Canada - Interior - Rattling Noise From The Instrument Panel

Bulletin
TSB2790R

Issue Date
July 16, 2007

Market
Canada

Title
INSTRUMENT PANEL RATTLE NOISE

Component
BODY COMPONENTS

Models
'07-'10 Camry & Camry HV

TSB REVISION NOTICE:

May 26, 2010: The entire content of this bulletin has been updated with the following changes:
- Applicable vehicle section has been updated.
- Warranty information section has been updated.
- Parts information section has been provided.
- Repair procedure has been updated to include 2009-2010 MY vehicles.

Previous versions of this TSB should be discarded. Be sure to review the entire content of this service bulletin before proceeding.

INTRODUCTION:

Some 2007 - 2010 model year Camry and Camry HV customers may experience a rattle noise from the instrument panel when driving on rough roads. The condition may also be worse when the weather is cold.

Use the following repair procedure to improve this condition.

APPLICABILITY:

WARRANTY INFORMATION:

PRODUCTION CHANGE INFORMATION:

REQUIRED TOOLS & MATERIALS:

PARTS INFORMATION:

REPAIR PROCEDURE:

NOTE
- For 2007-2008 MY Vehicles follow repair procedure A.
- For 2009-2010 MY Vehicles, follow repair procedure B.

Repair Procedure A

1. Record the radio station presets.
2. Remove the instrument panel sub-assembly.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Camry and Camry HV
- Year: 2007 / 2008
- Service Category: Vehicle Interior
- Section: Interior Panels/Trim
- Keyword: Instrumental Panel: Instrument Panel Safety Pad: Removal

3. Flip the instrument panel sub-assembly upside down and place on a clean blanket to protect the surface of the instrument panel.
4. Remove and inspect the 5 clips.
A. If the felt is worn, peeling or has any visible damage, then replace the clip (55328- 50170) before proceeding to step 5.

B. If the felt is not worn, peeling or does not have any visible damage, then proceed to step 5 using the existing clip.

5. Apply the NEW felt (55328-33140) starting at the top of the clip, making sure NOT to overhang the edge of the clip.

CAUTION
Attach the Felt by lining up the hole on the Felt with the hole on the Cowl Clip. To ensure proper re-installation it is important for the hole in the clip to be clear.

NOTE
After the holes are lined up, fold the felt around the clip. Make sure the Felt is secured into position.

6. Install the clips to the cowl panel.

CAUTION
The tab on the clip is located on the TOP of the clip.

7. Inspect the tightness of the two white clip holders that are screwed into the instrument panel.
A. Inspect for noise from the white clip holder. Lightly push the clip holders up & down.
B. If they make noise, remove the clip holder and add a small piece of EPT foam, (5 x 5 x 5 mm) from the wind noise kit, to the tip of the locating pin. Reinstall the white clip holder.

8. Add foam and felt to the defroster duct below the Instrument Panel.
A. Remove the defroster duct from the bottom of the instrument panel.
B. Separate the defroster duct and add foam and felt.

C. Add 0.5mm thick felt to the four edges of the "blades" (0.5 x 5 x 20 mm).

D. Add EPT foam (from the Wind Noise Kit) to the middle of the defroster duct in the "A" shaped area (5 x 5 x 30 mm).
E. Reassemble the defroster duct.

9. Inspect the condition of the upper duct clip on the HVAC box.

HINT
If tab is not fully locked in place, remove the upper duct assembly and bend the tab back into correct position.

10. Inspect the condition of wiring harness locating clips.
Verify the harness locating clip is fully seated. If NOT, fully seat the wiring harness clip.

11. Add foam to the base of the windshield/cowl top area.
The foam strip located at the base of the windshield, on the cowl structure should have an even impression where the edge of the instrument panel makes contact.

Add foam as needed to make sure that the instrument panel rests on foam and does not contact the cowl structure or windshield.

12. Add foam to the top of the defroster duct attached to the bottom of the instrument panel.
13. Install the instrument panel sub--assembly.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Camry and Camry HV
- Year: 2007 / 2008
- Service Category: Vehicle Interior
- Section: Interior Panels/Trim
- Keyword: Instrumental Panel: Instrument Panel Safety Pad: Installation Reset the radio presets and clock.

14. Test drive the vehicle to make sure that the noise is repaired.

Repair Procedure B

1. Record the radio station presets.
2. Remove the instrument panel sub-assembly.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Camry and Camry HV
- Year: 2009 / 2010
- Service Category: Vehicle Interior
- Section: Interior Panels/Trim
- Keyword: Instrumental Panel: Instrument Panel Safety Pad: Removal

B. If the felt is not worn, peeling or does not have any visible damage, then proceed to step 5 using the existing clip.

6. Install the clips to the cowl panel.

CAUTION
The tab on the clip is located on the TOP of the clip.

7. Install the instrument panel sub-assembly.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Camry and Camry HV
- Year: 2009 / 2010
- Service Category: Vehicle Interior
- Section: Interior Panels/Trim
- Keyword: Instrumental Panel: Instrument Panel Safety Pad: Installation

8. Reset the radio presets and clock.
9. Test drive the vehicle to make sure that the noise is repaired.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.