Lighting - HID Headlamps Abnormal Operation
T-SB-0182-11November 23, 2011
HID Headlamp Abnormal Operation
Service Category
Vehicle Exterior
Section
Lighting (ext)
Market
USA
Applicability
Introduction
Some Limited model Sienna vehicles equipped with HID headlamps may intermittently exhibit a condition when starting the vehicle where either the left side or right side headlamp may not illuminate. The headlight will illuminate however if the headlight is cycled off then on.
An updated repair procedure is available to address this condition for vehicles built prior to the production change effective VIN below. Follow the procedures in this bulletin to diagnose the Power Integration (P1) relay.
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
Parts Information
Repair Procedure
This TSB addresses a condition that could occur on startup due to Power Integration (P1) Relay.
NOTE
Be aware that there are other possible causes for a HID headlamp to be inoperative. Original equipment type OEM specification bulbs & ballast (HID Computer) should be in place prior to diagnosis of a P1 Relay.
1. Preserve P1 history by ensuring the P1 Relay and battery are not disconnected prior to diagnosis.
2. Confirm with the customer the driver or passenger side low beam (HID headlight not high beam) was NOT operational when starting the car.
3. Verify battery voltage is within specifications as per the repair manual using a DVOM.
4. Verify the issue can be duplicated by starting the vehicle and monitoring the HID (low beam) bulb for illumination.
5. Turn the headlamp position stalk to the "Auto" low beam position, then start the vehicle and see if both driver and passenger side headlamps come on.
6. Record the results.
7. Make sure the engine and ignition are both off.
8. Open the hood.
9. Remove the lid to the Relay Block (fuse box).
10. The P1 Relay is located in the engine room fuse box.
11. Switch the headlamps from the 'Auto" position to the manual "ON" low beam position using the headlamp switch so the low beam headlamps will illuminate.
12. Use a DVOM to measure the voltage at Port 0.
13. Place the DVOM positive lead into the Port 0 hole, assuring good contact.
14. Place and hold the negative lead of the DVOM on the negative terminal of the battery.
15. Record the voltage value on the DVOM.
16. Remove the positive lead from the Port 0 and move it to the Port 1 assuring the negative lead is again held to the negative terminal of the battery and record the voltage.
A. If the voltage is less than 0.5 volts for either of the test ports then a failure has been recorded and the P1 Relay should be replaced. Go to step 17.
NOTE
If the vehicle's headlamp is not illuminated during the test and the Port 0 voltage is above 3.5 volts, or normal battery voltage is present at the HID ECU and the headlamp is not illuminated, the P1 Relay is not likely the source of the problem.
B. If voltages on both ports are above 3.5 volts then a failure has not been recorded and the repair manual should be consulted for further diagnosis. This TSB does NOT apply.
NOTE
This PI Relay has two potential voltages, above 3.5 volts and below 0.5 volts. If the volt meter reading is less than 3.5 volts but greater than 0.5 volts please retest the voltage reading or try a different DVOM to test the circuit.
17. Install NEW PI Relay.
A. Remove the PI Relay in the car by disengaging the two black retainer tabs at the ends of the relay as shown.
B. Turn the ignition OFF.
C. Disengage the 2 black retainer tabs at the ends of the relay.
D. Grasp and pull straight up on the PI Relay after both retainer tabs have been released.
E. Release all three connectors on the bottom of the PI Relay.
F. Plug the connectors in the new PI Relay and insert it into the fuse box. Assure the locking retainers are fully seated.
18. After completing repairs confirm normal headlamp system operation on startup using the headlamp stalk in the automatic low beam position and then remove the object previously placed over the light control sensor.
19. If after replacement of the PI Relay the headlamp still does not illuminate do not replace the PI Relay again.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual.
^ 2011 Sienna
Vehicle Exterior - Lighting (Ext) - "High Intensity Discharge Headlight Bulb: On-Vehicle Inspection".
^ 2011 Sienna
Vehicle Exterior - Lighting (Ext) - "Lighting System: Problem Symptoms Table".