TECHNICAL INSTRUCTIONS FOR NONCOMPLIANCE E0B SEAT HEATER ASSEMBLIES CERTAIN SIENNA

Transcription

1 TECHNICAL INSTRUCTIONS FOR NONCOMPLIANCE E0B SEAT HEATER ASSEMBLIES CERTAIN SIENNA

2 I. OPERATION FLOW CHART The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps as outlined in the full technical instructions to confirm the campaign is completed correctly. Verify Vehicle Eligibility 1. Check the VIN range. 2. Check the TIS Vehicle Inquiry System. Not Covered No further action required. Covered Replace the seat heater assemblies. Campaign Complete. II. BACKGROUND The seat heater assemblies in the covered vehicles do not meet a provision of FMVSS 302 that requires a material not to transmit a flame across its surface at a rate greater than specified. This standard ensures that interior components retard burning. The seat heater assembly is installed inside the seat unit, between the seat cushion and the seat cover pad. These other seat components meet the standard; this noncompliance is related to the seat heater only. 2

3 III. PREPARATION A. PARTS Part Number Part Description Quantity or Hog Rings Seat Heater Assembly kit* 1 *The kit above contains the following parts Cushion Heater Assy RH/LH Seatback Heater Assy RH/LH 2 Hog ring quantity is only an estimate, the exact amount needed will differ depending on vehicle configuration. B. TOOLS & EQUIPMENT Standard hand tools Flashlight Techstream Hog ring pliers SST This is an essential special service tool that the dealership should have. Part Number Part Name Seat Heater Attachment Tool Kit Plastic Pry Tool Set Occupant Classification Seat Weight Set IV. IDENTIFICATION OF AFFECTED VEHICLES A. COVERED VIN RANGE MODEL WMI MY VDS START FINISH Sienna 5TD DK3DC S S YK3DC S S DK3DC S S YK3DC S S NOTE: Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Non-Compliance, and that the campaign has not already been completed prior to dealer shipment or by another dealer. TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer. 3

4 V. IMPORTANT REPAIR TIPS, READ PRIOR TO SEAT HEATER REPLACEMENT 1. ALWAYS DISCONNECT THE BATTERY WHEN REPLACING THE SEAT HEATERS a) Refer to the repair manual for the correct battery disconnection procedure for the model being repaired. b) Always wait at least 90 seconds after disconnecting the battery. 2. TO PREVENT DAMAGING AND/OR SOILING OF THE SEAT, PLACE THE REMOVED SEAT ON A CLEAN BENCH THAT HAS BEEN COVERED WITH A CLEAN BLANKET. 3. CONFIRM THE INSTALLATION OF THE SEAT AIRBAG STRAPS a) For vehicles with seat airbag assemblies, the airbag straps MUST be installed correctly. b) Confirm the straps are installed securely and not twisted. c) There is no need to remove the side airbag on any seat assembly when replacing the seat heater. d) On Avalon vehicles equipped with rear seat heaters, the airbag straps are attached with nuts, these nuts are NON-REUSABLE, they MUST be replaced. GOOD EXAMPLE BAD EXAMPLE 4. DO NOT REMOVE THE HEADREST SUPPORTS a) The repair manual may indicate that the headrest supports should be removed to remove the seatback heater. DO NOT remove the headrest supports as it is likely they may be damaged during removal. b) The seat cover can be turned back and the heater can be replaced without removing the headrest supports. DO NOT REMOVE THE HEADREST SUPPORTS TURN BACK THE SEAT COVER 4

5 IMPORTANT REPAIR TIPS CONTINUED 5. DO NOT REMOVE ALL HOG RINGS WHEN REMOVING THE SEAT COVER a) Depending on the model and seat heater being replaced, it may be possible to turn back the seat cover without removing all hog rings. 6. DO NOT BEND THE HOG RING ANCHOR RODS a) Do not apply excessive force to the anchor rods when removing and installing the hog rings. 7. ALWAYS INSTALL THE SEAT HEATER SO THAT THE COPPER WIRES FACE THE SEAT COVER a) Confirm the seat heater is installed with the copper wires facing the seat cover. b) Never install the heater with the copper wires facing the cushion. 8. USE CAUTION WHEN USING THE TAG PIN GUN a) The tag gun uses a needle to install the tag pins, use caution to not damage the seat cover. b) Confirm all of the tag pins are securely installed to ensure the seat heater stays in the correct position. Use caution when using the tag pin gun, the needle is very sharp. 9. CONFIRM ALL OF THE CLIPPED HOG RINGS ARE REMOVED a) To prevent seat damage and potential injury, confirm all clipped hog rings are removed from the seat. 10. WATCH THESE VIDEOS THAT HIGHLIGHT SOME OF THE KEY STEPS OF THE REPAIR Hog Ring Installation Hog Ring Removal Seat Heater Installation Airbag Strap Installation Seat Cover Installation 5

6 VI. SEAT ASSEMBLY REMOVAL NOTE: This procedure is shown using the left side, follow the same procedure for the right side. 1. ADJUST THE POSITION OF THE SEAT a) Move the seat to the center position. b) Move the seatback to the upright position. 2. DISCONNECT THE NEGATIVE BATTERY TERMINAL Wait at least 90 seconds after disconnecting the cable from the negative battery terminal to prevent airbag and seat belt pretensioner deployment. Follow all precautions as outlined on TIS before servicing the SRS system. 3. REMOVE THE HEADREST ASSEMBLY 4. REMOVE THE SEAT ASSEMBLY BOLTS a) Open the seat track covers. b) Remove the 4 bolts. 5. REMOVE THE SEAT ASSEMBLY a) Tip the seat back and disconnect the connectors on the bottom of the seat. b) Carefully remove the seat from the vehicle and place it on a clean bench. To prevent damaging and/or soiling of the seat, place the seat on a clean bench that has been covered with a clean blanket. 6

7 VII. SEAT DISASSEMBLY 1. REMOVE THE FRONT SEAT LEG COVER LH a) Remove the screw. b) Disengage the 2 claws and remove the cover. c) Repeat the procedure for the other seat leg. 2. REMOVE THE SEAT LEG COVER LH a) Remove the clip. b) Remove the screw and the cover. c) Repeat the procedure for the other seat leg. 5. REMOVE THE No.1 FRONT SEAT INNER CUSHION SHIELD a) Disengage the 2 clips. b) Disengage the 4 claws and remove the shield. 6. REMOVE THE FRONT SEAT CUSHION INNER SHIELD RH a) Disengage the clip and 5 claws and remove the shield. 7

8 7. REMOVE THE SWITCH KNOBS a) Carefully disengage the 2 claws and remove the reclining knob. b) Carefully disengage the 2 claws and remove the slide/vertical knob. 8. REMOVE THE FRONT SEAT CUSHION INNER SHIELD LH a) Disengage the 3 claws, the clip, and the guide and remove the shield. b) Disconnect the lift motor connector. c) Disengage the 3 claws and open the harness cover. d) Disengage the 3 wire harness clamps and disconnect the connector. 9. REMOVE THE POWER SEAT SWITCH a) Remove the 3 screws. b) Disconnect the connectors and remove the switch. 8

9 10. REMOVE THE LUMBAR SWITCH a) Disengage the 4 claws. b) Disconnect the lumbar switch connector and remove the switch. 11. DISCONNECT THE BOTTOM OF SEAT BACK COVER a) Remove the seat band. b) Remove the 3 hog rings. 12. REMOVE THE ARMREST ASSEMBLY a) Disengage the 2 claws and remove the bolt cover. b) Remove the bolt and the armrest assembly. 13. REMOVE THE FRONT SEAT BACK HOOK a) Disengage the 4 claws and remove the hook cover. b) Remove the screw and the hook. 14. PEEL BACK THE SEAT BACK COVER a) Carefully peel back the cover approximately 1/3 of the way up the seat. b) Remove the 2 hog rings. 9

10 c) Carefully peel back the cover until the seat airbag strap is visible. d) Remove the nut and disengage the strap from the seat frame and cushion. e) Peel the remainder of the cover off until the seat heater assembly is accessible. To avoid potential damage, DO NOT remove the headrest supports. DO NOT remove the 4 hog rings from the bungee cords at the top of the seatback foam. 15. REMOVE THE SEAT CUSHION WITH PAD a) Disengage the two hooks on each side of the seat back base. 10

11 b) Disengage the 7 hooks and remove the seat cushion and cover from the seat frame. 16. REMOVE THE RECLINING ADJUSTER INSIDE COVER a) Disengage the claw and remove the reclining cover. b) Repeat procedure for the other side. 17. REMOVE THE RECLINING ADJUSTER INSIDE COVER a) Disengage the claw and remove the seat reclining adjuster inside cover. 18. DISENGAGE SEAT CUSHION LOWER SHIELD HOOK a) Disengage the seat cushion lower shield retaining hooks from the seat frame bar. 11

12 Drivers Seat 19. REMOVE SEAT CUSHION EDGE PROTECTOR b) Remove the screw from the seat cushion edge protector and remove from seat. Note: Removal of these covers will make it much easier to reinstall the seat back cover after replacing the heater element. Passenger Seat 20. REMOVE THE SEAT CUSHION COVER a) Remove the 12 hog rings shown in red and peel the seat cushion cover to the side. Note: Do not remove all the hog rings. 21. REMOVE THE SEAT CUSHION HEATER ELEMENT a) Carefully cut off the 33 tag pins which fasten the heater element to the seat cushion cover. 22. REMOVE THE SEAT BACK HEATER ELEMENT ASSEMBLY a) Carefully cut the 19 tag pins which fasten the heater element to the cover. b) Remove the heat element from the cover and remove the tack pin remains. 12

13 VIII. SEAT ASSEMBLY 1. ATTACH NEW HEATER ELEMENTS a) Line up the new seat heater element with the back side of the seat cover. b) Holding the seat heater element tab and seat cover felt tab up away from the seat cover, use the tag gun to install the new seat heater element. Seat Cushion Seat Back c) Ensure that all tabs are secured with tag pins. Seat Back 19 Tag Pins Seat Cushion 33 Tag Pins 2. SEAT BACK COVER INSTALLATION a) Carefully reinstall the seat back cover onto the seat back foam while ensuring the bungee cords are feed through the seat cover felt channel. b) Only install the seat cover about ¾ of the way down. c) Reinstall the airbag strap through the seat foam and frame ensuring that it is not twisted. d) Torque the nut to spec. Torque: 5.5 Nm (56kgf cm, 49 in lbf) 13

14 e) Carefully complete reinstalling the seat back cover onto the seat back foam. f) Press the center of the seat cover firmly against the foam to secure the hook and loop so the seat cover is firmly installed. g) Route the seat heater wire and connectors correctly through the seat cover. h) Ensure there are no wrinkles in the leather. i) Carefully pull the bungee cords and secure them to the seat frame as shown using 3 hog rings. j) After installing the hog rings ensure that the seat back cover fit and finish is good with no unwanted wrinkles or stretch marks. Note: This step is much easier with two technicians. k) Hook the seat cover two large hooks to the bottom of the seat frame assembly. l) After confirming the seat back covers fit and finish install 3 new hog rings to secure the seat back cover over the foam. Drivers Seat 3. REINSTALL SEAT CUSHION EDGE PROTECTOR a) Reinstall the right and left side seat cushion edge protectors with the screws. Passenger Seat 14

15 4. REENGAGE SEAT CUSHION LOWER SHIELD HOOKS a) Reengage the seat cushion lower shield retaining hooks around the seat frame bar. 5. REINSTALL THE RECLINING ADJUSTER INSIDE COVER 6. REINSTALL THE RECLINING ADJUSTER INSIDE COVER a) Repeat procedure for the other side. 7. REINSTALL THE SEAT CUSHION COVER a) Reinstall the cushion cover to the foam using 12 new hog rings. b) Ensure that the cushion covers fit and finish is correct with no wrinkles or stretch marks. 15

16 8. REINSTALL SEAT CUSHION TO THE SEAT FRAME a) Engage the 7 hooks of the seat cover onto the seat frame as shown to secure the seat cushion and cover. b) Engage the two rear seat cushion hooks to the back of the seat frame as shown. 9. CONFIRM SEAT COVER FIT a) Ensure that the seat cover fit is correct with no unnecessary wrinkles or stretch mark areas. 16

17 10. REINSTALL THE NO. 1 SEATBACK HOOK a) Install the No. 1 seat back hook with the screw. b) Reinstall the hook cover by pressing the cover and engaging the 4 claws. 11. REINSTALL THE ARM REST ASSEMBLY a) Reinstall the arm rest assembly with the bolt. Torque: 19 Nm (194 kgf cm, 14 ft lbf) b) Reinstall the bolt cover. Drivers Seat 12. REROUTE WIRE HARNESS a) Reroute wire harness and connect the connectors and clamps as shown. Driver Side: Connect the 4 connectors and 8 wire clamps. Passenger Side: Connect the 8 connectors and 8 wire clamps. Passenger Seat 17

18 13. REINSTALL SEAT BAND 14. INSTALL LUMBAR SWITCH a) Engage the 4 claws into the inner cushion shield. b) Connect the lumbar switch connector. 15. INSTALL POWER SEAT SWITCH a) Install the power seat switch with the three screws and connect the connector(s). 16. INSTALL FRONT SEAT CUSHION INNER SHIELD a) Engage the three wire harness clamps and connect the seat wire connector. b) Close the wire harness cover and engage the three claws. c) Align the cushion shield with the guide at the front of the shield and install the clip and three claws. 18

19 17. REINSTALL THE SEAT SWITCH KNOBS 18. REINSTALL FRONT SEAT CUSHION INNER SHIELD a) Engage the clip, 5 claws, and reinstall the front cushion inner shield. 19. REINSTALL THE NO. 1 SEAT CUSHION SHIELD a) Reinstall the cushion inner shield by engaging 4 claws and 2 clips. 20. INSTALL THE SEAT LEG COVERS WITH SCREWS 19

20 IX. SEAT INSTALLATION 1. PLACE SEAT IN THE VEHICLE a) Tip the seat back and connect the connectors on the bottom of the seat. b) Carefully align the seats alignment pins. 2. REINSTALL THE SEAT ASSEMBLY BOLTS a) Open the seat track covers. b) Reinstall the 4 bolts and torque. Torque: 37 Nm (377 kgf cm, 27ft lbf) 3. REINSTALL THE HEADREST ASSEMBLY 4. CONNECT BATTERY 5. CONFIRM THE SEAT COVER FITMENT a) Confirm the seat covers are installed correctly and not bunched-up or crooked. 6. CONFIRM THE OPERATION OF THE SEAT FUNCTIONS a) Always confirm the operation of all of the seat functions after reassembly. 7. PERFORM PASSENGER SEAT ZERO POINT CALIBRATION / SENSITIVITY CHECK VERIFY REPAIR QUALITY Use caution to prevent damage to the interior panels Confirm the seat covers are aligned correctly to avoid poor appearance and wrinkles Confirm seat cleanliness Confirm the operation of all seat functions If you have any questions regarding this campaign, please contact your regional representative. X. APPENDIX A. CAMPAIGN DESIGNATION DECODER D 0 R Year Campaign is Launched Repair Phase Current Campaign Letter for this year 8 = = 2009 A = 2010 B = 2011 C = 2012 D = 2013 E = 2014 F = 2015 Etc... 0 = Remedy 1 = Prelim/Interim 2 = Prelim/Interim for Phase 2 Vehicles (Remedy not yet available) 1 or 2 will change to 0 when the Remedy is available 1 st Campaign = A 2 nd Campaign = B Etc... B. CAMPAIGN PARTS DISPOSAL Make sure all campaign 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. 20