Cell Phone - Safety Connect(R) Volume Too Low

T-SB-0226-12

November 15, 2012

Safety Connect Volume Improvement

Service Category
Audio/Visual/Telematics

Section
Audio/Video

Market
USA

Applicability

Introduction

Some 2012 model year Prius and Prius PHV vehicles may exhibit a lower speaker volume on the Safety Connect system. An updated wire harness is available to address this condition.

Production Change Information

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown.

Warranty Information

Parts Information

Required Tools & Equipment

Procedure Overview

^ Section 1: Diagnostic Procedure

This procedure will determine the correct repair method.

^ Section 2: Wire Harness Repair Procedure

This section will provide the detailed steps to install the new sub-wire harness.

^ Section 3: Verify Repair

This procedure will verify audio performance of the Safety Connect Function and the audio system.

^ Section 4: Electrical Wiring Diagram

Use this diagram to verify the new sub-wire harness installation.

Section 1: Diagnostic Procedure

1. Place vehicle in "IG-ON" mode. Wait about 15 seconds.

NOTE

Do NOT press brake pedal. Press Power switch twice.

2. Press the SOS button located on the overhead map light assembly. Then within 10 seconds, press the SOS button a second time (to cancel SOS call placement).

NOTE

The Safety Connect system when functioning with a valid account will facilitate audio communication with an emergency call center agent. The purpose of pressing the SOS button a second time is to terminate the call so that an emergency is not presumed by the Safety Connect call center.

3. Is there an audio prompt heard?

^ YES - Continue to step 4.

^ NO - STOP. Diagnose for inoperative Safety Connect function per the Repair Manual.

4. Was the audio prompt loud and clear?

^ YES - STOP. This bulletin does NOT apply.

^ NO - Proceed to the Wire Harness Repair Procedure in this bulletin.

5. Shut off car.

Wire Harness Repair Procedure

1. Remove the negative (-) terminal from the battery.

2. Remove the integration control and panel assembly.

A. Using a plastic pry tool slightly lift the panel at the position shown in the illustration.

B. Pull the integration control and panel assembly in the direction indicated by the arrow to disengage the 6 claws.

C. Disconnect each connector and remove the integration control and panel assembly.

3. Remove the lower center instrument cluster finish panel sub-assembly.

A. Pull the lower center instrument cluster finish panel sub-assembly in the direction indicated by the arrow to disengage the 2 claws and 2 clips.

B. Pull the lower center instrument cluster finish panel sub-assembly in the direction indicated by the arrow to disengage the 5 claws and remove the lower center instrument cluster finish panel sub-assembly.

4. Remove the No. 1 side defroster nozzle.

5. Remove the No. 2 instrument panel register.

6. Remove the glove compartment door.

A. Disengage the claw and release the glove compartment door stopper.

B. Insert the pry tool into the location shown in the illustration.

C. Move the pry tool in the direction indicated by the arrow to bend the lower instrument panel sub-assembly and release the stopper.

7. Remove the front door scuff plate RH.

8. Remove the cowl side trim sub-assembly RH.

9. Remove the right (passenger) side front seat.

Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:

^ 2012 Prius:
Vehicle Interior - Seat - "Seat Front Seat Assembly (for Power Seat) / (for Manual Seat): Removal"

^ 2012 Prius PHV:
Vehicle Interior - Seat - "Seat Front Seat Assembly (for Power Seat) / (for Manual Seat): Removal"

10. Remove the audio amplifier cover.

This is located just below where the passenger seat was just removed. Disengage the 2 clips and 2 claws and remove the audio amplifier cover.

11. Follow the next steps to install the new sub-wire harness. Highlighted (green) line shows the approximate route of the new sub-wire harness. The (red) circles show the location of connectors LI1 and NL2.

A. Disconnect connector LI1. Install both connectors from the new sub-wire harness into both sections of connector LI1.

B. Install sound insulation from new sub-wire harness kit around connector LI1. The recommended width of the sound insulation is about 75 mm (3.0 in.).

C. Route the new sub-wire harness. Attach tie wraps at red arrow location to secure the new sub-wire harness.

D. Continue to route the new sub-wire harness along right side lower dash just behind the glove box area.

E. Disconnect connector NL2. Install both connectors from the new sub-wire harness into both sections of connector NL2.

F. Secure the new sub-wire harness near connector NL2.

12. Unplug connectors L142 and L143 from the audio amplifier.

13. Identify the 4 wires which are to be cut and re-routed in the amplifier harness. These wires come from the terminals in connector L142 shown in Figure 21.

14. Mark the amplifier harness wires in the following locations with a light color ink marker pen.

Mark the BLUE wire from terminal 24 and LIGHT GREEN wire from terminal 9 at3O mm (1.18 in.) and 90 mm (3.54 in.) distances from connector L142.

15. Cut the following wires on the audio amplifier harness at a distance of 60 mm (2.36 in.) from the amplifier connector L142.

16. Remove 8 mm (0.32 in.) of insulation from the ends of the recently cut wires. There are 8 wire ends to remove insulation from.

17. Install the BLUE wire from terminal 30 splice to marked BLUE wire on amplifier harness that goes to the center console.

A. Identify the BLUE wire at the audio amplifier L142 connector terminal 30.

B. Identify the marked BLUE wire at the amplifier harness that goes towards the center console.

C. Install the thermo tubing on the marked BLUE wire.

NOTE

Move thermo tubing away from the referenced wire ends so that thermo tubing does not interfere with the next wire crimping operation.

D. Install a barrel sleeve onto each of the recently modified BLUE wires.

E. Place the sleeve into the 1.25 mm crimp die of the SST.

SST: 009042-2C100

F. With the sleeve correctly placed in the SST and wire fully inserted into the sleeve crimp one side of the sleeve in the area shown by closing the handles fully until they release. Crimp the other wire in the same manner.

G. Lightly tug on each connection to ensure that the wire is securely crimped.

H. Move the thermo tubing along on the wire in a manner that it covers the metal sleeve. Center the thermo tubing over the center of the barrel sleeve.

I. Using a heat gun, heat the thermo tubing until it shrinks and seals the repaired connection.

18. Install the LIGHT GREEN wire from terminal 15 splice to marked LIGHT GREEN wire on amplifier harness that goes to the center console.

A. Identify the LIGHT GREEN wire at the audio amplifier L142 connector terminal 15.

B. Identify the marked LIGHT GREEN wire at the amplifier harness that goes towards the center console.

C. Install the thermo tubing on the marked LIGHT GREEN wire.

NOTE

Move thermo tubing away from the referenced wire ends so that thermo tubing does not interfere with the next wire crimping operation.

D. Install a barrel sleeve onto each of the recently modified LIGHT GREEN wires.

E. Crimp the sleeve to attach the referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 17E to 17I for the referenced wires.

19. Install the marked BLUE wire from terminal 24 splice to BLUE wire on amplifier harness that goes to the center console.

A. Identify the BLUE wire at the audio amplifier L142 connector terminal 24.

B. Identify the BLUE wire at the amplifier harness that goes towards the center console.

NOTE

Move thermo tubing away from the referenced wire ends so that thermo tubing does not interfere with the next wire crimping operation.

C. Install the thermo tubing on the BLUE wire.

D. Install a barrel sleeve onto each of the recently modified BLUE wires.

E. Crimp the sleeve to attach the referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 17E to 171 for the referenced wires.

20. Install the marked LIGHT GREEN wire from terminal 9 splice to LIGHT GREEN wire on amplifier harness that goes to the center console.

A. Identify the LIGHT GREEN wire at the audio amplifier L142 connector terminal 9.

B. Identify the LIGHT GREEN wire at the amplifier harness that goes towards the center console.

C. Install the thermo tubing on the LIGHT GREEN wire.

NOTE

Move thermo tubing away from the referenced wire ends so that thermo tubing does not interfere with the next wire crimping operation.

D. Install a barrel sleeve onto each of the recently modified LIGHT GREEN wires.

E. Crimp the sleeve to attach the referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 17E to 17I for the referenced wires.

21. Reattach electrical connector L142 and L143 to the audio amplifier.

NOTE

Re-secure harness loom cover to harness. Use electrical tape to secure as required.

22. Reinstall cover on audio amplifier.

23. Install the left (driver) side front seat.

Refer to TIS, applicable model and model year Repair Manual:

^ 2012 Prius:
Vehicle Interior - Seat - "Seat Front Seat Assembly / Installation"

^ 2012 Prius PHV:
Vehicle Interior - Seat - "Seat Front Seat Assembly / Installation"

24. Reinstall the removed dash trim panels. Perform steps 8 - 2 in reverse order.

25. Reinstall the negative (-) battery terminal.

Section 3: Verify Repair Procedure

1. Place car into "READY ON" mode. Wait about 30 seconds to allow the navigation unit to read the HDD data.

2. Turn on radio and test audio operation. Listen to front door and front dash speakers.

Is the sound quality acceptable?

^ YES - Continue to step 3.

^ NO - STOP Verify wiring routing from steps 17 - 20. If wire routing is correct, diagnose per Repair Manual.

3. Test Safety Connect system. Press SOS button ONCE, listen to the audio prompt, and then press AGAIN (ONCE) to terminate call.

Is Safety Connect sound level acceptable?

^ YES - Repair is complete.

^ NO - STOP Diagnose per Repair Manual.