RECALL K0M – Passenger Front and Knee Airbags May Not Deploy as Designed – 2019 Toyota Camry

August 1, 2019 NHTSA CAMPAIGN NUMBER: 19V567000

Improperly Calibrated OCS

In the event of a crash, if the air bags do not deploy as designed, the front seat passenger has an increased risk of an injury.

 

NHTSA Campaign Number: 19V567

Manufacturer Toyota Motor Engineering & Manufacturing

Components AIR BAGS

Potential Number of Units Affected 680

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2019 Camry vehicles. The Occupant Classification System (OCS) may have been improperly calibrated, which may prevent the proper deployment of the front passenger air bag and knee air bag, in the event of a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 208, “Occupant Crash Protection.”

 

Remedy

Toyota will notify owners, and dealers will recalibrate the OCS, free of charge. The recall began August 27, 2019. Owners may contact Toyota customer service at 1-888-270-9371. Toyota’s number for this recall is K0M.

 

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

 

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Original Publication Date: August 01, 2019

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

SAFETY (NONCOMPLIANCE) RECALL K0M (Remedy Notice)

Certain 2019 Model Year Camry Vehicles
Passenger Front and Knee Airbags May Not Deploy as Designed

 

Model / Years	Production Period	Approximate Total Vehicles	Approximate Stop Sale Dealer Inventory
2019 Camry	Late August 2018 – Late November 2018	700	30

 

On August 01, 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 2019 model year Camry vehicles.

 

Condition

In the subject vehicles, the deployment strategy of the front passenger airbags is determined in part by using inputs from the occupant classification system in the front passenger seat. Because of a calibration error in the occupant classification system, the front passenger airbag and knee airbag may not deploy as designed under certain conditions in a crash. This can increase the risk of an injury to a front seat passenger.  In addition, the condition can lead to a noncompliance with certain parts of Federal Motor Vehicle Safety Standard (FMVSS) No. 208 “Occupant Crash Protection.”

 

Remedy

Any authorized Toyota dealer will recalibrate the occupant classification system FREE OF CHARGE.

 

Covered Vehicles

There are approximately 700 vehicles covered by this Safety (Noncompliance) Recall. There are no vehicles were distributed to Puerto Rico involved in this Safety (Noncompliance) Recall.

 

Owner Letter Mailing Date

Toyota will notify owners by mid – August 2019.

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 30 vehicles in new dealer inventory as of July 31, 2019.

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.

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 (Noncompliance) Recall on any used vehicles currently in dealer inventory that are covered by this Safety (Noncompliance) 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 K0M” 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.

 

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 (any specialty)
• Expert Technician (any specialty)
• 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.

 

Warranty Reimbursement Procedures

Warranty Reimbursement Procedure

 

Op Code	Description	Flat Rate Hours
K0M001	Perform OCS Zero Point Calibration	0.4 hrs/vehicle

 

• The flat rate times include 0.1 hours for administrative cost per unit for the dealership.

 

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

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.

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SAFETY (NONCOMPLIANCE) RECALL K0M (Remedy Notice)

Certain 2019 Model Year Camry Vehicles
Passenger Front and Knee Airbags May Not Deploy as Designed

Frequently Asked Questions
Original Publication Date: August 1, 2019

Q1:	What is the condition?
A1:	In the subject vehicles, the deployment strategy of the front passenger airbags is determined in part by using inputs from the occupant classification system in the front passenger seat. Because of a calibration error in the occupant classification system, the front passenger airbag and knee airbag may not deploy as designed under certain conditions in a crash. This can increase the risk of an injury to a front seat passenger.  In addition, the condition can lead to a noncompliance with certain parts of Federal Motor Vehicle Safety Standard (FMVSS) No. 208 “Occupant Crash Protection.”
Q2:	Are there any symptoms/warning before the condition appears in the vehicle?
A2:	Under this condition, if an adult size person is seated in the passenger seat, the “AIRBAG OFF” light may illuminate. Please refer to Page 47 of the owner’s manual for an image of the “AIRBAG OFF” light.
Q3:	What is Toyota going to do?
A3:	Any authorized Toyota dealer will recalibrate the occupant classification system FREE OF CHARGE.
Q4:	Which and how many vehicles are covered by this Safety (Noncompliance) Recall?
A4:	There are approximately 700 vehicles covered by this Safety (Noncompliance) Recall. Model Name Model Year Production Period Camry 2019 Late August 2018 – Late November 2018   Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety (Noncompliance) Recall in the U.S.? A4a: No, there are no other Lexus/Toyota/Scion vehicles covered by this Safety (Noncompliance) Recall.
Q5:	How long will the repair take?
A5:	The repair takes approximately forty-five minutes. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.
Q6:	How does Toyota obtain my mailing information?
A6:	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.
Q7:	What if I have additional questions or concerns?
A7:	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.

 

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TECHNICAL INSTRUCTIONS

FOR

SAFETY (NONCOMPLIANCE) RECALL K0M

PASSENGER SIDE FRONT AND KNEE AIRBAGS MAY NOT DEPLOY AS DESIGNED

CERTAIN 2019 MODEL CAMRY

 

 

The repair quality of covered vehicles is extremely important to Toyota.   All dealership technicians performing this recall 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 (any specialty)
• Expert Technician (any specialty)
• Master Technician
• Master Diagnostic Technician 

It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall 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.

 

 

I. OPERATION FLOW CHART

 

II. IDENTIFICATION OF AFFECTED VEHICLES

A. AFFECTED VIN RANGE

NOTE:

• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety (Noncompliance) Recall, and that the recall has not already been completed prior to dealer shipment or by another dealer.
• TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer.

 

III. PREPARATION

A. PARTS

There are no parts required for this Safety (Noncompliance) Recall.

 

B. TOOLS AND EQUIPMENT

• Techstream 2.0/ TIS Techstream / Techstream Lite (Software 14.1 or Higher)

 

IV. WORK PROCEDURE TABLE OF CONTENTS

PERFORM OCCUPANT CLASSIFICATION ZERO POINT CALIBRATION –  SECTION VI.

APPENDIX –  SECTION VlI.

 

V. BACKGROUND

In the subject vehicles, the deployment strategy of the front passenger airbags is determined in part by using inputs from the occupant classification system in the front passenger seat. Because of a calibration error in the occupant classification system, the front passenger airbag and knee airbag may not deploy as designed under certain conditions in a crash. This can increase the risk of an injury to a front seat passenger.  In addition, the condition can lead to a noncompliance with certain parts of Federal Motor Vehicle Safety Standard (FMVSS) No. 208 “Occupant Crash Protection.”

 

VI. PERFORM OCCUPANT CLASSIFICATION ZERO POINT CALIBRATION

1. CONFIRM THE FOLLOWING

1. The vehicle is parked on a level surface.
2. There are no objects on the front passenger seat.
3. Ensure there is nothing underneath the front passenger seat.

 

2. PREPARE THE PASSENGER SEAT

1. Slide the seat fully rearmost.
2. Adjust the seat back to the upright position.
3. Slide the headrest to its lowest position.
4. Seat height placed in its lowest position. (if equipped)
5. Seat cushion (front) angle to its lowest position. (if equipped)

 

The passenger seat must be in the correct position to correctly recalibrate the OCS system.

 

3. OCCUPANT CLASSIFICATION ZERO POINT CALIBRATION

1. Connect the Techstream to the vehicle.
2. Turn the IG to ON.
3. Start the Techstream.
4. Click on “Connect to Vehicle”.
5. Select the vehicle specifications.

 

6. Select the “Occupant Detection”.

 

7. Select the “Utility”.

 

8. Select the “Zero Point Calibration”.

 

9. Follow the on-screen instructions and then click on “Next”.

• DO NOT turn the IG on with the brake pedal depressed. Otherwise the engine starts.
• Ensure that the seat is in the correct position and empty.
• DO NOT produce vibrations and shocks by motions such as door and hood opening/closing or getting on/off the vehicle during calibration.

 

10. Click on the “Exit”.

 

11. Turn Techstream off, and then IG to the OFF position.

 

4. RETURN PASSENGER SEAT TO ORIGINAL POSITION

 

 

 

◄ VERIFY REPAIR QUALITY ► Confirm that the seat was in the correct position for calibration Confirm that the Zero Point Calibration was performed If you have any questions regarding this Safety (Noncompliance) Recall, please contact your regional representative.

 

VII. APPENDIX

A. CAMPAIGN DESIGNATION DECODER

 

B. CAMPAIGN PARTS DISPOSAL

As required by Federal Regulations, please make sure all campaign 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.

 

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August 1, 2019

 

NONCOMPLIANCE INFORMATION REPORT

  

1. Vehicle Manufacturer Name:

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

 

Affiliated U.S. Sales Company

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

 

2. 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 / Camry	2019	TMC	August 24, 2018 through November 29, 2018

 

Applicability	Part Number	Part Name	Component Description
Toyota / Camry	89952-12030	Computer, Occupant Detection	OCS Electronic Control Unit

 

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 that had the improper calibration procedure, described further below, performed on a specific line at this vehicle assembly plant during a specific manufacturing period are known to be potentially affected.

 

3. Total Number of Vehicles Involved:

Total      : 680

 

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

Unknown.  Toyota is unable to provide an estimate of the percentage of the vehicles to actually contain the noncompliance.  Whether the condition will occur will depend on variances that may occur in the calibration procedure and the OCS sensor.

 

5. Description of Noncompliance:

The front passenger seat of the subject vehicles is equipped with an occupant classification system (OCS) which provides input to the Supplemental Restraint System to determine the deployment strategy of the front passenger airbag and the front passenger knee airbag, depending on the weight and the posture of the seat occupant.  The OCS may not have been calibrated properly on the particular production line at the facility producing the subject vehicles.  If an OCS system is not calibrated properly, some portions of the requirements of FMVSS No. 208, paragraphs S14.5.2, S15.1(b), S15.2, S17, S19.2.1, S21.2.1 and S23.2.1 may not be met.  Under some conditions, the front passenger airbag and knee airbag may not deploy as designed in a crash, increasing the risk of an injury to a front seat passenger.

 

6. Test Results and Other Information:

In late June 2019, Toyota found, during the Quality Inspection process at a specific vehicle assembly plant, that the OCS zero point on a 2019 Camry was not properly set.  An investigation identified that vehicles produced on this specific line producing Camry vehicles at this vehicle assembly plant possibly had an improper zero point calibration procedure performed due to an unrelated process change that took place on August 20, 2018.  Toyota analyzed the potential deviation of the zero point between the correct and incorrect calibration procedures and analyzed the impact that this deviation would have on the airbag system.  Based on result of this analysis, on July 26, 2019, it was determined that there is a possibility that the front passenger airbag and knee airbag may not be activated correctly when a passenger is in the seat such that affected vehicles may not meet some portions of the requirements of FMVSS No. 208, paragraphs S14.5.2, S15.1(b), S15.2, S17, S19.2.1, S21.2.1, and S.23.2.1.

 

7. Description of Corrective Repair Action:

All known owners of the subject vehicles will be notified to return their vehicles to a Toyota dealer for re-calibration of the occupant classification system.

 

Reimbursement Plan for pre-notification remedies

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

 

8. Recall Schedule:

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

 

9. Distributor/Dealer Notification Schedule:

Notification to distributors/dealers will be sent on August 1, 2019.  Copies of the dealer communications will be submitted as they are issued.

 

10. Manufacturer’s Campaign Number:

K0M

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
TOYOTA	CAMRY	2019

 

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10 Associated Documents

Recall Quarterly Report #2, 2019-4

nhtsa.gov/odi/rcl/2019/RCLQRT-19V567-5683.PDF" target="_BLANK" rel="noopener no referrer noreferrer">RCLQRT-19V567-5683.PDF 211.236KB

 

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Recall Quarterly Report #3, 2020-1

RCLQRT-19V567-6888.PDF 211.322KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V567-2047.pdf 61.907KB

 

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Recall Acknowledgement

RCAK-19V567-6140.pdf 268.247KB

 

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Remedy Instructions and TSB

RCRIT-19V567-7387.pdf 326.613KB

 

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Miscellaneous Document – August 1, 2019 NONCOMPLIANCE INFORMATION REPORT

RMISC-19V567-4373.pdf 25.122KB

 

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Manufacturer Notices(to Dealers,etc) – SAFETY (NONCOMPLIANCE) RECALL K0M (Remedy Notice)

RCMN-19V567-5767.pdf 153.159KB

 

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Non-Compliance Notice 573 Report

RCLRPT-19V567-5798.PDF 214.201KB

 

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Miscellaneous Document – Head Unit Message

RMISC-19V567-7097.pdf 51.686KB

 

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Recall Quarterly Report #1, 2019-3

RCLQRT-19V567-0052.PDF 211.132KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V567&docType=RCL

 

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