Water Leak in 3rd Row Seat Stow Area

T-SB-0214-12 November 1, 2012 Service Category Vehicle Exterior Section Exterior Panels/Trim Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2011 2012 Sienna Introduction Some 2011 2012 model year Sienna vehicles may exhibit a water leak condition in the 3rd row seat stow area. Water can be found in the rear stow well with no indication of water present in other areas of the cabin. Typically, this condition can be found while the vehicle is parked on an incline during a rain storm. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 BD1250 Seal Front Bulkhead & Rear Crossmember 4.1 55701-08021 66 38 APPLICABLE WARRANTY This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 90333-30008 Same Body Sticker 5 08231-00810 Same Exterior Wind Noise Kit 1 90189-06145 Same Body Clips 8 90080-46362 Same Brake Line Clamp 1 53867-08020 Same Cowl Fender Seal LH 1 53866-08020 Same Cowl Fender Seal RH 1 71324-08010 Same Seat Leg Cushion 2 Page 1 of 22

T-SB-0214-12 November 1, 2012 Page 2 of 22 Required Tools & Equipment REQUIRED MATERIAL QUANTITY 3M Flexiclear Body Seam Sealer (or equivalent) 1 Dow FROTH PAK Polyurethane Spray Foam* 1 A/C Refresher Kit (part number #00289-ACRKT) 1 * Special Ordering Instructions for Dow FROTH PAK : Contact the following distributor to purchase Dow FROTH PAK kit for Toyota repair: Rudolf Bros. Customer Service Dept. Phone: (614) 833-0707 Ext. 4 Email: rbsupport@rudbro.com Procedure Overview This bulletin outlines water leak inspection procedures and 2 separate repair processes that must be applied to all vehicles exhibiting the condition. Water Leak Inspection Procedure 1. Visually confirm water is present in the 3rd row seat stow area. 2. Water test vehicle while parked on an incline. A. Raise the front of the vehicle to 17 degrees (front wheels approximately 24 inches off the ground). For example, this can be done by placing the front of the vehicle on an alignment rack. NOTE Make sure this process is done in an area that has adequate water drainage.

T-SB-0214-12 November 1, 2012 Page 3 of 22 Water Leak Inspection Procedure (Continued) Figure 1. CAUTION Do NOT engage parking brake. NOTICE Watch rocker panels, rear bumper, and exhaust while raising vehicle to prevent damage. B. Place a water hose on the windshield to simulate a rain storm. See attached video for water leak example. C. While water is running, inspect the rear of the vehicle in the 3rd row seat stow area for evidence of water entering through the sheet metal panels. NOTE Water leak inspection may take up to 5 minutes before leak condition can occur. Example of Water Leak Inspection Procedure D. If water leak is identified in the 3rd row seat stow area, proceed to the following repair procedures. If water leak condition has not been identified, STOP. This bulletin does not apply. Continue diagnosis using typical water leak procedures.

T-SB-0214-12 November 1, 2012 Page 4 of 22 Repair Procedure 1: Reduce Water Flow into Side Member Area 1. Remove cowl assembly. 2. Disconnect cable from negative (-) battery terminal. NOTICE When disconnecting the cable, some systems need to be initialized after the cable is reconnected. 3. Remove front wiper arm head cap. Figure 2.. Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the 2 front wiper arm head caps. 1 Protective Tape 4. Remove the nut and the front wiper arm and blade assembly LH. Figure 3.. HINT Use the same procedure for the RH side.

T-SB-0214-12 November 1, 2012 Page 5 of 22 5. Remove front fender to cowl side seal RH. Figure 4.. Disengage the claw and 2 guides, peel off the double-sided tape, and remove the front fender to cowl side seal LH. HINT Use the same procedure as for the LH side. 1 Double-sided Tape 6. Remove cowl top ventilator louver sub-assembly. Figure 5.. Disengage the 6 claws and 10 guides, and pull out the cowl top ventilator louver sub-assembly.

T-SB-0214-12 November 1, 2012 Page 6 of 22 7. Remove windshield wiper motor and link assembly. A. Disconnect the windshield wiper motor connector. Figure 6. B. Remove the 3 bolts and the windshield wiper motor and link assembly. Figure 7.

T-SB-0214-12 November 1, 2012 Page 7 of 22 8. Remove windshield wiper motor assembly. A. Using a screwdriver with its tip wrapped in protective tape, disengage the windshield wiper link rod from the crank arm pivot of the front wiper motor assembly. Figure 8. 1 Protective Tape B. Using a T30 "TORX" socket wrench, remove the 2 bolts and the windshield wiper motor assembly from the windshield wiper link assembly. Figure 9.

T-SB-0214-12 November 1, 2012 Page 8 of 22 9. Remove cowl panel sub-assembly. A. for 2GR-FE: Figure 10. Disconnect the fuel pump resistor connector. B. Disengage the 5 clamps and separate the engine room main wire from the cowl panel sub-assembly. Figure 11.

T-SB-0214-12 November 1, 2012 Page 9 of 22 C. Windshield Deicer System: Figure 12. Disengage the clamp and disconnect the connector. D. Remove the 5 bolts, 4 nuts and cowl panel sub-assembly. Figure 13.

T-SB-0214-12 November 1, 2012 Page 10 of 22 10. Remove No. 1 engine cover sub-assembly (4 cyl). A. Lift the rear of the No. 1 engine cover to detach the cover from the 2 pins, and then lift the front of the No. 1 engine cover to detach the cover from the pin and remove the No. 1 engine cover. Figure 14. NOTICE Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break. 11. Remove V-bank cover sub-assembly (6 cyl). Figure 15.. A. Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly. NOTICE Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

T-SB-0214-12 November 1, 2012 Page 11 of 22 12. Remove air cleaner inlet assembly (4 cyl). A. Remove the 2 bolts and air cleaner inlet. Figure 16. 13. Remove battery. A. Disconnect the positive (+) cable from the positive (+) battery terminal. B. Loosen the nut and remove the bolt from the battery clamp. Figure 17. C. Remove the battery clamp. D. Remove the battery and battery tray.

T-SB-0214-12 November 1, 2012 Page 12 of 22 14. Remove air cleaner assembly (6 cyl). Figure 18.. A. Disconnect the mass air flow meter connector. B. Disconnect the vacuum switching valve connector and disengage the wire harness clamp. C. Disconnect the vacuum hose and disengage the hose clamp. Figure 20.. D. Loosen the hose clamp. E. Remove the 2 bolts and air cleaner.

T-SB-0214-12 November 1, 2012 Page 13 of 22 15. Remove air cleaner hose. A. Loosen the hose clip and disconnect the No. 1 fuel vapor feed hose. Figure 21. 3 4 2 1 5 6 1 No. 1 fuel vapor feed hose 2 No. 2 fuel vapor feed hose 3 No. 1 air hose 4 Ventilation hose 5 Vacuum hose 6 Air cleaner hose B. Loosen the hose clip and disconnect the No. 2 fuel vapor feed hose. C. Disengage the hose clamp and separate the No. 2 fuel vapor feed hose. D. Loosen the hose clip and disconnect the No. 1 air hose. E. Loosen the hose clip and disconnect the ventilation hose. F. Disengage the 2 hose clamps and separate the vacuum hose. G. Loosen the hose clip and remove the air cleaner hose. 16. Remove Air Cleaner Assembly (6CYL) Remove air cleaner inlet cover assembly seal. A. Disengage the 3 vacuum hose clamps. B. Remove the 2 bolts and the air cleaner inlet cover assembly seal.

T-SB-0214-12 November 1, 2012 Page 14 of 22 17. Remove air cleaner and hose. A. Disconnect the mass air flow meter connector. B. Disengage the wire harness clamp. C. Disconnect the vacuum hose. D. Separate the vacuum hose from the hose clamp. E. Disconnect the vacuum switching valve connector. F. Disengage the 2 wire harness clamps. G. Disconnect the 2 vacuum hoses. H. Loosen the clip and disconnect the No. 2 ventilation hose. I. Separate the fuel vapor feed hose from the hose clamp. J. Loosen the hose clamp and disconnect the air cleaner hose. K. Remove the 2 bolts and the air cleaner.

T-SB-0214-12 November 1, 2012 Page 15 of 22 18. Apply seam sealer to front bulkhead locations. A. Identify locations on RH and LH side of the bulkhead where voids in the seam sealer are present. Only LH side shown. Use same procedure for RH side. B. Apply seam sealer to make sure there are no voids in the areas shown. Figure 22. Figure 23. 1 Drain Hole 1 Drain Hole NOTE Make sure drain holes are not blocked by seam sealer. 19. Remove & Replace Brake Line Clamp. A. Remove air cleaner bracket and remove brake line clamp on LH side member. Figure 24. Add 3mm thick EPT foam from exterior wind noise kit to the NEW brake line clamp and install. Confirm clamp is completely seated.

T-SB-0214-12 November 1, 2012 Page 16 of 22 B. EPT foam dimensions: Thickness: 3 mm Length: 25 mm Width: 35 mm Figure 25. Figure 26. Figure 27. 1 Good: Both Tabs Fully Engaged 2 No Good: Only One Tab Engaged

T-SB-0214-12 November 1, 2012 Page 17 of 22 C. Install the brake tube into the NEW clamp. NOTE Confirm no damage exists on the brake line tube. If damage exists, replace the brake line. 20. Apply Body Stickers. A. Cover Side Member Square Hole (via engine compartment - driver side only). Figure 28. 1 Square Hole 2 Front

T-SB-0214-12 November 1, 2012 Page 18 of 22 B. Remove Front Fender Liner LH & RH side. Figure 29. C. Remove 4 body clips, 4 screws & 3 10mm bolts to remove fender liner assembly on each side. Figure 30. NOTE Old body clips will be discarded. New body clips will be used for reassembly.

T-SB-0214-12 November 1, 2012 Page 19 of 22 D. Cover the hole inside LH & RH fender structure using body stickers. LH side shown. Figure 31. NOTE Paint sealer may interfere with body sticker installation. If necessary, scrape off paint sealer in order to ensure tight body sticker seal.

T-SB-0214-12 November 1, 2012 Page 20 of 22 21. Remove Body Stickers. Figure 32.. At the rear of the vehicle directly above the rear suspension member, remove body stickers located on the LH & RH frame rail. LH side shown. Repair Procedure 2: Seal Rear Crossmember 1. Remove 3rd row seat assembly RH & LH side. Refer to the Technical Information System (TIS), applicable model year Sienna Repair Manual: Manual seat LH side 2011 Sienna: Vehicle Interior Seat Seat: Rear No. 2 Seat Assembly (for Manual Seat Type LH Side): Removal Manual seat RH side Refer to the TIS, applicable model year Sienna Repair Manual: 2011 Sienna: Vehicle Interior Seat Seat: Rear No. 2 Seat Assembly (for Manual Seat Type RH Side): Removal Power Seat LH side Refer to the TIS, applicable model year Sienna Repair Manual: 2011 Sienna: Vehicle Interior Seat Seat: Rear No. 2 Seat Assembly (for Power Seat Type LH Side): Removal

T-SB-0214-12 November 1, 2012 Page 21 of 22 Repair Procedure 2: Seal Rear Crossmember (Continued) Power seat RH side Refer to the TIS, applicable model year Sienna Repair Manual: 2011 Sienna: Vehicle Interior Seat Seat: Rear No. 2 Seat Assembly (for Power Seat Type RH Side): Removal 2. Remove carpet assembly for rear stow area (if not already done). 3. Remove rear seat leg cushions and body stickers from the body. Figure 33. Figure 34. 1 Seat Leg Cushion 2 Sticker 1 Seat Leg Cushion 2 Sticker 4. Dow FROTH PAK kit application. A. Utilize the seat leg cushion holes to spray foam into the cross member. Remove body stickers for visual view of foam application. NOTE Follow instructions supplied with Dow FROTH PAK kit to ensure you have the proper PPE (personal protective equipment) and all safety precautions have been taken. B. Be sure to install applicator tip until it s fully seated (you will hear a click ). Yellow hook must go over the tab on the tip.

T-SB-0214-12 November 1, 2012 Page 22 of 22 Repair Procedure 2: Seal Rear Crossmember (Continued) C. You will need to add approx. 8-10 in of tubing to the nozzle (Use tubing from Air refresher kit max OD 7.5mm. Any thicker, and you will not be able to angle the tubing towards the desired points within the cross member. Figure 35. D. Enter cross member with the hose angled about 2.5 inches towards the corner near the tube, and 3.5 inches for corner furthest from the tube. E. Spray a total of 4 corners for a minimum of 5 seconds per corner. Ensure can is facing downward per instructions. Figure 36. NOTE Foam application can be visually seen from body sticker hole location 5. Wipe away any excess foam material as needed to replace seat leg cushions and body stickers removed during foam application. 6. Reassemble vehicle in reverse order. 7. Confirm condition has been eliminated by using the same water leak inspection procedure listed in this bulletin.