SAFETY (NONCOMPLIANCE) RECALL 20TA15 – Headlamp Beam Could be Improperly Adjusted Horizontally – 2021 Toyota RAV4 Prime

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November 12, 2020 NHTSA CAMPAIGN NUMBER: 20V698000

Headlights Can Be Misadjusted/FMVSS 108

Adjusting the horizontal headlight beam can increase glare, reducing the visibility of an oncoming driver or the vehicle operator, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V698

Manufacturer ToyotaeBay Motor Engineering & Manufacturing

Components EXTERIOR LIGHTING

Potential Number of Units Affected 413

 

Summary

ToyotaeBay Motor Engineering & Manufacturing (ToyotaeBay) is recalling certain 2021 RAV4 Prime vehicles. The headlight aiming caps may have been improperly closed, allowing for horizontal adjustment of the headlight beam. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, “Lamps, Reflective Devices, and Associated Equipment.”

 

Remedy

ToyotaeBay will notify owners, and dealers will close the aiming caps on the headlights, free of charge. The recall began January 6, 2021. Owners may contact ToyotaeBay customer service at 1-800-331-4331. ToyotaeBay’s number for this recall is 20TA15.

 

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

 


 

On November 12, 2020, 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 2021 model year RAV4 Prime vehicles.

 

Condition

The subject vehicle headlamps may improperly permit horizontal beam adjustment. Therefore, the headlamps do not meet a certain safety requirement and certain adjustments could reduce visibility for the driver or the driver of an oncoming vehicle, increasing the risk of a crash.

 

Remedy

Any authorized ToyotaeBay dealer will close the aiming caps on the headlamps to prevent horizontal adjustment of the headlamp beam FREE OF CHARGE.

 

Covered Vehicles

There are approximately 400 vehicles covered by this Safety (Noncompliance) Recall. There are no vehicles covered by this Safety (Noncompliance) Recall that were distributed to Puerto Rico.

 

Owner Letter Mailing Date

ToyotaeBay will notify owners by mid-January 2021.

ToyotaeBay 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.

 

 


 

Frequently Asked Questions
Original Publication Date: November 12, 2020

 

Q1: What is the condition?

The subject vehicle headlamps may improperly permit horizontal beam adjustment. Therefore, the headlamps do not meet a certain safety requirement and certain adjustments could reduce visibility for the driver or the driver of an oncoming vehicle, increasing the risk of a crash.

 

Q2: What is ToyotaeBay going to do?

ToyotaeBay will send, by mid-January 2021, an owner notification by first class mail advising owners to make an appointment with their authorized ToyotaeBay dealer to close the aiming caps on the headlamps to prevent horizontal adjustment of the headlamp beam FREE OF CHARGE.

 

Q3: Which and how many vehicles are covered by this Safety (Noncompliance) Recall?

There are approximately 400 vehicles covered by this Safety (Noncompliance) Recall.

Model NameModel YearProduction Period
RAV4 Prime*2021mid-June 2020 – mid-October 2020

 

*Equipped with Adaptive Front Lighting System (AFS) which is an option on certain grades.

 

Q3a: Are there any other Lexus/ToyotaeBay/ScioneBay vehicles covered by this Safety (Noncompliance) Recall in the U.S.?

No, there are no other Lexus/ToyotaeBay/ScioneBay vehicles covered by this Safety (Noncompliance) Recall.

 

Q4: How long will the repair take?

The repair takes approximately 45 minutes. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q5: How does ToyotaeBay obtain my mailing information?

ToyotaeBay 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.

 

Q6: What if I have additional questions or concerns?

If you have additional questions or concerns, please contact the ToyotaeBay Brand Engagement 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.

 


TECHNICAL INSTRUCTIONS

FOR

SAFETY RECALL 20TA15

HEADLAMP BEAM COULD BE IMPROPERLY ADJUSTED HORIZONTALLY

CERTAIN 2021 RAV4 PRIME

 

The repair quality of covered vehicles is extremely important to ToyotaeBay.  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 currently hold at least one of the following certification levels: 

  • Certified (any specialty)
  • Expert (any specialty)
  • Master
  • 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

Warranty Reimbursement Procedure

 

II. IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY

a. Compare the vehicles VIN to the VIN listed on the Repair Order to ensure they match.

b. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and that it has not already been completed.

Note: TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were previously completed, even by another dealer.

 

III. PREPARATION

1. PARTS

No parts will be required.

2. TOOLS & EQUIPMENT

No tools will be required.

 

IV. BACKGROUND

The subject vehicle headlamps may improperly permit horizontal beam adjustment. Therefore, the headlamps do not meet a certain safety requirement and certain adjustments could reduce visibility for the driver or the driver of an oncoming vehicle, increasing the risk of a crash.

 

V. CLOSE HEADLIGHT AIMING CAP COVERS

1. RELEASE AND OPEN HOOD

2. LOCATE THE HEADLIGHT AIMING CAPS LH & RH

a. Locate the headlight aiming cap on the top inside of the LH & RH Headlight Assembly as shown.

3. CLOSE THE HEADLIGHT AIMING CAP COVERS LH & RH

a. Fold the headlight aiming cap covers (LH & RH) 90 degrees to engage the two locking tabs on each cover.

4. CLOSE HOOD AND CONFIRM SECURED AND LATCHED.

 

◄ VERIFY REPAIR QUALITY ►

  • Confirm that BOTH headlight aiming caps are locked in place as indicated.

If you have any questions regarding this update, please contact your regional representative.

 

VI. APPENDIX

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.

B. CAMPAIGN DESIGNATION DECORDER

Campaign Designation / Phase Decoder

 


 

Description of Noncompliance:

The subject vehicles are equipped with headlamps that contain aiming caps which are closed during vehicle assembly to prevent horizontal adjustment of the headlamp beam.  Due to an incorrect work instruction, the caps on the subject vehicles’ headlamps may not have been closed appropriately.  In this condition, the subject vehicles may not meet certain requirements in FMVSS No. 108, paragraph S10.18.4 because the vehicle operator could potentially adjust the horizontal alignment of the headlamps by turning a gear in an open aiming cap with a screwdriver.  Certain adjustments could increase the glare (reduce the visibility) for an oncoming driver, or reduce the visibility for the vehicle operator, increasing the risk of a crash.

 

Test Results and Other Information:

In Mid-October 2020, a team member discovered a discrepancy between the design drawing and the standardized work instruction for headlamps of a certain design being installed on certain RAV4 vehicles.  It was determined that the standardized work instructions did not contain any instruction to close the aiming caps for these headlamps.   ToyotaeBay conducted a containment activity, which identified a vehicle where the aiming caps had not been closed.  Based on a review of production records, it was determined that some vehicles produced using the incorrect work instruction were not contained.  Based on the information collected in this investigation, on November 6, 2020, ToyotaeBay decided that the subject vehicles may have been sold with headlamps that contain open aiming caps that could enable horizontal adjustment of the headlamp beam and may not meet certain requirements in FMVSS No. 108, paragraph S10.18.4.

 

Description of Corrective Repair Action:

For all involved vehicles, ToyotaeBay dealers will close the aiming caps on the headlamps to prevent horizontal adjustment of the headlamp beam at no cost to customers.

Reimbursement Plan for pre-notification remedies

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

 

Recall Schedule:

Notifications to owners of the affected vehicles will occur by January 11, 2021.  A copy of the draft owner notification letter(s) will be submitted as soon as available.

 

Distributor/Dealer Notification Schedule:

Notification to distributors/dealers will be sent by November 12, 2020.  Copies of the dealer communications will be submitted as they are issued.

 

Manufacturer’s Campaign Number:

Remedy: 20TA15

 



1 Affected Product

Vehicle

MAKEMODELYEAR
TOYOTARAV4 PRIME2021

 


10 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-20V698-0602.pdf 354.605KB

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Recall Quarterly Report #1, 2021-1

RCLQRT-20V698-9070.PDF 211.148KB

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Recall Quarterly Report #2, 2021-2

RCLQRT-20V698-4795.PDF 211.245KB

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Manufacturer Notices(to Dealers,etc) – Date: November 12, 2020

RCMN-20V698-7552.pdf 418.586KB

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Miscellaneous Document

RMISC-20V698-2594.pdf 282.608KB

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Remedy Instructions and TSB

RCRIT-20V698-1929.pdf 396.198KB

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Noncompliance Notice 573 Report

RCLRPT-20V698-3353.PDF 214.416KB

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Manufacturer Notices(to Dealers,etc) – Toyota Date: November 12, 2020 SAFETY (NONCOMPLIANCE) RECALL 20TA15 – Remedy Notice

RCMN-20V698-5843.pdf 324.363KB

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Recall Acknowledgement

RCAK-20V698-8869.pdf 244.164KB

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Recall Quarterly Report #3, 2021-3

RCLQRT-20V698-1552.PDF 211.327KB

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