Rattle From Upper Instrument Panel Area - Interior
T-SB-0304-08Rev1
September 30, 2008
Upper Instrument Panel Rattle
Service Category
Vehicle Interior
Section
Interior Panels/Trim
Market
USA
Applicability
TSB REVISION NOTICE
^ April 29, 2009 Rev1:
^ The repair section has been updated to include Sedan repair procedure.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some customers of 2007-2008 Toyota Yaris vehicles may experience a condition where the instrument panel makes a rattling noise. Please use the following repair procedure to address customer concerns.
Required Tools & Equipment
Additional SSTs may be ordered by calling 1-800-933-8335.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive 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 correction of a problem based upon a customer's specific complaint.
Parts Information
Disassembly Procedure
NOTE
All bolts, screws and nuts relevant to installing and removing the instrument panel are shown, along with their alphabetic codes, in the above table.
1. Disconnect the negative battery terminal.
CAUTION
Wait for at least 90 seconds after disconnecting the battery cable to prevent possible airbag deployment.
2. Disengage the 2 claws and 2 clips and remove the instrument panel finish panel lower center.
3. Disengage the 6 claws and 3 clips and remove the instrument panel finish panel end LH.
4. Remove the instrument panel finish panel end RH.
NOTE
Use the same procedure as for the LH.
5. Disengage the 7 claws and 5 clips and remove the instrument cluster finish panel.
6. Remove the combination meter assembly.
A. Disconnect the 2 connectors.
B. Remove the 2 screws and pull the combination meter towards the rear of the vehicle to remove it.
7. Remove the front Right and Left door opening trim weather strip.
8. Remove the front pillar garnish RH.
A. w/ Curtain Shield Airbag:
(1) Install a protective cover onto the curtain shield airbag as soon as the front pillar garnish is removed.
(2) Replace the special clip with a new one when the front pillar garnish is removed.
(3) Disengage the 2 clips and the 2 claws and remove the front pillar garnish.
(4) Completely cover the curtain shield airbag with a piece of cloth or nylon and secure the ends of the fabric with adhesive tape as shown in the illustration.
B. w/o Curtain Shield Airbag:
^ Disengage the 2 clips and the 2 claws and remove the front pillar garnish.
9. Remove the front pillar garnish LH following the procedures from step 8.
10. Remove the glove compartment door assembly.
A. Disengage the claw and separate the 2 glove compartment door stoppers from the door.
B. Slightly flex the upper part of the glove compartment door to release the 2 stoppers and open the door assembly until it becomes horizontal.
C. Pull the glove compartment door assembly out horizontally to disengage the hinge portion and remove the glove compartment door.
NOTE
Pull the glove compartment door out horizontally, to prevent excessive play around the hinge and possible installation problems.
11. Remove the upper instrument panel sub-assembly.
A. Move the slider and disconnect the passenger airbag connector.
B. Disconnect the clamp.
C. Remove the 2 "C" bolts and 2 "B" screws.
D. Disengage the 7 clips while lifting the instrument panel up. Slide the instrument panel toward the rear of the vehicle to disengage the 5 claws at the front of the instrument panel.
Hatchback
NOTICE
All bolts, screws and nuts relevant to installing and removing the instrument panel are shown, along with their alphabetic codes, in the above table.
1. Disconnect the negative battery terminal.
Wait for at least 90 seconds after disconnecting the cable to prevent possible airbag deployment.
2. Remove the instrument panel finish panel end LH.
A. Pull the instrument panel finish panel end LH rearward and disengage the 5 claws and 3 clips.
NOTICE
^ To avoid damaging the instrument cluster finish panel center and the air conditioning panel, remove the instrument panel finish panel end without using any tools.
^ Grip portion A of the instrument panel finish panel end to remove it from the lower side.
B. Disconnect the connector and remove the instrument panel finish panel end LH.
3. Remove the instrument panel finish panel end RH.
A. Pull the instrument panel finish panel end RH rearward and disengage the 5 claws and 3 clips.
NOTICE
^ To avoid damaging the instrument cluster finish panel center and the air conditioning panel, remove the instrument panel finish panel end without using any tools.
^ Grip portion A of the instrument panel finish panel end to remove it from the lower side.
4. Remove the instrument cluster finish panel.
A. Disengage the 2 claws and 5 clips.
B. Insert your finger into the opening as shown push the upper portion of the instrument cluster finish panel center and the 2 "B" claws of the instrument cluster finish panel, and then disengage the claws "B". Disengage the 3 "A" claws and remove the instrument cluster finish panel.
Claw A may break if the instrument cluster finish panel is raised carelessly.
5. Remove the combination meter assembly.
A. Disconnect the 2 connectors.
B. Remove the 2 screws and pull the combination meter rearward to remove it.
6. Remove the front door opening trim weatherstrip RH.
7. Remove the front door opening trim weatherstrip LH.
Use the same procedure as for the RH side.
8. Remove the front pillar garnish RH.
A. w/ Curtain Shield Airbag:
(1) Install a protective cover onto the curtain shield airbag as soon as the front pillar garnish is removed.
(2) Replace the special clip with a new one when the front pillar garnish is removed.
(3) Disengage the 2 clips and the 2 claws and remove the front pillar garnish.
(4) Completely cover the curtain shield airbag with a piece of cloth or nylon and secure the ends of the fabric with adhesive tape as shown in the illustration.
B. w/o Curtain Shield Airbag:
Disengage the 2 clips and the 2 claws and remove the front pillar garnish.
9. Remove the front pillar garnish LH.
NOTE
Use the same procedure as for the RH side.
10. Remove the No.1 switch hole base.
A. Disengage the 2 clips and 2 claws and remove the switch hole base.
11. Remove the glove compartment door assembly.
A. Slightly deform the upper part of the glove compartment door assembly to release the 2 stoppers and open the glove compartment door assembly until it becomes horizontal.
B. Pull the glove compartment door assembly out horizontally to disengage the hinge portion and remove the glove compartment door assembly.
Pull the glove compartment door out horizontally, otherwise, installation failure caused by excessive play around the hinge portion will result.
12. Remove the upper instrument panel sub-assembly.
A. Slide the slider and disconnect the passenger airbag connector.
B. Disconnect the clamp.
C. Remove the 2 "C" bolts and 4 "B" screws.
D. Disconnect the connectors.
E. Disengage the claw and 3 clips while lifting the instrument panel up. Slide the instrument panel toward the rear of the vehicle to disengage the 5 claws at the front of the instrument panel.
Repair Procedure
1. Insulate the upper cowl attachment locations.
A. Cut 0.5 mm thick felt from the Interior noise kit to dimensions of 25 mm x 30 mm.
B. Apply 0.5 mm felt around the 5 indicated attachment locations along the upper cowl.
NOTE
^ Apply the felt to the upper cowl with the felt folded along the 30 mm side.
^ Yaris Hatchback shown. Yaris Sedan is similar.
(Sedan only)
2. Insulate Combination Meter and Cluster Cover.
A. Cut 2 pieces of 0.5 mm thick felt in the shape shown.
B. Peel oft the 2 factory white felts located on the top of meter cluster.
C. Apply the felt by starting at the base of the backside of the tab and fully wrap the front portion of the tab.
D. Cut 2 pieces of 1.0mm thick felt in the shape shown.
E. Apply the felt to the backside of the cluster finish panel at location shown.
3. Assemble components in reverse order of removal.
4. Test drive vehicle to verify repair.