TECHNICAL INSTRUCTIONS

IMV
INNOVA, FORTUNER, HILUX

SPIRAL CABLE SUB-ASSEMBLY

REPLACEMENT

1. OPERATION FLOW CHART --------------------------------- 3

2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4

3. PREPARATION -------------------------------------------------- 5

4. WORK PROCEDURE ------------------------------------------- 7

1
 Safety Precautions
Be sure to observe the following precautions to prevent accidents and injuries.

- Park the vehicle and chock the wheels.

- If it is necessary to start the engine, perform the operation in a well ventilated area.

- Before removing and reinstalling heavy parts such as the engine, transmission and differential
using specified tools, check that there are no problems with the tools.

- When working in a group of 2 or more, each person must work to ensure the safety of all team
members.

- To prevent burns and other injuries, use extra caution when handling parts that are subject to
high temperatures, as well as rotating, sliding, or vibrating parts.

- When lifting the vehicle using a jack, support it in the specified location using a safety stand.

- When lifting the vehicle using a lift, lock the lift for safety.

Also perform the following operation with care.

Use of auto lift

- Make absolutely certain that there are no other workers and no tools, parts, or other objects
within the movable range of the lift. Also, be sure to announce all lift operations out loud (such
as Raising the lift! and Lowering the lift!) to alert other workers.

- When raising or lowering the lift, pay attention to the positions of your arms, legs, and other
body parts, and be extremely careful to prevent them from being caught in the lift.

Use of brake cleaner

- Use brake cleaner for appropriate purposes in accordance with instructions in the manual.

- Do not use brake cleaner to remove dirt or stains from the engineer clothes and so forth, as it
can catch on fire and cause serious burns.

< Precautions >

- Do not use brake cleaner near flames or fire.

- Do not use large amounts of brake cleaner in a room where a fire is burning.

- Do not keep brake cleaner in a place subject to high temperatures exceeding 40C, such as a
place subject to direct sunlight or near fire.

- Do not put brake cleaner in fire.

Edges
- When handling the edges of parts and panels, wear protective gloves or apply protective tape to
the edges to prevent injuries to your hands and fingers.

2
1. OPERATION FLOW CHART

Receiving Vehicle

Check if vehicle has affected VIN and Frame Number NO

YES

NO
Check if vehicle has equipped with SRS AIRBAG.

YES

TWO CONNECTORS
Check spiral cable connector

ONE CONNECTOR

0(ZERO)
Check Lot Number of Spiral Cable

NOT ZERO

Replace Spiral Cable

Reinstall everything

Final Inspection

Work is completed

3
2. IDENTIFICATION OF AFFECTED VEHICLES
2.1. COVERED VIN RANGE

VIN Range
Model
Production Period
Name WMI VDS VIS

Fortuner 11JV5* *0001001*2000039 2005030720100127

Innova 11NV4* *0000001*8999993 2005030720100127

PN1
Fortuner 11NV5* *7999991*7999993 2005030720100127

Hilux 33JV2* *8000000*9006229 2005030720100127

ER32G* *4008359*4036036 2005060120101231

EX32G* *4016172*4031532 2005060120101231
EZ32G* *1001465*1008471 2005060120101231
EZ39G* *2501547*2517793 2005060120101231
Hilux
FR22G* *4509765*4548384 2005060120101231
8AJ FX22G* *6004283*6004419 2005060120101231
FZ22G* *5002716*5015754 2005060120101231
FZ29G* *6005097*6068656 2005060120101231
YZ59G* *3000007*3031334 2005060120101231
Fortuner ZX62G* *5000003*5001022 2005060120101231
ZZ62G* *0001002*0001583 2005060120101231
11ZV5* *6000000*6005328 2005061520100630
Fortuner
11ZV6* *3000001*6000006 2005061520100630
31NV2* *9000000*9000011 2005061520100630
31NV3* *9000000*9005449 2005061520100630
8XA 33JV2* *9000140*9002329 2005061520100630
Hilux 33JV3* *9000080*9002029 2005061520100630
33NV2* *9000000*9008109 2005061520100630
33NV3* *9000000*9005469 2005061520100630
33ZV2* *9000000*9009417 2005061520100630
11JV4* *7000013*7160078 2005020720081229
Innova MBJ
11NV4* *6000011*6004804 2005020720081229
XS42G* *2500514*2515753 2004110220100430
Innova MHF XW42G* *2097659*2160697 2004110220100430
XX42G* *5000002*5008636 2004110220100430

4
 XX43G* *0001376*0026603 2004110220100430
YU59G* *7000004*7010903 2004110220100430
Fortuner YX59G* *8000034*8018192 2004110220100430
ZX69G* *7001643*7015437 2004110220100430

Innova XW43G* *9200001*9399999 2006010720100119

RL4
YX59G* *4000067*4000067 2006010720100119
Fortuner
ZR69G* *4000003*4002536 2006010720100119
CK12G* *0032448*0032582 2005020420100412
CK32G* *0001001*0001666 2005020420100412
CR12G* *8600000*8604425 2005020420100412
CR32G* *8006520*8009507 2005020420100412
CS12G* *7500004*7535558 2005020420100412
CW12G* *4023553*4031558 2005020420100412
CX12G* *9002076*9002280 2005020420100412
CX39G* *5000000*5008298 2005020420100412
CZ39G* *5000002*5011459 2005020420100412
DK22G* *0005546*0006246 2005020420100412
DR22G* *5500195*5514814 2005020420100412
DZ29G* *9300001*9302060 2005020420100412
EK12G* *7000009*7005604 2005020420100412
Hilux
ER12G* *9100003*9102364 2005020420100412
ER19G* *8500000*8500578 2005020420100412
AHT
ER32G* *8500420*8500630 2005020420100412
ES12G* *9000001*9002621 2005020420100412
EX12G* *9503708*9504229 2005020420100412
EX39G* *7000001*7010740 2005020420100412
EZ39G* *7000001*7018253 2005020420100412
FK22G* *3000007*3045855 2005020420100412
FR22G* *6000000*6029862 2005020420100412
FR29G* *7000003*7021728 2005020420100412
FU29G* *7000005*7004377 2005020420100412
FX22G* *8000003*8009070 2005020420100412
FZ29G* *9000001*9045890 2005020420100412
YK59G* *0001007*0004639 2005020420100412
YU59G* *4000000*4003371 2005020420100412
Fortuner
YX59G* *6000004*6000527 2005020420100412
YZ59G* *8000000*8007877 2005020420100412

5
 ZU69G* *0001001*0002423 2005020420100412
ZZ69G* *5000002*5008683 2005020420100412
AS12G* *0001008*0003839 2004042620091208
AW12G* *0001001*0003373 2004042620091208
AX12G* *0001003*0011096 2004042620091208
CR12G* *2500000*2501227 2004042620091208
CS12G* *0000101*0081825 2004042620091208
CU12G* *0001001*0008755 2004042620091208
CW12G* *0001001*0017702 2004042620091208
CX12G* *0001001*0052216 2004042620091208
CX19G* *2600004*2604341 2004042620091208
CZ12G* *0000100*0023440 2004042620091208
DR22G* *0001001*0007319 2004042620091208
DU22G* *0001001*0002125 2004042620091208
DX22G* *0001001*0006140 2004042620091208
DZ22G* *0001001*0016082 2004042620091208
ER12G* *3550000*5501250 2004042620091208
ER19G* *0450001*4861227 2004042620091208
ER32G* *6003402*6004548 2004042620091208
ES12G* *0300000*3307009 2004042620091208
Hilux MR0
ES19G* *4000000*4350470 2004042620091208
EU12G* *4000000*4502007 2004042620091208
EU19G* *6000000*6300746 2004042620091208
EW12G* *2000001*3013338 2004042620091208
EX12G* *2000000*2316709 2004042620091208
EX19G* *3000001*3427713 2004042620091208
EX39G* *0001001*0250127 2004042620091208
EZ12G* *4000000*4154049 2004042620091208
EZ19G* *0500037*5303400 2004042620091208
FR22G* *0500001*0664475 2004042620091208
FR29G* *0100002*1151369 2004042620091208
FU22G* *2000001*2301336 2004042620091208
FU29G* *4000000*4302451 2004042620091208
FX22G* *1000000*1321083 2004042620091208
FX29G* *2500000*3101113 2004042620091208
FZ22G* *1000000*1172340 2004042620091208
FZ29G* *0150043*2513940 2004042620091208
GR12G* *6500000*6500801 2004042620091208

6
 GR19G* *7000000*7110350 2004042620091208
GS12G* *0500018*5029225 2004042620091208
GS19G* *0600073*6098342 2004042620091208
GU12G* *8000000*8003438 2004042620091208
GU19G* *9000000*9001245 2004042620091208
GX12G* *5000001*5001958 2004042620091208
GX19G* *8000000*8003004 2004042620091208
GZ19G* *0600060*6035036 2004042620091208
HR22G* *1500000*1512511 2004042620091208
HR29G* *0200006*2029853 2004042620091208
HU29G* *6000000*6001000 2004042620091208
HX29G* *4000000*4000506 2004042620091208
HZ22G* *3500000*3507481 2004042620091208
HZ29G* *0400035*4018632 2004042620091208
YU59G* *8000000*8004274 2004042620091208
YZ59G* *0001002*0092992 2004042620091208
Fortuner
ZR69G* *0001002*0016372 2004042620091208
ZX69G* *0001001*0017561 2004042620091208
YU59G* *0001001*0008164 2004042620091208
Fortuner MR1 YX59G* *3000000*3013628 2004042620091208
ZX69G* *8000000*8006067 2004042620091208

KUN40 NO VIN DATA 50000005034144 2004101820091222

Innova
TGN40 NO VIN DATA 50000005019875 2004101820091222

Note:
# indicates that various characters may occupy that position.
Not all vehicles in these VIN ranges, are affected and/or sold in your country.
For the detailed list of concerned vehicles, please refer to the attached VIN list.

7
 2.2. VEHICLE IDENTIFICATION NUMBER LOCATION

VIN is stamped on the cowl panel. It is also stamped on the certification label as shown in
the illustration.
A: Certification Label
A

3. PREPARATION
3.1. Replacement components
Parts:
Part Name Part No. Qty Remarks
Spiral Cable FLD Kit 04004-07122 1
Only for Initial Order:
CABLE SUB-ASSY, SPIRAL 84306-04080
(Except VSC Vehicle)
GREASE 84323-42010

3.2. Spiral cable sub-assembly replacement

Special Service Tools (SST):
Illustration Part Name Part No. Qty Remarks

Puller C Set 09950-50013 1

For removal and
installation of the
steering wheel

Hanger 150 (09951-05010) 1

8
 Slide Arm (09952-05010) 1

Center Bolt 150 (09953-05020) 1

Claw No.2 (09954-05021) 1

Recommended Tools:
Part Name Part No. Qty Remarks
For DTC checks
GTS (Global Techstream) - 1 (Intelligent Tester can
also be used instead.)
For removal and
"TORX" Socket T30 - 1 installation of the horn
button

Equipment:
Part Name Part No. Qty Remarks
For checking tightening
Torque Wrench - 1
torque
Appropriate
Grease - For lubrication
quantity
Appropriate
Protective Tape - For component protection
quantity
For marking (any color
Appropriate
Marker Pen - other than green, blue
quantity
and yellow)

9
 4. WORK PROCEDURE

<TABLE OF CONTENTS>

A. WORK OUTLINE ...................................................................................................... 11

B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE............................................. 11
C. PRECAUTIONS FOR AIRBAG REMOVAL AND REINSTALLATION ......................12
D. PRECAUTIONS FOR ALL OPERATIONS ...............................................................14
E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG ................................................16
F. CHECK SPIRAL CABLE ..........................................................................................17
G. REPLACE SPIRAL CABLE ......................................................................................19

10
A. WORK OUTLINE

Checking if the vehicle is applicable to

this safety recall. If the vehicle is
applicable, replacing the spiral cable
with a new one.

B. CAUTION FOR LOCK PIN OF NEW SPIRAL CABLE

1. LOCK PIN FOR NEW SPIRAL CABLE

(a) DO NOT break/snap off the lock pin until just
installing the steering wheel. Otherwise, the
center position of a new spiral cable will be
misaligned.

11
C. PRECAUTIONS FOR AIRBAG REMOVAL AND
REINSTALLATION

If the airbag system is not removed or reinstalled by the specified

procedures, the airbag system may unintentionally be activated during
the work, causing a serious accident that could lead to death.
In addition, any errors in work could cause the airbag system to fail to
operate when necessary.
For that reason, pay careful attention to the instructions in this
document and ensure safety during your work.

1. DISCONNECT CABLE FROM NEGATIVE

BATTERY TERMINAL
(a) In order to prevent the airbag system from
unintentionally operating, disconnect the
negative battery terminal cable.
(b) Wait at least 90 seconds after the battery cable
is disconnected, to prevent possible
deployment of the airbag. The airbag system is
provided with a backup power supply.

2. REMOVE STATIC ELECTRICITY

(a) Touch any metallic portion of the vehicle body
to discharge the static electricity before starting
work.

12
 3. HANDLING OF AIRBAGS
(a) After the horn button is removed from the vehicle, place and store it so that the airbag
deployment surface faces upward.
CAUTION:
If the airbag is stored in an improper manner, a serious accident that could lead to death may
result if the airbag is activated unexpectedly.

13
D. PRECAUTIONS FOR ALL OPERATIONS

1. PRECAUTIONS WHEN RAISING VEHICLE

USING A LIFT OR JACK
(a) Refer to the respective repair manual and
follow the instructions within the Introduction
section to ensure safety when working.
(b) Ensure the safety of all personnel near the lift
or jack, including yourself, before beginning
work. Also announce all lift and jack operations
out loud to prevent any personnel from being
caught or harmed in any way.

2. WEAR PROTECTIVE EYEWEAR

(a) Wear protective eyewear when working under
vehicle or where there is any risk of flying parts
or debris.

3. DO NOT USE BRAKE CLEANER AS STAIN

REMOVER
(a) Do not spray brake cleaner onto any clothes
since it is a flammable solvent that vaporizes
easily. Do not use it near cigarettes or stoves
as this can cause serious burns and injuries.

4. AVOID BURNS
(a) If the engine is hot, wear protective gloves to
prevent burns.

14
5. VEHICLE PROTECTION
(a) A fender cover, a grill cover, seat covers tape
etc. must be used to protect the vehicle from
dirt or scratches.

NOTE:
The protective measures listed above may not be
shown in some illustrations to allow easy
identification of the work location and to make the
illustrations simple and easy to read.

6. HANDLING OF REMOVED PARTS

(a) Destroy or mark and then store removed parts
in a separate container so as to not be
assembled again in error.
(b) Check the removed parts when performing the
completion inspection.

NOTE:
The parts shown in the illustration to the left are
examples only and differ from the actual
replacement parts.

7. DO NOT BREAK PARTS WHEN WORKING

INSIDE ENGINE COMPARTMENT
(a) Do not break parts by carelessly placing hands
inside and leaning on the engine compartment
while being preoccupied by work.

8. CHECK INSIDE ENGINE COMPARTMENT

BEFORE ENGINE START-UP
(a) Check that all necessary parts are installed.
(b) Check that no tools or pieces of cloth are left
inside the engine compartment.

15
E. CHECK IF VEHICLE IS EQUIPPED WITH AIRBAG

1. CHECK IF SRS AIRBAG IS IMPRINTED

(a) Check if SRS AIRBAG is imprinted on the horn
button.

SRS AIRBAG Required procedure

Imprinted Check the spiral cable
Proceed to F. CHECK SPIRAL
(Equipped with the airbag) CABLE (Page-17)

Not imprinted
Return the vehicle to the customer.
(No airbag is provided)

16
F. CHECK SPIRAL CABLE

CAUTION:
For details about the component removal, refer to the respective repair manual.

1. CHECK NUMBER OF SPIRAL CABLE CONNECTORS

(a) Disconnect the negative battery terminal cable.
(b) Remove the horn button assembly.
(c) Check the number of spiral cable connectors.

Number of
Required procedure
connectors

Check the lot number (Page-18)

Reinstall the removed components,

and return the vehicle to the customer.

17
2. CHECK LOT NUMBER OF SPIRAL CABLE
(a) Remove the steering wheel assembly.
(b) Detach the upper steering column cover.
(c) Check the value of the lot number indicated by an arrow in the illustration below.

Value indicated by
Required procedure
an arrow
Reinstall the removed components,
(Zero) and return the vehicle to the customer.
Replace the spiral cable with a new
Values other than 0 one.
(zero) Proceed to G. REPLACE SPIRAL
CABLE (Page-19)

18
G. REPLACE SPIRAL CABLE

CAUTION:
For details about component removal, refer to the respective repair manual.

1. REMOVE LOWER STEERING COLUMN COVER

2. REMOVE SPIRAL CABLE

3. REMOVE STEERING ANGLE SENSOR (Vehicles equipped with Steering Angle Sensor)
(a) Detach the steering angle sensor from the spiral cable.

4. REGARDING LOCK PIN OF NEW SPIRAL

CABLE
CAUTION:
DO NOT break/snap off the lock pin until just
installing the steering wheel. Otherwise, the
center position of a new spiral cable will be
misaligned.

5. REINSTALL STEERING ANGLE SENSOR

(Vehicles equipped with Steering Angle
Sensor)
(a) In order to prevent noise from occurring, apply
a small amount of grease (included in the new
spiral cable kit) onto the surface at the 4
locations shown in the illustration.
(b) Attach the steering angle sensor to a new
spiral cable.

6. INSTALL NEW SPIRAL CABLE

(a) Install the new spiral cable to the vehicle.

7. REINSTALL UPPER AND LOWER

STEERING COLUMN COVERS

19
8. REMOVE LOCK PIN FROM SPIRAL CABLE
(a) Snap the lock pin (orange) off the new spiral
cable.
NOTE:
There is no problem even if the lock pin is pulled out
without separation.

(b) Check that the part of the lock pin staying in

the new spiral cable has not jut out from the
surface.

(c) If the part of the lock pin has jut out, push in it.

20
9. CHECK SPIRAL CABLE CENTER
POSITION
(a) With the matchmarks aligned, check that the
orange (or yellow) roller can be seen through
the sight window.
NOTE:
If the orange (or yellow) roller can be viewed from
the sight window, misalignment of the matchmarks
is acceptable.

10. REINSTALL STEERING WHEEL

ASSEMBLY

11. REINSTALL HORN BUTTON ASSEMBLY

< WHERE NEW SPIRAL CABLE HAS 2
CONNECTORS >

(a) Connect the spiral cables wire terminal to the

horn button assembly.
(b) Connect the spiral cables orange connector to
the horn button assembly.

21
 (c) Cut the black connectors cable as shown in
the illustration (near the wrapped tape).
CAUTIONS:
DO NOT connect the black connector. No
voltage is applied to the black connector.
In order to prevent abnormal noise from
occurring, remove the black connector by
cutting the cable.

(d) Reinstall the horn button assembly.

12. REINSTALL HORN BUTTON ASSEMBLY

< WHERE NEW SPIRAL CABLE HAS 1
CONNECTOR >

(a) Connect the spiral cables wire terminal to the

horn button assembly.
(b) Connect the spiral cables connector to the
horn button.
(c) Reinstall the horn button assembly.

22
13. REINSTALL STEERING WHEEL
ASSEMBLY

14. RECONNECT CABLE TO NEGATIVE

BATTERY TERMINAL

15. CHECK SRS WARNING LIGHT

16. CHECK THAT HORN, WIPERS AND

LIGHTS OPERATE PROPERLY

17. CHECK STRAIGHT AHEAD POSITION FOR

STEERING WHEEL

18. RESTORE SYSTEM SETTINGS AFTER

BATTERY RECONNECTION
(a) Power Window Control System
(b) Meter / Gauge System

23