harness connector.

NOTICE

The wires in the SRS seat harness are the same
color. Follow the instructions in this bulletin to
prevent damage to the vehicle.

© 2074 Toyota Motor Sales, USA
CP TOYOTA T-SB-0069-12 Rev2 —s- May 1, 2012 Page 16 of 33

SRS Airbag Light "ON" - 80111/B0116 Open Side Squib Circuit

Repair Procedure

SRS Seat Wire Harness Connector: Power Seat (Continued)

5, Place a small piece of electrical tape behind the — Figure 26.
cut mark on the same wire that was taped above.
Cut the wires at the mark.

2004 Sienna:

Power Seat, Left: 338 mm (13.3 in.)
Power Seat, Right: N/A

2005 — 2009 Sienna:
Power Seat: 165 mm (6.5 in.)

Retain the cut-off SRS seat harness and
connector for later reference.

6. Prepare the new wires with the male terminals.

Figure 27. PiN 82998-45010: Repair Wire Harness Figure 28. P/N 82998-45020: Repair Wire Harness
(Male, Wire Color: Yellow-Red) (Male, Wire Color: Yellow-Green)

rr ft

1 Male Terminal 4 Male Terminal

2 | Wire 2 | Wire

A. Measure from the tip of the male terminal and = Figure 29.
cut each wire.
2004 Sienna:

Power Seat, Left: 348 mm (13.7 in.)
Power Seat, Right: N/A

2005 — 2009 Sienna:
Power Seat: 175 mm (6.89 in.)

© 2014 Toyota Motor Sales, USA
GP)TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 17 of 33

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

Repair Procedure

SRS Seat Wire Harness Connector: Power Seat (Continued)

B. Remove 8 mm (0.32 in.) of insulation from the Figure 30.
ends of the male terminal pig tails. -

7. Proceed to Crimping Seat Wires.

© 2014 Toyota Motor Sales, USA
T-SB-0069-12 Rev2 May 1, 2012 Page 18 of 33
SRS Airbag Light "ON" - B0111/B0116 Open Side Squib Circuit
Repair Procedure (Continued)

SRS Seat Wire Harness Connector: Manual & Fold Flat Seat

1. Unciip the SRS seat harness connector. Remove the yellow corrugated tubing and discard.

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

© 2014 Toyota Motor Sales, USA
CP TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 19 of 33

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

Repair Procedure

SRS Seat Wire Harness Connector: Manual & Fold Flat Seat (Continued)

2. Measure from the tip of the seat harness Figure 32.
connector and mark the wires.

2004 Sienna:
Manual Seat, Left: 85 mm (3.35 in.)
Manual Seat, Right: 55 mm (2.17 in.)

2005 - 2009 Sienna:
Manual Seat, Left: 85 mm (3.35 in.)
Manual Seat, Right: 70 mm (2.76 in.)

3. Install the floor harness SRS connector that was — Figure 33.
cut off in step 3 of the Floor Harness Connector
procedure.

4. Place a small piece of electrical tape behind the — Figure 34.
SRS seat harness connector that lines up with
the yellow wire with the red tracer on the SRS
floor harness connector.

NOTICE

The wires in the SRS seat harness are the same
color. Follow the instructions in this bulletin to
prevent damage to the vehicle.

© 2014 Toyota Motor Sates, USA
CPTOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 20 of 33

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

Repair Procedure
SRS Seat Wire Harness Connector: Manual & Fold Flat Seat (Continued)
5. Place a small piece of electrical tape behind the — Figure 35.

cut mark on the same wire that was taped in
step 4.

6. Cut the wires at the cut mark, and retain the cut-off SRS seat harness and connector for
later reference.

7. Prepare the new wires with the male terminals.

Figure 36. PIN 82998-45010: Repair Wire Harness Figure 37. PIN 82998-45020: Repair Wire Harness
(Male, Wire Color: Yellow-Red) (Male, Wire Color: Yellow-Green)

1 | Male Terminal 1 | Mate Terminal

2 | Wire 2 | Wire

A. Measure from the ends of the male terminals = Figure 38.
and cut the new wires.

2004 Sienna:
Manual Seat, Left: 75 mm (2.95 in.}
Manual Seat, Right: 65 mm (2.56 in.)

2005 — 2009 Sienna:
Manual Seat, Left: 95 mm (3.74 in.)
Manual Seat, Right: 80 mm (3.15 in.)

© 2014 Toyota Motor Sales, USA
CP TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 21 of 33

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

Repair Procedure

SRS Seat Wire Harness Connector: Manual & Fold Flat Seat (Continued)

B. Remove 8 mm (0.32 in.) of insulation from the Figure 39.

ends of the male terminal pig tails.

8. Proceed to Crimping Seat Wires.

© 2014 Toyota Motor Sales, USA
CP TOYOTA T-SB-0069-12 Rev2 May 1, 2012 Page 22 of 33

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

Repair Procedure (Continued)
Crimping Seat Wires
1. Install a sleeve onto each of the wires from the seat harness.

Figure 40. Figure 41.

1 | Sleeve
2 | Wire Stop
a | Wire

2. Place the sleeve into the 1.25 mm crimp die of Figure 42,
the SST.

HINT

Place the sleeve into the SST so that the split
in the sleeve is in the half circle of the SST.

NOTE

SST 09042-20100 is the only tool approved to
perform this repair — Do NOT use any other
tool to crimp the sleeve.

© 2014 Toyota Motor Sales, USA
CPTOYOTA T-SB-0069-12 Rev2 —- May 1, 2012 Page 23 of 33

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

Repair Procedure

Crimping Seat Wires (Continued)

3. With the sleeve correctly placed inthe SST and Figure 43.
wire fully inserted into the sleeve, crimp one side
of the sleeve in the area shown by closing the
handles fully until they release. Crimp the sleeve @ @
onto each of the floor harness wires.

v

4
Y

NOTE !
The SST has a ratcheting mechanism, and the Co i
handle will release when the proper crimp has —_J el

been achieved.

1 Crimp This Portion

4. Insert the new pig tail (yellow with red tracer) into Figure 44.
the sleeve that was marked with electrical tape
and crimp using the SST.

5. Insert the new pig tail (yellow with green tracer) — Figure 45.
into the other sleeve and crimp using the SST. rs

6. Lightly tug on each connection to ensure that the — Figure 46.
wire is securely crimped.

© 2014 Toyota Motor Sales, USA
CP TOYOTA T-SB-0069-12 Rev2 = May 1, 2012 Page 24 of 33

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

Repair Procedure

Crimping Seat Wires (Continued)

7. Install the thermo tubing on each wire.

A. Center the thermo tubing over the center of Figure 47.
the barrel sleeve.

= AE ===

B. Using a heat gun, heat the thermo tubing until it shrinks and seals the repaired connection.

Figure 48.
NOTICE

* When using the heat gun, keep the
heat gun about t0 mm (0.39 in.}
from the thermo tubing.

« Protect the surrounding areas (i.e.,
interior panels and carpet) from
heat damage.