TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS DOOR SIDE AIRBAG SENSOR REPLACEMENT RX450h / RX350 / RX200t RX450h/RX350/RX200t Fr ドアエアバッグセンサ交換 一般 _v2.0 1 OPERATION FLOWCHART IDENTIFICATION OF AFFECTED VEHICLES PREPARATION GENERAL DESCRIPTION PRECAUTIONS FOR ENTIRE WORK REPLACE DOOR SIDE AIRBAG SENSOR LH & RH (INSIDE FRONT DOOR)

2 <<SAFETY PRECAUTIONS>> A. Be sure to observe the following precautions to prevent accidents and injuries. B. Park the vehicle and chock the wheels. If it is necessary to start the engine, perform the operation in a well ventilated area. Before removing and reinstalling heavy parts such as the engine, transmission and differential using lifting equipment, check that there are no problems with the equipment. When working in a group of 2 or more, each person must work to ensure the safety of all team members. To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts. When lifting the vehicle using a jack, support it in the specified location using a rigid rack. When lifting the vehicle using a lift, lock the lift for safety. C. Also perform the following operation with care. Use of auto lift Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as Raising the lift! and Lowering the lift! ) to alert other workers. When raising or lowering the lift to adjust the vehicle position, etc., pay attention to the positions of your arms, legs, and other body parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner Use brake cleaner for appropriate purposes in accordance with instructions in the manual. Do not use brake cleaner to remove dirt or stains from work clothes, etc. It can catch on fire and cause serious burns. Precautions Do not use brake cleaner near flame or fire. Do not use large amounts of brake cleaner in a room where a fire is burning. Do not keep brake cleaner in a place subject to high temperatures exceeding 40 C, such as a place subject to direct sunlight or near fire. Do not put brake cleaner in fire. Edges When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers

3 1 OPERATION FLOWCHART Verify Vehicle Eligibility 1. Check the VIN range. Not Involved No further action required. Involved Replace the airbag sensor with a NEW one. Campaign completed, return the vehicle to the customer

4 2 IDENTIFICATION OF AFFECTED VEHICLES AFFECTED VEHICLE IDENTIFICATION NUMBER Model WMI VDS VIN Range Range RX450h 2T2 JTJ ZFMCA# #C #C BGMCA# #C #C BGMCA# # # EGMCA# # # JTH ZZMC9# # # RX350 JTJ 2T2 ZZMCA# # # BZMCA# # # ZZMCA# #C #C BZMCA# #C #C RX200t JTJ ZAMCA# # # BAMCA# # # NOTE: # indicates that various characters may occupy that position. As for the total number of affected vehicles shipped to your country, please refer to the attached VIN-list. 1. CHECK THE VEHICLE IDENTIFICATION NUMBER (a) Confirm that the VIN is within the range shown in the table above. HINT: The Vehicle Identification Number (VIN) is stamped on location from *1 and *2 shown in the illustration

5 3 PREPARATION PARTS Part Number Name Quantity Others A347 PRESSURE SIDE AIR BAG SENSOR A PRESSURE SIDE AIR BAG SENSOR 1 - RECOMMENDED TOOLS Part Number Name Quantity Others - Global TechStream Torque Wrench Standard Hand Tools Moulding Remover Set 1 - EQUIPMENT Name Quantity Others Protective Tape - - Marking Pen

6 4 GENERAL DESCRIPTION 1. Replace the door side airbag sensors LH&RH

7 6 PRECAUTIONS FOR ENTIRE WORK 1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK (a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working. (b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way. 2. WEAR PROTECTIVE EYEWEAR (a) Wear protective eyewear when working under vehicle or where there is any risk of flying parts or debris. 3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER (a) DO NOT spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. DO NOT use it near cigarettes or stoves as this can cause serious burns and injuries. 4. AVOID BURNS (a) If the engine is hot, wear protective gloves to prevent burns

8 5. PROTECT THE VEHICLE (a) A fender cover, a grill cover, seat covers tape etc. must be used to protect the vehicle from dirt or scratches. NOTICE: The protective measures listed above may not be shown in some illustrations to allow easy identification simple and easy to read. 6. HANDLING OF REMOVED PARTS (a) Destroy or mark and then store removed parts in a separate container so as to not be assembled again in error. (b) Check the removed parts when performing the completion inspection. NOTICE: The parts shown in the illustration to the left are examples only and differ from the actual replacement parts. 7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT (a) DO NOT break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work. 8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment

9 6.1 REPLACE DOOR SIDE AIRBAG SENSOR LH & RH (INSIDE FRONT DOOR) HINT The illustrations show LH side only. Replace the door side airbag sensor after disconnecting the negative battery cable and removing the front door trim board sub-assembly. COMPONENTS - 9 -

10 1. RECORD SETTINGS OF THE AUDIO SYSTEM, AIR CONDITIONER, ETC. (a) For devices such as the audio system, air conditioner, etc, record current settings before the negative (-) battery terminal is disconnected. 2. FULLY OPEN THE SIDE WINDOW 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait at least 90 seconds after disconnecting the cable from the negative battery terminal to prevent airbag and seat belt pretensioner deployment. For models with a HDD navigation system, wait at least 6 minutes before disconnecting the battery. It takes approximately 6 minutes for the system to save information and settings after the engine switch is turned off. Follow all precautions as outlined on TIS before servicing the SRS system. 4. REMOVE DOOR ARMREST COVER 5. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (a) Using a molding remover, disengage the 3 claws to remove the front door inside handle bezel plug

11 6. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (FOR DRIVER SIDE) (a) Using a moulding remover, disengage the 4 clips and 4 guides. (b) Disconnect the connector. 7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (FOR PASSENGER SIDE) (a) Using a moulding remover, disengage 2 claws. (b) Disconnect the connector. 8. REMOVE COURTESY LIGHT ASSEMBLY (a) Disengage the claw using a thin flathead screwdriver wrapped with protective tape. (b) Disconnect the connector and remove the courtesy light assembly. 9. REMOVE FRONT DOOR No. 1 STIFFENER CUSHION (a) Remove the screw and front door No. 1 stiffener cushion

12 10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY (a) Apply protective tape to the positions shown in the illustration. (b) Remove the 3 screws. (c) Disengage the 10 clips and lift up the front door trim board sub-assembly

13 (d) Disconnect the front door lock remote control cable assembly from the front door inside handle sub-assembly. (e) Disengage the 2 claws to disconnect the front door inside locking cable assembly and remove the front door trim board sub-assembly. 11. REMOVE FRONT DOOR No. 1 TRIM BRACKET (a) Remove the 2 screws and front door No. 1 trim bracket. 12. REMOVE FRONT DOOR SERVICE HOLE COVER (a) Disconnect the connector. (b) Turn each of the 4 front door weatherstrip clips 45 degrees in the direction of the arrow, and remove them

14 (c) Disengage the 5 clamps. (d) Disengage the 5 clips to remove the front door service hole cover. 13. REMOVE DOOR SIDE AIRBAG SENSOR (a) Remove the nut while holding the door side airbag sensor. (b) Disengage the claw and pull out the door side airbag sensor from the front door panel

15 (c) Disconnect the connector following the steps below. (1) To unlock the first lock, keep pushing down the white housing lock and then slide the yellow CPA towards the wire harness. (2) To unlock the second lock, keep pushing down the white housing lock again and disconnect the connector. NOTICE: This special connector has a double locking mechanism and needs to be handled with care. DO NOT apply pressure on the wire harness. (d) Mark and store the removed door side airbag sensor in a separate container so as not to reinstall it in error. 14. INSTALL DOOR SIDE AIRBAG SENSOR (a) Engage the connector of a NEW door side airbag sensor holding the sides of its yellow CPA (a click sound can be heard)

16 (b) Engage the claw of the NEW door side airbag sensor and hold it in place. (c) Install the nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) NOTICE: DO NOT use a sensor which has been affected by strong shocks such as a drop during work. 15. INSTALL FRONT DOOR SERVICE HOLE COVER (a) Engage the 5 clips to install the front door service hole cover. HINT: If the foam tape applied on the service hole cover is not peeled off or damaged, the service hole cover can be reused. (b) Engage the 5 clamps

17 (c) Insert 4 front door weatherstrip clips and turn them 45 degrees in the direction of the arrow to install them. (d) Connect the connector. 16. INSTALL FRONT DOOR No. 1 TRIM BRACKET (a) Install the front door No. 1 trim bracket with the 2 screws. 17. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (a) Engage the 2 claws to connect the front door inside locking cable assembly to the front door trim board sub-assembly. (b) Connect the front door lock remote control cable assembly to the front door inside handle sub-assembly

18 (c) Engage the 10 clips to install the front door trim board sub-assembly. (d) Install the 3 screws. 18. INSTALL FRONT DOOR No. 1 STIFFENER CUSHION (a) Install the front door No. 1 stiffener cushion with the screw. 19. INSTALL COURTESY LIGHT ASSEMBLY (a) Connect the connector. (b) Engage the claw to install the courtesy light assembly

19 20. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (FOR DRIVER SIDE) (a) Connect the connector. (b) Engage the 4 guides and 4 clips to install the multiplex network master switch assembly with front door upper armrest base panel. 21. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (FOR PASSENGER SIDE) (a) Connect the connector. (b) Engage the 2 claws to install the power window regulator switch assembly with front door upper armrest base panel. 22. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (a) Engage the 3 claws to install the front door inside handle bezel plug. 23. INSTALL DOOR ARMREST COVER

20 Before carrying out the following procedures, replace another sensor if needed. 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 25. INSPECT THE AIRBAG SENSORS USING THE JUDGMENT SOFTWARE(PERFORM THE INSPETION EXCEPT FOR THE FRONT DOOR AIRBAG SENSOR) 26. INSPECT DOOR LOCK AND POWER WINDOW OPERATION 27. RESTORE VEHICLE (a) After connecting the cable, perform settings as indicated, for the vehicle equipped with either of the systems below. (1) LKA/LDA system (2) Pre-crash safety system (3) Lighting system (W/ Automatic Headlight Beam Level Control System) (4) Parking assist monitor system (5) Panoramic view monitor system (6) Stop and start system (7) Power door lock control system (8) Power back door system