters may occupy that position.
· Not all vehicles in these VIN ranges, are affected and/or sold in your country.
· For the detailed list of concerned vehicles, please refer to the attached VIN list.
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2.2. VEHICLE IDENTIFICATION NUMBER LOCATION
3. PREPARATION
3.1. Replacement components
Parts: Part Name Part No. Qty Remarks
Spiral Cable FLD Kit 04004-07122 1
CABLE SUB-ASSY, SPIRAL 84306-04080 1
Only for Initial Order:
(Except VSC Vehicle)
GREASE 84323-42010 1
3.2. Spiral cable sub-assembly replacement
Special Service Tools (SST): Illustration Part Name Part No. Qty Remarks
Puller C Set 09950-50013 1
For removal and
installation of the
steering wheel
Hanger 150 (09951-05010) 1
VIN is stamped on the cowl panel. It is also stamped on the certification label as shown in the illustration.
A: Certification Label
A
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Slide Arm (09952-05010) 1
Center Bolt 150 (09953-05020) 1
Claw No.2 (09954-05021) 1
Recommended Tools: Part Name Part No. Qty Remarks
GTS (Global Techstream) - 1
For DTC checks
(Intelligent Tester can
also be used instead.)
"TORX" Socket T30 - 1
For removal and
installation of the horn
button
Equipment: Part Name Part No. Qty Remarks
Torque Wrench - 1 For checking tightening
torque
Grease - Appropriate
quantity For lubrication
Protective Tape - Appropriate
quantity For component protection
Marker Pen - Appropriate
quantity
For marking (any color
other than green, blue
and yellow)
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4. WORK PROCEDURE
<TABLE OF CONTENTS>
A. WORK OUTLINE ...................................................................................................... 11
B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE ............................................. 11
C. PRECAUTIONS FOR AIRBAG REMOVAL AND REINSTALLATION ...................... 12
D. PRECAUTIONS FOR ALL OPERATIONS ............................................................... 14
E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG ................................................ 16
F. CHECK SPIRAL CABLE .......................................................................................... 17
G. REPLACE SPIRAL CABLE ...................................................................................... 19
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A. WORK OUTLINE
Checking if the vehicle is applicable to
this safety recall. If the vehicle is
applicable, replacing the spiral cable
with a new one.
B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE
1. LOCK PIN FOR NEW SPIRAL CABLE
(a) DO NOT break/snap off the lock pin until just
installing the steering wheel. Otherwise, the
center position of a new spiral cable will be
misaligned.
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C. PRECAUTIONS FOR AIRBAG REMOVAL AND REINSTALLATION
If the airbag system is not removed or reinstalled by the specified
procedures, the airbag system may unintentionally be activated during
the work, causing a serious accident that could lead to death.
In addition, any errors in work could cause the airbag system to fail to
operate when necessary.
For that reason, pay careful attention to the instructions in this
document and ensure safety during your work.
1. DISCONNECT CABLE FROM NEGATIVE
BATTERY TERMINAL
(a) In order to prevent the airbag system from
unintentionally operating, disconnect the
negative battery terminal cable.
(b) Wait at least 90 seconds after the battery cable
is disconnected, to prevent possible
deployment of the airbag. The airbag system is
provided with a backup power supply.
2. REMOVE STATIC ELECTRICITY
(a) Touch any metallic portion of the vehicle body
to discharge the static electricity before starting
work.
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3. HANDLING OF AIRBAGS
(a) After the horn button is removed from the vehicle, place and store it so that the airbag
deployment surface faces upward.
CAUTION:
If the airbag is stored in an improper manner, a serious accident that could lead to death may
result if the airbag is activated unexpectedly.
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D. PRECAUTIONS FOR ALL OPERATIONS
1. PRECAUTIONS WHEN RAISING VEHICLE
USING A LIFT OR JACK
(a) Refer to the respective repair manual and
follow the instructions within the Introduction
section to ensure safety when working.
(b) Ensure the safety of all personnel near the lift
or jack, including yourself, before beginning
work. Also announce all lift and jack operations
out loud to prevent any personnel from being
caught or harmed in any way.
2. WEAR PROTECTIVE EYEWEAR
(a) Wear protective eyewear when working under
vehicle or where there is any risk of flying parts
or debris.
3. DO NOT USE BRAKE CLEANER AS STAIN
REMOVER
(a) Do not spray brake cleaner onto any clothes
since it is a flammable solvent that vaporizes
easily. Do not use it near cigarettes or stoves
as this can cause serious burns and injuries.
4. AVOID BURNS
(a) If the engine is hot, wear protective gloves to
prevent burns.
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5. VEHICLE PROTECTION
(a) A fender cover, a grill cover, seat covers tape
etc. must be used to protect the vehicle from
dirt or scratches.
NOTE:
The protective measures listed above may not be
shown in some illustrations to allow easy
identification of the work location and to make the
illustrations simple and easy to read.
6. HANDLING OF REMOVED PARTS
(a) Destroy or mark and then store removed parts
in a separate container so as to not be
assembled again in error.
(b) Check the removed parts when performing the
completion inspection.
NOTE:
The parts shown in the illustration to the left are
examples only and differ from the actual
replacement parts.
7. DO NOT BREAK PARTS WHEN WORKING
INSIDE ENGINE COMPARTMENT
(a) Do not break parts by carelessly placing hands
inside and leaning on the engine compartment
while being preoccupied by work.
8. CHECK INSIDE ENGINE COMPARTMENT
BEFORE ENGINE START-UP
(a) Check that all necessary parts are installed.
(b) Check that no tools or pieces of cloth are left
inside the engine compartment.
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E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG
1. CHECK IF SRS AIRBAG IS IMPRINTED
(a) Check if SRS AIRBAG is imprinted on the horn
button.
SRS AIRBAG Required procedure
Imprinted
(Equipped with the airbag)
Check the spiral cable
Proceed to “F. CHECK SPIRAL
CABLE” (Page-17)
Not imprinted
(No airbag is provided)
Return the vehicle to the customer.
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F. CHECK SPIRAL CABLE
CAUTION:
For details about the component removal, refer to the respective repair manual.
1. CHECK NUMBER OF SPIRAL CABLE CONNECTORS
(a) Disconnect the negative battery terminal cable.
(b) Remove the horn button assembly.
(c) Check the number of spiral cable connectors.
Number of connectors
Required procedure
Check the lot number (Page-18)
Reinstall the removed components,
and return the vehicle to the customer.
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2. CHECK LOT NUMBER OF SPIRAL CABLE
(a) Remove the steering wheel assembly.
(b) Detach the upper steering column cover.
(c) Check the value of the lot number indicated by an arrow in the illustration below.
Value indicated by an arrow
Required procedure
(Zero) Reinstall the removed components,
and return the vehicle to the customer.
Values other than 0 (zero)
Replace the spiral cable with a new
one.
Proceed to “G. REPLACE SPIRAL
CABLE” (Page-19)
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G. REPLACE SPIRAL CABLE
CAUTION:
For details about component removal, refer to the respective repair manual.
1. REMOVE LOWER STEERING COLUMN COVER
2. REMOVE SPIRAL CABLE
3. REMOVE STEERING ANGLE SENSOR (Vehicles equipped with Steering Angle Sensor)
(a) Detach the steering angle sensor from the spiral cable.
4. REGARDING LOCK PIN OF NEW SPIRAL
CABLE
CAUTION:
DO NOT break/snap off the lock pin until just
installing the steering wheel. Otherwise, the
center position of a new spiral cable will be
misaligned.
5. REINSTALL STEERING ANGLE SENSOR
(Vehicles equipped with Steering Angle
Sensor)
(a) In order to prevent noise from occurring, apply
a small amount of grease (included in the new
spiral cable kit) onto the surface at the 4
locations shown in the illustration.
(b) Attach the steering angle sensor to a new
spiral cable.
6. INSTALL NEW SPIRAL CABLE
(a) Install the new spiral cable to the vehicle.
7. REINSTALL UPPER AND LOWER
STEERING COLUMN COVERS
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8. REMOVE LOCK PIN FROM SPIRAL CABLE
(a) Snap the lock pin (orange) off the new spiral
cable.
NOTE:
There is no problem even if the lock pin is pulled out
without separation.
(b) Check that the part of the lock pin staying in
the new spiral cable has not jut out from the
surface.
(c) If the part of the lock pin has jut out, push in it.
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9. CHECK SPIRAL CABLE CENTER
POSITION
(a) With the matchmarks aligned, check that the
orange (or yellow) roller can be seen through
the sight window.
NOTE:
If the orange (or yellow) roller can be viewed from
the sight window, misalignment of the matchmarks
is acceptable.
10. REINSTALL STEERING WHEEL
ASSEMBLY
11. REINSTALL HORN BUTTON ASSEMBLY
< WHERE NEW SPIRAL CABLE HAS 2
CONNECTORS >
(a) Connect the spiral cable’s wire terminal to the
horn button assembly.
(b) Connect the spiral cable’s orange connector to
the horn button assembly.
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(c) Cut the black connector’s cable as shown in
the illustration (near the wrapped tape).
CAUTIONS:
DO NOT connect the black connector. No
voltage is applied to the black connector.
In order to prevent abnormal noise from
occurring, remove the black connector by
cutting the cable.
(d) Reinstall the horn button assembly.
12. REINSTALL HORN BUTTON ASSEMBLY
< WHERE NEW SPIRAL CABLE HAS 1
CONNECTOR >
(a) Connect the spiral cable’s wire terminal to the
horn button assembly.
(b) Connect the spiral cable’s connector to the
horn button.
(c) Reinstall the horn button assembly.
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13. REINSTALL STEERING WHEEL
ASSEMBLY
14. RECONNECT CABLE TO NEGATIVE
BATTERY TERMINAL
15. CHECK SRS WARNING LIGHT
16. CHECK THAT HORN, WIPERS AND
LIGHTS OPERATE PROPERLY
17. CHECK STRAIGHT AHEAD POSITION FOR
STEERING WHEEL
18. RESTORE SYSTEM SETTINGS AFTER
BATTERY RECONNECTION
(a) Power Window Control System
(b) Meter / Gauge System