RECALL K0L – Potential Loss of Power Brake Assist – 2019-2020 Toyota

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July 24, 2019 NHTSA CAMPAIGN NUMBER: 19V544000

Loss of Stability Control, Brake Assist/FMVSS 126

Deactivation of the vehicle stability control system or a loss of braking assist increases the risk of a crash.

 

NHTSA Campaign Number: 19V544

Manufacturer Toyota Motor Engineering & Manufacturing

Components ELECTRONIC STABILITY CONTROL, SERVICE BRAKES

Potential Number of Units Affected 6,925

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2019 Lexus LS500, LC500, ES300h, UX250h, LS500h, Toyota Prius, RAV4 HV, 2019-2020 Toyota Prius Prime, and 2020 Corolla HV vehicles. The brake booster pump may fail causing a deactivation of the Vehicle Stability Control system and a loss of braking assist. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, “Electronic Stability Control Systems.”

 

Remedy

Toyota will notify owners, and dealers will inspect and, if necessary, replace the brake booster pump, free of charge. The recall began September 20, 2019. Toyota owners may contact Toyota customer service at 1-888-270-9371 and Lexus owners may contact Lexus customer service at 1-800-255-3987. Toyota’s numbers for this recall are K1L/K0L. Lexus’ numbers for this recall are K2F/KLF.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


Original Publication Date: September 19, 2019

To: All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers

SAFETY (NONCOMPLIANCE) RECALL K0L (Remedy Notice)

Certain 2020 Model Year Corolla Hybrid
Certain 2019 Model Year Rav4 Hybrid
Certain 2019 – 2020 Model Year Prius Prime
Certain 2019 Model Year Prius
Potential Loss of Power Brake Assist
NHTSA Recall No. 19V-544

 

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2020 Corolla Hybrid April 2019 – May 2019 750 97
2019 Rav4 Hybrid April 2019 – June 2019 3,300 27
2019 – 2020 Prius Prime April 2019 – May 2019 400 131
2019 Prius April 2019 – May 2019 2,050 796

 

Red Stop STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

Red Stop

 

On July 24 2019, Toyota filed a Noncompliance Information Report (NCIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety (Noncompliance) Recall on certain 2020 model year Corolla Hybrid, certain 2019 model year Rav4 Hybrid, certain 2019 – 2020 model year Prius Prime and certain 2019 model year Prius vehicles.

 

Condition

In the subject vehicles, there is a possibility the brake booster pump may have been manufactured improperly, and in some cases, it may stop operating. If the brake booster pump stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound. In this condition, braking assist could be lost completely after several brake pedal applications, resulting in increased stopping distance. In addition, the Vehicle Stability Control will become deactivated, and other vehicle features could be affected. Deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the certain requirements of FMVSS No. 126. A deactivated Vehicle Stability Control or a sudden and complete loss of braking assist while driving could increase the risk of a crash.

 

Remedy

Based on the vehicle identification number or an inspection, the dealer will replace the brake booster pump with a new one, if necessary, FREE OF CHARGE.

 

Covered Vehicles

There are approximately 6,500 vehicles covered by this Safety (Noncompliance) Recall. Approximately 8 vehicles involved in this Safety (Noncompliance) Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will begin to notify owners in mid-September 2019. A sample of the owner notification letter has been included for your reference.

Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety (Noncompliance) Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

Dealer Inventory Procedures

New Vehicles in Dealership Inventory

There are approximately 1,051 vehicles in new dealer inventory as of September 19, 2019

Red Stop Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety.  Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory:  It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.

Toyota reimburses dealers for flooring costs associated with new vehicles held in dealership inventory until the recall remedy becomes available.  Toyota provides these flooring reimbursements at 60-day intervals.  Toyota reserves the right to withhold or charge-back any flooring reimbursement funds that may have been paid to the dealer if it determines that a new vehicle subject to a safety recall was sold without first being remedied.

Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.

 

NOTE:

  • New vehicles in dealer inventory subject to a Safety Recall must be remedied before delivery into commerce under a sale or lease. Dealer-to-dealer trades as well as vehicle sales between dealers should not be made until a vehicle is remedied.
  • Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Inspection Reminder Mirror Hang Tags for Covered Vehicles in New Dealer Stock

To easily recognize vehicles involved in this Safety (Noncompliance) Recall, each dealership should utilize Inspection Reminder Hang Tags. Inside the vehicle’s glove box are stickers containing the VIN. Apply one of these stickers to the hang tag and install the hang tag in the vehicle. A sample copy of the Inspection Reminder Hang Tag has been included for your reference.

Hold For Inspection

Part Number Description Quantity
00411-140003 Inspection Mirror Hang Tag 25 Per Pack

 

NOTE: Dealerships can order hang tags from the Material Distribution Center (MDC).

 

Pre-Owned Vehicles in Dealer Inventory

To ensure customer satisfaction, Toyota requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall.

Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.

Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email state, “Disclosure Form K0L/K1L” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Handling, Parts Ordering, and Remedy Procedures

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety (Noncompliance) Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Customer Experience Center (1-888-270-9371) – Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Tania Saldana (859) 815-9968 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Parts Ordering Process Non SET and GST Parts Ordering Process

It is possible that parts for this campaign are either required to be ordered in Campaign Part Order Request (CPOR) on Service Lane, or have been placed on Manual Allocation Control (MAC) due to potential limited part availability. Please check the CPOR/MAC report on Dealer Daily for the most up-to-date parts ordering information.

All Safety Recall, Service Campaign (SSC/LSC) parts are eligible for the Monthly Parts Return Program. Please refer to PANT Bulletin 2011-087 for campaign parts that are currently returnable under the Monthly Parts Return Program and for additional details.

 

Description Quantity Part Number
Prius –  Brake Booster Pump Assembly 1 04009-56647
Prius Prime – Brake Booster Pump Assembly 1
Corolla Hybird – Brake Booster Pump Assembly 1
Rav4 HybridBrake Booster Pump Assembly

 

 

1 04009-56942

 

Technician Training Requirements

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair 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 repair are required to currently hold at least one of the following certification levels:

  • Certified Technician (Chassis)
  • Expert Technician (Chassis)
  • Master Technician
  • Master Diagnostic Technician

Always check which technicians can perform the repair by logging on to https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above certification level or greater 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.

 

Remedy Procedures

Refer to TIS for Technical Instructions on repair. Conduct all non-completed Safety Recalls and Service Campaigns on the vehicle during the time of appointment.

 

Repair Quality Confirmation

The repair quality of covered vehicles is extremely important to Toyota. To help ensure that all vehicles have the repair performed correctly, please designate at least one associate (someone other than the individual who performed the repair) to verify the repair quality of every vehicle prior to customer delivery.

 

Parts Recovery Procedures

All parts replaced as part of this Safety Recall must be turned over to the parts department until appropriate disposition is determined. The parts department must retain these parts until notification via the Parts Recovery System (PRS) is received indicating whether to ship or scrap the parts. These parts are utilized by various departments for defect analysis, quality control analysis, product evaluation, as well as other purposes.

To help minimize dealer storage challenges, Toyota recommends that dealers:

  • File the campaign claim accurately and promptly. The time a dealer is required to hold parts is based on when the campaign claim is paid by Toyota.
  • Monitor the Warranty Parts Recovery Notifications and Part Scrap Report regularly.

Refer to Warranty Policies 9.3 and 9.6 for additional details.

 

Warranty Reimbursement Procedures

Loaner Vehicle or Alternative Transportation Reimbursement Procedure

For customers who requested a loaner vehicle or alternative transportation in the interim phase, a loaner vehicle or alternative transportation through Toyota Rent-A-CAR (TRAC) can be claimed for $35 per day.

Op Code Description
K0LRT1 Vehicle Rental 1-30 Days
K0LRT2 Vehicle Rental 31-50 Days

 

NOTE:

  • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • Rentals that exceed the maximum allowable daily rate will require DSPM authorization per the Toyota Transportation Assistance Policy (TTAP).

 

Warranty Reimbursement Procedure

Certain 2019 Model Year Rav4 Hybrid

Warranty Reimbursement Procedure

 

Warranty Reimbursement Procedure

Certain 2020 Model Year Corolla Hybrid
Certain 2019 – 2020 Model Year Prius Prime
Certain 2019 Model Year Prius

Warranty Reimbursement Procedure

 

Op Code Description Flat Rate Hours
K0L001 Prius, Prius Prime and Corolla HybridBrake Booster Pump Assembly Inspection, No Replacement Necessary 0.8
K0L002 PriusBrake Booster Pump Assembly Inspection and Brake Booster Pump Assembly Replacement 5.1
K0L003 Prius Prime – Brake Booster Pump Assembly Inspection and Brake Booster Pump Assembly Replacement 5.1
K0L004 Corolla HybridBrake Booster Pump Assembly Inspection and Brake Booster Pump Assembly Replacement 5.1
K0L005 Rav4 HybridBrake Booster Pump Assembly Inspection and Brake Booster Pump Assembly Replacement 6.0

 

  • The flat rate times include 0.1 hours for administrative cost per unit for the dealership.
  • Dealers may claim the cost of brake fluid up to $44.00 per vehicle as a sublet type “OF” under remedy Op codes K0L002, K0L003, K0L004 and K0L005
  • A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) can be claimed up to a maximum of 1 day at a maximum cost of $35.00 as a sublet type “RT” under remedy Op codes K0L002, K0L003, K0L004 and K0L005.

 

Claim Filing Accuracy and Correction Requests

It is the dealer’s responsibility to file claims correctly for this Safety (Noncompliance) Recall. This claim filing information is used by Toyota for various government reporting activities; therefore, claim filing accuracy is crucial. If it has been identified that a claim has been filed using an incorrect Op Code or a claim has been filed for an incorrect VIN, refer to Warranty Procedure Bulletin PRO17-03 to correct the claim.

 

Campaign Designation / Phase Decoder

Campaign Designation / Phase Decoder
Examples:

C1B = Launched in 2012, Interim Phase, 2nd   Campaign Launched in 2012

E0A = Launched in 2014, Remedy Phase, 1st  Campaign Launched in 2014

J0A = Launched in 2018, Remedy Phase, 1st  Campaign Launched in 2018.

 

Please review this entire package with your Service and Parts staff to familiarize them with the proper step-bystep procedures required to implement this Safety (Noncompliance) Recall.

 

Thank you for your cooperation.

TOYOTA MOTOR SALES, U.S.A., INC.


SAFETY (NONCOMPLIANCE) RECALL K0L (Remedy Notice)

Certain 2020 Model Year Corolla Hybrid
Certain 2019 Model Year RAV4 Hybrid
Certain 2019 – 2020 Model Year Prius Prime
Certain 2019 Model Year Prius
Potential Loss of Power Brake Assist
NHTSARecall No. 19V-544

Frequently Asked Questions
Original Publication Date: September 19, 2019

 

Q1: What is the condition?
A1: In the subject vehicles, there is a possibility the brake booster pump may have been manufactured improperly, and in some cases, it may stop operating. If the brake booster pump stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound. In this condition, braking assist could be lost completely after several brake pedal applications, resulting in increased stopping distance.  In addition, the Vehicle Stability Control will become deactivated, and other vehicle features could be affected.  Deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the certain requirements of FMVSS No. 126.  A deactivated Vehicle Stability Control or a sudden and complete loss of braking assist while driving could increase the risk of a crash.

Q1a: What is the Brake Booster Pump?
A1a: A brake booster pump is a component of the brake system which provides power and controls fluid pressure.

 

 

Q2: Are there any warnings that this condition exists?
A2: No. However, if the condition occurs, multiple warning lights and messages will illuminate, and audible chimes will sound prior to losing power brake assist.

multiple warning lights

NOTE: It is possible for the lights above to be illuminated and the condition not be related to this Safety (Noncompliance) Recall.

 

Q3: If the condition occurs, will the brakes remain operational?
A3: If the condition has occurred, the brakes will remain operational. However, the condition may result in loss of the power braking assist feature and, therefore, more force may need to be applied to the brake pedal to stop the vehicle.

 

Q4: What is Toyota going to do?
A4: Toyota is currently preparing the remedy. When the remedy becomes available, all known owners of the subject vehicles will be notified by first class mail to return their vehicles to an authorized Toyota dealer. Based on the vehicle identification number or an inspection, any authorized Toyota dealer will replace the brake booster pump with a new one, if necessary, FREE OF CHARGE.

 

Q5: How long will the repair take?
A5: The inspection will take approximately one hour. If the brake booster pump needs to be replaced, it will take approximately five additional hours. For vehicles that do not require an inspection, brake booster pump replacement will take approximately six hours. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q6: Which and how many vehicles are covered by this Safety (Noncompliance) Recall?
A6: There are approximately 6,500 vehicles covered by this Safety (Noncompliance) Recall.

Model Name Model Year Production Period
Corolla Hybrid 2020 Late April 2019 –  Late May 2019
RAV4 Hybrid 2019 Late April 2019 – Early June 2019
Prius Prime 2019 – 2020 Late April 2019 – Late May 2019
Prius 2019 Late April 2019 – Late May 2019

 

Q6a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety (Noncompliance) Recall in the U.S.?
A6a: Yes, certain 2019 ES 300 Hybrid, certain 2019 UX 250 Hybrid, certain 2019 LS 500/ LS 500 Hybrid and certain LC 500 vehicles are covered by this Safety (Noncompliance) Recall.

 

Q7: How does Toyota obtain my mailing information?
A7: Toyota uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q8: What if I have additional questions or concerns?
A8: If you have additional questions or concerns, please contact the Toyota Customer Experience Center at 1-888-270-9371 Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 

 


Original Publication Date: July 24, 2019

To: All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers

 

SAFETY (NONCOMPLIANCE) RECALL K0L (Interim Notice K1L)

Certain 2020 Model Year Corolla Hybrid
Certain 2019 Model Year Rav4 Hybrid
Certain 2019 – 2020 Model Year Prius Prime
Certain 2019 Model Year Prius
Potential Loss of Power Brake Assist

 

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2020 Corolla Hybrid April 2019 – May 2019 750 97
2019 Rav4 Hybrid April 2019 – June 2019 3,300 27
2019 – 2020 Prius Prime April 2019 – May 2019 400 131
2019 Prius April 2019 – May 2019 2,050 796

 

Red Stop

STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

Red Stop

 

On July 24 2019, Toyota filed a Noncompliance Information Report (NCIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety (Noncompliance) Recall on certain 2020 model year Corolla Hybrid, certain 2019 Rav4 Hybrid, certain 2019 – 2020 Prius Prime and certain 2019 Prius vehicles.

 

Condition

In the subject vehicles, there is a possibility the brake booster pump may have been manufactured improperly, and in some cases, it may stop operating. If the brake booster pump stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound. In this condition, braking assist could be lost completely after several brake pedal applications, resulting in increased stopping distance.  In addition, the Vehicle Stability Control will become deactivated, and other vehicle features could be affected.  Deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the certain requirements of FMVSS No. 126.  A deactivated Vehicle Stability Control or a sudden and complete loss of braking assist while driving could increase the risk of a crash.

 

Remedy

Toyota is currently preparing the remedy. When the remedy becomes available, based on the vehicle identification number or an inspection, the dealer will replace the brake booster pump with a new one, if necessary, FREE OF CHARGE.

 

Covered Vehicles

There are approximately 6,500 vehicles covered by this Safety (Noncompliance) Recall. Approximately 8 vehicles involved in this Safety (Noncompliance) Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will begin to notify owners via first-class mail by mid-September.

Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety (Noncompliance) Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

Dealer Inventory Procedures

New Vehicles in Dealership Inventory

There are approximately 1,051 vehicles in new dealer inventory as of July 23, 2019.

Red Stop Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety.  Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory:  It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.

Toyota reimburses dealers for flooring costs associated with new vehicles held in dealership inventory until the recall remedy becomes available.  Toyota provides these flooring reimbursements at 60 day intervals.  Toyota reserves the right to withhold or charge-back any flooring reimbursement funds that may have been paid to the dealer if it determines that a new vehicle subject to a safety recall was sold without first being remedied.

Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.

 

NOTE:

  • New vehicles in dealer inventory subject to a Safety Recall must be remedied before delivery into commerce under a sale or lease. Dealer-to-dealer trades as well as vehicle sales between dealers should not be made until a vehicle is remedied.
  • Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Inspection Reminder Mirror Hang Tags for Covered Vehicles in New Dealer Stock

To easily recognize vehicles involved in this Safety (Noncompliance) Recall, each dealership should utilize Inspection Reminder Hang Tags. Inside the vehicle’s glove box are stickers containing the VIN. Apply one of these stickers to the hang tag and install the hang tag in the vehicle. A sample copy of the Inspection Reminder Hang Tag has been included for your reference.

Hold For Inspection

Part Number Description Quantity
00411-140003 Inspection Mirror Hang Tag 25 Per Pack

 

NOTE: Dealerships can order hang tags from the Material Distribution Center (MDC).

 

Pre-Owned Vehicles in Dealer Inventory

Toyota typically requests that dealers NOT deliver any pre-owned vehicles in dealer inventory that are covered by a Safety (Noncompliance) Recall unless the defect has been remedied. In this case, until remedy parts are available, delivery of a pre-owned vehicle is acceptable if disclosed to the customer that the vehicle is involved in this Safety (Noncompliance) Recall and that the remedy is currently being prepared by Toyota.

Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.

Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email, state “Disclosure Form K0L/K1L” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Handling, Parts Ordering, and Remedy Procedures

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety (Noncompliance) Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Customer Experience Center (1-888-270-9371) – Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Tania Saldana (859) 815-9968 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Warranty Reimbursement Procedures

Alternate Transportation Reimbursement Procedure

Until the remedy is available, customers who are uncomfortable driving their vehicle during the interim phase may receive alternative transportation which can be claimed for $35 per day.

 

NOTE:

  • Toyota is currently preparing the rental opcodes and will update this document once they become available.
  • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • Rentals that exceed the maximum allowable daily rate will require DSPM authorization per the Toyota Transportation Assistance Policy (TTAP).

 

Campaign Designation / Phase Decoder

Campaign Designation / Phase Decoder
Examples:

C1B = Launched in 2012, Interim Phase, 2nd   Campaign Launched in 2012

E0A = Launched in 2014, Remedy Phase, 1st  Campaign Launched in 2014

J0A = Launched in 2018, Remedy Phase, 1st  Campaign Launched in 2018.

 

Please review this entire package with your Service and Parts staff to familiarize them with the proper step-bystep procedures required to implement this Safety (Noncompliance) Recall.

 

Thank you for your cooperation.

TOYOTA MOTOR SALES, U.S.A., INC.


SAFETY (NONCOMPLIANCE) RECALL K0L (Interim Notice K1L)

Certain 2020 Model Year Corolla Hybrid
Certain 2019 Model Year RAV4 Hybrid
Certain 2019 – 2020 Model Year Prius Prime
Certain 2019 Model Year Prius
Potential Loss of Power Brake Assist

Frequently Asked Questions
Original Publication Date: July 24, 2019

 

Q1: What is the condition?
A1: In the subject vehicles, there is a possibility the brake booster pump may have been manufactured improperly, and in some cases, it may stop operating. If the brake booster pump stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound. In this condition, braking assist could be lost completely after several brake pedal applications, resulting in increased stopping distance.  In addition, the Vehicle Stability Control will become deactivated, and other vehicle features could be affected.  Deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the certain requirements of FMVSS No. 126.  A deactivated Vehicle Stability Control or a sudden and complete loss of braking assist while driving could increase the risk of a crash.

Q1a: What is the Brake Booster Pump?
A1a: A brake booster pump is a component of the brake system which provides power and controls fluid pressure.

 

 

              

 

 

Q2: Are there any warnings that this condition exists?
A2: No. However, if the condition occurs, multiple warning lights and messages will illuminate, and audible chimes will sound prior to losing power brake assist.

multiple warning lights

NOTE: It is possible for the lights above to be illuminated and the condition not be related to this Customer Support Program.

 

Q3: If the condition occurs, will the brakes remain operational?
A3: If the condition has occurred, the brakes will remain operational. However, the condition may result in loss of the power braking assist feature and, therefore, more force may need to be applied to the brake pedal to stop the vehicle.

 

Q4: What is Toyota going to do?
A4: Toyota is currently preparing the remedy. When the remedy becomes available, all known owners of the subject vehicles will be notified by first class mail to return their vehicles to an authorized Toyota dealer. Based on the vehicle identification number or an inspection, any authorized Toyota dealer will replace the brake booster pump with a new one, if necessary, FREE OF CHARGE.

 

Q5: Which and how many vehicles are covered by this Safety (Noncompliance) Recall?
A5: There are approximately 6,500 vehicles covered by this Safety (Noncompliance) Recall.

Model Name Model Year Production Period
Corolla Hybrid 2020 Late April 2019 –  Late May 2019
RAV4 Hybrid 2019 Late April 2019 – Early June 2019
Prius Prime 2019 – 2020 Late April 2019 – Late May 2019
Prius 2019 Late April 2019 – Late May 2019

 

Q5a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety (Noncompliance) Recall in the U.S.?
A5a: Yes, certain 2019 ES 300 Hybrid, certain 2019 UX 250 Hybrid, certain 2019 LS 500/ LS 500 Hybrid and certain LC 500 vehicles are covered by this Safety (Noncompliance) Recall.

 

Q6: What if I have additional questions or concerns?
A6: If you have additional questions or concerns, please contact the Toyota Customer Experience Center at 1-888-270-9371 Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 

 


July 24, 2019

 

NONCOMPLIANCE INFORMATION REPORT

  

  1. Vehicle Manufacturer Name:

Toyota Motor Corporation, [“TMC”]
1, Toyota-cho, Toyota-city,
Aichi, 471-8571, Japan

Toyota Motor Manufacturing Canada Inc. [“TMMC”]
1717 Dundas Street, Woodstock, Ontario, Canada N4S 0A4

 

Affiliated U.S. Sales Company

Toyota Motor North America, Inc. [“TMNA”]
6565 Headquarters Drive, Plano, TX 75024

 

Manufacturer of the Brake Booster Pump

ADVICS CO., LTD.
4-29, Nitto-cho, Handa-city
Aichi, 475-0033, Japan +81-569-77-7000

 

  1. Identification of Involved Vehicles:

Based on production records, we have determined the involved vehicle population to be the vehicles listed in the table below.

Make/Car Line Model Year Manufacturer Production Period
Toyota / Corolla HV 2020 TMC April 25, 2019 through May 31, 2019
Toyota / Prius 2019 TMC April 26, 2019 through May 31, 2019
Toyota / Prius Prime 2019 – 2020 TMC April 26, 2019 through May 31, 2019
RAV4 HV 2019 TMC & TMMC April 26, 2019 through June 3, 2019
Lexus / ES300h 2019 TMC May 21, 2019
Lexus / LS500 2019 TMC May 15, 2019 through May 31, 2019
Lexus / LS500h 2019 TMC May 17, 2019 through May 27, 2019
Lexus / LC500 2019 TMC May 15, 2019 through June 3, 2019
Lexus / UX250h 2019 TMC May 6, 2019 through May 31, 2019

 

Applicability Part Number Part Name Component Description
Toyota / Corolla HV 47070-47070 Pump Assy, Brake Booster w/ Accumu lator Brake Booster Pump
Toyota / Prius
Toyota / Prius Prime
RAV4 HV 47070-42030
Lexus / ES300h 47070-33050
Lexus / LS500 47070-50050
Lexus / LS500h
Lexus / LC500 47070-11010
Lexus / UX250h 47070-12030

 

Note: (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S.

(2) Only vehicles in the above production range which had a brake booster pump containing a plastic brush holder produced with an improper shape discussed below could be affected.

 

  1. Total Number of Vehicles Involved:

Total: 6,925

 

  1. Percentage of Vehicles Estimated to Actually Contain the Noncompliance:

Based on production records during the specific manufacturing process discussed below, Toyota estimates approximately 25% of the vehicle population may contain a brake booster pump which was manufactured with inappropriate parts.  However, whether the noncompliance is present on each potentially affected vehicle depends on the variation of each individual part.

 

  1. Description of Noncompliance:

The subject vehicles are equipped with a brake booster pump consisting of an accumulator and a pump motor which contains a plastic brush holder to hold the motor brushes.  There is a possibility that the plastic brush holder may have been produced with an improper shape, causing one of the brushes to become stuck in the brush holder.  If this were to occur, the brush would be unable to maintain an electrical connection within the motor and may cause the pump motor to stop operating.  If the pump motor stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound.  In this condition, depending on brake fluid pressure in the accumulator and brake pedal stroke amount, braking assist could be lost completely after several attempts to apply the brake pedal.  In addition, the Vehicle Stability Control system will become deactivated, and other vehicle features could be affected.  A sudden and complete loss of braking assist while driving could increase the vehicle stopping distance and may increase the risk of a crash.  Further, deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the requirements of FMVSS No. 126, paragraph S5.1.2, which could increase the risk of a crash.

 

  1. Test Results and Other Information:

In late May 2019, warning lights were found illuminated on certain vehicles during a final inspection process for braking and/or while driving from the final inspection line to the vehicle yard at certain Toyota manufacturing plants.  Toyota inspected these vehicles and found Diagnostic Trouble Codes related to the brake booster pump.  Toyota and the supplier investigated the recovered brake booster pumps.  The brush holder within the pump motor was found to be out-of-specification.  The supplier found that a component of the upper mold of the die at one of two molding facilities used to produce brush holders was replaced on April 11, 2019, creating this condition.  If the brush holder is out-of-specification, the Vehicle Stability

Control system may become deactivated.  (In addition, the Regenerative Brake, Antilock

Brake, Electronic Brake force Distribution, Traction Control, Brake Assist, Brake Hold, PreCrash Brake, Adaptive Cruise Control, Intuitive Parking Assist, Intelligent Clearance Sonar, Emergency Stop Signal and Active Cornering Assist system will also become deactivated for certain vehicles, and for some vehicle models, the Electrical Parking Brake system function will also be limited.)  As a result, it was determined on July 18, 2019, that some vehicles may not meet the requirement of S5.1.2 of FMVSS 126.

 

  1. Description of Corrective Repair Action:

All known owners of the subject vehicles will be notified by first class mail to return their vehicles to a Toyota or a Lexus dealer.  For all involved vehicles, based on the vehicle identification number or an inspection, the dealer will replace the brake booster pump, if necessary, with a new one at no cost.

 

Reimbursement Plan for pre-notification remedies

As the owner notification letters will be mailed out well within the active period of the Toyota/Lexus New Vehicle Limited Warranty, all involved vehicle owners for this recall would have been provided a repair at no cost under Toyota’s or Lexus’s Warranty.

 

  1. Recall Schedule:

Notifications to owners of the affected vehicles will occur by September 22, 2019.  A copy of the draft owner notification letter(s) will be submitted as soon as available.

 

  1. Distributor/Dealer Notification Schedule:

Notifications to distributors/dealers will be sent on July 24, 2019.  Copies of dealer communications will be submitted as they are issued.

 

  1. Manufacturer’s Campaign Number:

Toyota’s Campaign Number: [Interim / Remedy] K1L / K0L
Lexus’ Campaign Number: [Interim / Remedy] K2F / KLF

 



10 Affected Products

Vehicles

MAKE MODEL YEAR
LEXUS ES300H 2019
LEXUS LC500 2019
LEXUS LS500 2019
LEXUS LS500 H 2019
LEXUS UX250 HYBRID 2019
TOYOTA COROLLA HYBRID 2020
TOYOTA PRIUS 2019
TOYOTA PRIUS PRIME 2019-2020
TOYOTA RAV4 HYBRID 2019

 


27 Associated Documents

ISSUED Owner Notification Letter(Part 577)- Lexus

RCONL-19V544-7901.pdf 188.449KB

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Recall Quarterly Report #2, 2019-4

RCLQRT-19V544-7617.PDF 211.278KB

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Remedy Instructions and TSB

RCRIT-19V544-1499.pdf 1047.748KB

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Remedy Instructions and TSB

RCRIT-19V544-9234.pdf 1047.748KB

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ISSUED Owner Notification Letter(Part 577)- RAV4 Hybrid

RCONL-19V544-8610.pdf 98.662KB

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Remedy Instructions and TSB

RCRIT-19V544-5341.pdf 1921.267KB

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ISSUED Interim Owner Notification Letter(Part 577)- Lexus UX250h

RIONL-19V544-0431.pdf 85.824KB

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Remedy Instructions and TSB

RCRIT-19V544-9054.pdf 983.047KB

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Remedy Instructions and TSB

RCRIT-19V544-4098.pdf 1984.79KB

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ISSUED Owner Notification Letter(Part 577)- Lexus

RCONL-19V544-3942.pdf 189.041KB

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ISSUED Owner Notification Letter(Part 577)- Corolla, Prius, Prius Prime

RCONL-19V544-2558.pdf 97.724KB

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Recall Quarterly Report #3, 2020-1

RCLQRT-19V544-7002.PDF 211.367KB

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Manufacturer Notices(to Dealers,etc) – SAFETY (NONCOMPLIANCE) RECALL K0L (Remedy Notice) dated 9-19-19

RCMN-19V544-2564.pdf 987.041KB

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Manufacturer Notices(to Dealers,etc) – Safety (Noncompliance) Recall dated 9-19-19

RCMN-19V544-8257.pdf 1275.191KB

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Manufacturer Notices(to Dealers,etc) – Dealer Notification Letter re Remedy now available for Certain 2019 Model Year UX 250h vehicles dated 10-18-19.

RCMN-19V544-4053.pdf 1348.327KB

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Remedy Instructions and TSB

RCRIT-19V544-3621.pdf 1659.185KB

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Recall Quarterly Report #1, 2019-3

RCLQRT-19V544-1719.PDF 211.168KB

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Recall Acknowledgement

RCAK-19V544-5898.pdf 298.421KB

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Miscellaneous Document – July 24, 2019 NONCOMPLIANCE INFORMATION REPORT

RMISC-19V544-8456.pdf 158.35KB

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Non-Compliance Notice 573 Report

RCLRPT-19V544-1026.PDF 220.524KB

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Manufacturer Notices(to Dealers,etc) – SAFETY (NONCOMPLIANCE) RECALL K0L (Interim Notice K1L)

RCMN-19V544-9206.pdf 465.54KB

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Manufacturer Notices(to Dealers,etc) – Lexus – SAFETY (NONCOMPLIANCE) RECALL KLF (Interim Notice K2F)

RCMN-19V544-4059.pdf 683.562KB

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ISSUED Interim Owner Notification Letter(Part 577)- Lexus UX 250h

RIONL-19V544-6015.pdf 84.462KB

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ISSUED Owner Notification Letter(Part 577)- Corolla H, Prius, Prius Prime

RCONL-19V544-8720.pdf 80.411KB

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ISSUED Owner Notification Letter(Part 577)- Lexus

RCONL-19V544-2954.pdf 85.471KB

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ISSUED Owner Notification Letter(Part 577)- Rav4 Hybrid

RCONL-19V544-4869.pdf 79.91KB

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Recall Quarterly Report #1, 2019-3

RCLQRT-19V544-7604.PDF 211.172KB

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Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V544&docType=RCL

 


 

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