TECHNICAL INSTRUCTIONS ES350 / ES250 / ES200 BRAKE ACTUATOR ASSEMBLY REPLACEMENT 1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 6 1
Safety Precautions Be sure to observe the following precautions to prevent accidents and injuries. - 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 specified tools, check that there are no problems with the tools. - 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 safety stand. - When lifting the vehicle using a lift, lock the lift for safety. 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, 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 the engineer clothes and so forth, as it can catch on fire and cause serious burns. < Precautions > - Do not use brake cleaner near flames 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. 2
1. OPERATION FLOW CHART Check whether or not the vehicle has the affected VIN. No No further action required. Yes Check whether or not the brake actuator has the affected serial number. Proceed to section F on page 13. Yes No Note the VIN and Serial number and report. Replace the brake actuator assembly. Proceed to section G on page 14. No further action required. Note the VIN and Serial number and report. Return the vehicle to original state and finish the work. 3
2. IDENTIFICATION OF AFFECTED VEHICLES 2.1. COVERED VIN RANGE AFFECTED VEHICLE IDENTIFICATION NUMBER Model WMI VIN Range VDS Range BJ1GG 02087366 ~ 02091299 BJ1GG F2087355 ~ F2090339 BJ1GG G2087364 ~ G2091458 ES350 ES250 ES200 JTH BK1GG 02223017 ~ 02241294 BK1GG G2222913 ~ G2241358 BK1GG H2239631 ~ H2239631 BT1GG 02003085 ~ 02019040 BT1GG F2003073 ~ F2015552 BT1GG G2015554 ~ G2019029 BK1GG GU002280 ~ GU008040 NOTICE: # 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. 2.2. VEHICLE IDENTIFICATION NUMBER LOCATION 1. CHECK THE VEHICLE IDENTIFICATION NUMBER (a) Confirm that the VIN is within the range shown in the table above. HINT: The Vehicle Identificat ion Number (VIN) is stamped on location A and B shown in the illustration. 4
3. PREPARATION 3.1. Replacement components Parts: 1 Brake Actuator Assembly Part Name Part No. Qty Remarks 44050-33740 44050-33750 44050-33760 44050-33780 44050-33790 44050-33800 44050-06370 44050-06480 3.2. Brake actuator assembly replacement Tools: Illustration Part Name Part No. Qty Remarks - Global Techstream - 1 1 For DTC checks and for bleeding the brake system - Torque Wrench - 1 For checking tightening torque 12mm Union Nut Wrench 09017-1C110 1 For brake tube removal/installation 10mm Union Nut Wrench 09017-1C100 1 For brake tube removal/installation Recommended Tool: Illustration Part Name Part No. Qty Remarks - Brake Fluid SAE J1703 or FMVSS No.116 DOT3 4.0L For refill 5
Equipment: Part Name Part No. Qty Remarks Protective Glasses - 1 For prevention of injury Protective Tape - Plastic Bag - Paper Towels - Vinyl Tube - Appropriate quantity Appropriate quantity Appropriate quantity Appropriate quantity Marker Pen - 1 For component protection For component protection For cleaning For brake bleeding For putting identification marks 6
4. WORK PROCEDURE A. TABLE OF CONTENTS A. TABLE OF CONTENTS...7 B. WORK OUTLINE...8 C. PRECAUTIONS FOR BRAKE ACTUATOR REMOVAL/INSTALLATION...9 D. PRECAUTIONS FOR ALL OPERATIONS... 11 E. COMPONENTS... 13 F. CHECK SERIAL NUMBER OF BRAKE ACTUATOR ASSEMBLY... 14 G. REPLACE THE BRAKE ACTUATOR ASSEMBLY... 16 7
B. WORK OUTLINE Check the serial number of the brake actuator, and if it is applicable, replace the brake actuator with a new one. 8
C. PRECAUTIONS FOR BRAKE ACTUATOR REMOVAL/INSTALLATION 1. HANDLING OF BRAKE FLUID (a) Do not allow brake fluid to come into contact with any painted body surface. Failure to do so could cause damage to the painted surface. If contact occurs, immediately rinse it off. (b) Do not reuse brake fluid. Brake fluid which has absorbed moisture or mineral oil may suffer significant degradation in quality or the condition of rubber seals, resulting in a potentially serious failure which may cause an accident. (c) If any brake fluid leakage is found, it must be repaired. (d) Wear protective glasses when bleeding air as this may cause brake fluid to spray outwards. 2. DO NOT USE CLOTH RAGS OR GLOVES (a) Do not use any cloths or fabric gloves so as to prevent threads and fibers from entering the brake system. (b) Keep your hands clean during work to prevent the entry of foreign objects into the components. 9
3. HANDLING OF BRAKE TUBES (a) Be careful not to damage or deform the brake tubes during removal and reinstallation. (b) Do not twist, bend or let the brake tubes interfere with other parts while performing the work. 4. BRAKE SYSTEM PROTECTION (a) Clean any brake system parts that are to be removed as well as other parts around them before removal. (b) When removing any brake system parts, prevent foreign objects from entering the brake system by covering them. 10
D. PRECAUTIONS FOR ALL OPERATIONS 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 GLASSES (a) Wear protective glasses when working under the 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. 11
5. VEHICLE PROTECTION (a) A fender cover, a grill cover, seat covers and protective tape etc. must be used to protect the vehicle from dirt or scratches. HINT: The protective measures listed above may not be shown in some illustrations to allow easy identification of the work location and to make the illustrations simple and easy to read. 6. HANDLING OF REMOVED PARTS (a) Destroy or mark and 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. HINT: 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. 12
E. COMPONENTS 13
F. CHECK SERIAL NUMBER OF BRAKE ACTUATOR ASSEMBLY 1. CHECK SERIAL NUMBERS (a) Check the serial number of the brake actuator assembly according to the following procedures. (1) Check the position of the serial number. Position and number of digits Result Action Required Proceed to confirmation of the serial number. (refer to the following pages) Not applicable to this safety recall. 14
(2) Confirm the 15-digit serial number of the brake actuator assembly in the order top, middle, and bottom as shown in the illustration. NOTICE: Illuminate the brake actuator with sufficient light when trying to read the serial numbers. If the serial numbers are not easy to see by eye, take pictures of them with a digital camera or smart phone, and enlarge pictures. Please record the brake actuator serial No. of all affected vehicles in the VIN list and send to TMC. Serial Number Top Middle Bottom Result Action Required See attachment 1 Replace the brake actuator with a new one. (refer to the following pages) Illegible Other than above Not applicable to this safety recall. 15
G. REPLACE THE BRAKE ACTUATOR ASSEMBLY 1. REMOVE BRAKE ACTUATOR ASSEMBLY Refer to TIS for instructions on BRAKE ACTUATOR / REMOVAL 2. INSTALL NEW BRAKE ACTUATOR ASSEMBLY Refer to TIS for instructions on BRAKE ACTUATOR / INSTALLATION 3. SEND THE BRAKE ACTUATOR (a) Take the new brake actuator out the package NOTICE: Do not discard the package. The package will be reused to send the brake actuator. (b) Send the package in a method similar to normal return of claim parts. 16
Attachment 1 Top Middle Bottom 010 151015 510972 010 151015 511054 010 151016 511381 010 151016 511388 010 151016 511408 010 151016 511549 010 151019 510213 010 151019 510381 010 151019 510382 010 151019 510465 010 151019 510481 010 151019 510496 010 151230 511355 010 151230 511359 010 160105 510102 010 160105 510122 010 160109 511661 010 160109 511677 010 160109 511704 010 160112 510266 010 160112 510268 012 151026 510045 012 151026 510050 012 151214 511317 012 151215 510532 012 151215 510547 012 151215 510628 012 151215 510636 012 151221 511019 012 160109 511155 012 160112 510584 012 160112 510611 038 150901 510282 038 150917 510497 038 150925 510238 038 151007 510253 038 151013 510303 038 151013 510704 038 151015 510647 038 151015 510764 038 151015 510828 038 151015 510829 038 151015 510865 038 151021 510819 038 151022 511106 038 151023 511340 038 151023 511499 038 151117 510620 038 151117 510759 038 151117 510792 038 160102 510934 038 160102 511035 038 160102 511054 038 160102 511057 038 160102 511126 038 160102 511133 038 160102 511211 038 160102 511221 038 160102 511262 038 160102 511263 038 160102 511369 038 160102 511512 038 160103 510159 040 150814 510037 040 150814 510201 040 150814 510204 040 150814 510205 040 150817 510012 040 150817 510021 040 150817 510028 040 150817 510030 040 150817 510041 040 150817 510062 040 150817 510064 040 150817 510066 17 040 150817 510068 040 150817 510071 040 150817 510072 040 150817 510073 040 150817 510074 040 150817 510075 040 150817 510081 040 150817 510083 040 150817 510084 040 150817 510087 040 150817 510089 040 150817 510091 040 150817 510094 040 150817 510095 040 150817 510100 040 150817 510107 040 150817 510112 040 150817 510113 040 150817 510116 040 150817 510119 040 150817 510121 040 150817 510124 040 150817 510130 040 150817 510132 040 150817 510134 040 150817 510145 040 150817 510154 040 150817 510156 040 150817 510158 040 150817 510162 040 150817 510164 040 150817 510165 040 150817 510172 040 150817 510173 040 150817 510179 040 150817 510192 040 150817 510197 040 150817 510198
040 150817 510199 040 150817 510207 040 150817 510211 040 150817 510213 040 150817 510218 040 150817 510222 040 150817 510224 040 150817 510259 040 150817 510260 040 150817 510261 040 150817 510262 040 150817 510263 040 150817 510272 040 150817 510278 040 150817 510279 040 150817 510280 040 150817 510285 040 150817 510296 040 150817 510299 040 150817 510302 040 150817 510305 040 150817 510308 040 150817 510312 040 150817 510318 040 150817 510323 040 150817 510331 040 150817 510347 040 150817 510348 040 150817 510349 040 150817 510354 040 150817 510361 040 150817 510362 040 150817 510365 040 150817 510367 040 150817 510369 040 150817 510374 040 150817 510379 040 150817 510386 040 150817 510400 040 150817 510402 040 150817 510419 040 150817 510423 040 150817 510424 040 150817 510425 040 150817 510428 040 150817 510430 040 150817 510457 040 150817 510461 040 150817 510462 040 150817 510464 040 150817 510483 040 150817 510485 040 150817 510579 040 150818 510237 040 150821 510100 040 150821 510119 040 150821 510131 040 150821 510139 040 150829 510541 040 150915 510166 040 150915 510316 040 151016 510482 040 151021 510383 040 151021 510394 040 151021 510520 040 151021 510677 040 151022 510347 040 151022 510364 040 151022 510636 040 151022 510653 040 151022 510838 040 151022 510840 040 151022 510878 040 151023 510176 040 151023 510280 040 151023 510400 040 151023 510415 040 151023 510510 040 151023 510537 040 151023 510623 040 151024 510032 040 151024 510072 040 151024 510163 040 151024 510165 040 151024 510248 040 151105 510940 040 151105 510946 040 151105 511205 040 151105 511215 040 151105 511297 040 151111 510342 040 151111 510348 040 151111 510510 040 151111 510533 040 151111 510541 040 151111 510546 040 151111 510550 040 151111 510551 040 151111 511074 040 151111 511082 040 151111 511119 040 151111 511195 040 151111 511199 040 151111 511214 040 151111 511253 040 151116 510892 18