Kluger 2003 Grande Navigation System Fault

[Leon2003Kluger]

An intermittant fault has developed with the Navigation System / Multi Function Display. Typically, when I first start the car, the Trip Info screen comes up but there is no data in it - i.e. no temperature reading, no yellow fuel usage bar etc. If I press the Map key, the message "external system is not connected" comes up. If I press the climate key, the message "check air con is connected properly" comes up. The Audio system doesn't work either. After about 10 minutes of driving, everything will suddenly start to work normally - all the systems, all the data. Sometimes it will continue to work normally until the ignition is switched off, but other times it will close down again after 10 or so minutes of driving, and then start working again after another 10 or so minutes.

I took the car to a Toyota Dealership. They said they hadn't seen the fault previously in this model Kluger. To fix it, they said they would remove the unit and send it to Fujitsu 10 for repair. They quoted about $800 to remove and reinstall the unit, plus whatever Fujitsu 10 charged for the repair - which might be thousands...

I'm hoping someone has got some good advice, or has had some experience with this type of fault and can suggest a better option than the Dealership's one.

[peterlts]

An intermittant fault has developed with the Navigation System / Multi Function Display. Typically, when I first start the car, the Trip Info screen comes up but there is no data in it - i.e. no temperature reading, no yellow fuel usage bar etc. If I press the Map key, the message "external system is not connected" comes up. If I press the climate key, the message "check air con is connected properly" comes up. The Audio system doesn't work either. After about 10 minutes of driving, everything will suddenly start to work normally - all the systems, all the data. Sometimes it will continue to work normally until the ignition is switched off, but other times it will close down again after 10 or so minutes of driving, and then start working again after another 10 or so minutes.

I took the car to a Toyota Dealership. They said they hadn't seen the fault previously in this model Kluger. To fix it, they said they would remove the unit and send it to Fujitsu 10 for repair. They quoted about $800 to remove and reinstall the unit, plus whatever Fujitsu 10 charged for the repair - which might be thousands...

I'm hoping someone has got some good advice, or has had some experience with this type of fault and can suggest a better option than the Dealership's one.

I have exactly the same problem in an 04 Kluger. Did u resolve it?

Peter

[Leon2003Kluger]

An intermittant fault has developed with the Navigation System / Multi Function Display. Typically, when I first start the car, the Trip Info screen comes up but there is no data in it - i.e. no temperature reading, no yellow fuel usage bar etc. If I press the Map key, the message "external system is not connected" comes up. If I press the climate key, the message "check air con is connected properly" comes up. The Audio system doesn't work either. After about 10 minutes of driving, everything will suddenly start to work normally - all the systems, all the data. Sometimes it will continue to work normally until the ignition is switched off, but other times it will close down again after 10 or so minutes of driving, and then start working again after another 10 or so minutes.

I took the car to a Toyota Dealership. They said they hadn't seen the fault previously in this model Kluger. To fix it, they said they would remove the unit and send it to Fujitsu 10 for repair. They quoted about $800 to remove and reinstall the unit, plus whatever Fujitsu 10 charged for the repair - which might be thousands...

I'm hoping someone has got some good advice, or has had some experience with this type of fault and can suggest a better option than the Dealership's one.

I have exactly the same problem in an 04 Kluger. Did u resolve it?

Peter

[Leon2003Kluger]

Sorry to hear that Peter. No, I haven't been able to resolve the issue, but it hasn't been thru lack of trying...

I have isolated the problem to a specific Printed Circuit Board that has the following information printed on a blue sticker:

>>

>> "Board, Multidisplay No.2

>>

>> Toyota

>>

>> 86114 - 48010

>>

>> 134160 - 6820 12V

>>

>> Fujitsu Ten Limited, Japan"

>>

>> On the reverse side is the number: 134941-4400 F910

I have been to Fujitsu Ten Australia. They say they can't repair boards, and they won't supply me with a replacement board, because the MFD unit was supplied by another company called Denso. I went to Denso. They say they can't repair boards, and they can't supply a replacement board because Fujitsu Ten Limited Japan won't supply them with replacement boards!! The only solution Denso will offer is to supply a complete changeover unit for $2200. I don't have that sort of money, but wouldn't pay that much anyway for 10 year old technology - it's a total rip off.

I have contacted Fujitsu Ten Limited Japan directly to try to get a replacement board, but they won't deal with me and have just referred me back to Denso. So much for customer service...

I have located a couple of MFD units at Toyota wreckers, but they are in on the act as well, asking as much as $2500 for them. I have spoken to a few companies that specialise in automotive electronics remanufacture and repair of circuit boards. They work on all makes and models EXCEPT Toyota. They say this is because Toyota won't provide circuit diagrams whereas other car manufacturers will.

I'm out of ideas on what to do. Toyota, Fujitsu Ten and Denso have created a ludicrous situation for their supposed "valued customers", and it has ruined my family's enjoyment of the Kluger. The pity of it is that, apart from the stupid single point of failure design of the MFD system, it is a great car.

[peterlts]

I am surprised that there is not a commonly available repair procedure on the web given that this seems to be affecting a hell of a lot of systems in different Toyota models.

Just got to keep looking, there will be someone out there who knows how to fix this thing. Problem may be related to a custom Denso ASIC chip or some other part that you can not buy easily though.

Such a waste to have to throw away and otherwise working system and spend thousands replacing it, ughh.

I have noticed that when mine locks up that if I eject the GPS DVD then reinsert that the system usually comes back to life. Need to test this some more.

Cheers

Peter

Edited June 21, 2010 by peterlts

[peterlts]

Does anyone know specifically where the M4 & M3 connectors referred to in the Toyota Technical Bulletin are located?

http://www.vfaq.net/docs/TSBs/EL002-05.pdf

Highlander M4 Wiring Harness Side Connector

Highlander M3 Wiring Harness Side Connector

Some customers may experience various malfunctions occurring with the multi--display.

Some examples are:

“

• Audio Off” is shown on audio screen while audio system is playing.
  
• Climate control is not responsive and may say “Check connection of the air conditioner.”
  
• Map, Destination buttons are inoperative and may display “External system not connected.”
  
• When pressing any button on the multi--display, the system takes 5 to 10 seconds to respond to the user’s input.
  
• Outside air temperature is not displayed.
  

A revised multi--display has been developed to resolve these conditions.

NOTE:

If the TX+ or TX- wires are loose at the multi-display, the same symptoms will occur.

Please confirm that all connections at the multi-display are secure and that pin fit of the TX+ and TX- wiring is good before ordering a replacement multi-display.

• 1. Check all the TX terminals on the multi--display connectors (please see connector diagrams) and confirm the terminals are fully seated. Replace any damaged terminals or connectors.
  
• 2. Confirm the connectors to the multi--display are fully seated. Replace any damaged connectors.
  
• 3. If all the TX terminals are tight and the connectors are fully seated, replace the multi--display.
  

I presume they are referring to the connectors plugged into the back of the actual display?

If anyone has had any success checking, cleaning or replacing these connectors let me know, thanks.

Peter

[peterlts]

Apparently there is a repair place in the US who may be able to tackle these repairs, anyone had any experience with:

Tom Jeroski

Mr. Whizard Technical Services

http://www.mrwhizard.com

Cheers

Peter

Edited June 22, 2010 by peterlts

[peterlts]

UPDATE - PROBLEM FIXED!

After searching Google extensively I have found the simple solution and have followed the instructions as many other have and fixed the problem for $20 and about 1 hour of time.

An exhaustive study has been done by an engineer in the US who believes the problem is associated with a poorly designed circuit board that has a large 60 pin connector on it. What happens is that when the board is made and tested in the factory it passes all tests. The board is then fitted to a GPS display head unit in a metal case, pretty standard manufacturing procedure. The 4 screws are used in the cases, here is the problem, the case is not properly aligned with the circuit board so the circuit board is pulled a few mm to one side putting a sideways pulling pressure on the 60 pin connector.

This pulling action combined with the naturally hostile car environment of bumps, vibrations, etc forces the connector to move and start to tear the contact pads that it is soldered to creating the tiniest of cracks.

The solution is to open the unit, remove the circuit board, resolder some or all the connections to the 60 pin connector and refit it and see if that resolves it.

This guy has now fixed 3-4 of the displays with 100% success rate.

The Link

This is the Toyota forum the guys belongs to, I read this post and found lots of people had tried his fix with 100% success.

Toyota User Forum

The $20 I actually spent was to pay an electronics tech with small tip soldering capabilities and a 30X microscope.

The screen has now been operating for about 4 hours over about 8 trips without failing. Normally over these 8 trips the screen would have failed and then started working again every 10-30 minutes so my test is not exhaustive but it looks good.

Cheers

Peter

[NimrodAUS]

Sounds like XBOX 360 RROD all over again.

[Leon2003Kluger]

Mine's now fixed too!! Followed Peterlts's research and advice. It was exactly the same problem...

[tfewster]

Mine's now fixed too!! Followed Peterlts's research and advice. It was exactly the same problem...

I would appreciate your advice on this issue as i have the same problem with a 2004 Kluger Grande - Could I have the details of who fixed yours? Can you advise where i could get it done in Melbourne?

Thanks

Tim

[Rabih (Rob)]

Mine's now fixed too!! Followed Peterlts's research and advice. It was exactly the same problem...

I would appreciate your advice on this issue as i have the same problem with a 2004 Kluger Grande - Could I have the details of who fixed yours? Can you advise where i could get it done in Melbourne?

Thanks

Tim

Tim, Peter, Leon, anybody,

I have the same problem with my 2004 Kluger Grande. I had the display unit removed and took it to an electrician, he followed Peter's instructions and yesterday we installed it back but this morning it still has the same problem. Can you tell me who fixed your display. I live in Hervey Bay, Queensland and it would be great if I could get the nearest technician.

My email: rassaf1@yahoo.com

Regards,

Rabih (Rob)

Edited September 3, 2010 by Rabih (Rob)

[Leon2003Kluger]

Mine's now fixed too!! Followed Peterlts's research and advice. It was exactly the same problem...

I would appreciate your advice on this issue as i have the same problem with a 2004 Kluger Grande - Could I have the details of who fixed yours? Can you advise where i could get it done in Melbourne?

Thanks

Tim

Tim, Peter, Leon, anybody,

I have the same problem with my 2004 Kluger Grande. I had the display unit removed and took it to an electrician, he followed Peter's instructions and yesterday we installed it back but this morning it still has the same problem. Can you tell me who fixed your display. I live in Hervey Bay, Queensland and it would be great if I could get the nearest technician.

My email: rassaf1@yahoo.com

Regards,

Rabih (Rob)

[kluger03]

i have the same problem with my Kluger 2003. Will it work for me??

[tfewster]

i have the same problem with my Kluger 2003. Will it work for me??

Hi,

Should work on any of the first few years of the Kluger models. I got mine resoldered and put it back in but it didn't work. So I then bought a replacement unit from a wrecker for $2000. Put that in and it worked straight away. Expensive fix. Then I did something stupid and tried the old one again. Geuss what - The damn thing worked. So now i have two working units.

Anybody want one?

Thanks

Tim

[Kim Vo]

Hi alls

I have the same problem but can someone help me how to remove the sat nav system and get the ciruit board out . I don't know how to take it off. give some instruction please. can i also do the resoldering my self because i can't find any electrician around my place. help me please.

Thanks a lot.