K0D-TI-Spray 16-

IMPORTANT UDPATE
TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN K0D
FRAME CORROSION RESISTANT COMPOUND (CRC) APPLICATION
CERTAIN 2016 – 2017 MODEL YEAR TACOMA
(2011-2015 model year instructions can be found on TIS)
COLD CLIMATE STATES ONLY
CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV and
District of Columbia
UPDATE 3/6/2020
Update 3/6/20
• Repair Type Confirmation Step has been added on page 8.
• Primary filter cleaning procedure added in appendix.
Update 1/23/20
• Wand cleaning process has been added for the wand tips in the appendix.
Update 1/10/20
• The Checksheet section was updated with details about aftermarket wax and Checksheet requirements
Update 11/15/19
• Updated browser and picture size requirements for Checksheet
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this service campaign are required to successfully complete the most current version of the E-Learning course
“Safety Recall and Service Campaign Essentials”. All Technicians will also be required to complete the ELearning Module SCK0D and FTS Instructor Led course TIR019A. 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 (any specialty)
• Expert (any specialty)
• Master
• Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this service campaign 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.
1
• For a complete list of Site Selection Guidelines and, Fire, Building, and Zoning Codes
information for your state, please refer to the Dealer Information Packet. Please ensure your
dealership complies with all regulations set forth in this packet.
• Keep records to comply with Federal/State/Local regulations and requirements. See the
Federal, State & Local Requirements Guide and any Supplements to that Guide.
OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the R.O.
Not Covered
No further action required
No
No further action required; these
vehicles can only be sprayed at
approved Toyota dealers
2. Check the TIS Vehicle Inquiry System
Covered
Is the vehicle located at a dealership approved
to spray 712-THV-T CRC?
Yes
No
Did the vehicle pass the ZKA Frame Inspection?
Yes
Open Frame Parts Lookup site and enter VIN
for required repair based on parts listed
Only Frame Plug
parts listed
Wax and Frame Plug parts listed
Perform drying and cleaning process
During the drying and cleaning process was
perforation 10mm or larger found in the
locations identified in green below?
Yes
Proceed with Frame
Replacement as outlined in
the ZKA TI
No
Install the specific Frame Plugs outlined in the
Technical Instructions
Apply the 712THV-T Internal CRC to the areas
of the frame outlined in the TI
Complete online check sheet
Install remaining Frame Plugs and Frame Side
Rail Seal
Campaign completed, return
the vehicle to the customer
Cold Climate States include - CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT,
WI, WV and District of Columbia
NOTE: Ensure to follow the entire procedure and perform all steps completely any deviation will be
subject to warranty claim debit.
If you find a vehicle with aftermarket wax already applied to the interior of the frame, contact
[email protected] for guidance
2
IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
NOTE:
• Vehicles currently registered in the Cold Climate States* or the District of Columbia (D.C.) that do
not have significant corrosion found are eligible for Corrosion-Resistant Compound (CRC)
application to the frame if it did NOT previously have the frame sprayed and/or had the frame
previously replaced.
• Check TIS to confirm the VIN is covered in K0D. This will verify the vehicle is covered and has
not already been completed prior to dealer shipment or by another dealer.
• TMNA warranty will not reimburse dealers for repairs conducted on vehicles that are not covered
or were completed by another dealer.
* CT, D.C. , DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, & WV
• If the vehicle is regular operated or registered in a cold climate state but is not included in K0D
contact Quality Compliance for instructions on how to include the vehicle in K0D
PREPARATION
A. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look up part
numbers by VIN. Please go to https://tacoma-2011-2017-frames.imagespm.info/ select the appropriate
campaign/vehicle, enter the VIN, and the correct part numbers to order will be displayed. The website is for
part(s) application reference only and won’t order the parts, confirm campaign completion status, or
confirm campaign applicability.
Based on the results shown in the parts look up site you will be able to
determine if the vehicle needs wax application or not. Confirm what parts are
listed in the site shown above before proceeding
A. WAX
Part Number
00289-TS00P
Part Name
WAX (18 Liters PAIL CAN)
Qty
4.5L (Per Vehicle)
3
B. SUPPORT MATERIALS
Individual Parts:
Part Number
90950-01987
Part Name
Plug, Hole
Model Year
2011-2017
Qty
2
Part Name
Plug Hole Kit CRC Application 2
Model Year
2016-2017
Qty
1
Parts Kits:
Part Number
04008-07835
The kit above includes the following parts:
Part Number
90950-01A24
90950-01A25
90950-01987
90950-01631
90950-01990
90950-01991
90950-01931
90333-30002
94183-00831
94611-10800
04008-21204
Part Description
Qty
2
2
4
4
2
2
1
4
2
4
Plug, Hole
Plug, Plate
Nut, Lock
Washer, Plate
Plug Hole Kit CRC Application 4
2016-2017
The kit above includes the following parts:
Part Number
Part Description
90950-A1008
Plug, Hole
90950-A1009
90080-46327
Clip
5114A-04010
Seal, Frame Side Rail, RH
5114B-04010
Seal, Frame Side Rail, LH
90178-A0112
Nut, Flange
90105-A0356
Bolt, Flange
1
Qty
2
2
2
1
1
2
2
4
C. STANDARD TOOLS & EQUIPMENT
• Standard hand tools
• Torque wrench
SPECIAL EQUIPMENT
The following equipment was shipped to your dealership prior to the launch of LSC K0D.
Equipment
Purpose
Application Area
Interior / Open Section
Drying Equipment Kit
Drying
Frame Drying
*Drying Kit Includes
Equipment
Air Mover
E-TES Heater
Air Duct Plate
Air Duct Plugs
Air Duct Hoses
Air Duct Adapters
4in Hose Clamps
3in Hose Clamps
Qty
1
1
1
2
2
2
4
2
*There will be 2 silver colored hoses that will be included in the kit but will not be
used in the campaign procedure
Cleaning Equipment
Kit
Interior / Open Section
Frame Drying and Cleaning
Cleaning
*Cleaning Kit Includes
Equipment
Power Tool Wire
Brush
Power Tool Wand
PVC Handle
Extended Wire Brush
2ft Air Gun
Qty
1
1
1
1
1
712THV-T Wax
Application
Wand Kit
Interior Frame CRC
Application.
*Wand Kit Includes
Equipment
Short Wand
Long Wand
LH Guide Plug
RH Guide Plug
Wax Application Spray 712THV-T Wax
Package
Application
Qty
1
1
1
1
Interior Frame CRC
Application.
*Wax Application Spray Package Includes
Equipment
Pump and Heater
Assembly
TSL Bottle
Owner’s Manual
Qty
1
1
1
The items below were previously shipped to your dealership for previous campaign (H0F and J0M).
Equipment
90o Drill Adapter
Drill Bits
J0M Endoscope
Purpose
Drill Holes
Inspect Frame
Application Area
These tools will be used to attach
the Frame Side Rail Seal.
Interior Frame Sections
5
D. MATERIALS & SUPPLIES (Locally Procured by Dealer)
• Wire Brush
• C-Clamp
• Bungee Cord / Strap
• Protective eyewear
• Air Coupler
• Gasket Scraper
• Dust mask
• Appropriate NIOSH approved respirator** (Follow all Federal, State, Local
Environmental, Health and Safety Requirements such as OSHA Regulations. Please
refer to the SDS for details on the appropriate mask for each CRC.)
Example of a NIOSH**NOTE:
approved respirator
• Refer to the SDS located in the Appendix for additional information on respirator use.
• It is up to the individual dealership to ensure compliance with OSHA regulations.
• If you require further assistance in regards to NIOSH approved respirators, we have found 3M® to be
a useful reference/source.
3M® Technical Assistance:
1-800-243-4630
3M® Customer Service:
1-800-328-1667
3M® Web Site:
www.3m.com/occsafety
• Protective gloves
• Chemical Resistant Gloves (refer to SDS for specific type)
• Masking tape
• Duct tape
• Plastic wrap (for storage of wands, guns and wax pail)
• Shop cloth/paper towels
• Garbage Bags
• Paint Prep Cup (Φ 10-15cm (3.94 - 5.91 in.) for paint work. This cup will be used to check wax application.)
E. SPACE
1 stall (with swing arm lift) + α (for wax application system space)
6
BACKGROUND
Toyota has received a number of reports regarding frame corrosion perforation
on 2011 – 2017 model year Tacoma vehicles. In these reports, customers have
indicated that vehicles operated in specific cold climate areas with high road salt
usage may exhibit more-than-normal corrosion to the vehicle’s frame. This
condition is unrelated to and separate from normal surface rust which is
commonly found on metallic surfaces after some years of usage and/or exposure
to the environment.
VEHICLE INSPECTION WORK PROCEDURE
NOTE:
Vehicle frame inspection is performed under CSP ZKA, for inspection instructions go to CSP ZKA
Frame Replacement Technical Instructions.
• Because of variations in State and local laws, dealerships conducting K0D in certain states
may require government approvals prior to starting the campaign. Depending upon the state,
dealerships also may be subject to restrictions on the number of vehicles to which the CRC
can be applied in any single day, week, or month. Please refer to the Dealer Information
Packet and any Supplements for important information about any such approvals or
restrictions that may apply to your dealership. Your dealership must adhere strictly to these
requirements.
• For a complete list of Site Selection Guidelines, Fire, Building, and Zoning Codes information
for your state, please refer to the Dealer Information Packet as well as any Supplements.
Please ensure your dealership complies with all regulations and all issued
packets/instructions.
OTHERS
1.
PRECAUTIONS WHEN HANDLING THE HIGH PRESSURE SYSTEMS
When the spray equipment, sealer gun or the wand tips are clogged, leaking, abnormal noise, etc., please
DO NOT operate the equipment and contact the following:
Bosch Technical Assistance Line - 1-800-933-8335 (Option 4)
Be careful as you are using the high pressure spray gun. Always follow the instructions and observe the
specified pressures. NEVER operate the pressure regulators to be over the specified values.
e.g. DO NOT try to blow out the wand or tip clogging by high-pressure air. It may result in splashing out
wax or breaking the wand or hose, and the scattered broken parts may cause serious injuries.
Make sure to check for leakage or breakage before each use. If any problems are found, stop using the
system immediately and please contact the following:
Bosch Technical Assistance Line - 1-800-933-8335 (Option 4)
DO NOT disassemble the parts other than the short wand or the long wand.
2. PRECAUTIONS WHEN HANDLING WAX
Attention should be paid as the wax is very slippery.
Wipe off the wax on the floor and shoes promptly to not slip and fall.
Perform work in a well-ventilated area.
Always work with clean tools and hands.
3. PRECAUTIONS WHEN USING APPLICATION SYSTEM
Attention should be paid to NOT get caught as the application hose is long and hard.
DO NOT bend or modify hoses or piping.
Pay attention to the position of the system.
4. KEEP YOUR WORK SPACE ORGANIZED
DO NOT place removed parts or unused items such as wands on the floor.
5. CONTACT INFORMATION FOR TROUBLESHOOTING
For any issues with the Spray Wax/Cleaning equipment contact your FTS for assistance. If your FTS is not
available, contact the Bosch Technical Assistance Line - 1-800-933-8335 (Option 4) for assistance.
7
REPAIR TYPE CONFIRMATION
It is critical that each VIN is confirmed using TIS to determine the repair type. Certain vehicles require CRC
application and parts, other vehicles require no CRC application and only needs parts. If an incorrect repair is
performed, the claim will be subject to debit.
Repair Type – No CRC Application Required
Repair Type – CRC Application Required
VEHICLE PREPARATION
1.
LIFT UP THE VEHICLE
Decide the center of gravity and support positions according
to the repair manual on TIS.
NOTE:
Observe the instructions of the lift manual.
When using a swing arm with a plate, set the position
of the plate to the rear (set by extending the arm).
Avoid the application hole.
2.
REMOVE THE FRONT SUSPENSION MEMBER BRACKET
(IF EQUIPPED)
Remove the front suspension member bracket.
8
DRILL HOLE FOR FRAME RAIL SEAL
1.
DRILL HOLE FOR FRAME RAIL SEAL
NOTE:
You may not have to drill a hole as some models will
already have a threaded hole for the bolt. Inspect for a
threaded hole before you begin the next steps.
Using Template A and B in the appendix, locate the location
on both outer frame side rails.
• Print the Template
• Cut the template out
• Align the template with the datum hole
• Mark location of hole on outer frame side rail
Use a center pin punch to create a dimple for the drill bit so
it will not wander during drilling.
Using the 90o drill adapter provided and the stepper bit, drill
a 9mm (3/8”) hole in the outer frame side rail as shown.
Repeat procedure for opposite side frame rail.
DRYING INITIAL SETUP (Required for initial setup only)
Before starting this process, review the SCK0D E-Learning
Drying section for key details
1.
INSTALL THE AIR MOVER INTO THE E-TES HEATER
a. Push the air mover into the E-TES heater. Ensure the air mover is
fully seated into the E-TES heater
2.
INSTALL THE AIR DUCT PLATE ONTO THE E-TES HEATER
a. Using the 4in hose clamps, attach the air duct plugs into the ends
of the air duct plate.
b.
Install the air duct plate to the front of the E-TES heater and
secure it with a bungee cord attached around the E-TES heater
9
3.
4.
ATTACH AIR DUCT HOSES TO E-TES HEATER
a. Install 4in hose clamp to the air duct adapter. Do this to both air
duct adapters.
b.
Attach the air duct adapter to the air duct hose using the 3in hose
clamp. Do this to both adapters and both hoses
c.
Install air duct adapters and hoses to the air duct adapter plate.
ATTACH HEATER TO VEHICLE
a. Lift the vehicle
b. Place the E-TES heater below the rear of the vehicle.
c. Connect the air mover power cord and the two E-TES heater
power cords (if not already connected)
d.
Insert the right-side hose into the right-side frame rail until it is
secure.
10
e.
Using a bungee cord or straps around the frame rail, secure the
left-side hose to the left side frame rail. The outlet of the hose
must be center with the frame rail opening.
DO NOT wrap the bungee cord around any fuel, evap,
or brake hoses. Only put the bungee cord around the
frame rail and air duct hose to avoid damage to
vehicle components.
5.
CALIBRATE E-TES HEATER
a. Plug in the air mover power cord and the two E-TES heater power cords.
The air mover and E-TES heater must be plugged into separate circuits. Check your
dealership electrical system to ensure the circuit you are plugging into can operate the air
mover and E-TES heater.
b. Press SELECT to set the Air Flow switch trigger point. Follow the
screen directions using the DOWN button to set the levels with the air
mover OFF & ON.
c. Turn the air mover OFF. When the air mover is off and the
number stops changing, press DOWN(most cases this will be 0.) This is
the Off Set Point. (Shown as 033 in this example)
d.
Then turn the air mover ON at high speed. Press DOWN as
soon as the number on the display steadies out (50-300). This is the
ON Set Point. (Shown as 076 in this example)
If you need assistance with the E-TES heater contact
the Bosch Technical Assistance Line - 1-800-933-8335
(Option 4)
DO NOT CONTACT TAS for E-TES Heater concerns.
11
DRYING PROCEDURE (Normal procedure after initial setup)
1.
ATTACH HEATER TO VEHICLE
a. Lift the vehicle
b. Place the E-TES heater below the rear of the vehicle.
c. Connect the air mover power cord and the two E-TES heater
power cords (if not already connected)
d.
Insert the right-side hose into the right-side frame rail until it is
secure.
e.
Using a bungee cord or straps around the frame rail, secure the
left-side hose to the left side frame rail. The outlet of the hose
must be center with the frame rail opening.
DO NOT wrap the bungee cord around any fuel, evap,
or brake hoses. Only put the bungee cord around the
frame rail and air duct hose to avoid damage to
vehicle components.
4.
2.
TURN THE AIR MOVER ON THE HIGH SETTING
3.
TURN THE E-TES HEATER ON AND DRY FRAME
a. Flip the switch on the E-TES Heater to the “on” position
b. Check that the air coming out of the heater is warm.
c. Leave the heater and air mover ON and attached to the vehicle
for 3 hours.
The drying procedure being performed as written is
critical for the wax application procedure success. If
the drying procedure is not performed correctly the
maximum rust prevention will not be achieved.
REMOVE E-TES HEATER AND HOSES FROM VEHICLE
12
5.
DRY THE OPEN SECTION OF THE FRAME AND INNER CAB MOUNTS
a. Using the 2ft air gun, remove all water from the open section of the frame and the inside of the cab
mounts on both the right and left side of the frame. All the water between the metal reinforcements in the
open section of the frame MUST BE REMOVED before proceeding
IT IS CRITICAL THAT YOUR SHOP AIR SYSTEM NOT HAVE WATER IN IT.
Confirm by spraying the air gun at a piece of carboard (or other water absorbant material)
to confirm that no water is present. If water is present then the shop air dryer may need to
be drained or replaced.
13
16-17 MODEL YEAR CLEANING PROCEDURE
Before starting this process, review the SCK0D E-Learning Cleaning
section for key details
1.
b.
USE EXTENDED WIRE BRUSH TO CLEAN THE INSIDE OF THE
RH FRAME RAIL BOXED SECTION
a. Insert the brush into the frame rail as shown in the
image/illustration. Push the brush past the top of the box inside
the frame
Move the brush in and out of the frame in a quick motion, twisting the brush left and right to get the
corners of the top of the frame
NOTE: The amount of time needed to use the brush will vary from frame to frame. The typical
time will be 15 to 20 minutes per side however it may take longer depending on how dirty the
frame is and the type of dirt/debris in the frame
c.
d.
Remove the brush from the top of the box section and insert it
past the bottom of the box section
Move the brush in and out of the frame in a quick motion, twisting
the brush left and right to get the corners of the bottom of the
frame
NOTE: The amount of time needed to use the brush will vary
from frame to frame. The typical time will be 15 to 20 minutes
per side however it may take longer depending on how dirty
the frame is and the type of dirt/debris in the frame
2.
USE EXTENDED WIRE BRUSH TO CLEAN THE LH FRAME RAIL BOXED SECTION
a. Follow steps 1.a – 1.d for cleaning on the left-hand side.
14
Be careful not to damage the brake lines when cleaning the LH frame
3.
INSTALL CAB MOUNT FRAME PLUG
a. Once all dirt and debris has been removed from the cab mount,
install the cab mount frame plug to prevent dirt from the frame
going into the cab mount.
Plug Part Number: 90950-A1008
4.
5.
CLEAN INSIDE BOTH FRONT CAB MOUNTS
a. If there is hardened dirt or other difficult to remove debris, use the
rubber mallet to hit the outside of the cab mount to break up the
debris
b. Using the 2ft Air Gun, blow out all the dirt and debris inside the
cab mount focusing on the inner corners.
CONFIRM CAB MOUNTS CLEANLINESS
a. Using the endoscope provided to your dealer in the J0M campaign, confirm the inside of the cab mount
is clean focusing on the inner corners
NOTE: The images below show the “minimum cleanliness” that the cab mounts can be. The
frame can be cleaner than the images below but cannot be less clean.
If the cab mount is not clean enough, repeat steps 1-2 until clean
Inner Corner of the Cab Mount
6.
CLEAN THE INNER OPEN SECTION OF THE FRAME (both LH and RH)
a. Clean the welds and area highlighted in the illustrations below using the wire brush (Hand Tool) show in
the illustrations below until no dirt, debris, or rust is present on the welds
NOTE: The cross member may not be present on short wheel base frames
FRONT
15
7.
REMOVE DIRT AND DEBRIS FROM INSIDE THE FRAME
a. Using the 2ft Air Gun, blow out all the dirt and debris working from the front of the vehicle to the back
using the various plug holes. You may have to remove plugs from the frame to blow out all debris. Only
remove the plugs in the sections being cleaned.
NOTE: It will normally take 4 to 5 passes with the air gun to remove the all the debris from the
frame
NOTE:
Confirm no rocks or other debris are stuck in the channel shown below on the LH and RH side of the
frame
8.
REMOVE DUST AND DEBRIS FROM OPEN SECTION (LH AND RH SIDE)
a. Blow any dust, debris, that might be on the opens section shown below
NOTE: The cross member may not be present on short wheel base frames
FRONT
16
9.
CONFIRM FRAME CLEANLINESS FOR LH AND RH SIDE
a. Using the endoscope provided to your dealer in the J0M campaign, confirm the inside of the frame is
clean by inserting the endoscope into various plug holes.
NOTE: The images below show the “minimum cleanliness” that the frame can be. The frame can
be cleaner than the images below but cannot be less clean.
b.
If the frame is not clean enough repeat the cleaning procedure until clean enough
The frame must be cleaned before applying the wax. If the frame is not completely clean
then the wax coating will not adhear to the frame properly
10. MOVE ANY LARGE ROCKS AND DEBRIS TO THE FRONT OF THE FRAME
NOTE: Some rocks and debris will not be able to be pushed past the box section of the frame.
For those cases follow the following steps
a.
Using the 2ft Air Gun, blow all the dirt and debris to the front of the frame working from the rear of the
vehicle to the front using the various plug holes.
11. CHECK FOR LARGE ROCKS AND DEBRIS
a. Using the J0M Endoscope, confirm all large rocks and debris have been removed. If not, repeat step 9
until the rocks are removed from the spray application area
If the wire brush has worn down to the point of not being effective or you have an issue with
any other tool related to K0D contact Bosch Technical Assistance Line - 1-800-933-8335
(Option 4) for instructions on how to acquire replacement parts
17
WAX APPLICATION WORK PROCEDURE
A. CIRCUIT OF THE APPLICATION UNIT
18
1.
B. COMPONENTS OF THE APPLICATION UNIT
SYSTEM
Control Panel
1. Air inlet port
2. Air closing lever
3. Air pressure Gauge
4. Air regulator
3
1
Heater
Adjust Dial
Temperature
Gauge
4
2
120V power
supply cable
Sealer Gun
(Low Pressure)
Ground cable
Short/Long Wand Spray Gun
(High Pressure)
Wax pail
Suction pipe
Filter drain hose / lever
Inlet drain lever
2.
Inlet drain hose
SETTINGS
Pump Output
Pressure Gauge
14 MPa (2031 psi)
Back Pressure
9 MPa (1305 psi)
Adjust air regulator
Adjust black dial
High Pressure
12 MPa (1741 psi)
Adjust red dial
Sealer Pressure
0.5 - 4 MPa (73 - 580 psi)
Adjust red dial
19
1.
C. WAND SPECIFICATION
WAND
SHORT WAND
LONG WAND
SEALER GUN
1. Simple tubular tip.
2. The amount of wax applied is judged visually.
2. WAND TIP
The tip of the short wand has 5 orifices to spray out wax.
The tip of the long wand has 6 orifices to spray out wax.
3. WAND TOP MARK
The punch marks found on the wand tip side and gun side are the TOP marks.
Confirm that the TOP mark is facing upward at all time.
Tip Side (Tip & Wand)
Gun Side (Wand & Joint)
20
4. INSTALLATION OF THE WAND TO THE GUN (SHORT & LONG WAND)
Connect the short or long wand to the gun by sliding in (Quick connector).
Adjust the wand connecting portion to set the TOP mark upward.
DO NOT use red shop towels or other lint products when handling the wands as they will
cause a clogged tip. Only use lint free towels when handling the wands
Direction for RH side
Direction for LH side
21
D. INITIAL SET UP
1.
PREPARE THE WAX PAIL
Press the center of the cap and remove.
Remove the plastic inner cap.
Open the lever and remove the lid.
Remove the strainer from the suction pipe and insert the
pipe into the cap hole of the lid.
Reinstall the strainer to the pipe and then reinstall the wax
lid to the can.
Be careful to NOT let the pipe, strainer
and lid contact foreign materials when
working and DO NOT allow any foreign
materials enter the wax pail.
2.
ADD THROAT SEALING LIQUID
a) A bottle of Throat Sealing Liquid (TSL) can be found on
attached near the wheel of the pump assembly. This
bottle will be used as part of maintenance of the pump.
Store the bottle in an accessible area.
b) Before pump operation fill the white colored TSL dish halfway with TSL fluid.
Contact Bosch Technical
Assistance line to order additional
TSL fluid.
Bosch Technical Assistance Line 1-800-933-8335 (Option 4)
3.
CHECK THROAT SEALING LIQUID LEVEL
a) Remove the TSL cover screw and remove the cover
b) Confirm the TSL dish is filled half way with TSL fluid
You will need to check the TSL level
every day, or if the pump has been
moved before pump operation.
4.
SYSTEM SET UP
Lock the triggers of the high pressure spray gun and sealer
gun.
Connect the short wand to the high pressure gun
22
Connect the ground cable.
DO NOT connect to vehicle ground.
Connect the shop air hose to the air inlet port.
Open the air closing lever.
Open the filter drain lever (yellow).
Turn the air regulator to adjust the air pressure to less than
0.07 MPa (10 psi) on the air pressure gauge.
Place a container under the filter drain hose and wait until
white wax continuously comes out.
Close the filter drain lever (yellow) once all the air is
removed.
Turn the inlet drain lever (black) to drain side (arrow to inlet
drain hose side) and place a container under the filter drain
hose and wait until white wax continuously comes out.
Close the inlet drain lever (black) once all air is removed by
turning the arrow back towards the inlet feed line.
Confirm the heater adjust dial is set to off
Connect the 120V power supply cable.
DO NOT turn the heater on until the
entire system is primed with wax and
free of air otherwise damage may
occur
Adjust the heater adjust dial to 6 to warm up the wax.
Confirm the green light turns on when heater adjust dial
first adjusted.
Note: It can take 30 minutes or more to bring the wax
up to temperature depending on room temperature.
Continue with the process while the wax heats up.
23
Turn the air regulator to adjust the pump output pressure to
14 MPa (2031 psi).
NEVER set the pressure to be over
14 MPa (2031 psi).
Turn the high pressure regulator (red dial) to adjust the
high pressure to 12 MPa (1741 psi).
NEVER set the pressure to be over
12 MPa (1741 psi).
Confirm the inlet drain lever (black) is pointing towards the
inlet feed hose.
Turn the back pressure regulator (black dial) to adjust the
back pressure to 9 MPa (1305 psi).
Turn the sealer pressure regulator (red dial) to adjust the
sealer pressure to 0.5 - 4 MPa (73 - 580 psi).
NOTE:
Adjust the pressure within the range to make it easy to
work with when applying wax.
NEVER set the pressure to be over
4 MPa (580 psi).
Operate the sealer gun to drain wax.
Reference Value: 100 ml
Operate the high pressure spray gun to drain wax.
Reference Value: 100 ml
24
5.
SET UP CONFIRMATION
Confirm that the wax temperature is 40 ºC (104 ºF) on
temperature gauge.
NOTE:
If the wax temperature is not heated enough, please
wait for a couple of minutes. It may be necessary
to turn the dial to a higher level depending on air
temperature in the shop.
DO NOT warm up the wax temperature higher than
50 ºC (122 ºF).
If the wax has been overheated the system will
need to be flushed with new wax prior to
application
If the system needs to be drained due
to overheating the wax you must drain
2L of wax from the inlet drain lever
(black)
Confirm pump cycle rate.
Standard Value: 7 – 10 times/min
NOTE:
If the pump cycle rate is faster or slower than the
standard value, turn the back pressure regulator to
adjust the rate within the range.
Confirm that the pump output pressure is 14 MPa (2031 psi).
If not, adjust the air regulator to meet 14 MPa (2031 psi).
NEVER set the pressure to be over
14 MPa (2031 psi).
Confirm that the high pressure is 12 MPa (1741 psi).
If not, adjust the high pressure regulator (red dial) to meet
12 MPa (1741 psi).
NEVER set the pressure to be over
12 MPa (1741 psi).
Confirm that the sealer pressure is 0.5 - 4 MPa
(73 - 580 psi).
NEVER set the pressure to be over
4 MPa (580 psi).
Check each line for wax leakage.
If there is any wax leakage, stop using the system immediately and contact the
following number for assistance:
Bosch Technical Assistance Line - 1-800-933-8335 (Option 4)
25
E. SETTINGS AFTER WORK
1.
SETTINGS AFTER WORK
Close the air closing lever.
Turn the heater adjust dial off.
Disconnect the shop air hose.
Disconnect the 120V power supply cable and ground
cable.
Cover the guns and wands with plastic wrap to protect
them from dust.
Close the lid of the wax pail securely and wrap the cover of
the pail with plastic wrap. Store the wax pail indoors
avoiding any heat source.
NOTE:
The wax can be used for 2 months once opened. After
that it must be replaced with new wax.
26
F. REMOVAL PARTS
Reference the appropriate repair manual on TIS for parts removal procedures.
27
G. MASKING AROUND WORK STALL
NOTE:
Depending on the shop layout, it may be necessary to put barriers to prevent accidental over spray
Masking on the floor is unnecessary. (if wax falls from the frame, clean the spill right away to avoid a
fall hazard)
1.
VEHICLE MASKING
NOTE:
In this work, masking needs to be done only partially as
the drips and scattering are few.
Using an infrared thermometer ensure the exhaust has
cooled.
Cover the holes from which wax can spill out using shop
cloths or the likes.
Protect each brake tube as the wand may hit them.
(LH Side Only)
28
2.
PLUG HOLES IN THE FRAME
Apply all the plugs other than the ones indicated with stars (★) on Hole Plugs Installation Check Sheet found
in appendix.
DO NOT install the plugs indicated with stars (★) until the wax application is completed. Those
plug holes will be used when inserting a wand to apply wax.
NOTE:
• You may have to remove certain stickers to install optional equipment.
• Some vehicles may not have plug holes or may have plugs already installed depending on the
vehicle specification or model year.
• Make sure all the plugs are flush with the frame.
• Make sure the surface of the frame is clean before you apply stickers.
Apply masking tape to the holes shown in the illustration from which wax can spill out.
NOTE:
The masking tape has to be applied on both LH and RH side of the frame even when the illustrations
show only one side.
29
H. APPLY WAX WITH SHORT WAND
Before starting this process, review the SCK0D E-Learning Spray
Application section for key details
1.
PREPARE FOR WAX APPLICATION
CHECK THE REMAINING WAX AMOUNT
1. Check that more than 1/3 of wax is in the wax pail.
If not, add NEW wax to fill up the can.
The wax level must NOT be less than
1/4 as the pump starts suctioning air.
NOTE :
1 wax pail (18 Liters) is for 3 to 4 vehicles.
CHECK PUMP CYCLE RATE
Standard Value: 7 - 10 times/mins
NOTE:
If the pump cycle rate is faster or slower than the
standard value, turn the back pressure regulator to
adjust the rate within the range.
CHECK EACH PRESSURE
Standard Value:
• Pump output pressure: 14MPa (2031 psi)
• High pressure: 12 MPa (1741 psi)
• Sealer pressure: 0.5 - 4 MPa (73 - 580 psi)
NEVER set the pressures to be over
the specified values.
CHECK WAX TEMPERATURE
Standard Value: 40 ºC (104 ºF)
DO NOT warm up the wax temperature
higher than 50 ºC (122 ºF)
30
CHECK SPRAY PATTERN
1. Connect the short wand to the high pressure spray gun.
2. Weigh the empty cup and zero the scale
3. Spray 1 shot of wax on Paint Prep cup (Φ 10 - 15 cm (3.94 - 5.91 in.) for paint work).
4. Visually inspect the wax discharged from 5 orifices is continuously connected.
(Refer to XII. C. WAND SPECIFICATION)
CHECK WAX DISCHARGE AMOUNT
1. Measure the weight of the empty Paint Prep cup.
2. Spray 10 shots of wax into Paint Prep cup and measure the entire weight.
NOTE:
• Fully pull the spray gun trigger to stabilize the discharge amount of wax per shot.
• You may need to practice to be able to spray 10 g (0.353 oz.) of wax per shot.
• DO NOT spray 10 shots continuously as the pressure lowers.
3. Subtract the weight of Paint Prep cup and calculate the weight of 1 shot.
Standard Value: 100 – 120 g (3.53 - 4.23 oz.) [10 - 12 g (0.353 - 0.423 oz.) per shot]
• When replacing the high pressure wands (short or long), make sure to perform the checks
shown above every time.
• If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, redo the procedure to check properly.
• DO NOT DISCARD INITIAL SPRAY CHECK CUP. You will need to upload an image of the spray
cup at a later step
CHECK WAND TOP MARKS
1. Confirm that the TOP marks on the wand are on the
upper side when using the high pressure spray gun
with short or long wand.
(Refer to XII. C. WAND SPECIFICATION)
31
2.
INSERT FROM THE INNER APPLICATION HOLE TOWARDS FRONT
* The illustrations show RH side only. Use the same procedure for LH side.
If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Insert the short wand forward up to mark 1 so that the wand
touches the middle of the side of the application hole.
Spray 1 shot to apply wax.
Pull back the wand 1 notch and spray 1 shot.
Repeat step c) until the gun hits the frame crossmember
sub-assembly No.3.
Change the wand angle upward at the position where the
gun hit the frame crossmember sub-assembly No.3.
NOTE:
• Place the wand so that it touches the opposing
corners of the application hole.
• Be cautious as the spraying interval will change
because the notch will be at every 5 mm (0.197 in.)
at the last part of the wand.
32
Spray 1 shot and repeat step c) until Mark 5 appears.
When spraying the last few shots, cover the application hole
with your hand so that wax does not splash out.
Apply masking tape on the application hole.
3.
REINSTALL THE FRONT SUSPENSION MEMBER
BRACKET (IF EQUIPPED)
Reinstall the front suspension member bracket.
Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
Be sure to install at this step.
33
4.
INSERT FROM THE INNER OPENING TOWARDS FRONT
* The illustrations show RH side only. Perform the same procedure for LH side.
If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Insert the short wand into the gap above the bulkhead forward, up to Mark 2.
NOTE:
The wand should be placed at the center of the gap.
Spray 2 shots.
Pull back the wand 10 mm (0.394 in.) and spray 2 shots.
34
Repeat step c) until Mark 4 comes to the reference line.
Insert the short wand into the gap below the bulkhead forward, up to Mark 2.
NOTE:
The wand should be placed at the center of the gap.
Spray 2 shots.
Pull back the wand 10 mm (0.394 in.) and spray 2 shots.
Repeat step g) until Mark 4 comes to the reference line.
35
Insert the short wand into the center hole of the bulkhead forward, up to Mark 2.
Spray 1 shot.
Pull back the wand 10 mm (0.394 in.) and spray 1 shot.
Repeat step k) until the wand comes out of the bulkhead center hole.
NOTE:
DO NOT spray wax at each 5 mm (0.197 in.) notch. Spray every 10 mm (0.394 in.) though the notches
are at both 10 mm (0.394 in.) and 5 mm (0.197 in.) intervals.
Once the wand comes out of the bulkhead center hole, place the wand as close to the center as possible and
keep spraying 1 shot at every 10 mm (0.394 in.) until Mark 5 appears.
36
5.
FROM THE BOTTOM SQUARE HOLE TO THE TOP
* The illustrations show RH side only. Perform the same procedure for LH side.
If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Remove the masking tape applied to the application hole.
Set the guide on the wand according to the mark.
(The guide is supplied for LH and RH respectively.)
Insert the wand until it hits the frame inner top.
Spray 4 shots to apply wax.
NOTE:
Spray 4 shots at one spot.
Apply masking tape to the application hole
6.
REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat from the step 2 to 7 on the other side of the frame side rail.
37
I.
APPLY WAX WITH LONG WAND
* The illustrations show RH side only. Perform the same procedure for LH side.
• Wax temperature
Confirmation
• Spray pattern
Before wax application
(Refer to XII. H. 1. PREPARE FOR WAX APPLICATION) • Wax Discharge Amount
• TOP mark positions
If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
1.
FROM THE OUTER SQUARE HOLE TO THE FRONT
Peel the masking tape half way back on the application hole.
Insert the wand forward until the wand hits the bulkhead and spray 1 shot
38
Pull back the wand 1 notch and spray 1 shot.
NOTE:
Be cautious as the spraying interval will change because the notches are at both 5 mm (0.197 in.) and
10 mm (0.394 in.) intervals.
Repeat step c) until Mark 2 appears.
When spraying the last few shots, cover the application hole with your hand so that wax does not splash out.
Apply masking tape on the application hole.
2.
REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat the step 1 on the other side of the frame side rail.
39
J. APPLY WAX WITH SEALER GUN
* The illustrations show RH side only. Perform the same procedure for LH side.
Confirmation
Before wax application
• Wax temperature
(Refer to XII. H. 1. PREPARE FOR WAX APPLICATION)
1.
AROUND THE REINFORCEMENT AND CROSSMEMBER
Apply wax to the gap and edge between the reinforcement and side rail.
NOTE :
The amount of wax can be visually controlled.
The distance between the crossmember and the reinforcement may vary depending on the vehicle
40
Fill wax into the gap between the side rail and reinforcement.
NOTE :
Cover the top of the gun with your hand as shown in the illustration and fill wax enough until it comes
out from between the fingers.
Fill wax from the upper side of the gap.
NOTE :
Make sure to fill the wax as much as they come out.
Apply wax to the gap and edge between reinforcement and side rail.
41
Apply wax to the gap and edge between reinforcement and side rail.
Apply wax to the gap and edge between crossmember and side rail.
NOTE:
• Insert the sealer gun tip from the front and rear hole of the crossmember to apply wax inside the
crossmember properly.
• These steps e) and f) are not needed for short wheel base vehicle configuration.
Apply wax to the gap and edge between reinforcement and side rail.
42
Apply wax to the gap and edge between reinforcement and side rail.
Apply wax to the gap and edge between front inner channel and side rail.
Apply wax to the gap and edge between front inner channel and side rail.
43
2.
INSIDE CAB MOUNT
Insert the sealer gun tip from the holes which are on the bottom surface of the cab mount and apply wax to
the gap between the cab mount and side rail.
3.
REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat the steps 1 and 2 on the other side of the frame side rail.
44
4.
INSTALL THE BODY PLUGS
Remove the masking tape and scrape out the wax applied around the inside of the plug hole, and then install
the NEW plug (90950-01A24).
The plug must be installed with the openings facing the side of the vehicle and the tabs
facing the front a rear to ensure road spray does not enter the frame through the plug.
Remove the masking tape and install the NEW plugs (90950-01991, 90950-01987).
45
XIII.
1.
CHECKSHEET AND RECORD KEEPING
COMPLETE POST-SPRAY CHECK SHEET (THIS MUST BE DONE FOR EVERY VEHICLE)
a. Click the link below to access the frame check sheet (USE IE FOR ALL SUBMISSIONS)
https://one.tis.toyota.com/t3Portal/frameSprayCheck?l=tis_frame_spray&campaignCode=K0D&vin=&c
ampaignId=5&source=tech
NOTE: VEHICLES FOUND WITH AFTERMARKET WAX
Vehicles that come into dealership that already have wax applied from the plant can be determined by
using the parts look up site mentioned on page 3. Any vehicle that has had wax application from the
plant do NOT require a Checksheet.
Vehicles found with an aftermarket wax sprayed over K0D coverage areas will need a Checksheet
completed to determine wax application coverage. Below are examples of aftermarket wax coverage. If
you find a vehicle with aftermarket wax send an email to [email protected] for further
instruction.
Examples of aftermarket CRC
46
b. Answer the questions and enter your initials throughout
the check sheet
c. Upload photos to the check sheet
Note:
-All the photos must be taken and have the required parts
as shown in the steps below
-All photos must be less than 3MB each
-All photos must be uploaded before the check sheet is
completed.
d. Spray Cup Image
- Photo must be taken from the top view and show a
completed wax ring in the cup
- R.O. Number must be in the picture
e. Left/Right Inner Box Section Image
- Photo must be taken at the opening of the box
section and show the top, bottom, and side walls of
the box section
- R.O. number must be in the picture
NOTE: It is recommended you either use a camera flash or
back light to clearly show the interior of the box section
f.
Left/Right Open Section Image
- Photo must be taken from a distance where the
entire wax application along the open section can
be seen.
- The R.O. must be in the picture
g. Left/Right Wheel Well Image
- Photo must be taken from an angle that has all the
plugs installed on the outer rail of the frame
- The R.O. must be in the picture
h.
i.
j.
k.
Sign the check sheet
Have your Service Manager or Shop Forman sign the check sheet.
Submit the check sheet.
Using the print function, attached the completed check sheet to the R.O.
A check sheet must be completed for each vehicle sprayed
47
XIV.
INSTALLATION OF FRAME SEAL
* The illustrations show LH side only. Perform the same procedure for RH side.
1. INSTALL FRAME RAIL SEAL
Using Template C and D, modify both the left and right side
frame seal by drilling a (3/8”) hole in the location shown.
Install the bolt through the frame and torque the flange nut.
Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf)
Install the washer onto the bolt.
Install the frame seal second washer and locking nut onto
the frame and torque to spec.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Plug Hole Kit CRC Application 2 (2016-2017MY)
Part #
94183-00831
94611-10800
Part Name
Nut, Lock
Washer, Plate
Qty
2
4
Plug Hole Kit CRC Application 4 (2016-2017MY)
Part #
90178-A0112
90105-A0356
5114A-04010
5114B-04010
Part Name
Nut, Flange
Bolt, Flange
Seal, Frame Side Rail, RH
Seal, Frame Side Rail, LH
Qty
2
2
1
1
XV.
RESTORATION WORKS
1. RESTORE THE VEHICLE
Remove all the remaining masking materials.
Wipe off all the unnecessary wax remaining on the vehicle.
Reinstall all the removed parts.
Reinstall wheels and torque to spec.
Steel Wheel / Aluminum Wheel
Torque: 113 N*m (1152 kgf*cm, 83 ft.*lbf)
Lower the vehicle.
RECORD-KEEPING AND OTHER REQUIREMENTS
To make sure that your dealership can satisfy specific state and local requirements, please refer to your
specific state Dealer Information Packet.
XVI.
A.
B.
C.
D.
APPENDIX
WAND TIP CLEANING
PRIMARY FILTER CLEANING
PLUG CHECKSHEET AND FISHTALE COVER TEMPLATES
NOX-RUST 712THV-T SDS
48
A. WAND TIP CLEANING
* The illustrations show the short wand tip; However, the process can be used for the long wand tip as
well.
1.
REMOVE TIP
Remove tip from the wand by using wrench.
Wipe off the wax on outer surface of the tip
2.
REMOVE WAX
a) Blow air into each orifice to remove wax and any foreign
material
b) Repeat air-blow until as much material can be removed as
possible
3.
RE-ASSEMBLE WAND
a) Tape the wand thread by sealant tape.
Reference: Tape the thread twice
The sealant tape should not be applied near
the end of the threads to avoid sealant tape
entering the wand.
b) Assemble the tip and wand by wrench until the end of tip is
24mm from 1st notch. (See picture)
c) Adjust the tip angle to meet the top mark on the tip and top
mark on the wand. (the long wand tip may not have marks to
align. In that case adjust the end of the tip to be 24mm from
the first notch)
Note : Only adjust the tip angle when tightening
The distance between the end of the tip and
the first notch is critical for a proper spray
pattern: Short Wand 26mm, Long Wand 6mm
End of tip
1st notch
d) Check spray pattern to confirm tip is no longer clogged. If
clogged repeat step one through 3.
35
Note: If the tip cannot be unclogged after multiple attempts
call the Bosch Technical Assistance Line - 1-800-933-8335
(Option 4) to order a new wand.
49
B. Primary Filter Cleaning
4.
Depressurize System
Remove shop air source from inlet port
5.
Drain Filter Housing Using Valve
Drain the filter by using the drain valve located directly
below Pump output pressure gauge.
*Note valve should remain open until completing step 9
6.
Filter Housing Removal
Remove filter housing by rotating filter housing counter
clockwise.
*Note filter housing should be removed by hand.
7.
Removing Filter From Filter Housing
Remove filter from filter housing
*Note filter should be removed by hand to prevent
damage to mesh.
8.
Separate Filter Body and Filter Mesh
Push down on locating pintle to assist in removing filter
body from mesh filter.
Remove filter body from filter mesh completely.
9.
Clean Filter Mesh and Filter body
Remove any foreign material or residual CRC from filter
mesh and filter body using mineral spirits or equivalent
cleaning solvent.
*Note lint free material should be used when wiping the
filter mesh clean.
Use compressed air to blow any remaining foreign material
or CRC from filter mesh or filter body.
10. Install Filter Body Into Filter Mesh
Install cleaned filter body into mesh filter, ensure pintle is
seated in locating hole.
11. Install Filter Into Filter Housing
Install cleaned filter into filter housing
*Note pintle side of filter should be inserted into filter
housing first.
12. Filter Housing Installation
Filter housing should be installed by rotating filter housing
clockwise.
*Note filter housing should be hand tight similar to
canister style oil filter.
13. Bleeding procedure
Connect the shop air hose to the air inlet port.
Open the air closing lever.
Open the filter drain lever (yellow).
Turn the air regulator to adjust the air pressure to less than
0.07 MPa (10 psi) on the air pressure gauge.
Place a container under the filter drain hose and wait until
white wax continuously comes out.
Close the filter drain lever (yellow) once all the air is
removed.
Turn the inlet drain lever (black) to drain side (arrow to inlet
drain hose side) and place a container under the filter drain
hose and wait until white wax continuously comes out.
Close the inlet drain lever (black) once all air is removed by
turning the arrow back towards the inlet feed line.
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