NHTSA ID Number: 10134372
Manufacturer Communication Number: F0U_Supplemental
TSB/Document Date: 2018-04-23
Summary
TI: Background-In the subject vehicles the front catalytic converter internal components may become deteriorated and begin to rattle. If continually operated in this condition, the deteriorated components could become dislodged and restrict the exhaust flow. If this occurs, the vehicle may illuminate a check engine light, and, depending on the level of exhaust restriction, the vehicle may experience a reduction in power. Toyota
has developed a new exhaust pipe with catalytic converters to prevent this condition from occurring.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.
24
8. REMOVE THE FRONT FLOOR FOOT REST
a) Disengage the 2 clips.
9. REMOVE FRONT DOOR SCUFF PLATE
a) Disengage the 9 claws and remove.
10. REMOVE COWL SIDE TRIM BOARD LH
a) Remove the clip.
b) Disengage the 2 clips and remove.
11. REMOVE STEERING COLUMN HOLE COVER
a) Disengage the 2 clips and remove.
12. REMOVE INSTRUMENT PANEL LOWER FINISH PANEL NO.1
a) Remove the 2 bolts.
b) Disengage the 3 clips and carefully remove.
c) Disconnect the electrical connectors.
13. REMOVE INSTRUMENT PANEL LOWER LH
a) Remove the 3 bolts and remove the panel.
25
14. REMOVE LOWER STEERING COLUMN COVER.
a) Remove the 2 screws.
Note: To access the screws you may need to turn the
steering wheel.
b) Disengage the 2 clips and remove.
15. REMOVE DRIVER SIDE JUNCTION BLOCK
a) Remove the 2 bolts and bracket.
b) Remove the 2 nuts and separate the driver side junction block.
16. REMOVE THE ENGINE ROOM MAIN HARNESS
a) Disengage the clamp from the connector holder No. 5.
b) Disconnect the 5 front connectors from the connector holder No. 5.
26
c) Remove the bolt and clamp to unfasten the connector holder No. 5
d) Disconnect the 5 female connectors and 2 male connectors that are located at the back of the connector holder
No. 5.
27
e) Disconnect the 5 female connectors and disengage the clamps located in the foot pedal area as shown.
f) Confirm all connectors and clamps have been disconnected.
g) Pull out the engine room main harness from the vehicle cabin
towards the engine compartment as shown.
h) Pull out the hood lock cable form the wire harness grommet.
i) Mark the removed harness so that it is not reused.
B. INSTALL NEW ENGINE ROOM MAIN HARNESS
1. INSTALL ENGINE ROOM MAIN HARNESS INTO THE VEHICLE
CABIN
a) Insert the hood lock cable into the harness grommet.
b) Insert the engine room main harness from the engine room into
the vehicle cabin as shown.
28
c) Connect the 5 female connectors and engage the clamps located in the foot pedal area as shown.
d) Connect the 5 female connectors and 2 male connectors that are located at the back of the connector holder No.
5.
29
e) Fasten the connector holder No. 5 with the bolt.
Torque Spec: 8.0Nm (82 kgf-cm, 71 in-lbf)
f)
Connect the 5 connectors to the connector holder No. 5.
30
g) Engage the clamp to the connector holder No. 5.
2. REINSTALL DRIVER’S SIDE JUNCTION BLOCK
a) Install the junction block with the 2 nuts.
Torque Spec: 8.0Nm (82 kgf-cm, 71 in-lbf)
b) Install the bracket with the 2 bolts.
Torque Spec: 8.0Nm (82 kgf-cm, 71 in-lbf)
3. REINSTALL THE LOWER STEERING COLUMN COVER.
a) Engage the 2 claws.
b) Install the 2 screws.
Note: To access the screws you may need to turn the
steering wheel.
4. REINSTALL INSTRUMENT PANEL LOWER LH
a) Install the panel with the 3 bolts.
5. REMOVE INSTRUMENT PANEL LOWER FINISH PANEL NO.1
a) Connect the electrical connectors
b) Engage the 3 clips.
c) Install the 3 bolts.
6. REINSTALL THE STEERING COLUMN HOLE COVER
a) Install the hole cover and engaged the 2 clips.
31
7. REINSTALL COWL SIDE TRIM BOARD LH
a) Engage the 2 clips.
b) Install the clip onto the stud.
8. REINSTALL FRONT DOOR SCUFF PLATE
a) Install the scuff plate and engage the 9 claws.
9. REINSTALL THE FRONT FLOOR FOOT REST
b) Install the foot rest and engage the 2 clips.
32
10. INSTALL THE NEW ENGINE ROOM MAIN HARNESS IN THE ENGINE ROOM
a) Connect the connectors and engage the clamps as shown.
b) Reinstall the 2 bolts and nuts
Torque Spec:
D3, D5: 8.0 Nm (82 kgf-cm, 71 in-lbf)
D4: 11.0 Nm (112 kgf-cm, 8 ft-lbf)
c) Reinstall the relay block cover No. 1
•
•
•
Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when connecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you connect all connectors and clamps.
33
d) Connect the connectors and engage the clamps as shown.
e) Reinstall the bolt.
Torque Spec:
C4: 8.0 Nm (82 kgf-cm, 71 in-lbf)
•
•
•
Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when connecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you connect all connectors and clamps.
34
f) Connect the connectors and engage the clamps as shown.
g) Reinstall the bolt.
Torque Spec:
B1: 8.0Nm (82 kgf-cm, 71 in-lbf)
•
•
•
Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when connecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you connect all connectors and clamps.
35
h) Connect the connectors and engage the clamps as shown.
•
•
•
Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when connecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you connect all connectors and clamps.
11. REINSTALL WINDSHIELD WASHER JAR
a) Install the washer jar and 2 bolts.
36
12. REINSTALL AIR CLEANER
a) Install the air cleaner base and 3 bolts.
Torque Spec: 12.Nm (122 kgf-cm, 9 ft-lbf)
b)
c)
d)
e)
f)
Install filter element.
Install air cleaner cap and hose.
Connect the mass air flow meter connector.
Connect the wire harness clamp.
Tighten the hose clamp bolt, and connect the air cleaner hose
No. 1.
g) Connect the 2 air cleaner lid clamps.
13. REINSTALL RADIATOR SUPPORT TO FRAME SEAL LH
a) Install seal and engage the 9 clips.
14. REINSTALL COWL TOP VENTILATOR LOUVER
a) Install the louver and engage the 15 claws.
b) Reinstall the RH and LH side front fender to cowl seal by
engaging the 2 claws as shown.
15. REINSTALL THE WINDSHIELD WIPERS
a) Install the wiper arms.
b) Install the wiper arm nuts.
Torque Spec: 21 Nm (209 kgf-cm, 15 ft-lbf)
c) Install the wiper arm caps.
17. REINSTALL BATTERY
d) Reinstall battery tray.
e) Install the battery.
f) Install the battery bracket and tighten the nut.
Torque Spec: 5.4 Nm (55 kgf-cm, 48 in-lbf)
g) Connect both the negative and positive battery cables.
h) Remove the nut and battery securing bracket.
i) Remove battery assembly.
37
IX. ENGINE WIRE HARNESS REPLACEMENT
38
COMPONENTS TO BE REPLACED/REMOVED OVERVIEW
39
A. ENGINE WIRE HARNESS REMOVAL
1. DISCONNECT THE BATTERY
2. REMOVE AIR CLEANER CAP
a) Disconnect the mass air flow meter connector.
b) Disconnect the wire harness clamp.
c) Loosen the hose clamp bolt, then disconnect the air cleaner
hose No. 1.
d) Disconnect the 2 air cleaner lid clamps.
e) Remove the air cleaner cap together with the air cleaner hose
No. 1.
3. REMOVE INTAKE AIR CONNECTOR
a)
b)
c)
d)
e)
f)
Disconnect the pressure sensor connector.
Disengage the wire harness clamp.
Disconnect the vacuum hoses.
Disconnect the No. 2 ventilation hose.
Loosen the hose clamp bolt.
Remove the 3 bolts and the air connector.
40
4. REMOVE ENGINE WIRE FROM ENGINE ROOM
a) Remove the upper relay block cover No. 1.
b) Disconnect the connectors and disengage the clamps as shown in the following illustrations.
c) Remove the 4 bolts and 2 nuts.
•
•
•
Exact wire harness configuration can vary based on vehicle model year, use the following
pages as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.
41
42
d) Raise the vehicle.
e) Remove the heat insulator (A/T trans only).
f) Disconnect the connectors and disengage the clamps on the transmission as shown.
•
•
•
Exact wire harness configuration can vary based on vehicle model year, use the following
pages as a guide when disconnecting the harness.
The engine wire clmaps/connectors are broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.
43
1. DISCONNECT THE ENGINE WIRE FROM VEHICLE CABIN
a) Lower the vehicle.
b) Remove the glove box door.
c) Disengage the claw and separate the glove box door form the
glove box stopper.
d) Slightly compress the side wall of the glove box door carefully
until it is horizontal, then pull ther glove box door toward the
rear of the vehicle.
e) Disconnect the conntectors and disengage the wire harness
clamps.
f) Release the wire harness grommet and pull the harness from
the vehicle cabin toward the engine room.
44
B. NEW ENGINE WIRE HARNESS INSTALLATION
1. ROUTE AND CONNECT THE ENGINE WIRE HARNESS
a) Connect the connectors and engage the clamps as shown in the following illustrations.
b) Reinstall the 4 bolts and 2 nuts.
Torque Spec:
E1: 14 Nm (143 kgf-cm, 10 ft-lbf)
E6: 9.8 Nm (100 kgf-cm, 87 in-lbf)
E7, F3: 8.0 Nm (82 kgf-cm, 71 in-lbf)
G8: 11.0 Nm (112 kgf-cm, 8 ft-lbf)
•
•
•
Exact wire harness configuration can vary based on vehicle model year, use the following
pages as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.
45
2. REINSTALL THE ENGINE HARNESS IN THE VEHICLE CABIN
a) Pass the engine wire harness through the bulk head and into
the vehicle cabin.
b) Install the connectors and clamps.
c) Confirm that the grommet is installed on the bulk head.
3. REINSTALL THE GLOVE BOX
a) Engage the glove box door hinges
b) Swing the door up and slightly compress the sides.
c) Engage the claw on the glove box door stop.
46
d) Raise the vehicle.
e) Connect the connectors and engage the clamps on the transmission as shown.
f) Reinstall the heat insulator. (A/T trans only)
Torque Spec: 7.5 Nm (76 kgf-cm, 66 in-lbf)
•
•
•
Exact wire harness configuration can vary based on vehicle model year, use the following
pages as a guide when disconnecting the harness.
The engine wire clmaps/connectors are broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.
47
5. REINSTALL INTAKE AIR CONNECTOR
a) Install the air intake connector.
b) Install the 3 bolts.
Torque Spec: 12 Nm (122 kgf-cm, 9ft-lbf)
c) Tighten the hose clamp bolt.
d) Connect the vacuum hoses.
e) Connect the No. 2 ventilation hose.
6. REINSTALL AIR CLEANER CAP
a)
b)
c)
d)
e)
f)
Install filter element.
Install air cleaner cap and hose.
Connect the mass air flow meter connector.
Connect the wire harness clamp.
Tighten the hose clamp bolt, and connect the air cleaner hose
No. 1.
Connect the 2 air cleaner lid clamps.
7. RECONNECT BATTERY
8. PROCEED TO SECTON X: FINAL VEHICLE CHECK
48
X. FINAL VEHICLE CHECK
1.
2.
3.
4.
5.
6.
CHECK AND CLEAR DTC
CHECK FOR ENGINE COOLANT LEAK
CHECK FOR BRAKE FLUID LEAK
CHECK FOR REFRIGERANT LEAK
CONDUCT TEST DRIVE
RESTORE SYSTEM SETTINGS
•
•
•
All catalytic converters must be returned to Toyota, the CPS system will send you a request
the day after the warranty claim is approved.
If the catalytic converters are not returned the warranty claims are subject to debit and core
charges.
Do not ship the full exhaust pipe assembly back to Toyota. If the exhaust pipe is shipped back
as a complete unit your dealer will debited for the additonal shipping charges.
◄ VERIFY REPAIR QUALITY ►
- Confrim that there are no exhaust leaks
- Confirm that all components were inspected and replaced as needed
- Confirm that the catalytic converter is returned to Toyota (REQUIRED)
If you have any questions regarding this update, please contact your regional representative.
XI. APPENDIX
A. CAMPAIGN DESIGNATION DECODER
F
0
Year Campaign is Launched Repair Phase
8 = 2008
9 = 2009
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Etc...
0 = Remedy
1 = Interim (Remedy
not yet available) “1”
will change to “0” when
the Remedy is
available
J
Current Campaign Letter
for this year
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
6th Campaign = F
7th Campaign = G
8th Campaign = H
9th Campaign = I
Etc...
Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5rd Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012
49
- 3X Stronger than the leading full synthetic*
- 10X Better high stress performance**
- 20,000 miles between oil changes***
- Viscosity breakdown as measured in Kurt Orbahn test on 5W...
- As measured in Seq IX test under high load/torque conditions...
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TSB/Document ID: F0U_Supplemental
Replacement Service Bulletin Number:
MFR Communication Date: 2015-12-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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