Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Precaution For Repairing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   PRECAUTION CHART
   
   

   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 in a pair or groups, 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 manual. 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 Seal Lock Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
   Fig 3: Precaution For Fuse
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
      Fig 4: Fuse Symbol Chart

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. CLIPS
   1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

      HINT:

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

      Fig 5: Clip Removal/Installation Procedure

      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 the table below.

      HINT:

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

      Fig 6: Claws Removal/Installation Procedure

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 7: Precaution For Vacuum Hose

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 step-down adapter if necessary.
      Fig 8: Identifying Tag On Vacuum Hoses

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 9: Identifying Torque Wrench Dimension

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: 

       T1 = L2/(L1 + L2) * T 

       Fig 10: Identifying SST Dimension

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       DIMENSION CHART
       
       

       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 information, the actual torque will be excessive and parts will be damaged.

The LEXUS ES350 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 engine 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 engine 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 the 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, driver side knee airbag assembly, front passenger side knee airbag assembly, front passenger airbag assembly, curtain shield airbag assembly, front seat side airbag assembly, rear seat side airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.

      (See DISPOSAL for steering pad)

      (See DISPOSAL for driver side knee airbag assembly)

      (See DISPOSAL for front passenger side knee airbag assembly)

      (See DISPOSAL for front passenger airbag assembly)

      (See DISPOSAL for curtain shield airbag assembly)

      (See DISPOSAL for front seat side airbag assembly)

      (See DISPOSAL for rear seat side airbag assembly)

      (See DISPOSAL 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. Driver side knee airbag assembly
      3. Front passenger side knee airbag assembly
      4. Front passenger airbag assembly
      5. Curtain shield airbag assembly
      6. Front seat side airbag assembly
      7. Rear seat side airbag assembly
      8. 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 11: Aligning Spiral Cable Marks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. STEERING PAD
   1. Always place a removed or new steering pad surface upward as shown in the illustration. 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 12: Precaution For Steering Pad

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 13: Precaution For Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 DISPOSAL ). Activate the airbag in a safe place away from electrical noise.
4. 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 14: Precaution For Driver Side Knee Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 15: Caution For - Measuring Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 DISPOSAL ). Activate the airbag in a safe place away from electrical noise.
5. FRONT 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 16: Precaution For Front Passenger Side Knee Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 Resistance Of Front Passenger Side Knee Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 DISPOSAL ). Activate the airbag in a safe place away from electrical noise.
6. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.
      Fig 18: Precaution For Front Passenger Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 19: Precaution For Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 DISPOSAL ). Activate the airbag in a safe place away from electrical noise.
7. 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 20: Precaution For Curtain Shield Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002