SAFETY RECALL 22TA02 – Pre-Collision System (PCS) Inoperative without Warning Indicator – 2021 Toyota C-HR

February 24, 2022 NHTSA CAMPAIGN NUMBER: 22V107000

Pre-Collision System May Be Inoperative

An inoperative PCS that does not provide a malfunction indicator to the driver, or braking assist as expected, can increase the risk of a crash.

 

NHTSA Campaign Number: 22V107

Manufacturer ToyotaeBay logo Motor Engineering & Manufacturing

Components FORWARD COLLISION AVOIDANCE

Potential Number of Units Affected 36,558

 

Summary

ToyotaeBay logo Motor Engineering & Manufacturing (ToyotaeBay logo) is recalling certain 2021 C-HR vehicles. The radar sensor may not have been activated during production, making the pre-collision system (PCS) inoperative.

 

Remedy

Dealers will inspect and activate the radar sensor as necessary, free of charge. Owner notification letters were mailed April 22, 2022. Owners may contact ToyotaeBay logo customer service at 1-800-331-4331. ToyotaeBay logo’s number for this recall is 22TA02.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


SAFETY RECALL 22TA02 (Remedy Notice)

Certain 2021 Model Year C-HR Vehicles

Pre-Collision System (PCS) Inoperative without Warning Indicator

 

Model / YearsProduction PeriodApproximate Total VehiclesApproximate Stop Sale Dealer Inventory
2021 C-HRMid-June 2020 – Late July 202136,6001

 

On February 24, 2022, ToyotaeBay logo filed a (Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on certain 2021 model year C-HR vehicles.

 

Condition

The radar sensor used by the Pre-Collision System (PCS) may not have been initialized properly in the involved vehicles during production.  In that case, PCS would be inoperative with no warning indicator to the driver.  An inoperative PCS, without a PCS malfunction indicator, may increase the risk of a crash in certain driving situations.

 

Remedy

For all involved vehicles, ToyotaeBay logo dealers will inspect the radar sensor and if necessary, properly initialize the radar sensor, FREE OF CHARGE.

 

Covered Vehicles

There are approximately 36,600 vehicles covered by this Safety Recall. Approximately 2,200 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

ToyotaeBay logo will begin to notify owners in mid-March 2022.

ToyotaeBay logo 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 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.

 

ToyotaeBay logo 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.

 

ToyotaeBay logo Rent-A-Car (TRAC) & Service Loaners

ToyotaeBay logo 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.

 

Head Unit Notifications

Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Customers who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed.

When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a customer chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the customer chooses ‘View’. If a customer views and then closes the message, the message will be available in the Notification App if the customer chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the customer to have this Safety Recall completed.

The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by ToyotaeBay logo. Then the message will be cleared at the next clearing cycle, which currently happens weekly.

Owners who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message. Owners with additional concerns can be directed to the ToyotaeBay logo Brand Engagement Center (1888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to ToyotaeBay logo Warranty Policy 4.17, “What Is Not Covered by The ToyotaeBay logo New Vehicle Limited Warranty”.

 

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.

 

Campaign Special Service Tools

Part NumberPart NameQuantityRemarks
09870-60000*Laser Radar Adjusting Reflector (Kit) *1For TRIANGLE TARGET
09870-60100Flat Target1For FLAT SURFACE TARGET
09870-60110Panel Stand1

 

*Essential SST

 

Repair Quality Confirmation

The repair quality of covered vehicles is extremely important to ToyotaeBay logo. 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.

 


Certain 2021 Model Year C-HR Vehicles
Pre-Collision System (PCS) Inoperative without Warning Indicator

Frequently Asked Questions
Original Publication Date: February 24, 2022

 

Q1: What is the condition?

The radar sensor used by the Pre-Collision System (PCS) may not have been initialized properly in the involved vehicles during production.  In that case, PCS would be inoperative with no warning indicator to the driver.  An inoperative PCS, without a PCS malfunction indicator, may increase the risk of a crash in certain driving situations.

 

Q2: What is ToyotaeBay logo going to do?

In mid-March 2022, ToyotaeBay logo will begin to notify owners to request they make an appointment with their authorized ToyotaeBay logo dealer.  Dealers will inspect the radar sensor and if necessary, properly initialize the radar sensor, free of charge.

 

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

There are approximately 36,600 vehicles covered by this Safety Recall.

Model NameModel YearProduction Period
C-HR2021Mid-June 2020 – Late July 2021

 

Q4: How long will the repair take?

The repair takes approximately 45 to 60 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 logo obtain my mailing information?

ToyotaeBay logo 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 logo Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Q7: Are there any warnings that this condition exists?

Yes. If the radar sensor has not been properly initialized, you may notice the following.

1. When Dynamic Radar Cruise Control (DRCC) speed is set, you cannot increase or decrease your speed using the cruise control switch.

NOTE: The DRCC function can be canceled at any time by pressing the on/off button on the cruise control switch or by pressing the brake pedal.

2. The lane centering function of the Lane Tracing Assist (LTA) system will not operate the steering wheel to maintain the vehicle’s lane position even if the display says the lane centering is active and DRCC speed is set.

NOTE: The Steering Assist function should still provide steering input and a warning message/chime if the system detects that the vehicle might depart from its lane or course as long as all operating conditions are met. Refer to Owner’s Manual for steering assist system operating conditions and limitations.

3. Vehicles ahead are not detected and the vehicle icon in the Multi-Information Display (MID) will not be shown while using DRCC. Furthermore, the vehicle will not slow down automatically, as designed, when approaching a vehicle with DRCC active.

 


TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 22TA02
PRE-COLLISION SYSTEM (PCS) INOPERATIVE WITHOUT WARNING INDICATOR
CERTAIN
2021 MODEL YEAR C-HR

 


Chronology of Principal Events:

December 2020 – April 2021
In December 2020, ToyotaeBay logo began to receive field reports related to the vehicles sold in the Japan market alleging that the vehicle did not detect the preceding vehicle when using the Traffic Movement Notification feature (a Japan-market feature not available in the U.S.). In these cases, dealer technicians observed that the beam axis for the radar sensor was out of specification and adjusted the beam axis during an inspection. After completing the beam axis adjustment and initializing the radar sensor, the vehicles in these cases were able to detect the preceding vehicle.

ToyotaeBay logo began a number of activities to further investigate this condition. Based on the reports from the dealers indicating that the repair to correct the reported issue was to perform the radar sensor beam axis adjustment and complete the initialization of the radar sensor, ToyotaeBay logo suspected that an uninitialized radar sensor was linked to the field allegations that ToyotaeBay logo had received up to this point, all of which alleged that the Traffic Movement Notification feature was unable to detect the preceding vehicle. An uninitialized radar sensor also meant that other features, which rely on the radar sensor could be affected by this condition. As a result, ToyotaeBay logo contacted the supplier to assist in this analysis and began a Fault Tree Analysis (FTA) with the supplier to attempt to identify potential causes for the uninitialized radar sensor. At this time, all functions that rely on the radar sensor including Pre-Collision System (PCS), Dynamic Radar Cruise Control (DRCC), and Lane Tracing Assist (LTA) were thought to be affected by this condition.

In March 2021, ToyotaeBay logo used remote data retrieval in the Japan market to attempt to identify vehicles that may have an uninitialized radar sensor. ToyotaeBay logo identified one potential vehicle and requested a dealer to recover the part.
In April 2021, ToyotaeBay logo received the recovered radar sensor from the aforementioned vehicle in Japan. Based on an inspection of the sensor, ToyotaeBay logo determined that it was not initialized due to an incomplete beam axis adjustment. At this time, it was unclear what may have led to the sensor having an incomplete beam axis adjustment.
In addition, no field reports or warranty claims related to an uninitialized radar sensor had been received for vehicles in the U.S. market at this time.

May 2021 to December 2021
In May, ToyotaeBay logo investigated the recovered part and discovered that, while a judgement flag which indicates the completion of the beam axis adjustment was found in the diagnostic area of the sensor ECU internal memory, a judgement flag in the operation area of the sensor ECU internal memory was missing. The missing judgment flag in the operation area indicated that the unadjusted beam axis caused the radar sensor to remain uninitialized.

Based on the results from this investigation and the review of the FTA that had been created in conjunction with the supplier, ToyotaeBay logo confirmed what systems on the vehicle might be affected by the uninitialized radar sensor. The results of the study identified that the potentially affected features included: PCS, DRCC and LTA, all of which rely on an initialized radar sensor to operate as designed.

In parallel, ToyotaeBay logo reviewed the FTA for the radar sensor and identified that a constant power supply is necessary to complete the initialization of the radar sensor. As a result, ToyotaeBay logo conducted bench testing in an attempt to determine how the beam axis adjustment could be incomplete during the initialization process, resulting in the same condition as the recovered part. At first, ToyotaeBay logo hypothesized that a low voltage input may be contributing to the incomplete initialization. However, testing with this condition determined that this would not cause the radar sensor to fail to initialize.
Beginning in September 2021, ToyotaeBay logo conducted additional testing to examine whether a low voltage input coupled with a low current input (to create an even more severe scenario) could result in an incomplete initialization of the radar sensor. In addition, the supplier developed new data analysis equipment that could be used during testing to analyze each data processing step within the internal memory of the radar sensor ECU.

In December 2021, during the duplication testing, ToyotaeBay logo was able to observe a temporary writing error in the internal nonvolatile memory during the beam axis adjustment task. During this testing, however, the error was corrected a few seconds later, because the system defaulted to reinitializing and completing the beam axis adjustment task. Although an incomplete initialization was initially observed, the automatic reinitialization of the radar sensor that occurred led to the successful initialization of the radar sensor, which was not the same condition observed in the field.

Although this testing failed to show how a radar sensor could fail to be properly initialized in the same manner as found in the reports from the field, ToyotaeBay logo observed that there were complex communications taking place between the radar sensor ECU and the other ECUs during the initialization process that could cause the time it takes to complete the initialization of the radar sensor to be longer than expected in some cases. At this point, ToyotaeBay logo had conducted approximately 60 duplication tests (a low voltage input coupled with a low current input) of the radar sensor initialization process using the recovered part, but the testing did not result in a failure to initialize the radar sensor.

Still no field reports or warranty claims related to an uninitialized radar sensor had been received for vehicles in the U.S. market at this time.

January 2022 – February 2022
Based on the observations from the testing conducted in December that revealed the additional communication that occurs during the initialization process, ToyotaeBay logo reviewed the manufacturing process for initializing the radar sensor. After a review of the production process, ToyotaeBay logo found that the time for the radar sensor to complete the initialization process (in some cases where reinitialization is potentially required) may be more than the time allotted during the vehicle production process.

ToyotaeBay logo also theorized that during vehicle inspection at the vehicle assembly plant, if the ignition was prematurely turned off before the processing of all necessary data, then the initialization of the radar sensor would be incomplete and there would be no further reinitialization to complete the process. Based on this information, from mid-January to early February, ToyotaeBay logo conducted another bench test on the recovered part to attempt to understand the effect of turning the ignition off prior to initialization of the radar sensor during the production process. As a result, ToyotaeBay logo was able to replicate the scenario of a radar sensor failing to initialize during the production process by turning the ignition off prematurely prior to completing the initialization of the radar sensor.

As stated above, if the initialization does not occur, the radar sensor would not be active. Thus, ToyotaeBay logo evaluated the implications of the performance effect that the uninitialized radar sensor would have on certain driver assistance systems (i.e., the effect that portions of the DRCC and LTA features would be deactivated and that the PCS would not be able to provide warnings or braking assist, as designed, in certain driving scenarios that would otherwise result in a PCS activation). Based on ToyotaeBay logo’s evaluation, ToyotaeBay logo’s engineering judgment concluded that an inoperative PCS, without a PCS malfunction indicator to the driver, may increase the risk of a crash in certain driving situations.

February 21, 2022
Based on the results of the above investigation, ToyotaeBay logo decided to conduct a voluntary safety recall campaign.

As of January 20, 2022, based on a diligent review of records, ToyotaeBay logo’s best engineering judgement is that there are 0 ToyotaeBay logo Field Technical Reports and 0 warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report.

 


1 Affected Product

Vehicle

MAKEMODELYEAR
TOYOTAeBay logoC-HR2021

 


11 Associated Documents

Defect Notice 573 Report

RCLRPT-22V107-4556.PDF 214.435KB

 


Manufacturer Notices(to Dealers,etc) – ToyotaeBay logo Date: February 24, 2022 SAFETY RECALL 22TA02 (Remedy Notice)

RCMN-22V107-8890.pdf 540.078KB

 


Manufacturer Notices(to Dealers,etc) – ToyotaeBay logo DATE 2/24/2022 TOPIC Warranty op codes corrected

RCMN-22V107-5468.pdf 610.864KB

 


TOYOTAeBay logo February 24, 2022 DEFECT INFORMATION REPORT

RMISC-22V107-3362.pdf 144.808KB

 


Remedy Instructions and TSB

RCRIT-22V107-5961.pdf 848.125KB

 


Recall Acknowledgement

RCAK-22V107-8526.pdf 743.335KB

 


In-Vehicle Message Important Safety Recall Message ? 22TA02

RMISC-22V107-3463.pdf 53.727KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V107-6613.pdf 520.41KB

 


Recall Quarterly Report #1, 2022-2

RCLQRT-22V107-7971.PDF 211.149KB

 


Recall Quarterly Report #2, 2022-3

RCLQRT-22V107-1642.PDF 211.248KB

 


Recall Quarterly Report #3, 2022-4

RCLQRT-22V107-9968.PDF 211.35KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V107&docType=RCL

 


 

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