SAFETY RECALL J0A/J0B/J0C – Front Passenger Airbag Inflator Module – 2007-2012 Toyota Yaris Sedan & 2007-2011 Hatchback

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TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL J0A/J0B/J0C
FRONT PASSENGER AIRBAG INFLATOR MODULE
CERTAIN 2007 – 2012 MY YARIS SEDAN AND
2007 – 2011 MY YARIS HATCHBACK
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 recall repair are required to have successfully completed E-Learning course SC18A (if you had previously completed E-Learning Course SC13B, you do not have to take SC18A), in addition to “Safety Recall and Service Campaign Essentials”, and currently hold at least one of the following certifications levels:
• Toyota Certified (Electrical)
• Toyota Expert (Any Specialty)
• Master
• Master Diagnostic Technicians
Always check which technicians can perform the recall remedy 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.
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I. OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps as outlined in the full technical instructions to confirm the campaign is completed correctly.
Verify Vehicle Eligibility1. Check the TIS Vehicle Inquiry System.No further action required.Not CoveredCampaign complete, return the vehicle to the customer.CoveredInstall the new passenger airbag assembly.Record the airbag serial numbers as instructed in the TIRemove the passenger airbag assembly.
II. BACKGROUND
The subject vehicles are equipped with front passenger airbag inflators produced by Takata. According to Takata, the propellant in these inflators may degrade after prolonged exposure to high absolute humidity and fluctuating high temperatures. Degraded propellant can cause inflator rupture during airbag deployment. In the event of an inflator rupture, metal fragments could pass through the airbag cushion material, striking the vehicle occupants, and result in serious injury or death.
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III. IDENTIFICATION OF AFFECTED VEHICLES
• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the campaign 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.
IV. PREPARATION
A. PARTS
Model
Part Number
Part Description
Quantity
Yaris Hatchback
04005-23752
Instrument Panel Airbag Module
1
04005-28352
Wire Harness
1
Local source
Tie-wrap
2
Model
Part Number
Part Description
Quantity
Yaris Sedan
04006-39252
Instrument Panel Airbag Module
1
04005-28352
Wire Harness
1
Local source
Tie-wrap
2
A. TOOLS & EQUIPMENT
• Standard hand tools
• Torque wrench
• Techstream
• Molding remover set
OPTIONAL SST – This is an essential special service tool that the dealership should have. This tool is not mandatory when performing this repair.
Part Number
Part Name
Quantity
09890-47010-01
Anti-Static Mat Set
1
G0P CAMPAIGN TOOLS – These tools where previously provided to the dealership for campaign D0F and will be used for campaign G0P. These tools are required when performing this repair.
Image
Name
Quantity
Barcode Scanner
1
NOTE: These tools CANNOT be ordered through the parts or tools system. There is a very limited supply of tools, but if additional tools are needed, contact your regional representative.
Non-Desiccated Part Recovery
Dealers should discontinue the installation of the non-desiccated parts listed below for recall, customer pay repairs AND over-the-counter sales (if applicable).
Model
Model Year
Part Number
Part Description
Yaris HB
2006-2011
73960-52030
AIR BAG ASSY,
INSTR PNL PASS L/DOOR
Yaris Sedan
2007-2012
73960-52080
Toyota requires all dealers to return any parts listed above that still remain in dealer inventory by utilizing the Hazmat Part Return Program available. Dealers will be issued a refund for all part returns. This part return program is outlined in PANT Bulletin 2014-042.
Important Note:
In order to return the inflator, packages must NOT be opened/tampered with.
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V. SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY
Failure to follow these procedures correctly could cause the SRS to unexpectedly deploy during servicing or the SRS may fail to operate correctly when required after reassembly. Confirm all work is performed as described in these instructions.
1. ELIMINATE STATIC ELECTRICITY
a) Before starting work and periodically while working on the vehicle, touch a metallic part of the vehicle to discharge static electricity in the body.
2. DO NOT MEASURE RESISTANCE
a) DO NOT measure resistance of airbag components, this may cause accidental activation.
3. HANDLE THE AIRBAG CAREFULLY
a) If an inflator is dropped, replace it with a NEW inflator.
4. WEAR PROTECTIVE EQUIPMENT
a) Always wear appropriate protective equipment when working on the SRS.
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VI. SRS SYSTEM HEALTH CHECK
1. PERFORM A HEALTH CHECK
a) Confirm the Techstream is connected to the dealership’s internet.
b) When launching the Techstream software the VIN may need to be entered manually.
NOTE: All letters of the VIN MUST be entered in ALL CAPS, or the VIN will need to be reentered when running the diagnostic report.
c) Perform a health check.
Note: The VIN may auto populate on the later model year vehicles, if this happens DO NOT change the VIN.
2. RUN A DIAGNOSTIC REPORT
a) After the health check has completed, run a diagnostic report by clicking on the link on the health check screen.
NOTE: If the VIN was not entered in ALL CAPS when Techstream was launched, an error will be displayed and there will be a prompt to reenter the VIN
b) Enter the vehicle mileage and repair order information, then click the ‘report’ button.
• The VIN MAY NEED to be entered manually in ALL CAPS when launching the Techstream software. The VIN MAY NOT auto-populate on vehicles prior to the 2006 MY.
• A health check and diagnostic report with VIN MUST be performed within the last 36 hours and recorded by TMS. If the diagnostic report is not run, the healthcheck will not be recognized by TMS.
• The serial number recording application will be disabled and the repair cannot be completed if a health check and diagnostic report is not performed and recorded by TMS.
• This campaign only covers the replacement of the passenger airbag module. NO other SRS components are covered under this campaign.
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VII. PASSENGER AIRBAG MODULE REPLACEMENT
COMPONENTS
Hatchback
Sedan
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1. REMOVE THE AIRBAG MODULE
a) Refer to TIS for instructions on airbag removal:
Sedan
2007MY
2008MY
2009MY
2010MY
2011MY
2012MY
Hatchback
2007MY
2008MY
2009MY
2010MY
2011MY
• Wait at least 90 seconds after disconnecting the cable from the negative battery terminal to prevent airbag and seat belt pre-tensioner deployment.
• Follow all precautions as outlined on TIS before servicing the SRS system.
2. LAUNCH THE SERIAL NUMBER RECORDING APPLICATION
• The AIRBAG MODULE serial number MUST be recorded using the barcode scanner (provided at the launch of SSC D0F).
• The barcode scanner application MUST be completed on every vehicle. These numbers MUST be included on every warranty claim that is submitted for module replacement or the claim may be subject to debit.
• The technician performing the work MUST have valid TIS login credentials and an internet connection to perform the inspection and scanning process.
a) Log in to TIS and input the VIN of the vehicle in the Vehicle Inquiry tab.
b) Confirm the VIN is applicable and that the campaign has not been completed.
c) Click on the link to launch the serial number recording application.
Note: The Serial Number Recording Application is the same as the DSF/E04 application, so the screens will still indicate campaign DSF or E04.
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d) Reenter TIS password in the serial number recorder application.
NOTE: The person logged-in to TIS MUST be the person performing the repair.
e) Record the vehicle mileage into the serial number recording application.
NOTE:
• If this screen indicates that the module has already been replaced on this VIN, there is no need to perform the campaign again.
3. CONNECT THE BARCODE SCANNER
a) Connect the barcode scanner to the USB port on the Techstream.
b) The scanner will automatically connect and a beep will be heard when the scanner is ready.
NOTE:
• The scanner was provided for SSC D0F.
• The scanner works best in low light conditions.
• Always hold the scanner directly in front of and parallel to the barcode label.
E04
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4. SCAN THE AIRBAG SERIAL NUMBER
ATTENTION: This information is CRITICAL
a) Scan the AIRBAG ASSEMBLY serial number 2 times.
1) Confirm the cursor is in the first serial number box then scan the serial.
2) Position the cursor in the second serial number box then scan the serial.
b) Click next.
NOTE:
• If both serial numbers that are entered do not match, confirm and reenter.
• If the serial number barcode will not scan, it can be entered manually.
AIRBAG SERIAL NUMBER IDENTIFICATION
• The airbag serial number is ALWAYS the 12 DIGITS located between the asterisks.
• The 3 digits before the asterisk ARE NOT part of the serial number, and SHOULD NOT be entered or an inaccurate response may be returned.
Airbag Serial Number Label Example
The AIRBAG serial number MUST be recorded prior to replacement.
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c) Check the box as shown below this will allow the scanning system to move to the next screen.
d) Click submit.
Checking this box will allow you to scan the replacement airbag on the next screen.
NOTE: The NEW AIRBAG serial number MUST be scanned prior to reinstallation to track the airbag to the vehicle (refer to page 11).
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e) Scan the NEW airbag barcode in the Serial Number Recording Application.
f) Verify the statements and click the two boxes.
g) Click next.
h) Confirm agreement by checking the two boxes.
i) Record the Warranty Authorization # to be included in the warranty claim.
j) Place the old module in the parts box and take it immediately to the parts department.
NOTE:
• Confirm the cursor is in the correct serial number input box before scanning.
• If the serial number barcode will not scan, it can be entered manually.
• If there are any difficulties or concerns with this process, email quality_compliance@toyota.com with details.
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AIRBAG SERIAL NUMBER IS MISSING OR IS UNREADABLE
If the airbag serial number and barcode are not legible or are not present, check the box in the application indicating the serial number is not legible.
a) If the airbag serial number cannot be scanned or is not present check the box as shown below.
Checking this box requires Air Bag replacement.
b) Go to Page 10 to continue airbag scanning.
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VIII. FRONT PASSENGER AIRBAG REINSTALLATION
1. REINSTALL THE AIRBAG
a) Install the new harness onto the new airbag by plugging in the two connectors.
NOTE: Match the color of the harness connector to that of the airbag. Ensure that the connectors are fully seated.
b) Engage the secondary locks.
NOTE: Ensure the secondary locks are fully engaged.
LOCKED
UNLOCKED
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c) Refer to TIS for instructions on airbag installation:
Sedan
2007MY
2008MY
2009MY
2010MY
2011MY
2012MY
Hatchback
2007MY
2008MY
2009MY
2010MY
2011MY
After the upper instrument panel has been installed secure the new airbag adaptor harness as shown.
Secure the adaptor harness to the dash harness.
Also secure the adaptor harness to the dash bracket.
NOTE: The upper instrument panel has been removed for clarity. Both areas can be accessed through the opening for the glove box door and/or the opening for the combination meter.
Check that the adaptor harness has the proper clearances and is not strained.
2. RECONNECT THE NEGATIVE BATTERY CABLE
a) Reconnect the negative battery cable.
b) Perform any needed system intialzations.
3. PERFORM A HEALTH CHECK AND DIAGNOSTIC REPORT
◄ VERIFY REPAIR QUALITY ►
− Confirm all precautions are follow to ensure safety during the repair
− Confirm the entire serial number checker application is completed and the warranty authorization # is recorded on EVERY vehicle
− Confirm the old module is handled safely and given to the appropriate parts professional for shipment
− Confirm the airbag harness connector is fully engaged.
If you have any questions regarding this update, please contact your regional representative.
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IX APPENDIX
A. CAMPAIGN DESIGNATION DECODER
C0TYear Campaign is Launched8 = 20089 = 2009A = 2010B = 2011C = 2012 D = 2013E = 2014F = 2015Etc…Repair Phase1st Campaign = A2nd Campaign = BEtc…Current Campaign Letter for this year 0 = Remedy1 = Prelim/Interim 2 = Prelim/Interim for Phase 2 Vehicles(Remedy not yet available) “1 or 2” will change to “0” when the Remedy is available
B. CAMPAIGN PARTS DISPOSAL
ALL inflators that are removed from vehicles under this campaign MUST be packaged and shipped back to the inflator manufacturer following the manufacturer’s instructions. The instructions can be found in the following locations:
• Attached to the dealer letter
• Included in the parts box
• On the laminated aid that was provided at the launch of the campaign

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