Lexus ES300 (2002 year). Service manual - part 444

2002 ES 300 Driver s Side Front Airbag
                                                                                                                                            

6

09082−00700

SRS Airbag

Deployment Tool

09082−30801

Wire C

Disposal horn

button assembly

Technical Training

The back of this handbook contains the repair procedures for this

SSC.  We suggest that all service department staff who will be

directly involved in completing the repair or supporting the SSC

should review the repair procedures to prepare for this SSC.

Parts

Availability / Ordering

Part Number

Part Description

Color Code

Qty/Vehicle

45130−33341−B0

Horn Button Assembly

(Saddle Gray)

17

1

45130−33341−C0

Horn Button Assembly

(Black)

27

1

45130−33341−E0

Horn Button Assembly

(Sandalwood)

07

1

In addition, the following Special Service Tool must be ordered
through the Toyota Special Service Tool Program.

Part Number

Description

Qty/

Vehicle

09082−30801*

SST: Wire Harness C (for air bag deployment)

1

*  

This SST may be claimed for reimbursement on the associated warranty
claim.

Since airbags are color−coded to match vehicle interiors and since

airbags may not be returned as new (undeployed), Lexus has not

put these parts on the Dealer Stocking Guide (DSG) or sent an

initial quantity to dealers.  Lexus strongly requests that dealers

order parts to meet confirmed customer appointments.  There will

be sufficient inventory to accommodate this SSC provided that

dealers do not overstock the parts.  Individual dealer tracking will

be done and irregularities in quantity ordering will be forwarded on

the Lexus Area Offices for follow−up and correction.

Special Airbag Handling

and Disposal Procedures

Lexus Special Service Campaign 1LG
                                                                                                                                              

7

Since this SSC involves replacement of airbags, several special

steps must be followed to assure compliance with Federal

hazardous materials shipping and safety regulations.  The

following procedures must be followed.

•

 

Dealers must complete and return the Airbag Serial Number
Registration postcard to Lexus.  Failure to return this
postcard with the correct information will result in a
debit of the associated claim.

•

 

The original airbag must be deployed and disposed of.
Dealers must ensure that all removed airbags are deployed
and disposed of in accordance to the procedures described
in the Repair Manual.

TDN System

The labor operation code has been transmitted to your dealership

(see page 13 for opcode).  Remember that each dealership must

request and apply it to the dealer system.  If your dealership has

not received the operation codes, call the TDN hotline at (800−

421−8154

).

Planning Your

Communication Strategy

It is important that you develop a strategy to communicate

effectively.  The following are some general statements that can

be used when explaining the SSC.

Q1:  What is the problem?

A1:  On certain 2002 model year ES 300 vehicles, during airbag

deployment, it is possible that the bottom seam of the driver s−side

front airbag module cover (horn pad) may be torn away allowing

the bottom portion of the cover to completely detach from the

airbag module.  If this should occur, there is a possibility that the

detached bottom portion may strike the driver causing personal

injury.

Q2:  What is the cause of this condition?

A2:  The condition is caused by a fabric tether strap inside the

front driver s side airbag module which was improperly designed.

2002 ES 300 Driver s Side Front Airbag
                                                                                                                                            

8

Q3:  Are there any warnings that this condition will occur?

A3:  No.  There are no warnings that this condition will occur.

Q4:  Which and how many vehicles are involved?

A4:  Certain 2002 model year ES 300 and Camry vehicles

equipped with a three−spoke style steering wheel are affected.

There are approximately 8,000 ES 300 and 11,000 Camry

vehicles involved in the U.S.

Q5:  What is the production range of the involved vehicles?

A5:  The affected ES 300 and Camry vehicles were produced from

July 2001 through late November 2001.

Q6:  How many cases of this condition have been reported?

A6:  There have been no reports of cases of this condition in the

affected ES 300 vehicles.

Q7:  Have there been any accidents reported?

A7:  There have been no reported cases of accidents related to

this condition.

Q8:  What is Lexus going to do?

A8:  Owners of the involved vehicles will receive a campaign

notification by first class mail beginning in December 2001.  Any

Lexus dealer will replace the driver s side airbag at NO COST to

the vehicle owner.

Q9:  How long will the repair take?

A9:  The repair will take less than one hour.  However, it may be

necessary for the owner to make the vehicle available for a longer

period of time depending upon the dealer s schedule.

Q10:  Does this condition affect other Toyota/Lexus models?

A10:  This condition only affects certain 2002 model year ES 300

and Camry vehicles equipped with a three−spoke style steering

wheel.

Q11:  What should an owner do if they are concerned about

Lexus Special Service Campaign 1LG
                                                                                                                                              

9

this condition?

Q11:  Owners are requested to contact their local Lexus dealer for

inspection and, if applicable, repair.

Calls to Your Customers

•

 Customers 

involved in the SSC

⇒

  Although each affected vehicle owner will receive a

notification letter, we would like your dealership to use the

customer list provided in the SSC package to help

manage your service volume.  We strongly suggest that

your dealership s service management and consulting

staff review the list and proactively contact customers for

prompt service.  Also let them know how valuable a

customer they are and that this Special Service Campaign

is being undertaken by Lexus to keep their confidence in

the Lexus brand.

Note:  Approximately one thousand of the 2002 ES

300 vehicles involved in SSC 1LG are also involved in

SSC 1LF.  Please be sure to check TDN or TIS to

identify these vehicles so that both campaigns may be

performed in one service visit.

•

 Customers 

not involved in the SSC

⇒

  Assure any customers with vehicles outside of the

involved VIN range that this repair is not needed.

Calls from Your

Customers

It is important to institute a system to respond to customers calling

for more information regarding the SSC.  We recommend

designating an individual to answer these inquiries to ensure that

callers get accurate, consistent information.

Calls from the Media