2/26/2016

2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

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2001ToyotaSiennaJBL
SpeakerDisassemblyand
Repair
Therightfrontdoorspeakersinmy2001ToyotaSienna
startedmakingarattlingnoise.Prettysoontheleftfront
speakersfollowedandIcouldnotlistentomusiclikeI
usedto.Thisreportwillexplainhowtorepairorreplace
thesespeakers.ThisreportshouldapplytotheToyota
Siennamodelsfrom1998to2003,whichusesimilar
components.
TheaudiosystemisbyJBL.Thereare6speakerstotal:2
tweetersatthesidesofthefrontdash,2midbassor
subwoofersspeakersatthefrontbottomcornersofthe
frontdoors,andtwomidrangespeakersattherear.The
speakersthatweneedtoreplace(orrepair)are6.5
inchesindiameteranduseacustomToyotaadaptorand
areoptimizedtoproducelowerfrequencysounds.They
areratedfor30wattsandhaveimpedanceof2.2ohms,
andtheirpartnumberis8616008110.
Firstensurewindowsareallthewayupanddoorlocks
areintheunlockedpositionsoyoudontaccidentally
damagethewindowsorlockyourselfout.Getalongish
flatheadandthinscrewdriverorsimilartoolandcoverthe
tipwithtapesufficientlysoitwontdamagethetrim.
Insertthescrewdriveratthefrontedgeofthearmrest
panelandgentlypryitup.Thescrewdriverneedstogo
underthepanelaboutaninchorsoandwhentheclip
hasreleasedyoushouldhearapopnoise.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Nextjustuseyourhandandpullthepanelstraightup
fromtheloosenedareaandyoushouldfeelmoreofthe
restrainingclipsrelease.Gofromthefronttotherearas
showninthefollowingimages.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Youshouldhearanotherpopnoiseasthesecondmetal
restrainingclipisreleased.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thearmrestpanelshouldnowbecompletelyfree.Setit
aside.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Nextfindthecourtesylightlocatedattherearcornerof
thedoor.Inserttheflatheadscrewdriverbehindthegrey
enclosureandpryitgentlyfrombothsides.Oneside
shouldcomeouteasierthantheother.Thelight
enclosurehasaclearplasticcoverwhichmayfallout
whileyouretryingtoremoveit.Itsnapsbackoneasily.
Alsothereisametallicclipononesidewhichmayfallout
orinsidethedoorpanel.Italsofitsbackintothesideof
thegreyenclosureeasily.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Itshouldcomeouteasily,withoutusingtoomuchforce.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Releasetheconnectorandwireandplaceitbackinside
thedoorpanelsoitdoesntgetinthewaywhen
removingthepanel.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Nextitstimetoremovethedoorlockbezel.Removethe
screwlocatedatthecenterofthedoorlockhousing.

Inserttheflatheadscrewdriverbetweenthelockand
plasticbezelandgentlypryitpartiallyout.Theninsert
thescrewdriverbetweenthedoorreleasehandleandthe
plasticbezelandpryitthereaswell.Gobackandforth
betweentheseareastoreleasethebezel.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Itshouldreleasefullywithouthavingtousetoomuch
force.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Mostofeverythingthatneedstoberemovedinorderto
takeoutthedoorpanelhasbeenremoved.Nextweneed
toremovethe3remainingscrews(thereare4total).
Thereare2locatedbehindthearmrest,soremovethose
andstorethemawaysafely.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thefinalscrewislocatedbehindabuttonatthefrontof
thedoor.Gentlypryallaroundthebuttonusingthe
flatheadscrewdriver,releasingitabitatatime.Once
youhaveitoff,removethescrewlocatedbehindit.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Beforethedoorpanelcancomeoffcompletely,youalso
needtoremovetheautomaticlockandwindowcontrol
unit.Youhavetoinsertascrewdriverinthefront,and
presswithalotofforceandpullthefrontup,butthisis
verydifficulttodo.Aneasierwaytodothisistotakeoff
thedoorpanelpartially,andtoreleasetheunitfromthe
inside.

Sonowletsremovethedoorpanel,partially.Todothis,
tugatthebottomcompartmentasshown,andtheentire
bottomshouldcomefree.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Nextyouhavetoreleasetherearsideofthedoor.Thisis
abitmoredifficult,butstilleasy.Therearetwoplastic
clipsholdingthepaneltothesheetmetal,andyouhave
toreleasethemusingyourflatheadscrewdriver.Insert
thescrewdriver(coveredwithtapeandalsoperhapsan
oldrag)neartheareawherethetwodifferenttypesof
plasticsmeet.Insertitinaboutaninchortwoandgently
prythescrewdriveruntilyouhearapopnoiseandthe
panelcomesfreeatthatarea.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Anotherclipislocatedslightlylower,soyouneedtodo
thesamethingabitlower.Youcanpullthepanelouta
bitwithyourhandstodeterminethelocationoftheclip.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thebottomandrearsideofthedoorpanelshouldbe
completelyfree.Nowtherearetwohooksholdingthe
paneltothesheetmetalnearthetopfrontandtoprear
areas.Youhavetograbthetopofthepanelnearthe
windowattherearandpullitup,usingabitofforce,
untilitunhooksandcomesfree.Youhavetodothesame
atthetopfrontarea.Thedoorpanelshouldnowbe
completelyfree,butbeforeyoucansetitasideyouhave
tounhooktheautomaticlockandwindowcontrolunit
wires.

Todothis,putyourhandbehindthepanelafterithas
comefreefromthesheetmetal,andpressatthefrontof
theunituntilitisreleased.Ithelpsifyouhaveanother
personholdingthepanelwhileyouaredoingthis.Takea
lookatthefollowingpictures.Itshouldcomeoutquite
easily.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Hookthedoorpanelbackintothesheetmetalwhileyou
workonremovingthisunit.Pulltheunittothefront

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

enoughtoreleaseclipattheback,anditshouldbe
completelyfree.

Youhavetodisconnectthetwoconnectors.Onthe
passengersidetherearetwoconnectorswhileonthe
driverssidethereisonlyone.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Useascrewdriveroryourhandstopressintheconnector
clipswhileyoupullitout.Itshouldcomeoutwithout
usingtoomuchforceaswell.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

(Onthedriverssideitisabitdifferent.)

Sowitheverythingoff,thedoorshouldlooklikethis.Lift
atthetoprearandtopfrontnearthewindowareato
releasethepanelcompletely.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Theplasticdoorpanelshouldcomeoffcompletely.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thespeakerwireconnectorneedstobereleasednext.It
islocatednearthefronttopofthedoor.Ithasgreenand
bluewiresatthepassengersideandpurpleandpinkon
thedriversside.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Pulldowntheplasticwaterproofingmaterialjustabit.
Youcanusewaxpapertocoverthegluedareaonthe
plasticsoitdoesnotcollectdust.Next,releasethe
connector.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Oncetheconnectorshavebeenreleased,youhaveto
removethespeakerwirefromthesheetmetal.Itis
attachedviaahook.Useaflatheadscrewdrivertogently
pryitout.Becarefulnottopressorpulltoohard,asthe
clipisfragileanditcouldbreak.

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Belowisthesamewireonthedriversside.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thefinalstepistoremovethespeakerassembly.There
arethreescrewsthatattachittothesheetmetal.Loosen
thescrewsinanalternatingmanner,andthenremove
themallandpulloutthespeakers.

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Themostcommonproblemisthattheglueholdingthe
outeredgeofthefoamhasdeterioratedandthefoam
edgingisnotattached.Ifyouarejustlookingtorepair
thespeakers,simplyattachthefoamedgingbacktothe
metalassemblyusingsuperglueorotherstrongadhesive
andletdryfor24hours.Makesurewhenhandlingthe
foamyouarenottooaggressiveasitmaybreakdown
further.

Replacement:

Ifyouarelookingtoreplacethespeakers,thenthereare
fourmorescrewsyouneedtoremove.Oncethosehave
beenremoved,therearetwoclipsbetweenthespeakers
andthebackthickhousingunit.Youneedtoinserta
flatheadscrewdriverbetweenthesetwosmallclipsand
prytoremovethespeakers.Thereisagasketbetween
theplasticassemblyandspeakersattachedwithglue,
andyouneedcarefullydeattachthataswell.

ReplacethespeakerswithOEMJBL8616008110,or
purchasea6.5"midbassorsubwooferunitsuchas
PyramidWX65X(lessbass,morerange~703500hz)or
Kicker10CVT654(morebass,lessrange~25350hz).

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2001 Toyota Sienna JBL Speaker Disassembly and Repair - prabhu

Thereplacementspeakerscanbe4ohmimpedanceunits
withoutproblems,butshouldntbe2ohmor8ohm.If
youtrytoreplacethespeakerswithafullrange6.5"
speakersuchastheonescommonlyrecommendedat
audioorelectronicsshops,youmaybedisappointedas
theydontworkwell(intermsofperceivedaudioquality)
withtheoriginaldesignofthesystem.Inordertoattach
aftermarketspeakerstotheplastichousingyoumay
havetousewashersand#83/4"sheetmetalscrews.
Thesecanbefoundatautoorhardwarestores.

Conclusion:Trytofixtheoriginalspeakers,orgetthem
cheaplyrefoamedusingaDIYkitorbyaprofessional.
Aftermarketspeakerinstallationisalsoanoption,but
maytakemoreworkandyoucantbesurethequality
willmatchtheoriginalJBLs.Forbestresultwith
aftermarketspeakersgetmidbassorsubwoofers
designedtoworkatabout3035watts.

Update(March2013).Itriedsomefullrange6.5"
speakersandIwasnotsatisfiedwiththequalityor
fullnessofsound.Ialsotriedtheaboverecommended
Pyramidspeakersbuttheyfailed(producedasimilar
rattlingnoise)after14monthsofusage.Howeverin
thosefewmonthstheysoundedreasonablygood.
YoucanchoosebetweentheKicker,oranotherreliable
pairofmidbassspeakersdependingonwhatyouare
lookingfor.Anothergoodoptionistopurchaseare
edging/refoamingkitandreplacetheouterdamaged
foamoftheoriginalspeakers.Alocalspeakerrepairshop
maybeabletodothatprocedureforyou.
Also,tothebestofmyknowledge,2ohmor4ohm
impedancespeakerunitsshouldbecompatiblewiththe
audiosysteminthisvehicle.

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