Vehicle - Flood Damage Inspection And Handling
T-SB-0229-12
November 21, 2012
Flood Damaged Vehicle Inspection & Handling
Service Category
Power Source/Network
Section
Battery/Charging
Market
USA
Applicability
Introduction
In the event that a Toyota vehicle becomes submerged in water, many components, may be physically damaged. Electrical and electronic components, including wiring harnesses, are particularly susceptible to corrosion and subsequent malfunction. Although any flooding can be damaging, salt water flooding elevates the potential for abnormal conditions and may increase risks due to its highly corrosive and conductive nature. Salt residue also continues to corrode and remain conductive even after a vehicle dries. This bulletin is intended to assist with safe handling and inspection of flood damaged vehicles as well as provide basic guidance on likely needed repairs.
NOTE
^ Damage associated with a vehicle being submerged in water is not covered by the Toyota new vehicle Warranty policy.
^ VIN and inspection results for vehicles currently within the warranty period should be forwarded to the DSPM for their reference and updates to the Warranty system.
^ This bulletin provides general guidance and inspection areas. Each individual vehicle must be carefully reviewed based on the situation (water level, water type, and duration of exposure).
Service Bulletin Overview
This bulletin contains 3 main sections:
1. Vehicle Safing - Making sure the vehicle is in a safe condition and the electrical system is disabled to minimize risks from corrosion, damaged circuits, and attempted operation.
2. Vehicle Inspection - Assessing the level of damage and determining necessary parts replacement, cleaning procedures, and potential long term effects.
3. Vehicle Repair - Guidance for repair decisions on vehicle systems, sub-systems, and components.
NOTE
^ Due to the potential level of damage after an extended partial or full submersion, some vehicles may not be repairable and should be decommissioned.
^ Final decisions on repair costs, vehicle value, and possible salvage or decommissioning are the responsibility of the customer, dealership, and insurer. Inspection and repair of flood damaged vehicles is NOT warrantable.
Warranty Information
Required Tools & Equipment
1. Vehicle Safing
The most important aspect of handling flooded vehicles is making sure the vehicle is safe. Water entry and resulting corrosion may cause electrical system anomalies or performance issues including:
^ Improper power distribution I system operation I overcurrent conditions.
^ High resistance from corrosion and abnormal heat generation that could lead to a potential fire.
^ Potential SRS Airbag Pretensioner and/or Side Curtain Airbag false activation/deployment.
1. Determine if the vehicle has been flooded with water above the rocker panels into the floor of the vehicle.
HINT
If no standing water is detected on the vehicle floor and the carpet is wet, assume that internal flooding has occurred.
^ If YES - Continue to step 2.
^ If NO - Go to section 2 for vehicle inspection.
2. Open doors and trunk or hatch to release trapped water, ventilate the cabin, and allow the interior to air dry.
3. Locate and remove body drain plugs at the rear corners of cabin floor and/or in spare tire well (if available) to assist with draining the vehicle.
4. Disconnect the 12V battery and make sure the cable is folded down and away from the terminal.
5. On hybrid vehicles disconnect the HV Battery Service Plug Connector (ONLY after the 12V auxiliary battery is disconnected).
CAUTION
If battery area contains standing water, drain BEFORE removing HV Battery Service Plug Connector.
6. Using a floor jack or GoJaks move and store the vehicle away from structures and vehicles.
2. Vehicle Inspection
Determining the level of water intrusion and whether the vehicle was contaminated with fresh or salt water will help assess the extent of damage that has occurred and may continue to occur. As salt water is more damaging, this bulletin focuses primarily on salt water flooding. If the vehicle was driven in flood waters additional inspections may be necessary.
Use the illustration to identify inspection level based on depth and angle of vehicle submersion.
Driven Vehicle Inspection - Salt Water
NOTE
If the vehicle was driven in flood waters, continue with the following checks after performing static inspection items.
Additional inspections must be made when the vehicle has been driven through or in flood waters. After a full inspection, repair of electrical systems replacement of fluids and other potential repairs, the vehicle should be driven while monitoring live Techstream data for each vehicle system. A full Health Check should be performed to complete confirmation of vehicle operation.
2. Vehicle Inspection
Driven Vehicle Inspection - Salt Water (Continued)
NOTE
For Fresh Water Flooding:
^ The dynamic inspection tables serve as a general inspection guide.
^ Residual corrosion and conductivity, once vehicle is dried, is not as great a concern as with salt water. All flooding situations should be inspected and judged individually.
3. Vehicle Repair
After identifying affected components and when making repair decisions, please consider the following.
Electrical
Any electrical components that have been submerged in salt water (examples: harnesses, connectors, terminals, ECUs, hybrid, and PHV batteries, switches, buttons, sensors) need to be replaced before operating the vehicle and should NOT be reused.
NOTE
^ Even after salt water has dried, salt residue may remain on nearby surfaces.
^ Cleaning and/or replacement of surrounding components may also be necessary to ensure proper operation of electrical systems.
Chassis
Brakes and suspension components not only need to move and slide freely for proper operation, but additional consideration needs to be given for subsequent corrosion that could impact future system performance. Disassemble, clean, reassemble, and lubricate all chassis components that have been submerged or subjected to extensive salt water exposure.
Powertrain
As in-depth performance analysis can be conducted using Techstream, repair must include testing and confirmation of proper live data performance, general Health Check (full Health Check for possible DTCs), inspection for oil and fuel contamination, consideration of all electrical components (as previously described in this bulletin), inspection and replacement of any rubber, plastic, and metal components that are deteriorating or damaged, and removal of salt water residue using appropriate cleaning agents.
Body and Interior
Vehicle body designs generally incorporate pressure relief vents (to minimize door closing pressure). These can allow water entry into the passenger cabin during a flood situation and also have inherent low points or pockets that can retain flood water. Be sure to inspect drain, and clean these locations.
3. Vehicle Repair
Any component that became wet or saturated that has fabric cloth padding or soft trim such as those listed below may need to be replaced and/or require follow-up mold remediation.
^ Carpet and padding ^ Console
^ Seats ^ Package tray
^ Door trim panels ^ Seals
Remaining salt water residue in any part of the vehicle may accelerate corrosion and affect vehicle operation. Be sure to clean all affected internal and external surfaces thoroughly to prevent long term damage.