TECHNICAL INSTRUCTIONS

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Wesley Long
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1 TECHNICAL INSTRUCTIONS Auris, Corolla, Verso, Aygo Yaris, RAV4, iq, Avensis, Sequoia ACCELERATOR PEDAL REINFORCEMENT BAR INSTALLATION PAGE 1. OPERATION FLOW CHART IDENTIFICATION OF INVOLVED VEHICLES VEHICLE IDENTIFICATION NUMBER RANGE VEHICLE IDENTIFICATION NUMBER LOCATION PREPARATION WORK PROCEDURE

2 1. OPERATION FLOW CHART Check whether or not the vehicle has the affected vehicle VIN number. No End YES Confirm accelerator pedal part number. NG OK No further action required. + Put a discrimination mark on the top of left side bolt or nut. Measure the pedal clearance and install the appropriate reinforcement bar. Put a discrimination mark on the top of left side bolt or nut. Record IT2 Data List Values on repair order for claim purpose Finish - 2 -

3 2. IDENTIFICATION OF INVOLVED VEHICLES 2.1. VEHICLE IDENTIFICATION NUMBER RANGE Refer to the "Affected VIN range list" that has been sent separately. IMPORTANT: Not all vehicles in the VIN range are affected. As always, confirm VIN eligibility to assure the campaign is applicable. This will verify the vehicle is affected and has not already been completed prior to dealer shipment or by another dealer. Warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number is the legal identifier for the vehicle. This number is stamped on the front right side frame, as shown in the illustration. This number is also stamped on the manufacture s plate. A : Vehicle Identification Number Plate (reference only) B : Certification Label(reference only) - 3 -

4 3. PREPARATION Necessary Parts: Part No. Thickness Estimated Repair Volume Low Low Low High High Mid Mid * Only 1 Reinforcement bar is used per vehicle. Part Name Q ty / Vehicle * Accelerator pedal plate* (Reinforcement bar) Note: Each NMSC to place an initial order on behalf of their dealers. Supplemental Parts: Only order this pin case irreversible damage occurred on the Accelerator link arm support cover. Part No. Part Name Q ty / Vehicle Note Accelerator Link arm support cover 1* 1 Others Sequoia Corolla - US Tools: Name Part No. Thickness gauge - Standard tools - Torque Wrench - Intelligent Tester - Material & Equipment: Part Name. White Marking Pen Tape (electrical, masking) Paper towel Application Put match marks on reinforced pedals Protect electrical connector - 4 -

4.WORK PROCEDURE ACCELERATOR PEDAL HANDLING NOTES: DO NOT drop. Avoid vibration and shock. DO NOT reuse an accelerator pedal that has been dropped. 1.

5 4.WORK PROCEDURE ACCELERATOR PEDAL HANDLING NOTES: DO NOT drop. Avoid vibration and shock. DO NOT reuse an accelerator pedal that has been dropped. 1. CONFIRM ACCELERATOR PEDAL PART NUMBER a) Verify the part number according to the information found on the pedal. Affected parts Numbers: Parts Numbers W W W W W W H H H D D D W C C011 For non-involved Part Number: In case P/N is not listed above, vehicle is NOT involved. Return vehicle to customer. For Involved Part Number : Continue with these Technical Instructions

6 Quick reference by model: Model LHD/RHD Pre C/M PN Avensis LHD RHD Verso LHD RHD LHD Auris TMUK TMMT Auris/Corolla - TMC RHD LHD Corolla - TSAM LHD RHD W020 LHD W021 iq W W030 RHD W W H010 LHD Aygo H030 RHD H D010 LHD Yaris D030 RHD D020 RAV4 LHD W010 Corolla - US LHD Sequoia LHD C C

7 2. SWITCH IGNITION OFF 3. PUMP ACCELERATOR PEDAL ASSEMBLY a) Pump the accelerator pedal at least 10 times in a full stroke. 4. REMOVE THE ACCELERATOR PEDAL ASSEMBLY a) Disconnect the accelerator pedal electrical connector. b) Remove the 2 or 3 bolts, 2 or 3 nuts depending on model. For additional information on accelerator pedal removal, please refer to repair manual. 5. CLEAN THE ACCELERATOR PEDAL ASSEMBLY a) Wipe and remove any dirt from the indicated area. Do not use a compressed air to clean. The compressed air may force dirt and debris into gaps. 6. PROTECT CONNECTOR a) Wrap the connector in electrical tape to protect the terminal from static electricity. 7. REMOVE THE ACCELERATOR LINK ARM SUPPORT COVER The accelerator link arm support cover will be reused. Do not forcefully twist or bend. a) Using a mini flat screwdriver, evenly and lightly twist up the 2 gaps (A) to disengage the 4 claws (B). Forcefully lifting the accelerator link arm support cover will cause bending. Stop once the claws have been disengaged. b) Using a mini flat screwdriver, evenly and lightly twist up the 2 gaps (C) to disengage the 2 claws (D). c) Remove the accelerator link arm support cover. Do not attempt to clean any wear debris inside the pedal. Attempts at cleaning may force debris into gaps causing future malfunctions

8 8. MEASURE SEPERATION GAP a) Measure the separation gap by using a thickness gauge which is inserted by 10 mm (0.39 inch) as shown on the left. Use a thickness gauge with a width of approximately 9.5 mm to 12.7 mm (0.37 inch to 0.50 inch). 9. SELECT REINFORCEMENT BAR a) Using the value obtained in step 8, refer to the chart below and select the correct reinforcement bar. Clearance Reinforcement bar Thickness Stamping 0.00mm 0.29 mm 1.4 mm 1.4 A 0.30 mm 0.59 mm 1.6 mm 1.6 B 0.60 mm 0.79 mm 1.8 mm 1.8 C 0.80 mm 1.09 mm 2.0 mm 2.0 D 1.10 mm 1.49 mm 2.3 mm 2.3 E 1.50 mm 1.89 mm 2.6 mm 2.6 F 1.90 mm 2.30 mm 2.9 mm 2.9 G *Note: New and low mileage vehicles may have a clearance greater than 2.3mm and less than 2.7 mm. The 2.9 mm thickness Reinforcement bar is specified for these cases. 10. CLEAN SCREWDRIVER a) Clean the thin-bladed flat screwdriver. Thoroughly clean the screwdriver. Any debris left on the screwdriver may cause future malfunctions

9 11. INSTALL REINFORCEMENT BAR a) To create space to insert the Reinforcement bar, from the location illustrated, insert a thin-bladed flat screwdriver into the gap between the housing and friction lever and carefully insert the screwdriver until the friction lever lowers. Be careful not to push beyond necessary as this may deform the housing. b) With the friction lever lowered, insert the Reinforcement bar selected in step 9 into the location illustrated. NOTES: To prevent the friction lever from moving up, push down the friction lever very slightly to create enough space for the Reinforcement bar to be inserted. Insert the Reinforcement bar with its stamped arrow facing up as shown

10 c) Using a thin-bladed flat screwdriver, from the accelerator link arm support cover side push the Reinforcement bar until it presses against the stopper. d) Position the Reinforcement bar in the centre as shown. e) Pump the accelerator pedal in a full stroke motion 5 times to sit down Reinforcement bar at correct position

11 12. VERIFY REINFORCEMENT BAR INSTALLATION a) Verify that the reinforcement bar is properly set as illustrated. If the Reinforcement bar is offset, fix its position using a thin-bladed flat screwdriver. b) Verify the friction lever is centered evenly in the housing. 13. INSTALL THE ACCELERATOR LINK ARM SUPPORT COVER a) Repair any bent claws on the accelerator link arm support cover. b) Press down on the 6 claws to firmly install the accelerator link arm support cover

12 14. REINSTALL THE ACCELERATOR PEDAL ASSEMBLY a) Reinstall the pedal with the 2 or 3 bolts, 2 or 3 nuts depending on model. b) Torque to specification. Model Auris Avensis Verso Rav 4 iq Yaris Corolla Aygo Sequoia Torque Specification: 5.4 Nm (55 kgf cm, 48 in. lbf) 5.5 Nm (56 kgf cm, 49 in. lbf) c) Remove the protective tape from the electrical connector. d) Reconnect the accelerator pedal connector. For additional information on accelerator pedal installation, please refer to repair manual. 15. PUT DISCRIMINATION MARK ON PEDAL a) Put a discrimination mark on the top of left side bolt or nut by using a white paint marker. 16. CHECK FOR DTC CODES b) Check for DTC codes. If DTC(s) are displayed, verify the code(s) and record the freeze frame data, then perform repairs as necessary

13 17. INSPECT THE ACCELERATOR PEDAL ASSEMBLY OPERATION ( except AYGO MT with VSC ) a) Connect the intelligent tester to the DLC3. b) Turn the ignition switch to ON. c) Turn the intelligent tester ON. d) Select the following menu items: *With the 1ND engine model : Powertrain / Engine and ECT / Data List / Accel Position *Aygo MMT model: Powertrain / Multi-Mode M/T / Data List / Accelerator pedal angle *Other engine model: Powertrain / Engine and ECT / Data List / Accel Sens No. 1, Accel Sens No. 2. Vehicle type Tester Display Normal Condition 1ND engine model Accel Position Accelerator Pedal Released: below 5% Accelerator Pedal Fully Depressed: More than 98% Diagnostic Note Other engine model Accel Sens. No.1 Volt % Accel Sens. No.2 Volt % Accelerator Pedal Released: 8~28% Accelerator Pedal Fully Depressed: 68~100% Read value with ignition switch to ON (Do not start engine) AYGO MMT model Accelerator pedal angle Accelerator Pedal Released: below 5% Accelerator Pedal Fully Depressed: More than 98% 17. INSPECT THE ACCELERATOR PEDAL ASSEMBLY OPERATION ( for AYGO MT with VSC ) a) Remove the fuse box cover

14 b) Measure the Accel Sensor Out No. 1 and Accel Sensor Out No. 2 voltage according to the value(s) in the table below. APP Sensor No. 1 Voltage: Pin No. 3 - Pin No. 4: APP Sensor No. 2 Voltage: Pin No. 6 - Pin No. 7 Tester Display Measurement: Range (Display) Normal Condition Diagnostic Note Accel Sensor Out No. 1 APP sensor No. 1 voltage Accelerator Pedal Released: 0.5 to 1.1 V Accelerator Pedal Fully Depressed: 2.6 to 4.5 V Read value with Ignition switch to ON (Do not start engine) Accel Sensor Out No. 2 APP sensor No. 2 voltage Accelerator Pedal Released: 1.2 to 2.0 V Accelerator Pedal Fully Depressed: 3.4 to 5.0 V Read value with ignition switch to ON (Do not start engine) 18. Record Electrical Tester List Values and pedal clearance on the repair order for claim purpose a) Observe the claim instruction in the WCPP

TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 90L ACCELERATOR PEDAL MODIFICATION Certain 2009 MODEL YEAR 4RUNNER

TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 90L ACCELERATOR PEDAL MODIFICATION 2003 Certain 2009 MODEL YEAR 4RUNNER I. OPERATION FLOW CHART Verify Vehicle Eligibility 1. Check the VIN range. 2. Check the