TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN ESS
CURRENTLY REGISTERED OUTSIDE OF THE 20 COLD CLIMATE STATES
SPARE TIRE CARRIER CABLE REPLACEMENT

2004 — 2011 MY SIENNA (2WD) VEHICLES EQUIPPED WITH A SPARE TIRE

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this repair are required to successfully complete the most current version of the E-Learning
course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair
performed correctly; technicians Performing this_repair are_required to currently hold_at_least one of the
following certification tevels:-

Toyota Certified (any classification)
Toyota Expert (any classifications)
Master Technician

Master Diagnostic Technicians

Always check which technicians can perform the recall remedy by logging on _ to
https :/Avwww.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above
certification level or greater to perform this repair. Carefully review your resources, the technician skill
Jevel, and ability before assigning technicians to this repair. It is important to consider technician days off
and vacation schedules to ensure there are properly trained technicians available to perform this repair at all
times.

OPERATION FLOW CHART

Verify Vehicle Eligibility
Check the TIS Vehicle Inquiry System.

. . . Does the service history for ASE/A7E
Lower the spare tire and inspect the show the nylon remedy part being
spare tire carrier cable coating. installed?

Non Nylon Coated

Not Involved —p No further action required.

Replace the Spare Tire Carrier No
Inspect the vehicle’s spare tire Yes
carrier toot kit to ensure it can ;

operate the new spare tire carrier. 6 Sided Driv

5 Sided Drive

Campaign Complete Install New Spare Tire Tool Kit

IDENTIFICATION OF AFFECTED VEHICLES

. AFFECTED VIN RANGE

e Check the TIS Vehicle Inquiry system to confirm the VIN is involved in this Safety Recall. This will verify
the vehicle is affected and has not already been completed prior to dealer shipment or by another dealer,

* TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were
completed by another deater.

PREPARATION
. PARTS
All vehicles will require these parts.
Part Number Part Description (Kit Contents) Quantity
04005-31108 Spare Tire Carrier 1
04005-30108 Spare Tire Carrier Hardware Kit 1
G0080-17 256 Nut C
90467-05197 Clio

Some vehicles will require the following kit because the new spare tire carrier contains a 5 point drive
nut instead of a 6 point drive nut to raise and lower the spare tire. Please inspect the vehicles spare
tire carrier tool kit to determine it the new kit is required and to ensure the customer will be able to
raise and lower the spare tire after the cam n repair.
Part Number Part Contents
04004-66108 Tire Carrier KitA

5

Qua
1

S

IV.

B. TOOLS, EQUIPMENT

e Standard Hand Tools

e Torque Wrench

« Wheel Nut wrench

« Pentagon spare tire carrier socket (vehicle spare tire tool set)
BACKGROUND

Toyota has received reports indicating that some vehicles may experience spare tire carrier or carrier cable
corrosion even after being inspected and/or repaired as part of a previous Special Service Campaign. During
normal usage, water splashing rearward can reach the spare tire carrier due to variation in the placement of
the foam splash guard or loss of the splash guard. If the splashed water contains high concentrations of road
salt, corrosion of the spare tire carrier and carrier cable may result. In limited instances, the spare tire may
become separated from the spare tire carrier and create a road hazard that could cause a vehicle crash.

V.

WORK PROCEDURE

A. LOWER AND REMOVE THE SPARE TIRE

Jack handle

LOCATE THE WHEEL NUT WRENCH AND JACK
HANDLE

a) When accessing the spare tire carrier tools place 1
tire bag in the tire bag slot.

Note: Ensure the tire bag is placed in the slot so the
customer has a spare tire bag in the case of a flat.

ACCESS THE SPARE TIRE CARRIER

LOWER AND REMOVE THE SPARE TIRE

a) Lower the spare tire using the spare tire carrier
wrench and remove the spare tire.

lower the spare tire, damage may occur

STOP DO NOT use an impact or power tool to
to the carrier.

B. INSPECTION OF SPARE TIRE CARRIER CABLE

e The spare tire MUST be removed to perform the spare tire cable Inspection.

« DO NOT inspect the cable type without removing the spare tire, otherwise
noxudoi that was previously applied on the cable could be mistaken for the
nylon coating:

aE }
This vehicle was previously sprayed, with Noxudol and appeared to have the hylon ‘coating
until the spare tire was removed. You MUST REMOVE the spare tire to inspaéct'the cable.
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e If you are unable to determine if the cable is nylon coated or was
previously applied with Noxudol, replace the spare tire carrier.

¢ A low percentage of spare tire carriers were replaced under Safety
Recail ASE and SSC A7E, it is anticipated that the majority of spare
tires carriers will be replaced.

1. CONFIRM THE SPARE TIRE CARRIER CABLE TYPE AND CONDITION

a) Clean the spare tire cable of dirt and debris.

b) Inspect the spare tire carrier to determine what kind of spare tire cable is on the vehicle. Use the table
below to determine your next step based on the inspection.

Need to Replace the Spare Tire Carrier

Confirm Spare Tire Carrier Part Number Installed by
the Vehicles Service History
« Nylon Coated

e Raw Steel Cable

e Raw Steel with Corrosion

e Raw Steel with Noxudol

e Black Resin Coated with Exposed Ferrule

All of the above cable type and cable conditions must
have the spare tire carrier replaced.

Go to section V.E.1 to inspect the spare tire
carrier tool design.

Go to section V. D.1

Raw Steel Cable Raw Steel with Corrosion Raw Steel with Noxudol

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