SAFETY RECALL JLI/JLJ/JLK – Front Passenger Airbag Inflator Replacement – 2007-2012 Lexus ES350

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IMPORTANT UPDATE
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL JLI/JLJ/JLK
FRONT PASSENGER AIRBAG INFLATOR REPLACEMENT
CERTAIN 2007 – 2012 MY ES 350
Update 02/20/2020
Update 2-20-20
− Inspection added for all repairs. Please see page 12 for details
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians
performing this recall are required to successfully complete the most current version of the E-Learning
course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair
performed correctly:
 MASTER SERVICE TECHNICIANS
 MASTER DIAGNOSTIC SPECIALISTS
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this recall 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.
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.
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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.
Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry
System.
No further Not Covered action required.
Campaign complete, return the vehicle
to the customer.
Covered
Replace the inflator
Reinstall the dash pad.
Replace the
Assembly
Remove the dash pad and remove the
airbag module.
Inflator Required
Take a picture of the airbag assembly
serial number and send to
Quality_Compliance@Toyota.com
Assembly Required No Replacement
Part Required
II. BACKGROUND
The subject vehicles are equipped with front passenger airbag inflators produced by Takata. The propellant in these
inflators may degrade after prolonged exposure to high absolute humidity and fluctuating high temperatures.
Degraded propellant can cause inflator rupture during airbag deployment. In the event of an inflator rupture, metal
fragments could pass through the airbag cushion material, striking the vehicle occupants, and result in serious injury
or death.
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III. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
 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
04007-06733 Instrument Panel Passenger Airbag
Inflator Kit 1
04006-66108* Front Pillar Garnish Kit
(*kit contains 2 clips) 1
Non-Desiccated Part Recovery
Dealers should discontinue the installation of the non-desiccated parts listed below for recall, customer
pay repairs AND over-the-counter sales (if applicable).
Model Model Year Part Number Part Description
ES350 2007-2012 73960-33110
73960-33111
AIR BAG ASSY,
INSTR PNL PASS L/DOOR
Lexus requires all dealers to return any parts listed above that still remain in dealer inventory by utilizing
the Hazmat Part Return Program available. Dealers will be issued a refund for all part returns. This part
return program is outlined in PANT Bulletin 2014-042.
Important Note:
In order to return the inflator, packages must NOT be opened/tampered with.
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B. TOOLS & EQUIPMENT
 Standard hand tools  Torque wrench  Techstream
 Molding remover set
GLG/GLH CAMPAIGN TOOLS – These tools where previously provided to the dealership for campaign DLC
and will be used for this campaign. These tools are required when performing this repair.
Image Name Quantity
Barcode Scanner 1
NOTE: This tool CANNOT be ordered through the parts or tools system. If additional tools are needed,
they can be sourced locally.
DLC CAMPAIGN TOOLS – These tools are required when performing this repair.
Image Name Quantity
Airbag Mounting Bracket
& hardware
(Provided to the
dealership at the launch
of SSC DLC)
1
579943 Adaptor set* 1
*The adapter set was sent to dealers prior to the start of this campaign.
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SST –These are essential service tools that the dealership should have.
Part Number Part Name Quantity
09950-50013 Puller C Set * 1
* The set above includes the following tools.
Part Number Part Name Quantity
09951-05010 Hanger 150 1
09952-05010 Slide Arm 2
09953-05020 Center Bolt 150 1
09954-05021 Claw No. 2 2
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V. SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY
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.
1. ELIMINATE STATIC ELECTRICITY
a) Before starting work and periodically while working
on the vehicle, touch a metallic part of the vehicle
to discharge static electricity in the body.
2. DO NOT MEASURE RESISTANCE
a) NEVER measure the resistance of an airbag, this
may cause accidental activation.
3. HANDLE THE AIRBAG CAREFULLY
a) If the airbag is dropped, replace it with a NEW one.
4. WEAR PROTECTIVE EQUIPMENT
a) Always wear appropriate protective equipment
when working on the SRS.
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VI. SRS SYSTEM HEALTH CHECK
1. PERFORM A HEALTH CHECK
a) Confirm the Techstream is connected to the
dealership’s internet.
b) When launching the Techstream software the VIN may
auto populate if not then it 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.
c) Perform a health check.
Note: The VIN may auto populate on the later model
year vehicles, if this happens DO NOT change
the VIN.
2. RUN A DIAGNOSTIC REPORT
a) 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
b) Enter the vehicle mileage and repair order information,
then click the ‘report’ button.
 A health check and diagnostic report with the VIN MUST be performed within the last 36
hours, and recorded by TMS. If the diagnostic report is not run, the healthcheck will not be
recognized by TMS.
 The serial number recording application will be disabled and the repair cannot be
completed if a health check and diagnostic report is not performed and recorded by TMS.
 This campaign only covers replacement of the passenger dash airbag. If other SRS repairs
are needed they are NOT covered under this campaign.
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VII. FRONT PASSENGER AIRBAG REMOVAL
COMPONENTS
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1. AIRBAG ASSEMBLY REMOVAL
 Wait at least 90 seconds after disconnecting the cable from the negative battery terminal to
prevent airbag and seat belt pre-tensioner deployment.
 Follow all precautions as outlined on TIS before servicing the SRS system.
a) Refer to TIS for removal instructions.
2007 MY 2008 MY 2009 MY 2010 MY 2011 MY 2012 MY
2. INSPECT AIRBAG ASSEMBLY
1. TAKE A PICTURE OF THE AIRBAG
ASSEMBLY SERIAL NUMBER
a) Take a picture of the airbag assembly serial
number exactly like the image to the left.
b) Email the picture to
Quality_Compliance@toyota.com for review.
Email Format
Subject: JLI/JLJ/JLK Airbag Serial Number Review
Body: (Insert Model/Model Year of vehicle)
c) You will receive a reply with instructions on
how to proceed with the repair.
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3. AIRBAG INFLATOR REMOVAL (Only required if instructed by Quality Compliance)
1. REMOVE THE INFLATOR
d) Mark the 5 self locking nuts to prevent reuse.
e) Mount the adaptors (579943-3R3) to the
airbag as shown.
NOTE: The 6mm stud mounts to the airbag.
f) Mount the airbag to the mouting bracket as
shown.
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g) Loosen the 5 nuts until each nut is flush with
the top of the stud as shown.
NOTE: You may need to slide the airbag to the
left or right to access the middle nut.
DO NOT use power tools to remove the
nuts.
h) Loosen and discard the 2 nuts on the end
where the postioning plate is removeable.
i) Remove and discard the plate.
NOTE:
DO NOT use power tools.
j) Remove the inflator.
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k) Mark the old inflator so it is not reused.
NOTE: Return the old inflator to the parts
department for recovery.
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VIII. AIRBAG RECORDING
1. LAUNCH THE SERIAL NUMBER RECORDING APPLICATION
Note: The Serial Number Recording Application is the same application used for a prior campaign.
 The serial numbers MUST be recorded using a barcode scanner (provided at the launch of
SSC DLC).
 The barcode scanner application MUST be completed on every vehicle. These numbers
MUST be included on every warranty claim that is submitted for airbag 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.
a) Log in to TIS and input the VIN of the vehicle in the Vehicle Inquiry tab.
b) Confirm the VIN is applicable and that the campaign has not been completed.
c) Click on the link to launch the serial number recording application.
d) Reenter TIS password in the serial number recording application.
NOTE: The person logged-in to TIS MUST be the person performing the repair.
e) Record the vehicle mileage into the serial number
recording application.
NOTE:
 A task status screen will populate next and at other
intervals during the repair. This screen will indicate if
the airbag was replaced. Click ‘next’ to proceed to the
next step. This information will be used for record
keeping by TMNA.
 If this screen indicates that the campaign has already
been completed on this VIN, there is no need to perform
the campaign again.
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2. CONNECT THE BARCODE SCANNER
a) Connect the barcode scanner to the USB port on the Techstream.
b) The scanner will automatically connect and a beep will be heard when the scanner is ready.
NOTE:
 The scanner was provided for SSC DLC.
 The barcode scanner works best in low light conditions.
 Always hold the scanner directly in front of and parallel to the barcode label. 3. SCAN THE AIRBAG SERIAL NUMBER
ATTENTION: This information is CRITICAL
a) Scan the AIRBAG ASSEMBLY serial number 2
times.
1) Confirm that the cursor is in the first serial number
box and scan the bar code.
2) Position the cursor in the second serial number
box and rescan the bar code.
b) Click next.
NOTE:
 If both serial numbers do not match, confirm and
reenter.
 If the serial number barcode will not scan, it can
be entered manually.
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.
Airbag Serial Number Label Example
The AIRBAG ASSEMBLY serial number MUST be recorded prior to replacement.
SSC DSC
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c) Confirm agreement by checking the two boxes and press submit.
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d) Record the Warranty Authorization # to be included in the warranty claim.
e) Confirm agreement by checking the two boxes.
f) Place the old airbag in the parts box and return it 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.
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NEW AIRBAG ASSEMBLY RECORDING
If the airbag serial number and barcode are not legible or are not present, check the box in the
application indicating the serial number is not legible.
a) If the airbag serial number cannot be scanned or is not present check the box as shown below.
Check this box if the Airbag serial number is not legible.
Note: Contact your area office in the event you are unable to read the serial number
DO NOT ATTEMPT TO INSTALL THE INFLATOR
SSC DSC
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b) After the Area office approves the Airbag replacement and the new part is received, scan the new Airbag
barcode in the Serial Number Recording Application.
c) Confirm agreement by checking the two boxes and press next to advance to the Warranty authorization
screen.
d) Return the old airbag to the parts department.
e) Proceed to Section IX Step 2.
The new AIRBAG ASSEMBLY serial number MUST be recorded prior to reinstallation to
track the airbag assembly to the vehicle.
SSC DSC
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IX. AIRBAG INFLATOR INSTALLATION
(Only required if instructed by Quality Compliance)
a) Install the inflator as shown below and ensure the inflator is oriented in the correct position as shown below.
 Make sure to follow the installation procedure carefully as the instrument panel wire
connector cannot be disconnected once connected
 Make sure the inflator is correctly positioned.
 The inflator cannot be fully inserted if it is upside down.
DO NOT connect the airbag connector
yet.
f) Install the NEW positioner plate.
g) Temporarily install 2 NEW nuts.
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h) Remove and discard the 3 remaining nuts.
i) Temporarily install 3 NEW nuts.
j) Push the inflator towards the position determining plate and eliminate any gaps.
 If any gaps exist, the flats may move apart and could result in abnormal operation
during airbag deployment.
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k) Tighten the 5 nuts evenly in several increments in the sequence shown. Use a socket driver or torque
wrench to tighten the nuts.
Torque: 35 in. lbf (3.9N∙m)
 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 over
torqueing and deforming the studs.
 You may need to slide the airbag to the left or right with in the mounting bracket to
access the center nut.
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l) Connect the airbag connector to the instrument panel passenger airbag assembly and then push in the
airbag connector lock as shown in the illustration.
m) Engage the clamp.
 Make sure to correctly align the connectors before connecting them.
 Make sure that the airbag connector is securely connected.
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X. AIRBAG ASSMEBLY INSTALLATION
1. INSTALL THE NEW AIRBAG ASSEMBLY INTO THE INSTRUMENT PANEL
2. REINSTALL THE DASH
a) Refer to TIS for reinstallation instructions
2007 MY 2008 MY 2009 MY 2010 MY 2011 MY 2012 MY
3. RECONNECT THE NEGATIVE BATTERY CABLE
4. PERFORM A HEALTH CHECK AND DIAGNOSTIC REPORT
5. PERFORM ANY NEEDED SYSTEM INTIALZATIONS
◄ VERIFY REPAIR QUALITY ►
− Confirm all precautions are followed 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 airbag is handled safely and given to the appropriate parts professional for shipment
If you have any questions regarding this update, please contact your area representative.
XI. APPENDIX
A. CAMPAIGN DESIGNATION DECODER
Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5th Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012
B. CAMPAIGN PARTS DISPOSAL
ALL airbags that are removed from vehicles under this campaign MUST be packaged and shipped back to
the 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

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