TECHNICAL INSTRUCTIONS RAV4 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 RAV4 VIN Range WMI VDS VIS Production Period JTM BA31V* *6001949 ~ *6056283 20051122~20070111 JTM BA33V* *6000011 ~ *D005221 20051031~20081128 JTM BC33V* *6055653 ~ *D005220 20070115~20081128 JTM BD32V* *6000002 ~ *6089718 20050901~20080804 JTM BD33V* *6000000 ~ *6089729 20050824~20080805 JTM BH31V* *6000262 ~ *D009483 20051111~20081128 JTM BH33V* *6000035 ~ *D009506 20051104~20081128 JTM BK32V* *6000011 ~ *6050082 20051219~20080805 JTM BK33V* *6000008 ~ *6050066 20050912~20080731 JTM ZD32V* *6000002 ~ *6081040 20051102~20080731 JTM ZD33V* *6000005 ~ *6081084 20051102~20080801 JTM ZK32V* *6000002 ~ *6016017 20050831~20080729 JTM ZK33V* *6000008 ~ *6016053 20060111~20080731 JTM BA31V* *5001075 ~ *5041330 20051122~20061219 JTM BA33V* *5000007 ~ *5090912 20051004~20080731 JTM BC33V* *5042442 ~ *5090919 20070109~20080731 JTM BD31V* *5000010 ~ *5215933 20050802~20080801 JTM BD32V* *5000029 ~ *5215895 20051031~20080801 JTM BD33V* *5000007 ~ *5215931 20050728~20080801 JTM BD35V* *5000031 ~ *5215906 20051031~20080731 JTM BH31V* *5000414 ~ *5058068 20051118~20080730 JTM BH33V* *5000028 ~ *5057837 20051103~20080724 JTM BK32V* *5000009 ~ *5071477 20051216~20080801 JTM BK33V* *5000012 ~ *5071478 20060107~20080801 JTM BK35V* *5000010 ~ *5071479 20060107~20080801 JTM ZD31V* *5000001 ~ *5116854 20050725~20080730 JTM ZD32V* *5000006 ~ *5117038 20051031~20080731 JTM ZD33V* *5000000 ~ *5117146 20050725~20080805 JTM ZD35V* *5000005 ~ *5117144 20051031~20080801 JTM ZK32V* *5000001 ~ *5024042 20050824~20080801 JTM ZK33V* *5000011 ~ *5024037 20060107~20080731 Continue to next page 4
Model Name RAV4 VIN Range WMI VDS VIS Production Period JTM ZK35V* *5000060 ~ *5024022 20060111~20080731 JTM BD31V* *D001449 ~ *D015025 20090401~20100329 JTM BD33V* *D001410 ~ *D014997 20090227~20100326 JTM ZD31V* *D000109 ~ *D011153 20090401~20100331 JTM ZD33V* *D000102 ~ *D011125 20090227~20100326 JTM BD31V* *5213025 ~ *5253369 20080731~20100331 JTM BD33V* *5215946 ~ *5253400 20080801~20100331 JTM ZD31V* *5117182 ~ *5152923 20080801~20100330 JTM ZD33V* *5117147 ~ *5153050 20080801~20100331 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. 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 A: Vehicle Identification Number Plate B: Manufacturer s Plate C:Frame Number B C 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 84306-04080 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. CAUTIONS FOR LOCK PIN OF NEW SPIRAL CABLE AND REMOVAL OF STEERING COLUMN COVERS...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... 22 8
A. WORK OUTLINE Replacing the spiral cable. B. CAUTIONS FOR LOCK PIN OF NEW SPIRAL CABLE AND REMOVAL OF STEERING COLUMN COVERS 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. 2. PREVENT CLAWS FROM BEING BROKEN (a) Observe the instructions in this document as there is the possibility of damaging the claws that fasten the steering column covers. 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. 16
7. 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. (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. 17
8. 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. 18
9. REMOVE STEERING COLUMN COVER CAUTION: Failure to observe the procedure instructed below could cause the claws of the steering column covers to be broken. (a) Disengage the claws of the upper column cover by pushing the portion at the left and right highlighted in the illustration below. (b) While holding the upper column cover as well as pushing the portion highlighted in the illustration below, move the lower column cover downward. CAUTION: Even if a service hole is provided, DO NOT push the cover with a screwdriver through that hole. Doing so could cause the claw to be broken. (c) Pull the lower column cover toward you to detach it from the steering column. 19
(d) Raise the upper column cover as shown in the illustration to disengage the claw. CUTION: The rear end of the upper column cover is integrated with the nonwoven fabric sheet, so DO NOT forcibly raise the cover. (e) Put cloths over the meter hood, and then set the upper column cover against the hood. 10. REMOVE SPIRAL CABLE SUB-ASSEMBLY (a) Disconnect the connectors (b) Disengage the claw at the 3 locations, and then remove the spiral cable. 20
(c) Disengage the 6 claws, and detach the steering angle sensor (where equipped). CAUTION: DO NOT damage the steering angle sensor as it will be reused. (d) Mark and store the removed spiral cable in a separate container so as not to be reinstalled in error. 21
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. REINSTALL STEERING ANGLE SENSOR (WHERE EQUIPPED) (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. NOTE: Apply approximately 2 mm thick, covering the surface shown in the illustration. (b) Confirm the orientation of the steering angle sensor before installing it to the spiral cable. Be careful of the positions of the 2 protrusions. (c) Engage and attach the steering angle sensor to the new spiral cable reliably. 22
2. 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. 23
3. REINSTALL STEERING COLUMN COVER (a) Engage the center claw of the upper column cover. (b) Engage the 4 claws to fasten the upper and lower column cover. 24
(c) Push the lower column cover from the bottom so as to allow the claw to be engaged with the steering column. CAUTION: Push the bottom surface of the lower column cover so that the claw can be engaged securely. (d) Check that neither any gap nor looseness is present in the column covers. 25
4. 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. 26
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. 5. 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. 27
6. 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. 7. 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. (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) 28
8. RECONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK 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 29