1998-2003 Toyota Sienna Service & Repair Manual

IN0I0-01 BO4111 Negative Cable IN-10 - INTRODUCTION FOR ALL OF VEHICLES 10 Author: Date: 2001 SIENNA (RM787U) FOR ALL OF VEHICLES PRECAUTION 1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) The SIENNA is equipped with an SRS (Supplemental Re- straint System), such as the driver airbag, front passenger airbag assembly, side airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct se- quence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. (b) GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI-358 ). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is fin- ished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-up power supply from another battery.

R11910 Red Mark - INTRODUCTION FOR ALL OF VEHICLES IN-1 1 11 Author: Date: 2001 SIENNA (RM787U) (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly and seat belt pretensioner should be inspected (See page RS-14 , RS-28 , and BO-155 ). (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical cir- cuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI-358 ). (c) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR-20 of this manual concerning correct steering wheel installation.

B09710 Example: Correct Wrong Z13950 Example: IN-12 - INTRODUCTION FOR ALL OF VEHICLES 12 Author: Date: 2001 SIENNA (RM787U) (d) STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, care should be taken to place it so the connector will not be damaged. In addition do not store a steering wheel pad on top of another one. Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be attached to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS-16 ). Carry out the operation in a safe place away from electrical noise.

B02919 Example: Correct Wrong Z13951 Example: - INTRODUCTION FOR ALL OF VEHICLES IN-13 13 Author: Date: 2001 SIENNA (RM787U) (e) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS-30 ). Perform the operation in a safe place away from electrical noise.

B02922 Example: Correct Wrong N21642 Example: IN-14 - INTRODUCTION FOR ALL OF VEHICLES 14 Author: Date: 2001 SIENNA (RM787U) (f) SIDE AIRBAG ASSEMBLY (1) Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the side airbag assembly and the surface should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the seat before starting work. (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS-42 ). Perform the operation in a safe place away from electrical noise.

B02121 Example: - INTRODUCTION FOR ALL OF VEHICLES IN-15 15 Author: Date: 2001 SIENNA (RM787U) (g) SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner activation which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See page BO-156 ). Per- form the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner.

IN-16 - INTRODUCTION FOR ALL OF VEHICLES 16 Author: Date: 2001 SIENNA (RM787U) (h) AIRBAG SENSOR ASSEMBLY (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. (3) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag sensor assembly. (i) WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS-66 .

- INTRODUCTION FOR ALL OF VEHICLES IN-17 17 Author: Date: 2001 SIENNA (RM787U) 2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Do not wind the antenna feeder together with the other wiring as much as possible, also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system.

IN-18 - INTRODUCTION FOR ALL OF VEHICLES 18 Author: Date: 2001 SIENNA (RM787U) 4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: S Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool’s instruction book or TOYOTA hand-held tester’s operator manual should be read thoroughly. S Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand- held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.) S Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand-held tester. 5. FOR VEHICLES EQUIPPED WITH POWER SLIDE DOOR CONTROL SYSTEM When the battery is disconnected or the power to the power slide door motor is cut, the power slide door control system does not operate. It is necessary to initialize the system in the following procedures. Other- wise slide door cannot be operated normally. (1) Disconnect the battery negative (-) terminal for more than 1 min., and install it. (2) Close the RH slide door manually. (3) Push the power slide door MAIN switch ON and wait for 5 secs. (4) Fully open the slide door by the power slide door control switch and wait for 3 secs. (5) Fully close the slide door by the power slide door control switch and wait for 3 secs. (6) Repeat the step (4) and (5).

B12976 w/o Tachometer: w/ Tachometer: B12977 - INTRODUCTION FOR ALL OF VEHICLES IN-19 19 Author: Date: 2001 SIENNA (RM787U) 6. FOR VEHICLES EQUIPPED WITH TRACTION CON- TROL (TRAC) & VEHICLE SKID CONTROL (VSC) SYS- TEM NOTICE: S When replacing the steering angle sensor or ECU, or when adjusting the front wheel alignment or steering wheel center point in accordance with the removing and installing or replacing the suspension, axle, or steering parts, make sure to perform the steering angle sensor zero point calibration (See page DI-259 ). S Do not remove or install the VSC related parts unless necessary. Otherwise, there is a possibility that the setting of the VSC to be affected. S When working on the VSC related operation, make sure to check that the preparations before and after work are completed according to the following instruction. S When using a 2- wheel drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the front wheels and driving the wheels, always push in the TRAC & VSC cut (”TRAC OFF”) switch and turn the TRAC & VSC system OFF. (a) Press the TRAC OFF switch. (b) Check that the TRAC OFF indicator light comes ON. HINT: The TRAC OFF indicator light should be always OFF when the engine is restarted. (c) Begin measurements. (d) Press the TRAC OFF switch again to change the TRAC & VSC system to operational condition and check that the TRAC OFF indicator light goes off. HINT: S The SLIP indicator light blinks when the TRAC system is operational. S The SLIP indicator light blinks and the VSC buzzer sounds when the VSC system is operational.

1998-2003 Toyota Sienna Service & Repair Manual

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