T-SB-0022-21 April 16, 2021 Low Call Volume During Safety Connect Calls Service Category Audio/Visual/Telematics Section Audio/Video Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2018 Sienna Introduction Some 2018 model year Sienna vehicles with DCM (Data Communication Module), not equipped with JBL audio may exhibit a condition in which the call volume is low when making a Safety Connect Call through the vehicle. Follow the Repair Procedure in this bulletin to address this condition. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 EL9061 Install New Wire Harness 1.1 82141-#####* 76 99 *Choose the correct OFP for the vehicle being repaired by searching the parts in EPC using the EPC VIN filter. Warranty claims must be submitted with the correct OFP with 10 digits. APPLICABLE WARRANTY This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 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. Parts Information PART NUMBER PART NAME QTY 82165-08140 Wire, Frame, No. 2 1 90980-10825 Housing, Connector Female 1 © 2021 Toyota Motor Sales, USA Page 1 of 17 T-SB-0022-21 April 16, 2021 Page 2 of 17 Low Call Volume During Safety Connect Calls Required Tools & Equipment SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY Minus Screwdriver 0.9mm* 09041-1C580 1 *Essential SST. NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Repair Procedure 1. Is the vehicle equipped with a DCM? YES — Continue to step 2. NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual. 2. Is the vehicle equipped with JBL audio? YES — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual. NO — Continue to step 3. 3. Confirm the condition exists. A. Make a non-emergency Safety Connect call. (1) Press the "SOS" button on the roof console box assembly. (2) Tell the response center agent it’s a test call and NOT an emergency. B. Listen to the call volume. Is it low? NOTE Audio will be coming from the RH instrument panel speaker assembly. YES — Continue to step 4. NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual. © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 3 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 4. Disconnect the negative battery terminal. 5. Disengage the 12 claws to remove the Figure 1. RH front door scuff plate. 1 Claw 1 RH Front Door Scuff Plate 6. Disengage the claw and two clips to Figure 2. remove the RH cowl side trim board. 1 1 RH Cowl Side Trim Board Claw Clip © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 4 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 7. Disengage the five claws and two clips to Figure 3. remove the RH instrument panel speaker panel sub-assembly. 1 1 RH Instrument Panel Speak Panel Sub-assembly Claw Clip 8. Remove the RH instrument panel Figure 4. RH Instrument Panel Speaker Assembly speaker assembly. NOTICE 1 Do NOT touch the cone part of the speaker assembly. A. Remove the two bolts. B. Disconnect the connector to remove the RH instrument panel speaker assembly. 1 Bolt © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 5 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 9. Disconnect connector GD1. Figure 5. Connector GD1 Disconnected 1 * 1 Connector GD1 © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 6 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 10. Remove connector GD1 (instrument panel wire harness side) from the connector holder. A. Separate the connector holder from the Figure 6. vehicle body by pulling it toward the left-hand rear direction. 1 1 Connector Holder © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 7 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) B. Use a small screwdriver to unclip connector GD1 from the connector holder from the back (bulkhead side). Figure 7. Connector GD1 Clipped Into the Figure 8. Connector GD1 Unclipped From the Connector Holder Connector Holder 1 1 Insert Screwdriver Here on Bulkhead Side 11. Remove the wires from the RH instrument panel speaker connector D81. A. Release the secondary lock by Figure 9. RH Instrument Panel Speaker inserting a small screwdriver, pick, or Connector D81 similar tool into the locations shown and pry up. 1 c 1 c 1 Insert Tool Here © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 8 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) B. Remove the wires. (1) Push the wire terminal toward the connector. (2) Release the primary lock by using Figure 10. RH Instrument Panel Speaker Minus Screwdriver 0.9mm SST Connector D81 (P/N 09041-1C580) or equivalent. 2 c 1 c 3 c 1 Location to Insert Tool 2 Primary Lock 3 Wire Terminal (3) Pull the wire out as shown. Figure 11. C. Repeat steps (1) – (3) for the second wire. © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 9 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 12. Install the wires into the NEW connector 90980-10825. A. Confirm the secondary lock is open on Figure 12. Connector 90980-10825 With Secondary the NEW connector. If the lock is NOT Lock Open open, release the secondary lock by inserting a small screwdriver, pick, or similar tool to into the locations shown and pry up. 1 2 2 1 Secondary Lock 2 Location to Insert Tool © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 10 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) B. Insert the blue wire into connector Figure 13. Connector 90980-10825 With Wire terminal 1. Terminals Installed C. Insert the green wire into connector terminal 2. 2 NOTE 1 Confirm the wires are installed correctly by listening for them to click past the primary lock and lightly tugging on them to make sure they do NOT come out. 1 Connector Terminal 1 2 Connector Terminal 2 D. Press down on the connector lock in Figure 14. Closed Secondary Lock the location shown. © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 11 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 13. Route the NEW wire harness (82165-08140 Wire, Frame, No. 2) from the RH kick panel area up to the RH instrument panel speaker opening. Figure 15. New Wire Harness Routing Without Figure 16. New Wire Harness Routing Along Current Vehicle Wiring Current Vehicle Wiring New Wire Harness Zip Tie Location Zip Tie Location New Wire Harness Instrument Panel Wire Harness Right Front Door Wire Harness © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 12 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 14. Connect NEW connector 90980-10825 to the Figure 17. NEW wire harness. 1 2 1 New Connector 90980-10825 2 New Wire Harness Figure 18. RH Instrument Panel Speaker Area with New Connector 90980-10825 1 RH Instrument Panel Speaker Instrument Panel Wire Harness 1 New Connector 90980-10825 Connected to New Wire Harness New Wire Harness © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 13 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 15. Connect the NEW wire harness Figure 19. New Wire Harness Connected to the RH instrument panel speaker. RH Instrument Panel Speaker NOTICE Do NOT touch the cone part of the speaker assembly. 16. Connect the instrument panel wire harness Figure 20. Instrument Panel Wire Harness connector GD1 to the NEW wire harness. Connector GD1 Connected to New Wire Harness 1 1 Wire Harness Connector GD1 © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 14 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 17. Clip the NEW wire harness connector to the connector holder. Figure 21. Before Clipping the New Wire Harness Figure 22. After Clipping the New Wire Harness Connector to the Connected Holder Connector to the Connected Holder 1 2 1 1 New Wire Harness Connector 1 New Wire Harness Connector 2 Connect New Wire Harness Connector Here 18. Connect the RF door wire harness connector Figure 23. GD1 to the NEW wire harness. 1 1 Connector GD1 © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 15 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 19. Confirm the connector holder is in its original position against the vehicle body. 20. Use zip ties to secure the NEW wire harness to the instrument panel wire harness as shown in step 13. 21. Ensure the NEW wire harness is routed securely and NOT rubbing on any sharp edges. 22. Install the RH instrument panel Figure 24. RH Instrument Panel Speaker Assembly speaker assembly with the two bolts. NOTICE 1 Do NOT touch the cone part of the speaker assembly during handling. 1 Bolt 23. Engage the five claws and two clips to Figure 25. install the RH instrument panel speaker panel sub-assembly. 1 RH Instrument Panel Speak Panel 1 Sub-assembly Claw Clip © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 16 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 24. Engage the claw and two clips to Figure 26. install the RH cowl side trim board. 1 1 Cowl Side Trim Board RH Claw Clip 25. Engage the 12 claws to install the Figure 27. RH front door scuff plate. 1 Claw 1 RH Front Door Scuff Plate © 2021 Toyota Motor Sales, USA T-SB-0022-21 April 16, 2021 Page 17 of 17 Low Call Volume During Safety Connect Calls Repair Procedure (continued) 26. Connect the negative battery terminal. Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf) 27. Initialize the necessary systems AFTER connecting the negative battery terminal. Refer to TIS, applicable model and model year Repair Manual: 2018 Sienna: General – Introduction – “Introduction: Repair Instruction: Initialization” 28. Make a non-emergency Safety Connect call to confirm the volume level has improved. A. Make a non-emergency Safety Connect call. (1) Press the "SOS" button on the roof console box assembly. (2) Tell the response center agent it’s a test call and NOT an emergency. B. Listen to the call volume. Is the audio coming from the RF door speaker assembly? YES — The repair is complete. NO — Refer to TIS, applicable model and model year Repair Manual: 2018 Sienna: Audio/Visual/Telematics – Audio/Video: “Audio / Video: Audio and Visual System: Problem Symptoms Table” © 2021 Toyota Motor Sales, USA
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