>) TOYOTA

T-SB-0069-12 Rev2 May 1, 2012 Technical Service Bulletin

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib
Circuit

Service
Category Vehicle Interior
Toyota Supports
Section Supplemental Restraint Systems Market USA ASE Certification
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2004 — 2009 Sienna

REVISION NOTICE
January 17, 2014 Rev2:

* Vehicle applicability has been updated to include 2004 model year Sienna vehicles.

* The Required Tools & Equipment and Repair Procedure sections have been updated.
January 22, 2013 Rev1:

* Side Airbag Replacement has been removed from the bulletin.

Any previous printed versions of this bulletin should be discarded.

SUPERSESSION NOTICE

The information contained in this bulletin supersedes SB No. T-SB-0162-10.
* Production Change Information has been added.
* The entire bulletin has been updated.

Service Bulletin No. T-SB-0162-10 is Obsolete and any printed versions should be discarded. Be
sure to review the entire content of this bulletin before proceeding.

Introduction

Some 2004 -— 2009 mode! year Sienna vehicles may exhibit an SRS lamp “ON” condition with
Diagnostic Trouble Code (DTC) BO111 and/or B0116. An updated repair procedure is available
to address this condition. Follow the procedures in this bulletin to repair the floor harness and
the side airbag squib circuit.

@ 2014 Toyota Motor Sales, USA Page 1 of 33
CP) TOYOTA T-SB-0069-12 Rev2 —- May 1, 2012

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit

Page 2 of 33

Service Bulletin Overview

After confirming the vehicle condition matches this bulletin, this SB will direct you to repair the floor
wire harness and the side airbag squib circuit. The wire repair to the floor harness and side airbag
squib circuit is only approved for vehicles covered by this bulletin and is not approved for use on
other vehicles. Carefully follow the steps outlined in this bulletin to prevent damage to the vehicle.

Production Change Information

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown

below.
MODEL DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN
. 2WD 5TDZK23C#9$233852
Sienna
AWD 5TDBK23C#9S023266
Warranty Information
OP CODE DESCRIPTION TIME ore T1 T2
EL1107 Wire Harness Repair (Driver Power} 1.5
EL1108 Wire Harness Repair (Driver Manual) 1.5
EL1109 Wire Harness Repair (Passenger Power) 1.5
EL1110 Wire Harness Repair (Passenger Manual) 1.5
EL1111 Wire Harness Repair (Passenger Fold Flat) 1.5
Wire Harness Repair
EL1112 . 1.5
P dP
(Driver = = eee Flat) 82161-08270 ep | 41
ire Harness Repair
ELI113 (Driver Manual and Passenger Fold Flat) 1.8
Wire Harness Repair
ae (Driver Manual and Passenger Manual) ue
Wire Harness Repair
oe (Driver Power and Passenger Manual) ce
Wire Harness Repair
ELI116 (Driver Power and Passenger Power) ue)
APPLICABLE WARRANTY
* This repair is covered under the Toyota Restraint System Warranty. This warranty is in effect
for 60 months or 60,090 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.

© 2014 Toyota Motor Sales, USA

TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 3 of 33
SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit
Parts Information
PART NUMBER PART NAME QTy
04001-22145 Repair Wire, Kit* 1
89279-08010 Corrugated Tubing 1
Wire Repair Kit Cantents*
PART NUMBER PART NAME aQTy
82999-52010 Sleeve 4
82999-30010 Thermo Contact Tube 4
90980-11863 Connector (Male) 1
90980-11864 Connector (Female} 1
Repair Wire Harness
cee (Male, Wire Color: Yellow — Red) :
Repair Wire Harness
62998-45020 (Male, Wire Color: Yellow - Green) 1
Repair Wire Harness
82998-45030 (Female, Wire Color: Yellow — Red) :
Repair Wire Harness
eee (Female, Wire Color: Yellow -— Green) :
* Repair kit components are not available separately.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST) PART NUMBER QTy

Plastic Pry Tool Kit**

00002-06020-01

Occupant Classification Seat Weight Set**

00002-09090-01

Wire Crimper (Non Insulated)**

09042-20100

** Essential SST.

NOTE

Additional SSTs may be ordered by calling 1-800-933-8335,

© 2014 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0069-12 Rev2 —- May 1, 2012 Page 4 of 33

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit

Required Tools & Equipment (Continued)

REQUIRED EQUIPMENT SUPPLIER PART NUMBER ary
Techstream 2.0° TS2UNIT
TIS Techstream ADE TSPKG1 1
Techstream Lite TSLITEDLRO1

* Essential SST.

NOTE
« Only ONE of the Techstream units listed above is required.

« Software version 8.30.023 or later is required.

* Additional Techstream units may be ordered by calling Approved Deater Equipment (ADE) at
1-800-368-6787.

Repair Procedure Overview
* Section 1: Diagnostic Procedure

This procedure, using Techstream and the Technical Information System (TIS), will determine
the correct repair method.

* Section 2: Wire Harness Repair
This section will provide the detailed steps to repair the SRS floor harness and SRS seat
harness connectors.

Diagnostic Procedure
Connect Techstream to vehicle and confirm DTC B01117 or BO116 is stored.

* If DTC BO111 or BO116 is stored, then proceed with the repair described in this Service Bulletin.

* Ifa different DTC is stored, this Service Bulletin does NOT apply. Follow the Repair Manual
to complete the diagnosis.

Repair Procedure

NOTICE

* This SRS wire harness repair has only been approved for vehicles covered in this bulletin and
is NOT approved for use on any other vehicles.

* Follow the procedures outlined in this bulletin to prevent damage to the vehicle.

© 2014 Toyota Motor Sales, USA

TOYOTA

T-SB-0069-12 Rev2 May 1, 2012 Page § of 33

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit

Repair Procedure (Continued)

SRS Floor Harness Connector

NOTE

Repairing the floor harness connector is applicable to all vehicles covered by this bulletin and
should be performed FIRST.

1. Remove the front seat.

Refer to TIS, applicable model year Sienna Repair Manual, for each type of seat assembly:

2004 Sienna:
Vehicle Interior — Seat — “Front Seat Assembly LH (Power Seat Type) / LH (Manual Seat
Type) / RH (Fold Fiat Type): Overhaul”

2005 Sienna:
Vehicle Interior — Seat — “Front Seat Assembly LH (Power Seat Type) / LH (Manual Seat
Type) / RH (Fold Flat Type): Overhaul”

2006 Sienna:
Vehicle interior — Seat — “Seat: Front Seat Assembly (for Fiat Type) / (for Manual Seat)

/ (tor Power Seat): Removal”

2007 Sienna:
Vehicle interior - Seat — “Seat: Front Seat Assembly (for Flat Type) / (for Manual Seat)

/ (for Power Seat); Removal”

2008 Sienna:
Vehicle Interior - Seat - “Seat: Front Seat Assembly (for Flat Type) / (for Manual Seat)

/ (for Power Seat): Removal”

2009 Sienna:
Vehicle Interior — Seat — “Seat: Front Seat Assembly (for Flat Type) / (for Manual Seat)

/ (for Power Seat): Removal”

© 2014 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 6 of 33

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit

Repair Procedure

SRS Floor Harness Connector (Continued)

2. Remove the tape from around the corrugated Figure 4.
tubing. Remove and save the corrugated tubing.

NOTE

Some vehicles may have an additional
sleeve protecting the wiring that will need
to be removed. The additional sleeve can
be discarded.

Figure 2.

3. Measure 80 mm (3.15 in.) from the tip of the floor Figure 3.
harness connector and cut the wires.

Retain the old floor harness connector
for reference.

© 2014 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 7 of 33

SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit

Repair Procedure

SRS Floor Harness Connector (Continued)

4, Remove & mm (0.32 in.) of insulation from the Figure 5.
ends of the 2 floor harness wires.

5. Prepare the new wires with the female terminals.

Figure 6. PIN 82998-45030: Repair Wire Harness Figure 7. PN 82998-45040: Repair Wire Harness
(Female, Wire Color: Yellow-Red) (Female, Wire Color: Yellow-Green}