Flood Damaged Vehicle Inspection & Handling (T-SB-0229-12 REV1)

Publication date: 2017-11-22
Reference number: T-SB-0229-12 REV1
Supersedes refnos: T-SB-0229-12

FLOOD DAMAGED VEHICLE INSPECTION & HANDLING

TECHNICAL SERVICE BULLETIN

Reference Number(s): T-SB-0229-12, Date of Issue: November 21, 2012

TOYOTA:	: 2000 - 2013 4Runner, Avalon, Avalon HV, Camry, Camry HV, Celica, Corolla, Echo, FJ Cruiser, Highlander, Highlander HV, Land Cruiser, MR2 Spyder, Matrix, Prius, Prius C, Prius PHV, Prius V, RAV4, RAV4 EV, Sequoia, Sienna, Solara, Tacoma, Tundra, Venza, Yaris
SERVICE CATEGORY:	: Power Source/Network
SECTION:	: Battery/Charging
COPYRIGHT:	© 2018 Toyota, USA License Agreement TMS1002

APPLICABILITY

YEAR(S)	MODEL(S)	ADDITIONAL INFORMATION
2000 - 2013	4Runner, Avalon, Avalon HV, Camry, Camry HV, Celica, Corolla, Echo, FJ Cruiser, Highlander, Highlander HV, Land Cruiser, MR2 Spyder, Matrix, Prius, Prius C, Prius PHV, Prius V, RAV4, RAV4 EV, Sequoia, Sienna, Solara, Tacoma, Tundra, Venza, Yaris

INTRODUCTION

In the event that a Toyota vehicle becomes submerged in water, many components may be physically damaged. Electrical and electronic components, including wiring harnesses, are particularly susceptible to corrosion and subsequent malfunction. Although any flooding can be damaging, salt water flooding elevates the potential for abnormal conditions and may increase risks due to its highly corrosive and conductive nature. Salt residue also continues to corrode and remain conductive even after a vehicle dries. This bulletin is intended to assist with safe handling and inspection of flood damaged vehicles as well as provide basic guidance on likely needed repairs.

NOTE:

Damage associated with a vehicle being submerged in water is not covered by the Toyota new vehicle Warranty policy.
VIN and inspection results for vehicles currently within the warranty period should be forwarded to the DSPM for their reference and updates to the Warranty system.
This bulletin provides general guidance and inspection areas. Each individual vehicle must be carefully reviewed based on the situation (water level, water type, and duration of exposure).

SERVICE BULLETIN OVERVIEW

This bulletin contains 3 main sections:

Vehicle Safing - Making sure the vehicle is in a safe condition and the electrical system is disabled to minimize risks from corrosion, damaged circuits, and attempted operation.
Vehicle Inspection - Assessing the level of damage and determining necessary parts replacement, cleaning procedures, and potential long term effects.
Vehicle Repair - Guidance for repair decisions on vehicle systems, sub-systems, and components.
NOTE:
- Due to the potential level of damage after an extended partial or full submersion, some vehicles may not be repairable and should be decommissioned.
- Final decisions on repair costs, vehicle value, and possible salvage or decommissioning are the responsibility of the customer, dealership, and insurer. Inspection and repair of flood damaged vehicles is NOT warrantable.

WARRANTY INFORMATION

OP CODE	DESCRIPTION	TIME	OFP	T1	T2
N/A	Not Applicable to Warranty	-	-	-	-

REQUIRED TOOLS & EQUIPMENT

REQUIRED EQUIPMENT

SUPPLIER

PART NUMBER

QTY

TIS Techstream (1) or Techstream Lite

NOTE: Software version 7.31.003 or later is required.

ADE

TSPKG1
or
TSLITEDLR01

⁽¹⁾	Essential SST.

SPECIAL SERVICE TOOLS DESCRIPTION

SPECIAL SERVICE TOOLS (SST)

PART NUMBER

QTY

Electrical Insulating Gloves (1)

00002-03100-S (Small)

00002-03200-M (Medium)

00002-03300-L (Large)

⁽¹⁾	Essential SST.

NOTE:

Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.
Additional SSTs may be ordered by calling 1-800-933-8335.

REQUIRED MATERIAL

REQUIRED MATERIAL	QTY
GoJak® (or Equivalent)	4
Particulate Mask (Respirator)	1

1. Vehicle Safing

The most important aspect of handling flooded vehicles is making sure the vehicle is safe. Water entry and resulting corrosion may cause electrical system anomalies or performance issues including:

Improper power distribution / system operation / overcurrent conditions.
High resistance from corrosion and abnormal heat generation that could lead to a potential fire.
Potential SRS Airbag, Pretensioner, and/or Side Curtain Airbag false activation/deployment.

CAUTION: Read all instructions and cautions before approaching a suspected flooded vehicle.

If the flooded vehicle is equipped with a hybrid drivetrain, be sure to use Electrical Insulating Gloves (high voltage safety gloves).
If any water is found in the vehicle or carpet is found wet, DO NOT attempt to start the vehicle until after the inspection and potential needed repairs can be completed.
Flood waters can be contaminated. Take precautions to minimize exposure including use of a respirator, face shield, safety glasses, and gloves. Wash exposed skin thoroughly after any contact with flood damaged components.
If fire, smoke, or abnormal sounds are detected, DO NOT approach or open vehicle.
Keep ignition sources away from the vehicle due to potential battery outgassing.
If the 12V battery is found disconnected in a potential flood vehicle, DO NOT connect battery until a complete inspection is performed and course of action determined.

Determine if the vehicle has been flooded with water above the rocker panels into the floor of the vehicle.
HINT

If no standing water is detected on the vehicle floor and the carpet is wet, assume that internal flooding has occurred.
- If YES -- Continue to step 2.
- If NO -- Go to section 2 for vehicle inspection .
Open doors and trunk or hatch to release trapped water, ventilate the cabin, and allow the interior to air dry.
Locate and remove body drain plugs at the rear corners of cabin floor and/or in spare tire well (if available) to assist with draining the vehicle.
Disconnect the 12V battery and make sure the cable is folded down and away from the terminal.
On hybrid vehicles, disconnect the HV Battery Service Plug Connector (ONLY after the 12V auxiliary battery is disconnected) .
CAUTION: If battery area contains standing water, drain BEFORE removing HV Battery Service Plug Connector.
Using a floor jack or GoJaks, move and store the vehicle away from structures and vehicles.

2. Vehicle Inspection

Determining the level of water intrusion and whether the vehicle was contaminated with fresh or salt water will help assess the extent of damage that has occurred and may continue to occur. As salt water is more damaging, this bulletin focusses primarily on salt water flooding. If the vehicle was driven in flood waters, additional inspections may be necessary.

Use the following illustration to identify inspection level based on depth and angle of vehicle submersion.

NOTE: If the vehicle was parked at an angle during flooding, establish the highest point of the water line and the corresponding inspection level as shown in Figure 1 for the appropriate key inspection areas identified on the following pages.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Key inspection areas are cumulative from Level 1 through 5 as water level increases (for example, Level 4 includes all inspection areas from Levels 1 to 4).
Any vehicle that was driven through flood waters will require BOTH the Parked Vehicle Inspection and Driven Vehicle Inspection.

Parked Vehicle Inspection -- Salt Water

PARKED VEHICLE INSPECTION - SALT WATER

TYPE

WATER LEVEL

KEY INSPECTION AREAS

REPLACEMENT GUIDELINES

Level 1

Up to Lower Edge of Rim/Wheel

Steel or alloy wheel surfaces
Schrader valve/TPMS sensor
Check for splashing on undercarriage surfaces

Clean or replace as needed
Rinse with fresh water, and/or salt water neutralizer⁽¹⁾

Level 2 (Continued below)

Up to Axle Centerline

Brake components:

Brake rotors or drums
Caliper pistons, slides, pads, and mounting hardware
Drum cylinders, shoes, parking brake components
Wheel speed sensors
Sensor connectors

Clean, lube, replace as needed.
Rinse with fresh water, and/or salt water neutralizer

Suspension:

Links and arms
Tie rods
Ball Joints
Unpainted surfaces
Lug nuts/studs
Power Steering rack and connectors
Wheel hubs and bearings
Axle shafts and boots

Level 2 (Continued)

Up to Axle Centerline

Electrical:

Wheel speed sensors
Sensor connectors
Starter and solenoid
ATM neutral start switch
ATM solenoid connector

Exhaust:

Pipe(s)
Muffler(s)
Catalyst(s)
O² / A/F sensor(s) connector and harness

Replace any electrical components that have been submerged in salt water

Level 3 (Continued below )

Up to Lower Edge of Door/Top of Rocker Panel

Driveline:

Driveshaft/Axle shaft
ATM fluid level/contamination
Differential oil level/contamination
Transfer oil level/contamination

Drain and refill as needed

Electrical:

ECU, sensors, airbags, pretensioners, related harnesses
Seat motor, switches, harness, seat heater/cooler
Door locks, window switches and harness
All electrical components that come in contact with salt water
All electrical components indirectly affected (inspect all interior systems for proper operation)

Replace any electrical components that have been submerged in salt water

Level 3 (Continued)

Up to Lower Edge of Door/Top of Rocker Panel

HV Battery, harnesses, Battery ECU, A/C compressor with inverter
Evaporative Emissions Control System components/harness

Only a hybrid certified technician should inspect and/or replace components

Body and Chassis:

Frames channels
Body panel lower edges

Remove salt residue with cleaning agent

Interior Components:

Full disassembly of interior and body components for physical inspection and cleaning
Carpet/padding/jute/mats
Seats/material/seat frame/seat electrical
Door and interior trim panels

Replace all electrical components that have been submerged in salt water
Replace interior components as needed and consider mold inspection and possible remediation

Level 4

Up to Lower Edge of Dash Panel

All electrical harnesses, junction and relay blocks, junction connectors
All exposed and wet interior components
All under hood electrical and electronic components
Engine oil level/contamination
Transmission or transaxle fluid level/contamination
Fuel system contamination

Replace all electrical components that have been submerged in salt water
Replace interior components as needed and consider mold inspection and possible remediation

Level 5

Up to Top Edge of Dash Panel

Interior Components:

Full disassembly of interior and body components for physical inspection and cleaning

Replace all components submerged in or damaged by salt water.

⁽¹⁾	Salt water neutralizer products are available at marine or industrial supply companies. Be sure to check ingredients and confirm application is appropriate for motor vehicles. Also review the MSDS and instructions carefully for safe handling and application.

NOTE: If the vehicle was driven in flood waters, continue with the following checks after performing static inspection items.

Additional inspections must be made when the vehicle has been driven through or in flood waters. After a full inspection, repair of electrical systems, replacement of fluids, and other potential repairs, the vehicle should be driven while monitoring live Techstream data for each vehicle system. A full Health Check should be performed to complete confirmation of vehicle operation.

Please review the following inspection list:

KEY INSPECTION REFERENCE

TYPE	WATER LEVEL	KEY INSPECTION AREAS	REPLACEMENT GUIDELINES
Driven	Dynamic	Engine abnormal knock/rattle Engine live data Health Check DTCs Misfire and Fuel Trim status AFRS B1 and B2 Sub O2 signal and impedance Spark Advance VG (AFM) HV Battery/Charging	Engine mechanical repair as needed Replace electrical components that have been submerged in salt water
		Engine oil level/contamination	Drain and refill as needed Clean out water and residue
		Engine intake air filter, box, piping	Drain and refill as needed Clean out water and residue
		Exhaust sensor connectors	Replace electrical components that have been submerged in salt water
		All under hood electrical components
		Transmission/transaxle NSW harness/terminals
		Transmission/transaxle abnormal noises/shift quality	Drain and refill as needed
		Transmission/transaxle/differential/transfer case oil level/contamination
		Transmission/transaxle lockup ON/OFF shudder
		Fender wells above plastic liners	Rinse with fresh water and/or salt neutralizer
		Speed sensor harness connectors	Rinse with fresh water and/or salt neutralizer

NOTE: For Fresh Water Flooding:

The dynamic inspection tables serve as a general inspection guide.
Residual corrosion and conductivity, once vehicle is dried, is not as great a concern as with salt water. All flooding situations should be inspected and judged individually.

3. Vehicle Repair

After identifying affected components and when making repair decisions, please consider the following.

Electrical

Any electrical components that have been submerged in salt water (examples: harnesses, connectors, terminals, ECUs, hybrid and PHV batteries, switches, buttons, sensors) need to be replaced before operating the vehicle and should NOT be reused.

NOTE:

Even after salt water has dried, salt residue may remain on nearby surfaces.
Cleaning and/or replacement of surrounding components may also be necessary to ensure proper operation of electrical systems.

Chassis

Brakes and suspension components not only need to move and slide freely for proper operation, but additional consideration needs to be given for subsequent corrosion that could impact future system performance. Disassemble, clean, reassemble, and lubricate all chassis components that have been submerged or subjected to extensive salt water exposure.

Powertrain

As in-depth performance analysis can be conducted using Techstream, repair must include testing and confirmation of proper live data performance, general Health Check (full Health Check for possible DTCs), inspection for oil and fuel contamination, consideration of all electrical components (as previously described in this bulletin), inspection and replacement of any rubber, plastic, and metal components that are deteriorating or damaged, and removal of salt water residue using appropriate cleaning agents.

Body And Interior

Vehicle body designs generally incorporate pressure relief vents (to minimize door closing pressure). These can allow water entry into the passenger cabin during a flood situation and also have inherent low points or pockets that can retain flood water. Be sure to inspect, drain, and clean these locations.

Any component that became wet or saturated that has fabric, cloth, padding, or soft trim such as those listed below may need to be replaced and/or require follow-up mold remediation.

Carpet and padding
Seats
Door trim panels
Console
Package tray
Seals

Remaining salt water residue in any part of the vehicle may accelerate corrosion and affect vehicle operation. Be sure to clean all affected internal and external surfaces thoroughly to prevent long term damage.