F0U_Updated_Tech

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN F0U
EXHAUST PIPE REPLACEMENT FOR CATALYTIC CONVERTER
CERTAIN 2010- 2014 MODEL YEAR TACOMA 2TR-FE VEHICLES
UPDATED NOVEMBER 30, 2015
Updated 11/30/15
− The parts section has been updated for the 2010 MY.
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this procedure are required to successfully complete the most current version of the E-Learning course
“Safety Recall and Service Campaign Essentials” To ensure that all vehicles have the repair performed
correctly; technicians are required to currently hold at least one of the following certification levels to perform
this operation:
•
•
•
•
*Toyota Certified
*Toyota Expert
Master
Master Diagnostic Technicians
*Note: Certified technicians can perform the inspection and catalytic converter replacement, however if the
inspection determines that the vehicle requires additional electrical repairs it must be performed by a
technician that is Toyota Expert or above.
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform
this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians
to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly
trained technicians available to perform this repair at all times.
I.
OPERATION FLOW CHART
II. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
•
•
Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, 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
THE OLD CATALYTIC CONVERTERS MUST BE RETURNED TO TOYOTA, GO TO SECTION VIII FOR
CATALYTIC CONVERTER SHIPPING PREPARATION.
Model Year
2010
2011-2012
Trans.
AT/MT
A/T
M/T
2013-2014
2010-2014
MT/AT
Part Number
17410-0C100
17410-0C120
17410-0C100
17410-0C150
17451-0D020
90080-43033
90177-A0004
90080-10064
90080-10291
Part Description
PIPE ASSY, EXHAUST, FR
PIPE ASSY, EXHAUST, FR
PIPE ASSY, EXHAUST, FR
PIPE ASSY, EXHAUST, FR
GASKET, EXHAUST PIPE
GASKET, EXHAUST PIPE
NUT, LOCK
BOLT, FLANGE
BOLT
Qty.
1
1
1
1
1
1
2
2
2
B. TOOLS & EQUIPMENT
・ Techstream
・ Standard Hand Tools
・ Vernier Calipers
・ Protective Glasses
・ Wooden Pieces
・ Inspection Mirror
・ Protective Gloves
・ Torque Wrench
SST- These are essential special service tools that the dealership should have.
Part Number
Description
09224-00010
O2 Sensor Wrench
Quantity
1
2
IV. BACKGROUND
In the subject vehicles the front catalytic converter internal components may become deteriorated and begin to
rattle. If continually operated in this condition, the deteriorated components could become dislodged and restrict the
exhaust flow. If this occurs, the vehicle may illuminate a check engine light, and, depending on the level of exhaust
restriction, the vehicle may experience a reduction in power.
3
V. COMPONENTS
4
VI. VISUAL INSPECTION AND DTC CHECK
A. CHECK FOR DTCS
Note: If DTCs are presesnt record the DTC and continue with the visual inpection prior to perfroming
any repairs.
B. UNDERHOOD COMPONENT INSPECTION
1. INSPECT THE FOLLOWING COMPONENTS UNDER THE HOOD FOR HEAT DAMAGE
Note: The following pages of the TI have more detailed pictures of each component to be inspected. The
picture below is to assist you in locating the component within the engine bay.
Heat damaged components should be very rare, if you do find a damaged compoent it is
required that a TAS case is created with pictures attached of the damage. This TAS case will be
reviewed by your FTS for parts and repair time approval.
For damaged component replacement please refer to the supplemental technical instructions.
a
Windshield Washer Hose Joint
c
Engine Wire
e
g
i
k
m
Intake Air Connector
Air Cleaner Assembly
Air Pump Assembly
Outer Dash Panel Insulator (if equipped)
No. 1 Breather Plug (Auto Trans Only)
b1
b2
d1
d2
f
h
j
l
n
Engine Room Main Wire Harness
Brake Tube Clamp
Air Switching Valve Assembly
Air Pump Cover (if equipped)
Piping Clamp
Breather Plug Hose (Auto Trans Only)
No. 2 Breather Plug (Auto Trans Only)
5
a. INSPECT WINDSHIELD WASHER HOSE JOINT FOR HEAT
DAMAGE
b. ENGINE ROOM MAIN WIRE HARNESS
1. Check the engine room wire harness in the area highlighted for
heat damage.
Note: The area highlighted is the most probable location
where heat damage will occur, but be sure to inspect all
areas that get close to the exhaust.
2. Check the wire harness in the area highlighted for heat damage.
Note: The area highlighted is the most probable location
where heat damage will occur, but be sure to inspect all
areas that get close to the exhaust.
c. INSPECT THE ENGINE WIRE HARNESS FOR HEAT DAMAGE
IN THE HIGHLIGHTED AREA
Note: The area highlighted is the most probable location where
heat damage will occur, but be sure to inspect all areas that get
close to the exhaust.
6
d. BRAKE TUBE CLAMP INSPECTION
1. Inspect the two brake tube clamps on the bulk head for heat
damage.
e. INSPECT THE INTAKE AIR CONNECTOR FOR HEAT DAMAGE.
f. INSPECT THE AIR SWITCHING VALVE GOR HEAT DAMAGE
g. INSPECT THE AIR CLEANER ASSEMBLY FOR HEAT DAMAGE
Note: The area highlighted is the most probable location where
heat damage will occur, but be sure to inspect all areas that
get close to the exhaust.
h. INSPECT AIR PUMP COVER FOR HEAT DAMAGE (If Equipped)
7
i. AIR PUMP ASSEMBLY INSPECTION (Requires Removal)
1. Remove the two bolts securing the washer fluid tank.
Note: This will allow you to move the washer fluid tank and
give you more room when removing the air pump.
2. Disconnect the air injection system No.1 hose.
3. Disconnect the air pump connector and wire harness clamp.
4. Remove the 3 bolts and remove the air pump and bracket
assembly.
5. Inspect the air pump for heat damage in the highlighted area.
6. Reinstall the air pump and bracket with the 3 bolts.
Torque Spec: 13ft-lbf (184 kgf-cm, 18 Nm)
8
7. Reconnect the air pump connector and wire harness clamp.
8. Reinstall the 2 washer fluid tank bolts.
Torque Spec: 49in-lbf (56 kgf-cm, 6 Nm)
j. INSPECT THE A/C PIPING CLAMPS FOR HEAT DAMAGE
k. INSPECT THE OUTER DASH PANEL INSULATOR (If Equipped)
INSPECT THE FOLLOWING FOR HEAT DAMAGE
l. AUTO TRANS BREATHER HOSE
m. NO. 1 BREATHER PLUG
n. NO. 2 BREATHER PLUG
9
C. UNDER VEHICLE COMPONENT INSPECTION
2. INSPECT THE FOLLOWING COMPONENTS UNDER THE VEHICLE FOR HEAT DAMAGE
Note: The following pages of the TI have more detailed pictures of each component to be inspected. The
picture below is to assist you in locating the component.
Heat damaged components should be very rare, if you do find a damaged compoent it is
required that a TAS case is created with pictures attached of the damage. This TAS case will be
reviewed by your FTS for parts and repair time approval.
For damaged component replacement please refer to the supplemental technical instructions.
a
Air Fuel Ratio Sensor
c
Oxygen Sensor
e1
e2
Engine Wire Harness
b1
d
No. 2 Frame Wire (If Equipped)
f
Air Switching Valve Assembly
Auto Trans Temperature Sensor
10
a. INSPECT THE AIR FUEL RATIO SENSOR AND WIRE FOR HEAT DAMAGE
b. INSPECT THE NO. 2 FRAME WIRE HARNESS FOR HEAT
DAMAGE
c. INSPECT THE OXYGEN SENSOR AND WIRE FOR HEAT
DAMAGE
d. INSPECT THE AUTO TRANS TEMPERATURE SENSOR AND
WIRE FOR HEAT DAMAGE (If Equipped)
11
e. INSPECT THE ENGINE WIRE HARNESS FOR HEAT
DAMAGE IN THE LOCATIONS SHOWN
f.
INSPECT THE TRANSFER CASE BREATHER HOSE FOR HEAT DAMAGE
12
VII. FRONT EXHAUST PIPE ASSEMBLY REPLACEMENT
The exhaust assembly maybe hot, use cation and safety equipment when performing this
procedure.
A. REMOVE FRONT EXHAUST PIPE ASSEMBLY
1. REMOVE THE AIR FUEL (A/F) RATIO SENSOR
a) Disconnect the air fuel ratio connector.
b) Using the SST, carefully remove the A/F sensor.
SST: 09224-00010
If the sensor becomes tight during removal,
alternate between loosening and slightly
tightening. This will help protect the sensor
from being damaged.
2. REMOVE THE O2 SENSOR
a) Disconnect the O2 sensor connector.
b) Using the SST, carefully remove the O2 sensor.
SST: 09224-00010
3. REMOVE FRONT EXHAUST PIPE
a) Remove the 2 bolts and compression springs.
b) Remove the two bolts and nuts connecting the front exhaust pipe
to the tail pipe assembly.
c) Disconnect the front exhaust pipe support from the exhaust
assembly.
d) Slowly and carfeully lower the exhaust.
e) Ensure that exhuast gaskets have been removed from the
exhaust mainforld and the tail pipe assembly.
13
B. INSTALL NEW FRONT EXHAUST PIPE
1. MEASURE THE EXHAUST COMPRESSION SPRING
a) Using a vernier caliper, measure the free length of the exhaust
compression spring.
Minimum Spec: 40.5 mm (1.594 in.)
If the compression spring is below the minimum spec. replace
the exhaust compression spring.
2. INSTALL EXHAUST PIPE GASKETS
a) Using a wooden block gently tap the front exhaust pipe gasket
into the exhaust manifold.
3. INSTALL THE FRONT EXHAUST PIPE SUPPORT
4. INSTALL THE EXHAUST COMPRESSION SPRINGS AND
NEW BOLTS
a) Losely install the exhaust compression springs and NEW bolts.
b) Tighten the bolts in mutiple increments evenly to spec.
Torque Spec: 35ft-lbf (489 lgf-cm, 48 Nm)
c) Measure the gap between the left and right flange to ensure
they are even after tightening the bolts.
5. INSTALL THE FRONT EXHAUST PIPE TO THE TAIL PIPE
ASSEMBLY
a) Install the new gasket into the front exhaust pipe assembly.
b) Install the 2 NEW bolts and 2 NEW nuts.
Torque Spec: 35ft-lbf (489 lgf-cm, 48 Nm)
6. REINSTALL THE O2 SENSOR
a) Using the SST, install the O2 sensor.
Torque Spec: 30ft-lbf (408 lgf-cm, 40 Nm)
SST: 09224-00010
b) Connect the O2 sensor to the wire harness.
14
7. REINSTALL THE A/F SENSOR
c) Using the SST, install the A/F sensor.
Torque Spec: 30ft-lbf (408 lgf-cm, 40 Nm)
SST: 09224-00010
d) Connect the A/F sensor to the wire harness.
8. INSPECT FOR EXHAUST LEAKS
9. CHECK AND CLEAR DTCS
VIII. CATALYTIC CONVERTER RETURN PREPARATION
•
•
•
•
All catalytic converters must be returned to Toyota, the CPS system will send you a request
the day after the warranty claim is approved.
If the catalytic converters are not returned the warranty claims are subject to debit and core
charges.
Ensure to follow the steps below to ensure that the catalytic coverter is prepared for shipping.
Do not ship the full exhaust pipe assembly back to Toyota. If the exhaust pipe is shipped back
as a complete unit your dealer will debited for the additonal shipping charges.
1. CUT THE EXHAUST PIPE AT THE LOCATIONS SHOWN
2. APPLY TAPE TO THE SHARP EDGES OF EACH CATALYTIC
COVERTER
Use caution when cutting because sharp edges
will be created.
3. RETURN BOTH CATALYTIC CONVERTERS THROUGH THE CPS
SYSTEM.
◄ VERIFY REPAIR QUALITY ►
- Confrim that there are no exhaust leaks
- Confirm that all components were inspected for heat damage
- Confirm that the catalytic converter is returned to Toyota (REQUIRED)
If you have any questions regarding this update, please contact your regional representative.
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IX. APPENDIX
A. CAMPAIGN DESIGNATION DECODER
F
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
J
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:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5rd Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012
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