CSV_TI_REM_Publi

TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN CSV PHASE
CERTAIN 2001 THROUGH 2004 MODEL YEAR TACOMA
CURRENTLY REGISTERED OUTSIDE OF THE 20 COLD CLIMATE STATES
SPARE TIRE CARRIER INSPECTION/REPLACEMENT
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this LSC are required to successfully complete the most current version of the ELearning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have
the repair performed correctly; technicians performing this LSC repair are required to currently hold
at least one of the following certification levels:
•
•
•
•
Toyota Certified (Any Specialty)
Toyota Expert (Any Specialty)
Master
Master Diagnostic Technicians
I.
OPERATION FLOW CHART
Verify Vehicle Eligibility
Check the TIS Vehicle Inquiry System.
Yes
Lower the Spare Tire and Inspect the
Spare Tire Carrier Lift Plate
No
Replace the Spare Tire Carrier
Did the Spare Tire Carrier Lift Plate
pass the inspection?
Yes
Campaign complete.
Return the vehicle to the customer.
II. IDENTIFICATION OF AFFECTED VEHICLES
• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall Campaign,
and that the campaign has not already been completed prior to dealer shipment or by another dealer.
• TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were
completed by another dealer.
III. PREPARATION
A. PARTS
Part Number
04002-11104
04002-11204
90080-11180
Part Description
Spare Tire Carrier Kit (2WD Non PreRunner)
Spare Tire Carrier Kit (4WD and PreRunner)
Bolt w/Washer
Quantity
1
1
4
B. TOOLS & EQUIPMENT
• Standard Hand Tools
• Torque Wrench
• Screw Jacks
C. MATERIALS
• Shop Cloth
• Wood Pieces (30mm Thick)
2
IV. BACKGROUND
On 2001-2004 model year Tacoma vehicles, prolonged exposure to road salts and other environmental factors
could cause the Spare Tire Carrier Lift Plate to corrode. In limited cases, the lift plate may excessively corrode and
break resulting in detachment of the spare tire from the vehicle.
V. SPARE TIRE CARRIER INSPECTION WORK PROCEDURE
A.
INSPECT THE SPARE TIRE CARRIER
Perform the Spare Tire Carrier Inspection with the vehicle on the ground to ensure that the spare
tire will not fall due to lift plate corrosion.
1. PERFORM FUNCTIONAL CHECK OF THE SPARE TIRE
CARRIER
a) With the vehicle on the ground, lower and raise the spare
tire carrier utilizing the tools provided with the vehicle and
ensure it is operating properly.
Note: Do not operate the spare tire carrier with an impact
gun because damage will occur to the spare tire carrier.
b) Completely lower the spare tire and remove it from the spare
tire lift plate.
2. VISUALLY INSPECT THE SPARE TIRE CARRIER LIFT PLATE
Does the top and bottom of the spare tire carrier lift
plate have obvious corrosion?
YES
No
Obvious Rust Corrosion
Minimal Rust Corrosion
No
CONTINUE INSPECTION
ON THE NEXT PAGE
3
VISUALLY INSPECT THE SPARE TIRE CARRIER LIFT PLATE (Continued)
CONTINUE INSPECTION
Does the spare tire lift plate wheel contact area (Red)
have rust corrosion holes or deterioration?
YES
No
Rust, but no Holes/Deterioration
Rust Holes/Rust Deterioration
No
Does the bottom edge of the spare tire lift plate have
rust/corrosion around the entire perimeter?
YES
No
Rust/Corrosion does not reside on the entire perimeter
of the bottom edge
Rust Corrosion Around Entire Edge
No
Does the top center of the spare tire lift plate (side
facing the bed) contain 80% rust/corrosion in the center
Area (40mm Diameter)?
YES
No
80% Rust Corrosion in Center Area
Contains less than 80% Rust in Center Area
No
REPLACE THE SPARE TIRE CARRIER
Inspection Complete
Reinstall Spare Tire and Return to Customer
PROCEED TO SPARE TIRE CARRIER
REPLACEMENT (Section VI)
4
VI. SPARE TIRE CARRIER REPLACEMENT PROCEDURE
B.
VEHICLE PREPARATION
1. INSPECT THE BED ASSY
20mm
a) Confirm the bed has had all heavy loads removed.
b) Inspect that there is adequate clearance (20mm) between
the cab, bed, and any mounted accessories.
2. PROTECT THE BED AND CAB ASSY
a) Place a blanket or pair of fender covers between the cab
and bed assy to protect the paint.
C.
SPARE TIRE CARRIER REMOVAL
1. COVER THE SPARE TIRE STOPPERS (IF EQUIPPPED)
a) Place the vehicle on a lift and raise the vehicle
b) Wrap the spare tire carrier stoppers with shop clothes to
prevent injury.
2. MAKE SPACE FOR THE REMOVAL/INSTALLATION OF THE
SPARE TIRE CARRIER BOLTS
a) Remove the 2 bolts, 2 nuts, and 2 washers located on the
rearward portion of the bed.
Note: it is not necessary to remove the 2 bolts located at the
front of the bed.
5
3. LIFT THE BED ASSEMBLY
a) Using a screw jack and a wood block as an intermediary lift
the bed carefully by approximately 30mm.
b) After lifting, place 30mm wood blocks under the left and right
middle bed mount/bracket locations as shown.
Note:
• Be careful not to have your finger pinched.
• Ensure not to pinch the wire harness with the
wood/shims.
• Do not lift the bed assy too high; otherwise damage
could occur to the wire harness, cab, or bed assy.
4. REMOVE THE SPARE TIRE CARRIER
a) Remove the 4 bolts holding the spare tire carrier.
D.
INSTALL THE SPARE TIRE CARRIER
1. INSTALL THE SPARE TIRE CARRIER
a) Install the NEW spare tire carrier with the 4 NEW bolts.
b) Torque the 4 bolts evenly in several increments.
Torque Spec: 15 ft∙lbf (20 N∙m, 204 kgf∙cm)
2. REINSTALL THE BED ASSEMBLY
a) Remove the wood/shims and lower the bed assembly back
onto the frame.
b) Install the 2 bolts, 2 washers and 2 nuts.
Torque Spec: 77lbf (105Nm, 1071 kgf)
6
3. REMOVE THE PROTECTORS FROM THE SPARE TIRE
CARRIER STOPPER
4. REINSTALL THE SPARE TIRE
−
−
−
◄ VERIFY REPAIR QUALITY ►
Confirm that all steps of the spare tire carrier lift plate inspection was performed properly
Confirm that the bed raising procedure was performed properly
Confirm that the spare tire is properly secured before returning the vehicle
If you have any questions regarding this recall, please contact your regional representative
VII. APPENDIX
A. CAMPAIGN DESIGNATION DECODER
E
0
Year Campaign is Launched Repair Phase
8 = 2008
9 = 2009
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Etc...
0 = Remedy
1 = Interim (Remedy
not yet available) “1”
will change to “0” when
the Remedy is
available
C
Current Campaign Letter
for this year
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
6th Campaign = F
7th Campaign = G
8th Campaign = H
9th Campaign = I
Etc...
Examples:
th
A0D = Launched in 2010, Remedy Phase, 4 Campaign Launched in 2010
rd
B1E = Launched in 2011, Interim Phase, 5 Campaign Launched in 2011
rd
C1C = Launched in 2012, Interim Phase, 3 Campaign Launched in 2012
B. RECALL PARTS DISPOSAL
As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the
vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery
return.
7