JLG-GX460-050219

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN JLG
AIR INJECTION PUMPS AND AIR SWITCHING VALVES
CERTAIN 2010 GX 460
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing
this recall 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 performing this recall repair are required to currently hold at least one of the following certification
levels:
• Certified
• Senior
• Master
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this recall 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
Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry System
Not Covered
No further action required
YES
Replace the Air Pump Assembly and
Air Switching Valve Kit
Covered
Perform Heath Check. Are DTC s P2444,
P2445, P2447 and/or P0418 present?
No
Install the Air Pump Repair Kit and
Air Switching Valve Kit
Campaign completed, 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,
and that it has not already been completed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs completed on vehicles that are not
affected or were completed by another dealer.
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III. PREPARATION
A.
PARTS
Part Number
04006-37138
04008-3520C
17610-0C040
Part Description
Air Switching Valve Kit* (required on all repairs)
Air Pump Repair Kit** (used on most repairs)
Assembly, Air Pump*** (used on very few repairs)
Quantity
1
1
1
Part Number
25701-38100
25702-38050
17613-31010
17376-38030
*Air Switching Valve Kit Contains:
Valve Set, Emission Control, No .2
Valve Set, Emission Control, No .1
Cover, Air Pump
Gasket, Air Tube, No.1
Quantity
1
1
1
2
Part Number
90166-A0010
17617-0C010
17602-0C010
**Air Pump Repair Kit Contains:
Screw, Hexalobular Tapping
Filter, Air Pump
Cover Sub-Assembly, Air Pump Filter (w/ Air Pump Inlet)
Quantity
1
1
1
*** The Air Pump assembly will need to be replaced only in rare cases, depending on the inspection results.
Note: Warranty will only reimburse the dealership for the cost of the kit. Claims for individual parts listed
will be denied.
B. TOOLS & EQUIPMENT
•
•
Techstream
Torque Wrench
•
•
Standard Hand Tools
Torx T25 socket
IV. BACKGROUND
There is a possibility that moisture in the air may cause a filter in the vehicle emissions system to
degrade. This degradation could cause damage to other parts of the vehicle emission system
and illuminate the check engine light (Malfunction Indicator Light).
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V. COMPONENTS
4.5 (45.9, 3.3)
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VI.
WORK PROCEDURE
1. CHECK FOR DTC’S
a. Using a Techstream, perform a Health Check to determine
if relevant Diagnostic Trouble Codes are present.
Note: This Service Campaign covers only the inspection and
replacement of the air pump and switching valves, as
detailed in these instructions. It does not cover the
diagnosis or replacement of any other parts on the
vehicle.
Are DTC s P2444, P2445, P2447 or
P0418 set?
No
Install the Air Pump Repair Kit.
Proceed to Section VII on p. 5
VII.
Yes
Replace the Air Pump Assembly.
Proceed to Section VIII on p. 7
INSTALL AIR PUMP REPAIR KIT
1.
REMOVE THE ENGINE ROOM COVERS
2.
INSTALL THE AIR PUMP REPAIR KIT
a. Using a Torx T25 socket, remove the screw and air pump filter
cover sub-assembly.
Note. The cover assembly and the screw will not be reused.
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b. Remove and discard the air pump filter.
c. Install the NEW air pump filter.
BE SURE TO CORRECTLY POSTION THE AIR PUMP
FILTER ELEMENT.
d. Install the NEW air pump inlet to the NEW air pump filter cover
sub-assembly.
e. Using a Torx T25 socket, install the NEW air pump filter cover
sub-assembly with the NEW hexalobular tapping screw.
Torque: 4.5 N∙m {45.9 kgf∙cm, 40 in.lbs}
3.
INSTALL THE NEW AIR PUMP COVER
a. Install the NEW air pump cover by engaging the 3 claws.
Skip to Section IX. Replace Emission
Control Valve #1 (LH) on p. 9
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VIII.
REPLACE AIR PUMP ASSEMBLY
Complete this section only if DTC’s P2444, P2445,
P2447 or P0418 are set.
1. REMOVE THE ENGINE ROOM COVERS
2. REMOVE AIR PUMP ASSEMBLY
a. Disconnect the No. 4 air injection system hose from the air
pump.
b. Disconnect the air pump connector and detach the wire
harness clamp.
c. Remove the 3 bolts and air pump with bracket.
d. Detach the 2 air pump connector clamps.
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e. Detach the 3 fittings of the air pump insulator and remove
the air pump from the bracket.
3. INSTALL NEW AIR PUMP ASSEMBLY
a. Attach the 3 fittings of the air pump insulator to install the
NEW air pump to the bracket.
b. Attach the 2 air pump connector clamps.
c. Install the air pump with bracket with the 3 bolts.
Torque: 20 N∙m {204 kgf∙cm, 15 ft. lbs}
d. Connect the air pump connector and attach the wire
harness clamp.
e. Connect the No. 4 air injection hose so that it’s paint mark
aligns with the rib of the air pump.
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IX.
REPLACE EMISSION CONTROL VALVE No. 1 (LH)
1. DISCONNECT No.2 AIR INJECTION SYSTEM HOSE
a. Disconnect the air switching valve connector.
b. Disconnect the No. 2 air injection system hose.
2. REMOVE EMISSION CONTROL VALVE No. 1 (LH)
a. Remove the bolt and disconnect the wire harness clamp
bracket.
b. Remove the 2 bolts.
c. Remove the 3 bolts, valve assembly, and gasket.
3. INSTALL EMISSION CONTROL VALVE No. 1
a. Install the NEW gasket.
b. Install the NEW Emission Control Valve with the 3 bolts.
Torque: 24 N∙m {245 kgf∙cm, 18 ft.lbs}
Note: Make sure the claws of the gasket are not caught
between the air switching valve and No. 4 air tube.
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c. Install the 2 bolts.
Torque: 10 N∙m {102 kgf∙cm, 84 in.lbs}
d. Connect the wire harness clamp bracket with the bolt.
Torque: 8.0 N∙m {82 kgf∙cm, 71 in.lbs}
e. Align the paint mark with the projection to connect the No.
2 air injection system hose.
f. Connect the air switching valve connector.
g. Install the Engine Room Side Cover.
Note: Make sure the direction of the hose clamp is as shown in
the illustration.
X.
REPLACE EMISSION CONTROL VALVE No. 2 (RH)
1. REMOVE AIR CLEANER CAP AND HOSE
a. Disconnect the Mass Air Flow meter.
b. Disconnect No. 1 air hose.
c. Disconnect the No. 2 ventilation hose.
d. Detach the wire harness clamp.
2. REMOVE AIR CLEANER CASE
a. Remove the 3 bolts.
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3. REMOVE EMISSION CONTROL VALVE No. 2
a. Disconnect the No. 3 Ventilation hose.
b. Disconnect No. 1 Air Injection Hose
c. Detach the wire harness clamp
d. Disconnect the connector.
e. Remove the bolt and disconnect the wire harness clamp
bracket.
f. Remove the 2 bolts.
g. Remove the 3 bolts.
h. Remove the valve assembly with gasket.
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4. INSTALL EMISSION CONTROL VALVE No. 2
a. Install the NEW gasket.
b. Install the NEW Emission Control Valve with the 3 bolts.
Torque: 24 N∙m {245 kgf∙cm, 18 ft.lbs}
Note: Make sure the claws of the gasket are not caught
between the air switching valve and No. 3 air tube.
a. Install the 2 bolts.
Torque: 10 N∙m {102 kgf∙cm, 84 in.lbs}
b. Attach the wire harness clamp.
c. Connect the electrical connector.
c. Align the mark with the projection and connect the No. 1
air injection system hose.
d. Connect the No. 3 Ventilation hose.
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5. INSTALL AIR CLEANER ASSEMBLY
a. Install the 3 bolts in the case.
Torque: 12 N∙m {122 kgf∙cm, 108 in.lbs}
b.
c.
d.
e.
Connect the No. 2 ventilation hose.
Connect No. 1 air hose.
Connect the Mass Air Flow meter.
Attach the wire harness clamp.
6. INSTALL ENGINE ROOM COVERS
◄ VERIFY REPAIR QUALITY ►
•
Confirm that no DTC’s are set
If you have any questions regarding this update, please contact your area representative.
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10. APPENDIX
A. 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.
B. CAMPAIGN DESIGNATION DECORDER
H
0
A
Year Campaign is Launched
Repair Phase
Current Campaign Letter
for this year
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
G = 2016
H = 2017
Etc...
0 = Remedy
1 = Interim (Remedy not yet
available)
will change to
when the Remedy is available
(May use other characters in
unique cases)
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
27th Campaign = 1
28th Campaign = 2
Etc...
Examples:
C1B = Launched in 2012, Interim Phase, 2nd Campaign Launched in 2012
E0A = Launched in 2014, Remedy Phase, 1st Campaign Launched in 2014
H0A = Launched in 2017, Remedy Phase, 1st Campaign Launched in 2017.
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