1

IMV INNOVA, FORTUNER, HILUX

SPIRAL CABLE SUB-ASSEMBLY REPLACEMENT

1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 7

TECHNICAL INSTRUCTIONS

2

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.

3

1. OPERATION FLOW CHART

Check Lot Number of Spiral Cable

Check spiral cable connector

Check if vehicle has equipped with SRS AIRBAG.

Check if vehicle has affected VIN and Frame Number

Work is completed

Receiving Vehicle

Replace Spiral Cable

Final Inspection

NOT ZERO

NO

YES

YES

NO

ONE CONNECTOR

TWO CONNECTORS

“0”(ZERO)

Reinstall everything

4

2. IDENTIFICATION OF AFFECTED VEHICLES

2.1. COVERED VIN RANGE

Model

Name

VIN Range

Production Period WMI VDS VIS

Fortuner

PN1

11JV5* *0001001～*2000039 20050307～20100127

Innova 11NV4* *0000001～*8999993 20050307～20100127

Fortuner 11NV5* *7999991～*7999993 20050307～20100127

Hilux 33JV2* *8000000～*9006229 20050307～20100127

Hilux

8AJ

ER32G* *4008359～*4036036 20050601～20101231

EX32G* *4016172～*4031532 20050601～20101231

EZ32G* *1001465～*1008471 20050601～20101231

EZ39G* *2501547～*2517793 20050601～20101231

FR22G* *4509765～*4548384 20050601～20101231

FX22G* *6004283～*6004419 20050601～20101231

FZ22G* *5002716～*5015754 20050601～20101231

FZ29G* *6005097～*6068656 20050601～20101231

Fortuner

YZ59G* *3000007～*3031334 20050601～20101231

ZX62G* *5000003～*5001022 20050601～20101231

ZZ62G* *0001002～*0001583 20050601～20101231

Fortuner

8XA

11ZV5* *6000000～*6005328 20050615～20100630

11ZV6* *3000001～*6000006 20050615～20100630

Hilux

31NV2* *9000000～*9000011 20050615～20100630

31NV3* *9000000～*9005449 20050615～20100630

33JV2* *9000140～*9002329 20050615～20100630

33JV3* *9000080～*9002029 20050615～20100630

33NV2* *9000000～*9008109 20050615～20100630

33NV3* *9000000～*9005469 20050615～20100630

33ZV2* *9000000～*9009417 20050615～20100630

Innova MBJ 11JV4* *7000013～*7160078 20050207～20081229

11NV4* *6000011～*6004804 20050207～20081229

Innova MHF

XS42G* *2500514～*2515753 20041102～20100430

XW42G* *2097659～*2160697 20041102～20100430

XX42G* *5000002～*5008636 20041102～20100430

5

XX43G* *0001376～*0026603 20041102～20100430

Fortuner

YU59G* *7000004～*7010903 20041102～20100430

YX59G* *8000034～*8018192 20041102～20100430

ZX69G* *7001643～*7015437 20041102～20100430

Innova

RL4

XW43G* *9200001～*9399999 20060107～20100119

Fortuner YX59G* *4000067～*4000067 20060107～20100119

ZR69G* *4000003～*4002536 20060107～20100119

Hilux

AHT

CK12G* *0032448～*0032582 20050204～20100412

CK32G* *0001001～*0001666 20050204～20100412

CR12G* *8600000～*8604425 20050204～20100412

CR32G* *8006520～*8009507 20050204～20100412

CS12G* *7500004～*7535558 20050204～20100412

CW12G* *4023553～*4031558 20050204～20100412

CX12G* *9002076～*9002280 20050204～20100412

CX39G* *5000000～*5008298 20050204～20100412

CZ39G* *5000002～*5011459 20050204～20100412

DK22G* *0005546～*0006246 20050204～20100412

DR22G* *5500195～*5514814 20050204～20100412

DZ29G* *9300001～*9302060 20050204～20100412

EK12G* *7000009～*7005604 20050204～20100412

ER12G* *9100003～*9102364 20050204～20100412

ER19G* *8500000～*8500578 20050204～20100412

ER32G* *8500420～*8500630 20050204～20100412

ES12G* *9000001～*9002621 20050204～20100412

EX12G* *9503708～*9504229 20050204～20100412

EX39G* *7000001～*7010740 20050204～20100412

EZ39G* *7000001～*7018253 20050204～20100412

FK22G* *3000007～*3045855 20050204～20100412

FR22G* *6000000～*6029862 20050204～20100412

FR29G* *7000003～*7021728 20050204～20100412

FU29G* *7000005～*7004377 20050204～20100412

FX22G* *8000003～*8009070 20050204～20100412

FZ29G* *9000001～*9045890 20050204～20100412

Fortuner

YK59G* *0001007～*0004639 20050204～20100412

YU59G* *4000000～*4003371 20050204～20100412

YX59G* *6000004～*6000527 20050204～20100412

YZ59G* *8000000～*8007877 20050204～20100412

6

ZU69G* *0001001～*0002423 20050204～20100412

ZZ69G* *5000002～*5008683 20050204～20100412

Hilux MR0

AS12G* *0001008～*0003839 20040426～20091208

AW12G* *0001001～*0003373 20040426～20091208

AX12G* *0001003～*0011096 20040426～20091208

CR12G* *2500000～*2501227 20040426～20091208

CS12G* *0000101～*0081825 20040426～20091208

CU12G* *0001001～*0008755 20040426～20091208

CW12G* *0001001～*0017702 20040426～20091208

CX12G* *0001001～*0052216 20040426～20091208

CX19G* *2600004～*2604341 20040426～20091208

CZ12G* *0000100～*0023440 20040426～20091208

DR22G* *0001001～*0007319 20040426～20091208

DU22G* *0001001～*0002125 20040426～20091208

DX22G* *0001001～*0006140 20040426～20091208

DZ22G* *0001001～*0016082 20040426～20091208

ER12G* *3550000～*5501250 20040426～20091208

ER19G* *0450001～*4861227 20040426～20091208

ER32G* *6003402～*6004548 20040426～20091208

ES12G* *0300000～*3307009 20040426～20091208

ES19G* *4000000～*4350470 20040426～20091208

EU12G* *4000000～*4502007 20040426～20091208

EU19G* *6000000～*6300746 20040426～20091208

EW12G* *2000001～*3013338 20040426～20091208

EX12G* *2000000～*2316709 20040426～20091208

EX19G* *3000001～*3427713 20040426～20091208

EX39G* *0001001～*0250127 20040426～20091208

EZ12G* *4000000～*4154049 20040426～20091208

EZ19G* *0500037～*5303400 20040426～20091208

FR22G* *0500001～*0664475 20040426～20091208

FR29G* *0100002～*1151369 20040426～20091208

FU22G* *2000001～*2301336 20040426～20091208

FU29G* *4000000～*4302451 20040426～20091208

FX22G* *1000000～*1321083 20040426～20091208

FX29G* *2500000～*3101113 20040426～20091208

FZ22G* *1000000～*1172340 20040426～20091208

FZ29G* *0150043～*2513940 20040426～20091208

GR12G* *6500000～*6500801 20040426～20091208

7

GR19G* *7000000～*7110350 20040426～20091208

GS12G* *0500018～*5029225 20040426～20091208

GS19G* *0600073～*6098342 20040426～20091208

GU12G* *8000000～*8003438 20040426～20091208

GU19G* *9000000～*9001245 20040426～20091208

GX12G* *5000001～*5001958 20040426～20091208

GX19G* *8000000～*8003004 20040426～20091208

GZ19G* *0600060～*6035036 20040426～20091208

HR22G* *1500000～*1512511 20040426～20091208

HR29G* *0200006～*2029853 20040426～20091208

HU29G* *6000000～*6001000 20040426～20091208

HX29G* *4000000～*4000506 20040426～20091208

HZ22G* *3500000～*3507481 20040426～20091208

HZ29G* *0400035～*4018632 20040426～20091208

Fortuner

YU59G* *8000000～*8004274 20040426～20091208

YZ59G* *0001002～*0092992 20040426～20091208

ZR69G* *0001002～*0016372 20040426～20091208

ZX69G* *0001001～*0017561 20040426～20091208

Fortuner MR1

YU59G* *0001001～*0008164 20040426～20091208

YX59G* *3000000～*3013628 20040426～20091208

ZX69G* *8000000～*8006067 20040426～20091208

Innova

KUN40 NO VIN DATA 5000000～5034144 20041018～20091222

TGN40 NO VIN DATA 5000000～5019875 20041018～20091222

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.

8

2.2. VEHICLE IDENTIFICATION NUMBER LOCATION

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

Only for Initial Order:

(Except VSC Vehicle)

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

For removal and

installation of the

steering wheel

Hanger 150 (09951-05010) 1

VIN is stamped on the cowl panel. It is also stamped on the certification label as shown in the illustration.

A: Certification Label

A

9

Slide Arm (09952-05010) 1

Center Bolt 150 (09953-05020) 1

Claw No.2 (09954-05021) 1

Recommended Tools: Part Name Part No. Qty Remarks

GTS (Global Techstream) - 1

For DTC checks

(Intelligent Tester can

also be used instead.)

"TORX" Socket T30 - 1

For removal and

installation of the horn

button

Equipment: Part Name Part No. Qty Remarks

Torque Wrench - 1 For checking tightening

torque

Grease - Appropriate

quantity For lubrication

Protective Tape - Appropriate

quantity For component protection

Marker Pen - Appropriate

quantity

For marking (any color

other than green, blue

and yellow)

10

4. WORK PROCEDURE

<TABLE OF CONTENTS>

A. WORK OUTLINE ...................................................................................................... 11

B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE ............................................. 11

C. PRECAUTIONS FOR AIRBAG REMOVAL AND REINSTALLATION ...................... 12

D. PRECAUTIONS FOR ALL OPERATIONS ............................................................... 14

E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG ................................................ 16

F. CHECK SPIRAL CABLE .......................................................................................... 17

G. REPLACE SPIRAL CABLE ...................................................................................... 19

11

A. WORK OUTLINE

Checking if the vehicle is applicable to

this safety recall. If the vehicle is

applicable, replacing the spiral cable

with a new one.

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.

12

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.

13

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.

14

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.

15

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.

16

E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG

1. CHECK IF SRS AIRBAG IS IMPRINTED

(a) Check if SRS AIRBAG is imprinted on the horn

button.

SRS AIRBAG Required procedure

Imprinted

(Equipped with the airbag)

Check the spiral cable

Proceed to “F. CHECK SPIRAL

CABLE” (Page-17)

Not imprinted

(No airbag is provided)

Return the vehicle to the customer.

17

F. CHECK SPIRAL CABLE

CAUTION:

For details about the component removal, refer to the respective repair manual.

1. CHECK NUMBER OF SPIRAL CABLE CONNECTORS

(a) Disconnect the negative battery terminal cable.

(b) Remove the horn button assembly.

(c) Check the number of spiral cable connectors.

Number of connectors

Required procedure

Check the lot number (Page-18)

Reinstall the removed components,

and return the vehicle to the customer.

18

2. CHECK LOT NUMBER OF SPIRAL CABLE

(a) Remove the steering wheel assembly.

(b) Detach the upper steering column cover.

(c) Check the value of the lot number indicated by an arrow in the illustration below.

Value indicated by an arrow

Required procedure

(Zero) Reinstall the removed components,

and return the vehicle to the customer.

Values other than 0 (zero)

Replace the spiral cable with a new

one.

Proceed to “G. REPLACE SPIRAL

CABLE” (Page-19)

19

G. REPLACE SPIRAL CABLE

CAUTION:

For details about component removal, refer to the respective repair manual.

1. REMOVE LOWER STEERING COLUMN COVER

2. REMOVE SPIRAL CABLE

3. REMOVE STEERING ANGLE SENSOR (Vehicles equipped with Steering Angle Sensor)

(a) Detach the steering angle sensor from the spiral cable.

4. REGARDING LOCK PIN OF NEW 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.

5. REINSTALL STEERING ANGLE SENSOR

(Vehicles equipped with Steering Angle

Sensor)

(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.

(b) Attach the steering angle sensor to a new

spiral cable.

6. INSTALL NEW SPIRAL CABLE

(a) Install the new spiral cable to the vehicle.

7. REINSTALL UPPER AND LOWER

STEERING COLUMN COVERS

20

8. 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.

21

9. 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.

10. REINSTALL STEERING WHEEL

ASSEMBLY

11. REINSTALL HORN BUTTON ASSEMBLY

< WHERE NEW SPIRAL CABLE HAS 2

CONNECTORS >

(a) Connect the spiral cable’s wire terminal to the

horn button assembly.

(b) Connect the spiral cable’s orange connector to

the horn button assembly.

22

(c) Cut the black connector’s cable as shown in

the illustration (near the wrapped tape).

CAUTIONS:

DO NOT connect the black connector. No

voltage is applied to the black connector.

In order to prevent abnormal noise from

occurring, remove the black connector by

cutting the cable.

(d) Reinstall the horn button assembly.

12. REINSTALL HORN BUTTON ASSEMBLY

< WHERE NEW SPIRAL CABLE HAS 1

CONNECTOR >

(a) Connect the spiral cable’s wire terminal to the

horn button assembly.

(b) Connect the spiral cable’s connector to the

horn button.

(c) Reinstall the horn button assembly.

23

13. REINSTALL STEERING WHEEL

ASSEMBLY

14. RECONNECT CABLE TO NEGATIVE

BATTERY TERMINAL

15. CHECK SRS WARNING LIGHT

16. CHECK THAT HORN, WIPERS AND

LIGHTS OPERATE PROPERLY

17. CHECK STRAIGHT AHEAD POSITION FOR

STEERING WHEEL

18. RESTORE SYSTEM SETTINGS AFTER

BATTERY RECONNECTION

(a) Power Window Control System

(b) Meter / Gauge System