TECHNICAL INSTRUCTIONS RECALL 22TA03 – Vehicle Stability Control System May Not Default to “On” – 2020-2022 Toyota

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TECHNICAL INSTRUCTIONS FOR SAFETY (NONCOMPLIANCE) RECALL 22TA03 Vehicle Stability Control System May Not Default to “On” Certain 2020 – 2022 Model Year Highlander Hybrid Certain 2021 – 2022 Model Year Mirai Certain 2021 – 2022 Model Year Rav4 Prime Certain 2022 Model Year Rav4 Hybrid Certain 2021 – 2022 Sienna Hybrid Certain 2021 – 2022 Venza Hybrid The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this special service campaign 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; technicians performing this special service campaign repair are required to currently have completed all of the following courses: -T623 Electrical Circuit Diagnosis It is the dealership’s responsibility to select technicians that have completed the above courses to perform this 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. 2 I. OPERATION FLOW CHART II. IDENTIFICATION OF AFFECTED VEHICLES • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and that it has not already been completed prior to dealer shipment or by another dealer. • TMS warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were completed by another dealer. III. PREPARATION A. TOOLS, SUPPLIES & EQUIPMENT • Standard Hand Tools • Techstream ADVi / Techstream 2.0 / Techstream Lite • DCA-8000P Battery Diagnostic Tool • T-SB-0107-20 • T-SB-0134-16 No Covered Yes Perform Health Check. Is a Update available for the Brake/EPB System? Update the Skid Control ECU CID’s. Not Covered Verify Vehicle Eligibility 1.Confirm vehicle VIN matches the RO. 2.Check Vehicle Inquiry System for Campaign eligibility. No further action required. Campaign completed, return the vehicle to the customer. Perform Verification Heath Check 3 IV. BACKGROUND A software error can cause the Vehicle Stability Control system (VSC) not to default to “ON” the next time the car is started under certain circumstances. This can result in noncompliance with a federal safety requirement. Operating the vehicle with VSC deactivated could increase the risk of a crash in certain driving conditions. Note: The illustration is an example of RAV4 Hybrid. 4 V. DETERMINE STATUS OF CURRENT CALIBRATION 1. CHECK FOR DTC’S a. Using a Techstream, perform a Health Check to check for any Diagnostic Trouble Codes. Notice: This Campaign covers only the Calibration ID update to the Brake/EPB system, as detailed in these instructions. It does not cover the diagnosis or replacement of any other issues on the vehicle. • For MIRAI w/ advanced drive, make sure to use a VIM which supports Ethernet communication. • For MIRAI w/o Advanced drive, a VIM which does not support Ethernet communication can be used. Even if “Please connect the Ethernet communication supported cable.” is displayed Click “Next” and proceed with the work. Notice: Before completing Health Check, “Send Vehicle Information” window may be displayed. If displayed, then click “Yes” to send the vehicle information. • If “Failed to send data to the server” is displayed, click “No” to close the window and proceed to the next step. 5 2. CHECK CURRENT CALIBRATION a. Locate the Update column for the Brake/EPB System in the Stored Data tab for this vehicle. b. Determine the status of an available update for the Brake/EPB System; indicated by a YES or NO. Is there an update available to the Brake/EPB System? No update is necessary. Campaign is complete. Proceed to section VI. Vehicle preparation on p. 6 Yes No 6 VI. VEHICLE PREPERATION The CID Update Procedure is detailed in T-SB-0134-16 and T-SB-0107-20 ECU Flash Reprogramming With Security Signature Please reference these Bulletins for more detailed procedures and information. 1. VEHICLE PREPARATION a. Confirm the following conditions: • Vehicle in the IG position (engine off). • Transaxle in Park. • Parking brake engaged. • Turn off all electrical accessories (i.e. climate control, audio system, etc.) • Headlight switch in the DRL OFF position. • Windshield wiper switch in the OFF position. 2. PRESSURIZE HYDRO-BOOSTER a. Depress the brake pedal fully 2 times within 2 seconds. b. Release brake pedal c. Wait 10 seconds NOTICE: You may hear the hydro-boost pump run for a few seconds when completing these steps. The procedure will prevent the pump from running during the re-flash procedure. 3. CONNECT THE 12v BATTERY TO A POWER SUPPLY (DCA-8000) a. Connect the DCA-8000 or other type of a power supply (not a battery charger) to the 12v battery. b. Tap the Reflash icon from the Main Menu screen of the DCA-8000. A power supply MUST be used during reprogramming. Please ensure DCA-8000 is connected and set to power supply mode. Voltage MUST be set to 13.5V. Power supply must be connected directly to the 12v battery terminals and NOT the remote jump posts under the hood (if equipped). ***ECU damage will occur if the battery voltage is not properly maintained during this re-flash procedure. 7 4. VERIFY TECHSTREAM SETUP a. Verify that the Techstream meets the following conditions: • The latest version of software is loaded. • The Techstream battery is fully charged. If not, connect the Techstream to a 120v source. • The DLCIII cable is in good condition. The Techstream’s battery voltage MUST be maintained during the update procedure. If necessary, plug the Techstream into a 120v outlet during this procedure. ***If the Techstream’s communication with the vehicle fails during the update procedure, the ECU will be damaged. 5. DISCONNECT COOLING FAN a. Disconnect the electrical connector from the cooling fan ECU on the radiator fan shroud. If the cooling fans run during the Calibration update procedure, the battery voltage will be inconsistent and could cause damage to the control module(s). 8 VII. UPDATE CALIBRATION 1. UPDATE THE CID’S FOR THE BRAKE/EPB SYSTEM a. Identify the vehicles Original CID for the Brake/EPB System on the Stored Data tab. b. Locate the vehicles Original CID in the chart below. c. Select the corresponding NEW CID link to load the update. d. Follow the on-screen instructions to complete the Calibration Update procedure. ◄ CRITICAL MESSAGE ► MIRAI ONLY After “Flash Calibration Update Successful” is displayed, turn the IG off and keep with IG OFF for 5 minutes. 9 The CID Update Procedure is detailed in T-SB-0134-16 and T-SB-0107-20 ECU Flash Reprogramming With Security Signature Please reference the chart below to determine which Bulletin to follow for more detailed procedures and information. Model Current Calibration ID NEW Calibration ID Applicable T-SB VENZA HV F152648A9300 F152648A9400 T-SB-0107-20 F152648A9200 F152648J2000 RAV4 HV F15264283100 F15264283200 T-SB-0134-16 RAV4 PRIME F15264284000 F15264284100 T-SB-0107-20 F15264228400 F15264228500 F15264228300 HIGHLANDER HV F15264872400 F152648J4000 T-SB-0134-16 F15264872500 MIRAI F15266204200 F15266204500 T-SB-0107-20 F15266204300 F15266204400 F15266203200 F15266203500 F15266203300 F15266203400 SIENNA HV F15260815000 F15260815100 T-SB-0107-20 F15264505000 F15264501300 10 VIII. COMPLETE REPAIR 1. CONNECT COOLING FAN a. Connect the electrical connector to the cooling fan motor on the radiator fan shroud. 2. CONFIRMATION OF MIL OFF a. Activate the hybrid system and confirm that the Malfunction Indicator Lamp (MIL) in the combination meter assembly is not illuminated. NOTICE: If MIL is off, it is unnecessary to perform the next step. b. It is necessary that 4 Ready OFF/ON cycles be performed to turn off the MIL. Follow the steps below. • The interval from Ready OFF to Ready ON should need more than 5 minutes, and from Ready ON to Ready OFF should need more than 10 seconds. • After performing the step above, confirm the MIL is off. • DO NOT depress the brake pedal or open/close the driver-side door during the 5 minutes with Ready OFF. Ensure operation is performed after the 5 minutes have passed. • If the brake pedal is depressed or driver-side door is opened/closed during the 5 minutes with Ready OFF, start the cycle to turn off the MIL from the beginning. 11 3. PERFORM VERIFICATION HEALTH CHECK a. Using a Techstream, perform a Health Check. b. Clear DTC’s that may have set during the re-flash procedure. c. Re-run the Health Check to confirm that no DTC’s reappear. THIS VERIFICATION HEALTH CHECK IS NECESSARY to update the results and CID’s to the National database. 4. CONFIRM CID UPDATE a. On the Stored Data tab, confirm the following for the Brake/EPB Systems: • The Calibration number has the “New CID” number. • The “Update” column says “No”. 5. PRINT CUSTOMER HEALTH CHECK REPORT a. From the Stored Data tab, select the Customer Health Check Report button (TIS will launch when button is pressed). 12 b. Log in to TIS. c. Input Vehicle Mileage and Repair Order number. d. Check the “Performed” campaign button for the applicable campaigns. e. Select the Report button. f. Confirm Customer Health Check Report information is correct. g. Print Customer Health Check Report from TIS. h. Sign and provide to the customer. IX. REASSEMBLY 1. REMOVE THE POWER SUPPLY FROM THE BATTERY ◄ VERIFY REPAIR QUALITY ► − Confirm the cooling fans are re-connected. − Confirm the system Calibration has been updated successfully. − Confirm there are no DTC’s after the Calibration update. A. PARTS DISPOSAL In accordance with Federal law, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. 13 1919 = 201920 = 202021 = 202122 = 202223 = 2023Etc…Year Campaignis Launched19TA01TT = ToyotaL = LexusVehicle MakeAA = Safety Recall RemedyB = Safety Recall InterimC = Special Service CampaignD = Limited Service CampaignE = Customer Support ProgramF = Emissions Recall(May use other characters in unique cases)Field Action Category and Phase0101 = 1st Field Action of the year02 = 2nd Field Action of the year03 = 3rd Field Action of the year(The sequence is unique for each Field Action category)(May use other characters in unique cases)Field Action Sequence Examples: 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021 Campaign Designation / Phase Decoder

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TECHNICAL INSTRUCTIONS FOR SAFETY (NONCOMPLIANCE) RECALL 22TA03 Vehicle Stability Control System May Not Default to “On” Certain 2020 – 2022 Model Year Highlander Hybrid Certain 2021 – 2022 Model Year Mirai Certain 2021 – 2022 Model Year Rav4 Prime Certain 2022 Model Year Rav4 Hybrid Certain 2021 – 2022 Sienna Hybrid Certain 2021 – 2022 Venza Hybrid Update 7/21/22 – Added step in section VIII. to check for Fan Operation Update 04/21/22 – Added new target calibration ID for Highlander HV The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this special service campaign 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; technicians performing this special service campaign repair are required to currently have completed all of the following courses: -T623 Electrical Circuit Diagnosis It is the dealership’s responsibility to select technicians that have completed the above courses to perform this 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. 2 I. OPERATION FLOW CHART II. IDENTIFICATION OF AFFECTED VEHICLES • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and that it has not already been completed prior to dealer shipment or by another dealer. • TMS warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were completed by another dealer. III. PREPARATION A. TOOLS, SUPPLIES & EQUIPMENT • Standard Hand Tools • Techstream ADVi / Techstream 2.0 / Techstream Lite • DCA-8000P Battery Diagnostic Tool • T-SB-0107-20 • T-SB-0134-16 No Covered Yes Perform Health Check. Is a Update available for the Brake/EPB System? Update the Skid Control ECU CID’s. Not Covered Verify Vehicle Eligibility 1. Confirm vehicle VIN matches the RO. 2. Check Vehicle Inquiry System for Campaign eligibility. No further action required. Campaign completed, return the Perform Verification Heath Check vehicle to the customer. 3 IV. BACKGROUND A software error can cause the Vehicle Stability Control system (VSC) not to default to “ON” the next time the car is started under certain circumstances. This can result in noncompliance with a federal safety requirement. Operating the vehicle with VSC deactivated could increase the risk of a crash in certain driving conditions. Note: The illustration is an example of RAV4 Hybrid. 4 V. DETERMINE STATUS OF CURRENT CALIBRATION 1. CHECK FOR DTC’S a. Using a Techstream, perform a Health Check to check for any Diagnostic Trouble Codes. Notice: This Campaign covers only the Calibration ID update to the Brake/EPB system, as detailed in these instructions. It does not cover the diagnosis or replacement of any other issues on the vehicle. • For MIRAI w/ advanced drive, make sure to use a VIM which supports Ethernet communication. • For MIRAI w/o Advanced drive, a VIM which does not support Ethernet communication can be used. Even if “Please connect the Ethernet communication supported cable.” is displayed Click “Next” and proceed with the work. Notice: Before completing Health Check, “Send Vehicle Information” window may be displayed. If displayed, then click “Yes” to send the vehicle information. • If “Failed to send data to the server” is displayed, click “No” to close the window and proceed to the next step. 5 2. CHECK CURRENT CALIBRATION a. Locate the Update column for the Brake/EPB System in the Stored Data tab for this vehicle. b. Determine the status of an available update for the Brake/EPB System; indicated by a YES or NO. Is there an update available to the Brake/EPB System? No update is necessary. Campaign is complete. Proceed to section VI. Vehicle preparation on p. 6 Yes No 6 VI. VEHICLE PREPERATION The CID Update Procedure is detailed in T-SB-0134-16 and T-SB-0107-20 ECU Flash Reprogramming With Security Signature Please reference these Bulletins for more detailed procedures and information. 1. VEHICLE PREPARATION a. Confirm the following conditions: • Vehicle in the IG position (engine off). • Transaxle in Park. • Parking brake engaged. • Turn off all electrical accessories (i.e. climate control, audio system, etc.) • Headlight switch in the DRL OFF position. • Windshield wiper switch in the OFF position. 2. PRESSURIZE HYDRO-BOOSTER a. Depress the brake pedal fully 2 times within 2 seconds. b. Release brake pedal c. Wait 10 seconds NOTICE: You may hear the hydro-boost pump run for a few seconds when completing these steps. The procedure will prevent the pump from running during the re-flash procedure. 3. CONNECT THE 12v BATTERY TO A POWER SUPPLY (DCA-8000) a. Connect the DCA-8000 or other type of a power supply (not a battery charger) to the 12v battery. b. Tap the Reflash icon from the Main Menu screen of the DCA-8000. A power supply MUST be used during reprogramming. Please ensure DCA- 8000 is connected and set to power supply mode. Voltage MUST be set to 13.5V. Power supply must be connected directly to the 12v battery terminals and NOT the remote jump posts under the hood (if equipped). ***ECU damage will occur if the battery voltage is not properly maintained during this re-flash procedure. 7 4. VERIFY TECHSTREAM SETUP a. Verify that the Techstream meets the following conditions: • The latest version of software is loaded. • The Techstream battery is fully charged. If not, connect the Techstream to a 120v source. • The DLCIII cable is in good condition. The Techstream’s battery voltage MUST be maintained during the update procedure. If necessary, plug the Techstream into a 120v outlet during this procedure. ***If the Techstream’s communication with the vehicle fails during the update procedure, the ECU will be damaged. 5. DISCONNECT COOLING FAN a. Disconnect the electrical connector from the cooling fan ECU on the radiator fan shroud. If the cooling fans run during the Calibration update procedure, the battery voltage will be inconsistent and could cause damage to the control module(s). 8 VII. UPDATE CALIBRATION 1. UPDATE THE CID’S FOR THE BRAKE/EPB SYSTEM a. Identify the vehicles Original CID for the Brake/EPB System on the Stored Data tab. b. Locate the vehicles Original CID in the chart below. c. Select the corresponding NEW CID link to load the update. d. Follow the on-screen instructions to complete the Calibration Update procedure. ◄ CRITICAL MESSAGE ► MIRAI ONLY After “Flash Calibration Update Successful” is displayed, turn the IG off and keep with IG OFF for 5 minutes. 9 The CID Update Procedure is detailed in T-SB-0134-16 and T-SB-0107-20 ECU Flash Reprogramming With Security Signature Please reference the chart below to determine which Bulletin to follow for more detailed procedures and information. Model Current Calibration ID NEW Calibration ID Applicable T-SB VENZA HV F152648A9300 F152648A9400 F152648A9200 F152648J2000 T-SB-0107-20 RAV4 HV F15264283100 F15264283200 T-SB-0134-16 RAV4 PRIME F15264284000 F15264284100 F15264228400 F15264228500 T-SB-0107-20 F15264228300 HIGHLANDER HV F15264872300 F15264872400 F152648J4000 T-SB-0134-16 F15264872500 MIRAI F15266204200 F15266204500 T-SB-0107-20 F15266204300 F15266204400 F15266203200 F15266203300 F15266203500 F15266203400 SIENNA HV F15260815000 F15264505000 F15260815100 T-SB-0107-20 F15264501300 10 VIII. COMPLETE REPAIR 1. CONNECT COOLING FAN a. Connect the electrical connector to the cooling fan motor on the radiator fan shroud. 2. CHECK THE OPERATION OF THE ELECTRIC FAN a. READY ON the vehicle. b. Turn the air conditioner ON to check if the electric fan operates. 3. CONFIRMATION OF MIL OFF a. Activate the hybrid system and confirm that the Malfunction Indicator Lamp (MIL) in the combination meter assembly is not illuminated. NOTICE: If MIL is off, it is unnecessary to perform the next step. b. It is necessary that 4 Ready OFF/ON cycles be performed to turn off the MIL. Follow the steps below. • The interval from Ready OFF to Ready ON should need more than 5 minutes, and from Ready ON to Ready OFF should need more than 10 seconds. • After performing the step above, confirm the MIL is off. • DO NOT depress the brake pedal or open/close the driver-side door during the 5 minutes with Ready OFF. Ensure operation is performed after the 5 minutes have passed. • If the brake pedal is depressed or driver-side door is opened/closed during the 5 minutes with Ready OFF, start the cycle to turn off the MIL from the beginning. 11 4. PERFORM VERIFICATION HEALTH CHECK a. Using a Techstream, perform a Health Check. b. Clear DTC’s that may have set during the re-flash procedure. c. Re-run the Health Check to confirm that no DTC’s reappear. THIS VERIFICATION HEALTH CHECK IS NECESSARY to update the results and CID’s to the National database. 5. CONFIRM CID UPDATE a. On the Stored Data tab, confirm the following for the Brake/EPB Systems: • The Calibration number has the “New CID” number. • The “Update” column says “No”. 6. PRINT CUSTOMER HEALTH CHECK REPORT a. From the Stored Data tab, select the Customer Health Check Report button (TIS will launch when button is pressed). 12 b. Log in to TIS. c. Input Vehicle Mileage and Repair Order number. d. Check the “Performed” campaign button for the applicable campaigns. e. Select the Report button. f. Confirm Customer Health Check Report information is correct. g. Print Customer Health Check Report from TIS. h. Sign and provide to the customer. IX. REASSEMBLY 1. REMOVE THE POWER SUPPLY FROM THE BATTERY ◄ VERIFY REPAIR QUALITY ► − Confirm the cooling fans are re-connected. − Confirm the system Calibration has been updated successfully. − Confirm there are no DTC’s after the Calibration update. A. PARTS DISPOSAL In accordance with Federal law, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. 13 19 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 19TA01 T T = Toyota L = Lexus Vehicle Make A A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program F = Emissions Recall (May use other characters in unique cases) Field Action Category and Phase 01 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 3rd Field Action of the year (The sequence is unique for each Field Action category) (May use other characters in unique cases) Field Action Sequence Examples: 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021 Campaign Designation / Phase Decoder

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