TECHNICAL INSTRUCTIONS PRADO SPIRAL CABLE SUB-ASSEMBLY REPLACEMENT 1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 7 1
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. 2
1. OPERATION FLOW CHART Check whether or not the vehicle has the affected VIN. No Yes Replace the spiral cable sub-assembly Finish Return the vehicle to original state and finish the work. 3
2. IDENTIFICATION OF AFFECTED VEHICLES 2.1. COVERED VIN RANGE Model Name Prado VIN Range WMI VDS VIS Production Period JTE BH3FJ* *5000227~*5009064 20090831~20100630 JTE BH9FJ* *5000128~*5009060 20090831~20100630 JTE BU3FJ* *5000119~*5009540 20090831~20100630 JTE BU9FJ* *5000103~*5009544 20090511~20100630 JTE BX3FJ* *5003537~*5005882 20091208~20100527 JTE BX9FJ* *5000110~*5007797 20090831~20100630 JTE CH3FJ* *5000537~*5002768 20091002~20100629 JTE CX9FJ* *5000105~*5000784 20090902~20100628 JTE JU9FJ* *5000186~*5009571 20090901~20100630 JTE BD3FJ* *K000105~*K003211 20090901~20100630 JTE BD9FJ* *K000109~*K003203 20090901~20100630 JTE BH3FJ* *K000126~*K028499 20090901~20100630 JTE BH9FJ* *K000145~*K028477 20090831~20100630 JTE BU3FJ* *K000620~*K020464 20090910~20100630 JTE BU9FJ* *K000101~*K020460 20090518~20100630 JTE BX3FJ* *K005870~*K025298 20091222~20100629 JTE BX9FJ* *K000106~*K025421 20090901~20100630 JTE JU9FJ* *K000225~*K020413 20090902~20100630 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. 4
2.2. VEHICLE IDENTIFICATION NUMBER LOCATION VIN is stamped on the cowl panel. It is also stamped on the certification label as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label C:Name Plate Label D:Frame Number A A B C B D 5
3. PREPARATION 3.1. Replacement components Parts: Part Name Part No. Qty Remarks Spiral Cable FLD Kit 04004-07122 1 CABLE SUB-ASSY, SPIRAL 84306-22010 1 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 Hanger 150 (09951-05010) 1 Slide Arm (09952-05010) 1 For removal and installation of the steering wheel Center Bolt 150 (09953-05020) 1 Claw No.2 (09954-05021) 1 Recommended Tools: Part Name Part No. Qty Remarks GTS (Global Techstream) - 1 "TORX" Socket T30-1 For DTC checks (Intelligent Tester can also be used instead.) For removal and installation of the horn button 6
Equipment: Part Name Part No. Qty Remarks Torque Wrench - 1 Grease - Protective Tape - Marker Pen - Appropriate quantity Appropriate quantity Appropriate quantity For checking tightening torque For lubrication For component protection For marking (any color other than green, blue and yellow) 7
4. WORK PROCEDURE <TABLE OF CONTENTS> A. WORK OUTLINE...9 B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE...9 C. PRECAUTIONS FOR AIRBAG REMOVAL AND REINSTALLATION... 10 D. PRECAUTIONS FOR ALL OPERATIONS... 12 E. COMPONENTS... 14 F. REMOVE SPIRAL CABLE... 15 G. INSTALL SPIRAL CABLE... 19 8
A. WORK OUTLINE Replacing the spiral cable. 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. 9
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. 10
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. 11
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. 12
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. 13
E. COMPONENTS 14
F. REMOVE SPIRAL CABLE 1. CHECK FOR DTC (a) If DTCs are output, check and record the DTCs and freeze frame data and repair as necessary. 2. RECORD AUDIO AND AIR CONDITIONING SETTINGS (a) When the battery cable is disconnected, audio, air conditioning etc. settings may be reset. Therefore, before disconnecting the cable from the negative (-) battery terminal, make a note of the settings. 3. RECORD STEERING COLUMN TILT AND TELESCOPING POSITIONS 4. MOVE STEERING COLUMN (a) In order to obtain an enough space for removal of the steering column cover, lift up the steering wheel to the most upward position, and pull the steering wheel toward you as far as it can go. 5. CHECK STRAIGHT AHEAD POSITION FOR STEERING WHEEL 15
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Turn the ignition switch off. (b) Disconnect the cable from the negative (-) battery terminal. Work must be started at least 90 seconds after the cable is disconnected from the negative (-) battery terminal. CAUTION: 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. 7. REMOVE LOWER No.3 AND No.2 STEERING WHEEL COVER (a) Using a thin flat tip screwdriver with its tip wrapped in protective tape, disengage the claws to detach the No.3 steering wheel cover. (b) Do the same for the No.2 steering wheel cover. 8. REMOVE HORN BUTTON ASSEMBLY CAUTION: The airbag system has the backup power supply. For that reason, wait at least 90 seconds after disconnecting the negative terminal cable before removing the horn button. (a) Using a "TORX" socket (T30), loosen the 2 "TORX" screws until they rotate freely. NOTE: The screws cannot be removed because they are in the screw case. 16
(b) Pull out the horn button toward you. CAUTION: DO NOT pull on the wire harness when the horn button is extracted. (c) Using a flat-tip screwdriver, unlock the airbag connectors, and then disconnect them. (d) Disconnect the horn connector, and then remove the horn button. (e) Place and store the horn button so that the portion where the airbag is deployed faces upward. 9. REMOVE STEERING WHEEL ASSEMBLY (a) Disconnect the horn wire connector. (b) Turn the nut 2 to 3 times to loosen it. (c) Put matchmarks onto the steering wheel and main shaft. (d) Using an SST, disengage the steering wheel. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) CAUTION: Apply a small amount of grease to the thread portion and end portion of the center bolt of the SST. (e) Remove the SST and nut, and then detach the steering wheel. 17
10. REMOVE STEERING COLUMN COVER (a) Remove the 2 screws. (b) Disengage the 2 claws and remove the lower column cover. (c) Disengage the claw and remove the upper cover. 11. REMOVE SPIRAL CABLE SUB-ASSEMBLY (a) Disconnect the connectors. (b) Disengage the claw at the 3 locations, and then remove the spiral cable. (c) Mark and store the removed spiral cable in a separate container so as not to be reinstalled in error. 18
G. INSTALL 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. 1. INSTALL NEW SPIRAL CABLE (a) Move the turn signal switch to the OFF position. CAUTION: If the turn signal switch is NOT in the OFF position, the protruding pin of the switch interferes with the spiral cable, which may result in damage to the pin. (b) Engage the 3 claws to fasten the new spiral cable. (c) Reconnect the connectors. 19
2. INSTALL STEERING COLUMN COVER (a) Engage the claw to fasten the upper column cover. (b) Engage the 2 screws to fasten the lower column cover. (c) Attach and tighten the 2 screws. (d) Check that neither any gap nor looseness is present in the column covers. 20
3. 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 it in. 21
NOTE: If the spiral cable was rotated and the center position has been misaligned, perform the following procedure. (1) Using a finger, gently turn the spiral cable counterclockwise until it stops. CAUTION: DO NOT rotate the spiral cable holding the wire harness or connector. (2) Return the spiral cable 2.5 turns clockwise to align the matchmarks. 4. 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. 22
5. REINSTALL STEERING WHEEL ASSEMBLY (a) While aligning the matchmarks, reinstall the steering wheel. (b) Attach and tighten the nut. Specified torque: T = 50 N*m (510 kgf*cm, 37 ft.*lbf) (c) Reconnect the horn wire connector. 6. REINSTALL HORN BUTTON ASSEMBLY (a) Reconnect the horn connector to the horn button. (b) Reconnect the 2 airbag connectors and securely lock them. CAUTION: Be careful of the connector colors when reconnecting. 23
(c) Reinstall the horn button to the steering wheel. (d) While holding the horn button by hand, tighten the 2 bolts with a "TORX" socket (T30). Specified torque: T = 8.8 N*m (90 kgf*cm, 78 in.*lbf) 7. REINSTALL LOWER No.3 AND No.2 STEERING WHEEL COVER (a) Engage the claw and reinstall the cover. (b) Do the same for the other cover. 8. RECONNECT CABLE TO NEGATIVE BATTERY TERMINAL 24
9. INSPECT SRS WARNING LIGHT (a) Check that the SRS warning light comes on when the ignition switch is turned on. (b) Check that the warning light will go off when about 6 seconds have elapsed after the ignition switch is turned on. (c) If the warning light does not come on or remains on, check if DTCs have occurred. 10. CHECK THAT HORN, WIPERS AND LIGHTS OPERATE PROPERLY 11. INITIALIZE STEERING ANGLE SENSOR NEUTRAL (ZERO) POINT (a) On a level ground, start the engine, and turn the steering wheel left and right as far as it can go. 12. CHECK STRAIGHT AHEAD POSITION FOR STEERING WHEEL (a) Check that the front wheels are in the straight ahead position when the steeling wheel is in the center position. 13. CHECK FOR DTCS 14. RESTORE SYSTEM SETTINGS AFTER BATTERY RECONNECTION 15. RETURN STEERING COLUMN TILT AND TELESCOPING POSITIONS 25