Safety Recall DLC (Interim D2C) - Preliminary Notice 2002 Through Certain 2003 Model Year And One 2004 Model Year SC 430 Vehicles Front Passenger Air Bag Inflator (L-CP-DLC)

Publication date: 2013-09-15
Reference number: L-CP-DLC
Supersedes refnos: L-CP-D2C

SAFETY RECALL DLC (INTERIM D2C) - PRELIMINARY NOTICE 2002 THROUGH CERTAIN 2003 MODEL YEAR AND ONE 2004 MODEL YEAR SC 430 VEHICLES FRONT PASSENGER AIR BAG INFLATOR

SERVICE CAMPAIGN BULLETIN

Reference Number(s): L-CP-D2C, L-CP-DLC, Date of Issue: September 20, 2013

LEXUS:	2002 - 2004 Model Year SC 430
SERVICE CATEGORY:	Preliminary Notice
SECTION:	Campaign
COPYRIGHT:	© 2018 Lexus, a division of Toyota Motor Sales, USA License Agreement TMS1002

Superceded Bulletin(s): L-CP-DLC, Date of Issue: September 5, 2013

NOTE: UPDATED SEPTEMBER 5, 2013

NOTE: Updated 9/5/2013 - The TI has been updated to provide an explanation of the airbag serial number. (SECTION VII, STEP 6)

SUBJECT

Dear Dealer Principal:

On April 11, 2013, a Defect Information Report (DIR) was filed with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2002 through certain 2003 model year and one 2004 model year SC 430 vehicles.

This preliminary information is being provided to keep you informed of the filing. Lexus is currently preparing the remedy parts for this condition. We will notify dealers again at the time of the next phase, prior to owner notification starting.

CONDITION

The subject vehicles are equipped with front passenger airbag inflators which could have been assembled with improperly manufactured propellant. Improperly manufactured propellant could cause the inflator to rupture and the front passenger airbag to deploy abnormally in the event of a crash, increasing the risk of injury to the occupant.

Below are a few highlights of the preliminary notice; please review this entire package with your staff to familiarize them with this notification and implementation requirements.

COVERED VEHICLES

There are approximately 35,000 SC430 vehicles (2002 through certain 2003 and one 2004 MY) covered by this Safety Recall in the US. Only a portion of these vehicles have the subject Airbag Inflator installed that will require replacement.

STATUS/IMPLEMENTATION AT DEALERSHIPS

DLC ("D2C" until the remedy is launched) Preliminary Notification documents will be posted on TIS starting the morning of Thursday, April 11, 2013
For reference purposes only, VINs covered by this Safety Recall are now available on TIS.
Lexus is currently preparing the remedy parts for this condition.

MEDIA CONTACTS

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Cindy Knight (310) 468-2170 in Toyota Corporate Communications. (Please do not provide this number to customers. Please provide this contact to only media associates.)

CUSTOMER HANDLING

A Q&A is attached to assist you in responding to any questions or customer concerns. If the customer has any further questions they are requested to contact the Lexus Customer Assistance Center at 1-800-255-3987 Monday through Friday, 5:00 am to 6:00 pm PST, or Saturday, 7:00 am through 4:00 pm PST.

PRE-OWNED VEHICLES IN DEALER INVENTORY

Lexus generally requests that dealers do not deliver any pre-owned vehicles in dealer inventory that are covered by a Safety Recall until the vehicle has been remedied. However, in this case, until the remedy is available, dealers can deliver pre-owned vehicles if they disclose to the customer that the vehicle is subject to a Safety Recall and Lexus will send them a notification when the remedy is available.

Please review this preliminary notification with your staff to familiarize them with the proper step-by-step procedures required to implement this Safety Recall.

Thank you for your understanding and cooperation.

ATTACHMENT

CC: Customer Satisfaction Manager

General Manager

Parts Manager

Pre-owned Manager

Service Manager

SAFETY RECALL DLC (D2C)

This preliminary information is being provided to keep you informed of the filing. Lexus is currently preparing the remedy parts for this condition.

Q1: What is the condition?

A1: The subject vehicles are equipped with front passenger airbag inflators which could have been assembled with improperly manufactured propellant. Improperly manufactured propellant could cause the inflator to rupture and the front passenger airbag to deploy abnormally in the event of a crash, increasing the risk of injury to the occupant.

Q1a: What is the Inflator?

A1a: The inflator is a device contained within the airbag assembly. It contains a solid propellant wafer which is ignited in the event airbag deployment is necessary. When ignited, the wafer expands into an inert gas, inflating the airbag.

Q1b: What is the cause of this condition?

A1b: Propellant wafers manufactured with inadequate compression force or with improper humidity levels may have been used during assembly of the inflator.

Q2: Are there any warnings that this condition exists?

A2: No. There are no warnings that this condition exists.

Q3: What is Lexus going to do?

A3: Lexus is currently working on obtaining the necessary remedy parts. Once the parts are available, we will notify owners.

Once the remedy parts have been produced in sufficient quantities, Lexus will send (consistent with parts availability and repair capacity) an owner notification by first class mail advising owners to make an appointment with his/her authorized Lexus dealer to have the airbag inflator module replaced at no charge.

Q3a: When does Lexus anticipate the remedy will be available?

A3a: Lexus is currently working on obtaining the remedy parts for this Safety Recall. Lexus anticipates it will take several weeks to prepare a sufficient quantity of remedy parts.

Q3b: How does Lexus obtain my mailing information?

A3b: Lexus uses an industry provider who works with each state's Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

Q3c: When the remedy becomes available, do I need my owner letter to have the remedy performed?

A3c: You do not need an owner letter to have this recall completed; however, to assist the dealer in confirming vehicle eligibility, we request that you present this notice at the time of your service appointment.

Q4: Which and how many vehicles are covered by this Safety Recall?

Q4: There are approximately 35,000 SC430 vehicles (2002 through certain 2003 and one 2004 MY) covered by this Safety Recall in the US. Only a portion of these vehicles have the subject Airbag Inflator installed that will require replacement.

VEHICLES SAFETY RECALL

Model Name	Model Year	Production Period
SC430	2002 through certain 2003 and one 2004	Early January, 2001 through Late September, 2003

Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.?

A4a: Yes, there are also approximately 731, 300 (2003 - certain 2004 Model Year) Corolla, Corolla Matrix, Tundra, and (2002 - Early 2004) Model Year Sequoia vehicles covered by this Safety Recall. Only a portion of these vehicles have the subject Airbag Inflator installed that will require replacement.

Q5: What if I previously paid for repairs to my vehicle for this condition?

A5: Reimbursement consideration instruction will be provided in the remedy owner letter.

Q6: What if I have additional questions or concerns?

A6: If you have additional questions or concerns, please contact the Lexus Customer Assistance Center at 1-800-255-3987 Monday through Friday, 5:00 am to 6:00 pm, or Saturday 7:00 am through 4:00 pm Pacific Time.

TECHNICAL INSTRUCTIONS

FOR

SAFETY RECALL DLC

FRONT PASSENGER AIRBAG INFLATOR MODULE

CERTAIN 2002 - 2003 & 1 (one) 2004 MODEL YEAR SC430

UPDATED SEPTEMBER 20, 2013

Updated 9/20/2013

The TI has been updated to include a diagnostic report requirement when performing a health check. (SECTION VII, STEP 2 )

Updated 9/5/2013

The TI has been updated to provide an explanation of the airbag serial number. (SECTION VII, STEP 6 )

ONLY TECHNICIANS WHO HAVE COMPLETED TRAINING COURSES LSC13A, LSC13B, AND HAVE THE FOLLOWING LEVEL OF CERTIFICATION CAN PERFORM THIS REPAIR:

MASTER SERVICE TECHNICIANS
MASTER DIAGNOSTIC SPECIALISTS

NOTE: To support additional service capacity, Lexus Certified and Senior Service Technicians, with at least 36 months Lexus experience AND L652 course credit , may also perform this repair following successful completion of course LSC13B.

Complete DLC Technical Video Supplement

multimedia:A supplement to the article is available.

I. OPERATION FLOW CHART

The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps as outlined in the full technical instructions to confirm the campaign is completed correctly.

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II. BACKGROUND

The subject vehicles are equipped with front passenger airbag inflators which could have been assembled with improperly manufactured propellant wafers. Improperly manufactured propellant wafers could cause the inflator to rupture and the front passenger airbag to deploy abnormally in the event of a crash, increasing the risk of injury to the occupant.

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III. IDENTIFICATION OF AFFECTED VEHICLES

A. COVERED VIN RANGE

WMI	Year	VIN Range
WMI	Year	VDS	Range
JTH	2002	FN48Y	0001059-0035548
JTH	2003	FN48Y	0035116-0046972
JTH	2004	FN48Y	0051445-0051445

NOTE:

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.

IV. PREPARATION

A. PARTS

Part Number	Part Description	Quantity
04003-28124	Instrument Panel Airbag Inflator Kit*	1
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B. TOOLS & EQUIPMENT

Standard hand tools
Molding remover set
Torque wrench
Techstream

CAMPAIGN TOOLS - These tools are provided to the dealership. These tools are necessary when performing this repair.

CAMPAIGN TOOLS

Image	Name	Quantity
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Airbag Mounting Bracket & hardware	1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Barcode Scanner	1

NOTE: These tools CANNOT be ordered through the parts or tools system. There is a very limited supply of tools, but if additional tools are needed, contact your regional representative.

V. SAFETY PRECAUTIONS

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CRITICAL INFORMATION - READ THOROUGHLY

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Failure to follow these procedures correctly could cause the SRS to unexpectedly deploy during servicing or the SRS may fail to operate correctly when required after reassembly. Confirm all work is performed as described in these instructions.

ELIMINATE STATIC ELECTRICITY

Before starting work and periodically while working on the vehicle, touch a metallic part of the vehicle to discharge static electricity in the body.

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DO NOT MEASURE RESISTANCE

DO NOT measure resistance of airbag components, this may cause accidental activation.

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HANDLE THE AIRBAG CAREFULLY

If an inflator is dropped, replace it with a NEW inflator.

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DO NOT ALLOW FOREIGN OBJECTS NEAR AIRBAG

Be sure to collect and account for all removed nuts/bolts to prevent them from landing in the airbag assembly.

Any foreign objects in the airbag assembly may cause damage or injury if the airbag is activated.

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WEAR PROTECTIVE EQUIPMENT

Always wear appropriate protective equipment when working on the SRS.

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VI. WORK AREA PREPARATION

Video Supplement: Introduction

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CRITICAL INFORMATION - READ THOROUGHLY

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The bracket assembly that was provided at the launch of this campaign is a critical added-safety feature that MUST be used when replacing the inflator module. Confirm the bracket assembly is installed securely in the vise and confirm the work area being used is appropriate. Before starting work and periodically while working on the vehicle, touch a metallic part of the vehicle to discharge static electricity in the body.

Confirm there are no loose objects or people exposed to the back side of the bracket for safety in the unlikely event of airbag deployment due to improper work procedures (Remember that the inflator IS NOT being replaced due to an inadvertent deployment concern).

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VII. FRONT PASSENGER AIRBAG ASSEMBLY INSPECTION

Video Supplement: Inspection

PERFORM A HEALTH CHECK

Confirm the Techstream is connected to the dealership's internet.
When launching the Techstream software the VIN MUST be entered manually.
NOTE: All letters of the VIN MUST be entered in ALL CAPS, or the VIN will need to be reentered when running the diagnostic report.

Perform a health check.

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RUN A DIAGNOSTIC REPORT

After the health check has completed, run a diagnostic report by clicking on the link on the health check screen.

NOTE: If the VIN was not entered in ALL CAPS when Techstream was launched, an error will be displayed and there will be a prompt to reenter the VIN

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Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Enter the vehicle mileage and repair order information, then click the 'report' button.

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The VIN MUST be entered manually in ALL CAPS when launching the Techstream software, the VIN WILL NOT auto-populate due to vehicle age.
A health check and diagnostic report with VIN MUST be performed within the last 36 hours and recorded by TMS. If the diagnostic report is not ran, the healthcheck will not be recognized by TMS.
The serial number checker application will be disabled and the inspection cannot be completed if a health check and diagnostic report is not performed and recorded by TMS.

LAUNCH THE SERIAL NUMBER CHECKER APPLICATION

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The AIRBAG ASSEMBLY serial number MUST be inspected using TIS and the barcode scanner (provided at the launch of this campaign) to determine if INFLATOR replacement is necessary.
The barcode scanner application MUST be completed on every vehicle to obtain the Warranty Authorization #. This number MUST be included on every warranty claim that is submitted for inflator module replacement or the claim may be subject to debit.
The technician performing the work MUST have valid TIS login credentials and an internet connection to perform the inspection and scanning process.

Log in to TIS and input the VIN of the vehicle in the Vehicle Inquiry tab.
Confirm the VIN is applicable and that the campaign has not been completed.

Click on the link to launch the serial number checker application.

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Reenter TIS password in the serial number checker application.

NOTE: The person logged-in to TIS should be the person performing the repair.

NOTE:

A task status screen will populate next and at other intervals during the repair. This screen will indicate if the inspection has previously been performed, who performed it, and where it was performed; review this information and then click 'next' to proceed to the next step. This information will be used for record keeping by TMS.
If this screen indicates that the campaign has already been completed on this VIN, there is no need to perform campaign again.

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REMOVE THE GLOVE BOX

Disengage the 3 clips and 2 claws and lower the panel under cover.

Disconnect the connectors and remove the cover.

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Remove the 2 bolts and 2 screws and lower the glove box.

Disconnect the connectors and remove the glove box.

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LOWER THE JUNCTION BLOCK

Remove the 2 screws and position the junction block out of the way for serial number scanning.

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CONNECT THE BARCODE SCANNER
1. Connect the barcode scanner to the USB port on the Techstream.
2. The scanner will automatically connect and a beep will be heard when the scanner is ready.
NOTE:
- The barcode scanner is included in the campaign tool kit.
- The barcode scanner works best in low light conditions.
- Always hold the scanner directly in front of and parallel to the barcode label.

INSPECT AND SCAN THE AIRBAG SERIAL NUMBER

Scan the AIRBAG ASSEMBLY serial number 2 times.
1. Confirm the cursor is in the first serial number box then scan the serial.
2. Position the cursor in the second serial number box then scan the serial.
Click validate to determine if the inflator is affected.

NOTE:

If both serial numbers that are entered do not match, confirm and reenter.
If the serial number barcode will not scan, it can be entered manually.
If the serial number and barcode are not legible or are not present, take a picture and contact your area representative.

AIRBAG SERIAL NUMBER IDENTIFICATION

The airbag serial number is ALWAYS the 12 DIGITS located between the asterisks.

The 3 digits before the asterisk ARE NOT part of the serial number, and SHOULD NOT be entered or an inaccurate response may be returned.

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Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

The AIRBAG ASSEMBLY serial number and the INFLATOR serial number are DIFFERENT . The AIRBAG ASSEMBLY serial number MUST be scanned to determine if INFLATOR replacement is required.

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CONDITION 1
Inflator replacement REQUIRED
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The inflator is affected and replacement is required. Proceed to STEP VIII . for instructions on airbag removal.

CONDITION 2
NO NEED to replace inflator
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The inflator IS NOT affected and DOES NOT need to be replaced. Complete the following steps: Record the Warranty Authorization # provided at the end of the serial number checker application to be included in the warranty claim. Reassemble the vehicle. Perform a health check and diagnostic report on the vehicle.

VIII. FRONT PASSENGER AIRBAG ASSEMBLY REMOVAL

REMOVE THE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Refer to TIS for removal instructions.

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Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE THE AIRBAG FROM THE INSTRUMENT PANEL

Remove the 3 screws and the side defroster nozzle.
Remove the 2 screws and the heater to register duct.
Remove the 4 bolts, disengage the straps, then remove the airbag assembly.

NOTE: Only remove the components highlighted in red, there is NO NEED to remove any other components.

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IX. INFLATOR REPLACEMENT

Video Supplement: Inflator Replacement

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CRITICAL INFORMATION - READ THOROUGHLY

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The connector of the inflator module contains a short circuiting mechanism to eliminate voltage variances when the connector(1) is disconnected. To allow for the replacement of the inflator module, a new short circuit(2) MUST be created before cutting the wires(3) and removing the inflator. The following steps MUST be followed exactly as described to ensure the work is completed correctly and safely.

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MOUNT THE AIRBAG IN THE MOUNTING BRACKET

Position the airbag so that the airbag weld-nuts are between the support bars and mounting bracket and install the bolts.

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Position the support bars at an angle as shown in the illustration.

Confirm the center airbag bracket is facing up.

NOTE: The position of the support bars is critical to create clearance for the removal of the inflator.

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Position the airbag so that all four nuts can be removed through the access holes.
Tighten the nuts holding the support bars to the mounting bracket.

Confirm the following:

Mounting bracket is secure in the vise.
Airbag is secure in the support bars.

Support bars are secure on the mounting bracket using 1 bolt/nut at the top of each support bar and 2 nuts/bolts at the bottom of each support bar.

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Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CRITICAL INFORMATION - READ THOROUGHLY	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002		ALWAYS keep as much of your body as possible in front of the bracket when working on the airbag assembly.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002		Remember to periodically touch a metallic part of the vehicle to discharge static electricity in the body.

PREPARE TO INSTALL THE SHORT CIRCUIT

Disengage the harness clamp.

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Cut the yellow corrugated tube on the harness approximately 4 inches (10 cm) using nippers.

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DO NOT damage the wires in the tube.
DO NOT use a knife or razor blade to cut the tube to avoid damaging the wires.
This may be performed on either end of the inflator.

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Cut off the tab of the electro tap shown in the illustration.

NOTE: The electro tap is included in the inflator parts kit.

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This tab MUST be removed to ensure a good short.

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CREATE A NEW SHORT CIRCUIT IN THE INFLATOR HARNESS

Place one wire in the electro tap as shown in the illustration.

Fold and pinch the half of the electro tap with the wire and use pliers to lock the electro tap.

NOTE:

DO NOT work on both wires at the same time to avoid errors.
Pliers MUST be used to confirm the electro tap is firmly locked in place.

Set the other wire in the electro tap and lock it in place using pliers.

DO NOT measure resistance of the inflator wires, this may cause accidental activation.

CUT THE INFLATOR WIRES

Cut the 2 wires at the side of the electro tap that is farthest away from the inflator.

DO NOT measure resistance of the inflator wires, this may cause accidental activation.

LOOSEN THE SELF LOCKING NUTS

Use the access holes in the bracket to loosen the 4 nuts.

NOTE:

DO NOT use power tools.
DO NOT remove the nuts or the bag may fall out of the airbag assembly.

Loosen the nuts until they are flush with the studs.
Use a marker to mark the nuts as they are not to be reused.

NOTE: DO NOT reuse the old nuts, new nuts MUST be used.

REMOVE THE INFLATOR

Gently push in the 4 studs until the nuts contact the airbag case to allow for inflator removal.

Remove the inflator from the airbag assembly and place it on a safe work surface.

SCAN THE OLD AND NEW INFLATOR SERIAL NUMBER

Scan the OLD inflator serial number and mark the old inflator so that it will not be reused.

Scan the NEW inflator serial number.

NOTE: This information is CRITICAL

It is used to confirm the correct inflator is removed from the vehicle.
It is recorded by TMS to trace the return parts shipment.
It is used to track new the inflator that is being installed on the vehicle.

Step a) Old Inflator
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Step b) New Inflator
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Confirm agreement by checking the two boxes.
Record the Warranty Authorization # to be included in the warranty claim.
Place the old inflator in the parts box and take it immediately to the parts department.

NOTE:

Keep all shipping paperwork with the box that it came in.
Confirm the cursor is in the correct serial number input box before scanning.
If the serial number barcode will not scan, it can be entered manually.
If there are any difficulties or concerns with this process, email quality_compliance@toyota.com with details.

Step d)
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Step e)
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INSTALL THE NEW INFLATOR

Carefully slide the new inflator into the airbag assembly.

FOLD THE CONNECTOR SEAL

Fold the seal in order to prevent it from being caught under the position determining plate in the next step.

NOTE: DO NOT fully remove the seal until just before connecting the harness.

INSTALL THE NEW SELF LOCKING NUTS AND POSITION DETERMINING PLATE

Remove the 2 old nuts.

Install the position determining plate and install the 2 NEW nuts by hand. They will be torqued on a later step.

The position determining plate can only be installed on one side in one position, confirm the plate is aligned correctly.

Remove the 2 old nuts.

Install the 2 NEW nuts by hand. They will be torqued on the next step.

TORQUE THE NUTS

Push the inflator so that it contacts the position determining plate.
Tighten the nuts evenly in two increments following the sequence shown in the illustration. Use a socket driver or torque wrench to tighten the nuts.

Torque: 35in. lbf (3.9N.m)

If the inflator is not positioned correctly in the position determining plate the airbag may not deploy correctly when activated.
There will be some resistance when tightening the nuts because they are self-locking, confirm the nuts are tightened correctly.
DO NOT use a power tool, T-handle, or ratchet when tightening the nuts to avoid overtorqueing.

CONNECT THE INFLATOR CONNECTOR

Remove the connector seal from the inflator.
Confirm the alignment of the harness connector as shown in the illustration, then connect the harness. The connector wires should lead toward the center mounting bracket on the airbag assembly.

The connector should be connected IMMEDIATELY after removing the seal.
The connector is one-way, once it is installed it CANNOT be removed.
If the connector is installed in the incorrect orientation the terminals may be bent or the connector may not fully engage.

CONNECT THE HARNESS CLAMP

INSPECT THE AIRBAG BEFORE INSTALLATION

Confirm that the 4 NEW nuts are installed and tight.
Confirm the NEW position determining plate is installed.

Confirm the flats on the position determining plate and inflator are aligned.

X. VEHICLE REASSEMBLY

REINSTALL THE AIRBAG ASSEMBLY IN THE INSTRUMENT PANEL

Position the airbag assembly in the instrument panel, engage the straps, then install the 4 bolts.
Install the 2 screws and the heater to register duct.

Install the 3 screws and the side defroster nozzle.

INSTALL THE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
1. Refer to TIS for installation instructions.
RECONNECT THE NEGATIVE BATTERY CABLE
PERFORM A HEALTH CHECK AND DIAGNOSTIC REPORT

< VERIFY REPAIR QUALITY >

Confirm all precautions are follow to ensure safety during the repair
Confirm the entire serial number checker application is completed and the warranty authorization # is recorded on EVERY vehicle
Confirm the old inflator is handled safely and given to the appropriate parts professional for shipment
Confirm the inflator harness connector is fully engaged and that the position determining plate is installed correctly
If you have any questions regarding this update, please contact your area representative.

XI. APPENDIX

A. CAMPAIGN DESIGNATION DECODER

B. CAMPAIGN PARTS DISPOSAL

Video Supplement: Parts Handling

ALL inflators that are removed from vehicles under this campaign MUST be packaged and shipped back to the inflator manufacturer following the manufacturer's instructions. The instructions can be found in the following locations:

Attached to the dealer letter
Included in the parts box
The laminated aid that was provided at the launch of the campaign