Adjusting Cable Tension: Inner and Outer Cables
1. One tensioner at a time, grasp both tensioners and align them with the white marks on the housing, as shown in Figure 3.
A. Once the white marks are aligned on both tensioners, insert locating tools into the two holes, using any of the follow:
^ Plastic pins (supplied with a new power drive assembly)
^ or two 1/2" diameter wooden dowels
^ or two # 2 Phillips screwdrivers
Figure 3 shows a view from inside the vehicle with two screwdrivers in the proper position. Plastic pins or wooden dowels may be used in place of screwdrivers.
2. Technician # 1 inside the vehicle should have a 6-point 14 mm socket/ratchet wrench ready for use.
3. Using the outside door handle, Technician # 2 should manually open the sliding door slowly, while Technician # 1 inside the vehicle looks through stopper window until a blank section of the internal drum appears through the window (look for a section on the internal drum that has no ribs attached). (See Figure 4).
NOTE:
^ The stopper window is located on the side of the motor drive assembly,as shown in Figure 4.
^ The internal drum has a blank section and a ribbed section that will appear through the window as the internal drum rotates when Technician # 2 opens the sliding door manually.
NOTE:
DO NOT push the 14 mm nut inward - this will release the tension on the drum assembly.
4. Once the section of the drum without the rib appears in the stopper window, Technician # 1 should insert a # 2 Phillips screwdriver into the stopper window.(See Figure 4).
5. Once the screwdriver is in place slowly move the sliding door open position until the screwdriver becomes wedged between the internal drum and the motor housing. The door should be open approximately one 1/2 inch at this point. If it is not, try to move the door until it is open approximately one inch (with the screwdriver still wedged in place).
6. Technician # 2 outside of the vehicle should grasp the exposed rear cable (near the center roller) and pull on the cable using very little tension (see Figure 5). keep tension on the cable at all times.
7. While Technician # 2 outside continues to keep tension on the outside cable, Technician # 1 inside should attach a 14 mm 6-point socket/ratchet wrench to the plastic adjusting nut (attached to the inner drum assembly). Technician # 1: Rotate the nut counterclockwise. (Refer to Figure 6.) Technician # 2 outside of the vehicle should start to see the slack being removed from the outside cable, as the plastic 14 mm nut is being rotated counterclockwise. As soon as there is no longer any slack in the outside cable stop rotating the nut and remove the socket/ratchet wrench from the 14 mm plastic nut.
8. Remove the tools that were inserted in the drive unit (screwdrivers or plastic pins or wooden dowels.)
9. While watching the operation of the rear outside cable, Technician # 2 outside the vehicle should manually close the sliding door completely, then manually open the sliding door all the way, then manually close the sliding door completely.
NOTE:
Both inside and outside cables should now be properly tensioned. If the rear cable appears to have any slack in it, at any time, the cable adjustment procedure MUST be repeated until all the slack is removed.
10. IMPORTANT: Re-initialize the electrical system after reconnecting the battery. See TSB B0003-00, Power Sliding Door Diagnostic Procedure -'99 -'00 Sienna, dated January 28, 2000, for initializing procedure details.
11. Before reassembling the vehicle, confirm that the power function of the sliding door operates properly by pressing the power button in any of the following locations:
^ the door "B" pillar
^ or the dash
^ or the hand-held transmitter