Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Basic Repair Hint - Operations

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   REPAIR INSTRUCTION
   
   

   1	Attire	Always wear a clean uniform. Hat and safety shoes must be worn.
   2	Vehicle protection	Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
   3	Safety operation	When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment.
   4	Preparation of tools and measuring gauge	Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
   5	Removal and installation, disassembly and assembly operations	Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check.
   6	Removed parts	Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this article. Retain the removed parts for customer inspection, if requested.

2. JACKING UP AND SUPPORTING VEHICLE
   1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
3. PRECOATED PARTS
   1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
   2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air.

      Then apply new seal lock adhesive appropriate to that part.

   4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
   Fig 2: Identifying Precoated Parts

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4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.
6. FUSES
   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   2. When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. Seal Lock Adhesive
   Fig 3: Identifying Fuses Correct & Incorrect

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   FUSES REFERENCE
   
   

   Graphic	Symbol	Part Name	Abbreviation
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

7. CLIPS
   1. The removal and installation methods of typical clips used for vehicle body parts are shown in RIVETS DESCRIPTION TABLE  .

      HINT:

      If clips are damaged during work, always replace the damaged clip with a new one.

   RIVETS DESCRIPTION TABLE
   
   

   Shape (Example)	Removal/Installation
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips with clip remover or pliers. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove fasteners with clip remover or screwdriver. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips with wide scraper to prevent panel damage. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by pushing center pin through and prying out shell. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by unscrewing center pin and prying out shell. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by prying out pin and then prying out shell. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

8. CLAWS
   1. The removal and installation methods of typical claws used for vehicle body parts are shown in CLAWS DESCRIPTION TABLE  .

      HINT:

      If claws are damaged during a procedure, always replace the damaged claws with a new caps or covers.

   CLAWS DESCRIPTION TABLE
   
   

   Shape (Example)	Graphic	Procedures
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.

9. REMOVAL AND INSTALLATION OF VACUUM HOSES
   1. To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose.
      Fig 4: Identifying Vacuum Hose Handling Procedure

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   2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
   3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
   4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a stepdown adapter if necessary.
   Fig 5: Using Tags For Disconnecting Vacuum Hoses

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10. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 6: Identifying Torque Wrench Height

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    1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.

       Formula: 

       T' = L2/(L1 + L2) * T 

    Fig 7: Measuring Length Of Torque Wrench

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    FORMULA DESCRIPTION
    
    

    T'	Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}
    T	Torque {N*m (kgf*cm, ft.*lbf)}
    L1	Length of SST or extension tool {cm (in.)}
    L2	Length of torque wrench {cm (in.)}

    NOTE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this article, the actual torque will be excessive and parts will be damaged.

The LEXUS IS250/350 is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE
   1. As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery.
   2. Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal.

      The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy.

      When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

      CAUTION: Never use a back-up power source (battery or other) to avoid erasing system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.
   3. In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, passenger side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.

      (See STEERING PAD for steering pad)

      (See FRONT PASSENGER AIRBAG ASSEMBLY for front passenger airbag assembly)

      (See FRONT SEAT SIDE AIRBAG ASSEMBLY for front seat side airbag assembly)

      (See DRIVER SIDE KNEE AIRBAG ASSEMBLY for driver side knee airbag assembly)

      (See FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY for passenger side knee airbag assembly)

      (See CURTAIN SHIELD AIRBAG ASSEMBLY for curtain shield airbag assembly)

      (See FRONT SEAT OUTER BELT ASSEMBLY for front seat outer belt assembly)

   4. Never use SRS parts from another vehicle. When replacing parts, use new parts.
   5. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and attempt to repair all airbag sensor assemblies and all airbag assemblies.
      1. Steering pad
      2. Front passenger airbag assembly
      3. Driver side knee airbag assembly
      4. Passenger side knee airbag assembly
      5. Front seat side airbag assembly
      6. Curtain shield airbag assembly
      7. Front seat outer belt assembly
   7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   8. Do not directly expose the airbag sensor assembly or airbag assembly to hot air or flames.
   9. Use a voltmeter / ohmmeter with high impedance (minimum= 10 kΩ) for troubleshooting electrical circuits.
   10. Information labels are attached to the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning light.
2. SPIRAL CABLE
   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See INSTALLATION ).
   Fig 8: Identifying Spiral Cable Mark Location

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3. STEERING PAD
   1. Always place a removed or new steering pad surface upward as shown in Fig 9. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button.
      Fig 9: Identifying Steering Pad Handling Procedure

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 10: Precaution For Measuring Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the horn button.
   4. Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal (See STEERING PAD ). Activate the airbag in a safe place away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in Fig 11. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.
      Fig 11: Identifying Front Passenger Airbag Assembly Handling Procedure

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 12: Precaution For Measuring Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See FRONT PASSENGER AIRBAG ASSEMBLY ). Activate in a safe place, away from electrical noise.
5. DRIVER SIDE KNEE AIRBAG ASSEMBLY
   1. Always place a removed or new knee airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.
      Fig 13: Identifying Driver Seat Side Knee Airbag Assembly

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 14: Precaution For - Never Measuring Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the knee airbag assembly.
   4. Store the knee airbag assembly where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be inflated using SST before disposal (See DRIVER SIDE KNEE AIRBAG ASSEMBLY ). Activate in a safe place, away from electrical noise.
6. PASSENGER SIDE KNEE AIRBAG ASSEMBLY
   1. Always place a removed or new knee airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.
      Fig 15: Identifying Passenger Side Knee Airbag Assembly

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 16: Precaution For - Never Measuring Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the knee airbag assembly.
   4. Store the knee airbag assembly where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be inflated using SST before disposal (See FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY ). Activate in a safe place, away from electrical noise.
7. FRONT SEAT SIDE AIRBAG ASSEMBLY
   1. Always place a removed or new front seat side airbag assembly with the airbag inflation direction facing up.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 17: Precaution For Never Measuring Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the front seat side airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See FRONT SEAT SIDE AIRBAG ASSEMBLY ). Activate in a safe place away from electrical noise.
8. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      Fig 18: Precaution For Correct & Incorrect Way Of Clear Plastic Bag

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