Cts & DENSO Accelerator Pedal Modification (T-CP-90L)

A. AFFECTED VIN RANGE

A. PARTS

• No parts are required for this activity.

B. TOOLS & EQUIPMENT

• Dust mask
• Hand file
• Orbital sander*
• Hack-saw
• Protective eyewear
• Protective work gloves
• Reciprocating Saw*
• Scribe
• Standard hand tools
• Techstream
• Torque wrench
• Workbench with vise

*One orbital sander and one reciprocating saw were provided to each dealership during Phase 1 of this Safety Recall. 

C. ACCELERATOR PEDAL TEMPLATE & GAUGE

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

D. MATERIALS

• Bubble wrap
• Shop cloth
• Masking tape
• Sandpaper 400 grit

A. PRELIMINARY INSPECTION

1. CONFIRM THE ACCELERATOR PEDAL IS A CTS OR DENSO MADE PEDAL 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   STEP A: PRELIMINARY INSPECTION 

B. CTS ACCELERATOR PEDAL MODIFICATION (For Denso accelerator pedal modification procedure, continue to STEP C)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ACCELERATOR PEDAL HANDLING NOTES:  DO NOT drop the pedal, or reuse an accelerator pedal that has been dropped  Avoid vibration and shock of the pedal  DO NOT place sensor portion of the pedal in vise  Cover and uncover the sensor portion of the pedal while in the vehicle to prevent damage and debris from entering

1. REMOVE THE ACCELERATOR PEDAL ASSEMBLY 
   1. Record the radio station preset.
   2. Disconnect the negative battery cable and wait 90 seconds.
   3. Disconnect the accelerator pedal connector.
   4. Remove the 2 bolts.
   5. While still inside the vehicle, use bubble wrap and masking tape to cover and protect the pedal sensor.
      NOTE:

      • For additional information on accelerator pedal removal, refer to TIS.
      • Be sure to use bubble wrap to protect the sensor.
      • Be sure to seal the bubble wrap with masking tape to prevent damage to the sensor, and cutting debris from entering the pedal's movable lock.
      • DO NOT  reuse the bubble wrap

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. MARK THE AREA TO BE CUT 
   1. Firmly set the template to the pedal and scribe guide lines to outline the area to be cut.

      Cutting Template:

      • Color: Orange
      • Stamping: RAV4 CTS

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • DO NOT  mark the area beyond the template.
      • Use a flat tip screwdriver if a scribe is not available.
      • Make sure to use the correct cutting template by verifying the color and stamping.
      • NEVER  cut or sand the pedal while the template is on the pedal.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. SECURE THE ACCELERATOR PEDAL ASSEMBLY 
   1. Set the pedal in the vise at a right angle using a shop cloth while avoiding the sensor.
      NOTE:

      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT  over tighten the vise.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Pay close attention to the following points when modifying the accelerator pedal assembly.	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      DO NOT  leave a protrusion DO NOT  remove excessive amounts of material DO NOT  create a hole

4. CUT THE LOWER SECTION OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. The cut line is slightly outside from the scribed line and it is positioned 90 degrees from the pedal foot pad as illustrated.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   2. Using a hack-saw, cut the pedal 0.2 in. (5 mm) to create a guide cut for the reciprocating-saw.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves, and dusk mask when cutting.
      • Guide cut MUST be straight and clean.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   3. Using the reciprocating-saw, cut off the lower section of the pedal as illustrated.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves, and dust mask when cutting.
      • Guide cut MUST be straight and clean.
      • Apply consistent pressure during cutting.
      • DO NOT  stop while cutting.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. SAND THE CORNERS OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. Using an orbital sander, sand the pedal corners as illustrated.
      NOTE: ALWAYS  wear protective eyewear, gloves, and dust mask when sanding.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. SAND THE RADIUS LINE 
   1. Using an orbital sander, sand the radius line which was scribed and remove the sharp edges and burrs.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves, and dust mask when sanding.
      • DO NOT  sand the back of the pedal arm as illustrated.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

7. REMOVE ALL BURRS FROM THE CUTTING SURFACE 
   1. Remove the pedal from the vise.
   2. Turn the pedal over and set it in the vise using a shop cloth while avoiding the sensor.
      NOTE:

      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT  over tighten the vise.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   3. Using an orbital sander and file, remove all burrs from the cutting surface. The cut edges along the foot pad should be rounded and not square.
   4. Finish the cut surface and all edges with 400 grit sandpaper.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE: ALWAYS  wear protective eyewear, gloves, and dust mask when sanding or filing.
8. CONFIRM THE SHAPE OF THE BACK SIDE OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. Confirm the back side of the pedal assembly matches the illustration.
      NOTE:

      • DO NOT  leave a protrusion
      • DO NOT  remove excessive amounts of material
      • DO NOT  create a hole

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

9. CHECK THE SHAPE OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. Using the correct cutting template and shape gauge, check the shape of the pedal.

      Cutting Template

      Color: Orange

      Stamping: RAV4 CTS

      Shape Gauge

      Color: Yellow

      Stamping: RAV4

   2. If the shape DOES NOT  match the template and/or gauge, continue filing.
   3. If the shape matches the template AND  gauge, touch the cut surface with your hand to verify it is smooth and free of burrs.
      NOTE:

      • ALWAYS wear protective eyewear, gloves and dusk mask when sanding or filing.
      • A tolerance of -1.0 mm is permissible between the final cut surface and the template.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   4. Check for any pin holes, chips, nicks or sharp edges on the finished surface edge. If there are any chips, nicks or sharp edges, file them to make them smooth.
      NOTE: The key point of judgment is a "smooth pedal surface".
   5. If a "smooth pedal surface" cannot be achieved due to a pinhole / cavity, repair the pedal utilizing the steps below.

      Materials Needed:

      • KBS Coatings - NuMetal® Epoxy Putty (Black)

        Contact: 1-888-531-4527

        Website: www.kbs-coatings.com/KBS-NuMetal-Epoxy-Putty_p_9-19.html 

        OR 

      • Milliput® Black Epoxy Putty

        Website: www.milliput.com/home.htm 

      Repair Instructions:

      • Make sure to follow all manufacturer directions and cautions when using the Epoxy Putty.
      • Fill in the pin hole/cavity with the Epoxy Putty, and then smooth it out with a wet finger as outlined in the instructions included with the putty.
        NOTE:

        • Make sure to use black Epoxy Putty, both brands listed above are offered in that color.
        • Milliput® Black Epoxy Putty is from a UK supplier, and may be difficult to locate in the US. If you should encounter this, please utilize KBS Coatings - NuMetal® Epoxy Putty (Black) that is locally supplied and easier to locate.
10. REINSTALL THE ACCELERATOR PEDAL ASSEMBLY 
    1. With the pedal inside the vehicle, remove and discard the masking tape and bubble wrap from the accelerator pedal assembly.
    2. Reinstall the pedal with the 2 bolts and torque to specification.

       Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

    3. Reconnect the accelerator pedal connector.
    4. Reconnect the negative battery cable.
    5. Set the clock and radio station presets.
    6. Reinitialize the vehicle system(s) as outlined in the repair manual on TIS for the vehicle you are working on.
       NOTE:

       • DO NOT  reuse the bubble wrap.
       • For additional information on accelerator pedal installation, please refer to TIS.

       Continue to  STEP D   for floor mat inspection and repair confirmation 

C. DENSO ACCELERATOR PEDAL MODIFICATION (For CTS accelerator pedal modification procedure, go back to STEP B)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ACCELERATOR PEDAL HANDLING NOTES:  DO NOT drop the pedal, or reuse an accelerator pedal that has been dropped  Avoid vibration and shock of the pedal  DO NOT place sensor portion of the pedal in vise  Cover and uncover the sensor portion of the pedal while in the vehicle to prevent damage and debris from entering

1. REMOVE THE ACCELERATOR PEDAL ASSEMBLY 
   1. Record the radio station preset.
   2. Disconnect the negative battery cable and wait 90 seconds.
   3. Disconnect the accelerator pedal connector.
   4. Remove the 2 bolts.
   5. While still inside the vehicle, use bubble wrap and masking tape to cover and protect the pedal sensor.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • For additional information on accelerator pedal removal, refer to TIS.
      • Be sure to use bubble wrap to protect the sensor.
      • Be sure to seal the bubble wrap with masking tape to prevent damage to the sensor, and cutting debris from entering the pedal's movable lock.
      • DO NOT  reuse the bubble wrap
2. MARK THE AREA TO BE CUT 
   1. Firmly set the template to the pedal and scribe guide lines to outline the area to be cut.

      Cutting Template:

      • Color: Yellow
      • Stamping: RAV4 DN

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • DO NOT  mark the area beyond the template.
      • Use a flat tip screwdriver if a scribe is not available.
      • Make sure to use the correct cutting template by verifying the color and stamping.
      • NEVER  cut or sand the pedal while the template is on the pedal.
3. SECURE THE ACCELERATOR PEDAL ASSEMBLY 
   1. Set the pedal in the vise at a right angle using a shop cloth while avoiding the sensor.
      NOTE:

      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT  over tighten the vise.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. CUT THE LOWER SECTION OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. The cut line is slightly outside from the scribed line and it is positioned 90 degrees from the pedal foot pad as illustrated.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   2. Using a hack-saw, cut the pedal 0.2 in (5 mm) to create a guide cut for the reciprocating-saw.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves, and dusk mask when cutting.
      • Guide cut must be straight and clean.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   3. Using the reciprocating-saw, cut off the lower section of the pedal as illustrated.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves and dust mask when cutting.
      • The cut must be straight and clean.
      • Apply consistent pressure during cutting.
      • DO NOT  stop while cutting.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. SAND THE CORNERS OF THE ACCELERATOR PEDAL ASSEMBLY 
   1. Using an orbital sander, sand the pedal corners as illustrated.
      NOTE: ALWAYS wear protective eyewear, gloves, and dust mask when sanding.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. SAND THE RADIUS LINE 
   1. Using an orbital sander, sand the radius line which was scribed and remove the sharp edges and burrs.
      NOTE:

      • ALWAYS  wear protective eyewear, gloves, and dust mask when sanding.
      • DO NOT  sand the back of the pedal arm as illustrated.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

7. REMOVE ALL BURRS FROM THE CUTTING SURFACE 
   1. Remove the pedal from the vise.
   2. Turn the pedal over and set it in the vise using a shop cloth while avoiding the sensor.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • DO NOT  place the sensor in the vise to avoid damage.
      • Firmly secure the pedal to prevent it from moving.
      • DO NOT  over tighten the vise.
   3. Using an orbital sander and file, remove all burrs from the cutting surface. The cut edges along the foot pad should be rounded and not square.
   4. Finish the cut surface and all edges with 400 grit sandpaper.
      NOTE: ALWAYS  wear protective eyewear, gloves, and dust mask when sanding or filing.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

8. CHECK THE SHAPE OF THE PEDAL 
   1. Using the correct cutting template and shape gauge, check the shape of the pedal.

      Cutting Template

      Color: Yellow

      Stamping: RAV4 DN

      Shape Gauge

      Color: Yellow

      Stamping: RAV4

   2. If the shape DOES NOT  match the template and/or gauge, continue filing.
   3. If the shape matches the template AND  gauge, touch the cut surface with your hand to verify it is smooth and free of burrs.
      NOTE:

      • ALWAYS wear protective eyewear, gloves and dusk mask when sanding or filing.
      • A tolerance of -1.0 mm is permissible between the final cut surface and the template.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   4. Check for any pin holes, chips, nicks or sharp edges on the finished surface edge. If there are any chips, nicks or sharp edges, file them to make them smooth.
      NOTE: The key point of judgment is a "smooth pedal surface".
   5. If a "smooth pedal surface" cannot be achieved due to a pinhole / cavity, repair the pedal utilizing the steps below.

      Materials Needed:

      • KBS Coatings - NuMetal® Epoxy Putty (Black)

        Contact: 1-888-531-4527

        Website: www.kbs-coatings.com/KBS-NuMetal-Epoxy-Putty_p_9-19.html 

        OR 

      • Milliput® Black Epoxy Putty

        Website: www.milliput.com/home.htm 

      Repair Instructions:

      • Make sure to follow all manufacturer directions and cautions when using the Epoxy Putty.
      • Fill in the pin hole/cavity with the Epoxy Putty, and then smooth it out with a wet finger as outlined in the instructions included with the putty.
        NOTE:

        • Make sure to use black Epoxy Putty, both brands listed above are offered in that color.
        • Milliput® Black Epoxy Putty is from a UK supplier, and may be difficult to locate in the US. If you should encounter this, please utilize KBS Coatings - NuMetal® Epoxy Putty (Black) that is locally supplied and easier to locate.
9. REINSTALL THE ACCELERATOR PEDAL ASSEMBLY 
   1. g) With the pedal inside the vehicle, remove and discard the masking tape and bubble wrap from the accelerator pedal assembly.
   2. h) Reinstall the pedal with the 2 bolts and torque to specification.

      Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

   3. i) Reconnect the accelerator pedal connector.
   4. j) Reconnect the negative battery cable.
   5. k) Set the clock and radio station presets.
   6. l) Reinitialize the vehicle system(s) as outlined in the repair manual on TIS for the vehicle you are working on.
      NOTE:

      • DO NOT  reuse the bubble wrap.
      • For additional information on accelerator pedal installation, please refer to TIS.

      Continue to STEP D for floor mat inspection and repair confirmation 

D. INSPECT THE FLOOR MAT & CONFIRM THE REPAIR

1. INSPECT THE FLOORMAT 
   1. Inspect the carpet and floor mat and clean them as appropriate.
   2. Confirm the correct floor mat for this model is secured with the retaining hooks (clips).

      Locate the ten digit floor mat part number on the bottom of the back side of the mat as illustrated below.

      PLEASE NOTE, the floor mat part numbers are 12 digits but only the first ten are shown. 

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      For Carpeted Floor Mats: 

      Utilizing the ten digit part number and the chart below, confirm the vehicle has the correct carpeted floor mat.

      PARTS INFORMATION FOR CARPETED FLOOR MATS
      
      

      Part Number	'06	'07	'08	'09	'10	Color
      PT208-42051-04	X	X	X			Taupe
      PT208-42061-04	X	X	X			Taupe
      PT208-42051-31	X	X	X	X	X	Ash
      PT208-42051-11	X	X	X	X	X	Dark Charcoal
      PT208-42061-31	X	X	X	X	X	Ash
      PT208-42091-11				X	X	Dark Charcoal
      PT208-42081-40				X	X	Sand Beige
      PT208-42083-40				X	X	Sand Beige

      NOTE:

      • If an incorrect carpet floor mat is found in the vehicle, it should be removed.
      • If installed, the semi-permanent installation plastic straps for the carpeted floor mat can be removed.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      For AWFM: 

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      DO NOT use the recalled AWFM listed below. These AWFM MUST be removed from the vehicle and recovered by the dealer.

      PARTS INFORMATION
      
      

      Part Number	'06	'07	'08	'09	'10	Color
      PT908-42060-02	X	X	X	X	X	Black
      PT908-42061-02	X	X	X	X	X	Black

      NOTE: All recalled AWFM will be placed on Warranty Parts Recovery, and dealers will be required to return them to TMS. AWFM that are not returned will result in the claim being debited.

      Confirm the vehicle has the newly designed AWFM listed below. 

      PARTS INFORMATION
      
      

      Part Number	'06	'07	'08	'09	'10	Color
      PT908-4200W-20	X	X	X	X	X	Black

   3. Confirm the pedal does not get caught on the floor or floor mat during operation.
   4. Confirm the pedal operates properly.
2. INSPECT THE ACCELERATOR PEDAL ASSEMBLY OPERATION 
   1. Connect Techstream to the DLC3.
   2. Enter the following menus: Powertrain / Engine and ECT / Data List.
   3. Check the values by referring to the table below.
      ACCELERATOR PEDAL ASSEMBLY INSPECTION CHART
      
      

      Tester Display	Measurement: Range (Display)	Normal Condition	Diagnostic Note
      Accel Sensor Out No. 1	APP sensor No. 1 voltage	Accelerator Pedal Released: 0.5 to 1.1 V	Read value with ignition switch to ON (Do not start engine)
      		Accelerator Pedal Fully Depressed: 2.6 to 4.5 V
      Accel Sensor Out No. 2	APP sensor No. 2 voltage	Accelerator Pedal Released: 1.2 to 2.0 V	Read value with ignition switch to ON (Do not start engine)
      		Accelerator Pedal Fully Depressed: 3.4 to 5.0 V

      NOTE: There are two sets of Accel Sensor Out No. 1 & No. 2 parameters. Select ALL DATA (A to Z) on the pull down menu at the bottom of the screen when searching for the correct parameter set.
3. CHECK FOR DTCs 
4. PRINT A CUSTOMER HEALTH CHECK REPORT 
   1. From the Health Check Results screen select the Customer Health Check Report button (TIS will launch when button is pressed).

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   2. Log in to TIS.
   3. Input Vehicle Mileage and Repair Order number.
   4. Check the "Performed" radio button for the 90L campaign and any other campaigns completed during this service event.
   5. Select the Report button.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   6. Confirm Customer Health Check Report information is correct.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   7. Print Customer Health Check Report from TIS.
   8. Sign and provide to the customer
5. TEST DRIVE THE VEHICLE 

   VERIFY REPAIR QUALITY  

   • Confirm that all parts removed from the vehicle are reinstalled correctly
   • Confirm the accelerator pedal assembly is modified correctly using the template and gauge
   • Confirm the floor mat inspection is performed correctly
   • If you have any questions regarding this recall, please contact your regional representative