Safety Recall 23TA15 (Remedy Notice) - Multiple Models And Model Years - Passenger Airbag May Not Deploy (23TA15)

NEW VEHICLES IN DEALERSHIP INVENTORY - REMINDER

Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer's obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:

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.

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.

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 in the remedy phase of 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 visit https://toyota-recall-disclosure.imagespm.info/  and complete a Customer Contact and Vehicle Disclosure Form. 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.

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. Vehicles in the interim phase that are TCUV stock cannot be remedied until the applicable phase is launched.

RENT A TOYOTA & SERVICE LOANERS

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

CUSTOMER CONTACTS

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety 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 Brand Engagement Center (1-888-270-9371) - 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 Toyota Warranty Policy 4.17  , "What Is Not Covered by The Toyota New Vehicle Limited Warranty".

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 the Toyota Newsroom https://pressroom.toyota.com/ 

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. Dealers can identify which parts ordering method to use by reviewing the parts information section of Dealer Daily and checking for a MAC code on the part numbers below. For MAC code C, order through CPOR. For MAC code D, refer to the MAC report for further instructions.

TECHNICIAN TRAINING REQUIREMENTS

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair are required to 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 completed all of the following courses currently:

• TIC206A - Electrical Repair

Always check which technicians can perform the repair by logging on to https://www.uotdealerreports.com  . The dealership is responsible for selecting technicians who have completed the above courses to perform this repair. Carefully review your resources, the technician's skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure properly trained technicians are 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.

I. OPERATION FLOW CHART

II. IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY 
   1. Compare the vehicle's VIN to the VIN listed on the Repair Order to ensure they match.
   2. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign and that it has not already been completed.

III. PREPARATION

A. TOOLS AND EQUIPMENT

TOOLS INFORMATION

Standard Hand Tools	Techstream/GTS+	T50 "TORX" Socket
Torque Wrench	Flashlight	Masking Tape
Inspection Application	Protective Cover	Seat Jig Assembly
3.5-4.5" Spacer (foam block, wood block or equivalent)	OCS Inspection App. (Apple Only)

NOTE:

• Recall SST: Seat Jig Assembly (This was shipped to your dealer at Phase 1 Remedy Launch). 
• It is critical that the seat jig assembly is used during sensor replacement, so the seat tracks remain square and do not become misaligned. Seat track out of alignment will impact the occupant detection weight readings by the ECU. 

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

1. UNBOLT THE PASSENGER FRONT SEAT AND CONFIRM OCS SERIAL NUMBERS 
   1. Install the mobile inspection app on your device using the QR code or by clicking on the links below:

      Apple: Click Here 

      Android: Here 

      DO NOT disconnect any seat harness connectors at this time.

   2. Take note of the passenger seat position, so seat can be returned to this position later.
   3. Place the passenger front seat in the following positions before unbolting:
      • Recline Angle - Upright Position
      • Front Tilt Height - Highest Position
      • Seat Lifter Height - Highest Position
   4. Using a T50 "TORX" socket, unbolt the 4 passenger seat bolts.

      Lean the passenger front seat back to view the underside of the seat. 

2. IDENTIFY THE FRONT AND REAR OCS SERIAL NUMBERS 
   1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
   2. Log into the QA - Dealer Inspection Application.
   3. Select the appropriate campaign: "23TA15/23LA03".
   4. Follow the instructions in the application to scan the front and rear OCS serial numbers.

      Do the front and/or rear OCS units require replacement? 

      YES  : Front and/or rear OCS require replacement; proceed to Section VII  .

      NO  : Proceed to step 3  .

   If the first 5 digits of the OCS serial number are illegible, the sensor must be replaced.

   NOTE: In the event that the application cannot successfully scan the vinyl VIN certification label due to its compromised condition or if it is missing, please reach out to the Quality Compliance team at quality_compliance@toyota.com  . Include a photograph of the damaged VIN label, if applicable, as well as the VIN label located beneath the windshield in your correspondence.
3. REINSTALL PASSENGER FRONT SEAT 
   1. Install the passenger front seat following the repair manual steps:
      • Camry (Manual Seat) 
      • Camry (Power Seat) 
      • Avalon 
   NOTE: Be sure to tighten the bolts in the order shown in the repair manual.
4. RESTORE FRONT PASSENGER SEAT TO ORIGINAL POSITION 
5. CAMPAIGN COMPLETE 

VII. REPLACE FRONT AND/OR REAR OCS ASSEMBLIES

HINT: 

Perform this procedure only when OCS replacement has been determined in the previous section.

1. REMOVE PASSENGER FRONT SEAT ASSEMBLY 

   Before removing the seat assembly, ensure that the rear seat track bolt holes are accessible for mounting to the jig assembly in step   3 .

   1. Remove the passenger front seat following the repair manual steps:
      • Camry (Manual Seat) (Steps   3 -  8  only) 
      • Camry (Power Seat) (Steps 1-  7 (f) only) 
      • Avalon (Steps 2-  8 (f) only) 
2. PREPARE THE JIG ASSEMBLY 
   1. Identify the correct rear bolt and front alignment pinhole combination to match the seat frame type being mounted to the jig.

   HINT: 

   Be sure to position the jig safely and clear of any moving vehicles or machinery.

3. INSTALL SEAT ASSEMBLY TO THE JIG 
   1. Place the passenger front seat assembly onto the jig and secure it using the 2 provided bolts, nuts, and washers through the rear seat track mounting holes.

      Torque: 27 N*m (20 ft.*lbf) 

      NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
   2. Ensure seat is properly secured to the jig.
4. DISCONNECT THE OCS CONNECTORS 
   1. Disconnect the front and rear OCS connectors.
      NOTE: Be sure to disconnect both front and rear OCS connectors before lifting up the seat track in the following step.
5. REMOVE LEFT SIDE SEAT TRACK NUTS 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the front and rear seat track nuts using a 14mm socket and ratcheting wrench.
6. INSTALL A 3.5-4.5" SPACER BETWEEN THE LOWER SEAT TRACK RAIL AND THE UPPER TRACK ASSEMBLY 

   HINT: 

   Be sure to use a foam block, tape roll, wood block, or similar, to provide enough space to access the front and rear OCS nuts.

   DO NOT exceed 4.5" of space when inserting tape roll. Damage may occur if this is not followed.

7. REMOVE OCS(S) 

   DO NOT loosen any nuts other than the ones instructed.

   1. Using a 13mm box wrench or socket wrench, remove the front and/or rear OCS as instructed by the mobile inspection app.
8. INSTALL NEW OCS(s)TO THE SEAT TRACK ASSEMBLY 
   NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
   1. b) If necessary, install the NEW  rear OCS to the seat track assembly.
      NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

      Torque: 30 N*m (22.5 ft.*lbf) 

   2. c) If necessary, install the NEW  front OCS assembly to the seat track assembly.
   NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

   Torque: 30 N*m (22.5 ft.*lbf) 

   1. Remove the spacer and place the upper seat assembly back onto the seat track assembly.
   2. Re-install the rear seat track nut.

      Torque: 47 N*m (35 ft.*lbf) 

   3. Re-install the front seat track nut.

      Torque: 47 N*m (35 ft.*lbf) 

   4. Reconnect both front and rear OCS connectors.
   5. Remove the 2 mounting nuts securing the seat assembly to the jig and remove the seat assembly from the jig.
9. REINSTALL PASSENGER FRONT SEAT 
   1. Install the passenger front seat following the repair manual steps:
      • Camry (Manual Seat) 
      • Camry (Power Seat) 
      • Avalon 
   2. Continue to Zero Point Calibration section VIII  .

VIM. CALIBRATION AND CONFIRMATION

1. PERFORM ZERO POINT CALIBRATION 

   Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS/OCCUPANT CLASSIFICATION SYSTEM/INITIALIZATION.

   • Camry 
   • Camry HV 
   • Avalon 
   • Avalon HV 
2. PERFORM OCCUPANT CLASSIFICATION SYSTEM - DATA LIST/ACTIVE TEST 
   1. Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS: OCCUPANT CLASSIFICATION SYSTEM: DATA LIST/ACTIVE TEST.
      • Camry 
      • Camry HV 
      • Avalon 
      • Avalon HV 
   2. For 4-way seat  :

      Confirm that the Total Weight Information  value is within ±3.70 lbs  at each confirmation point.

      HINT: Refer to the chart above for reference.

      1. With the seat in the lowest and forward most position, move the seat to the rear most position  and confirm the "Total Weight Information" value in the data list.
      2. Move the seat to the forward most position  and confirm the "Total Weight Information" value in the data list.

      Do all the confirmation point values fall within the target range value? 

      YES  - Proceed to Step 3  .

      NO  - STOP  and contact FTS to report findings.

   3. For 6-way and 8-way seats  :

      Confirm that the Total Weight Information  value is within ±4.80 lbs  at each confirmation point.

      HINT: Refer to the chart above for reference.

      1. With the seat in the lowest and forward most position, move the seat to the rear most position  and confirm the "Total Weight Information" value in the data list.
      2. Move the seat to the rear upper position  and confirm the "Total Weight Information" value in the data list.
      3. Move the seat to the front upper position  and confirm the "Total Weight Information" value in the data list.
      4. Move the seat to the front lower position  and confirm the "Total Weight Information" value in the data list.

   Do all the confirmation point values fall within the target range value? 

   YES  - Proceed to Step 3  .

   NO  - STOP  and contact FTS to report findings.

3. PERFORM FINAL CONFIRMATION CHECK 

   Sit on the passenger front seat and confirm if the airbag light changes from "OFF"  to "ON"  .

   Does the passenger airbag indicator light switch to ON? 

   YES  - Campaign complete.

   NO  - Perform zero point calibration again and recheck.

   VERIFY REPAIR QUALITY  

   • Confirm all bolts are properly torqued. 
   • Confirm all seat track bolts and wire harness connectors are installed correctly. 
   • Confirm no DTCs present after repair. 

IX. APPENDIX

B. CAMPAIGN DESIGNATION DECODER

Examples:

19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019

20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020

21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

I. OPERATION FLOW CHART

II. IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY 
   1. Compare the vehicle's VIN to the VIN listed on the Repair Order to ensure they match.
   2. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign and that it has not already been completed.

III. PREPARATION

A. TOOLS AND EQUIPMENT

TOOLS INFORMATION

Standard Hand Tools	Techstream/GTS+	T50 "TORX" Socket
Torque Wrench	Flashlight	Masking Tape
Inspection Application	Protective Cover
3.5-4.5 Spacer (foam block, wood block or equivalent)	SST 14mm Torque Adapter (100mm/150mm)	SST 12mm Torque Adapter (100mm/150mm)
6" 3/8 Extension

NOTE:

• Recall SST: Seat Jig Assembly (This was shipped to your dealer at Phase 1 Remedy Launch). 
• It is critical that the seat jig assembly is used during sensor replacement, so the seat tracks remain square and do not become misaligned. Seat track out of alignment will impact the occupant detection weight readings by the ECU. 

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

1. UNBOLT THE PASSENGER FRONT SEAT AND CONFIRM OCS SERIAL NUMBERS
   1. Install the mobile inspection app on your device using the QR code or by clicking on the links below:

      Apple: Click Here 

      Android: Click Here 

      DO NOT disconnect any seat harness connectors at this time

   2. Take note of the passenger seat position, so seat can be returned to this position later.
   3. Place the passenger front seat in the following positions before unbolting:
      • Recline Angle - Upright Position
      • Front Tilt Height - Highest Position
      • Seat Lifter Height - Highest Position
   4. Using a T50 "TORX" socket, unbolt the 4 passenger seat bolts.

   Lean the passenger front seat back to view the underside of the seat. 

2. IDENTIFY THE FRONT AND REAR OCS ASSEMBLY SERIAL NUMBERS 
   1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
   2. Log into the QA - Dealer Inspection Application.
   3. Select the appropriate campaign: "23TA15/23LA03".
   4. Follow the instructions in the application to scan the front and rear OCS serial numbers.

   Do the front and/or rear OCS units require replacement? 

   YES  : Front and/or rear OCS require replacement; proceed to Section VII  .

   NO  : Proceed to step 3  .

   If the first 5 digits of the OCS serial number are illegible, the sensor must be replaced.

   NOTE: In the event that the application cannot successfully scan the vinyl VIN certification label due to its compromised condition or if it is missing, please reach out to the Quality Compliance team at quality_compliance@toyota.com  . Include a photograph of the damaged VIN label, if applicable, as well as the VIN label located beneath the windshield in your correspondence.
3. REINSTALL PASSENGER FRONT SEAT 
   1. Install the passenger front seat following the repair manual steps:
      • Highlander 
      • RAV4 (Manual) 
      • RAV4 (Power) 
      • Sienna HV 
   NOTE: Be sure to tighten the bolts in the order shown in the repair manual.
4. RESTORE FRONT PASSENGER SEAT TO ORIGINAL POSITION 
5. CAMPAIGN COMPLETE 

VII. REPLACE FRONT AND/OR REAR OCS ASSEMBLIES

HINT:

Perform this procedure only when OCS replacement has been determined in the previous section.

1. REMOVE PASSENGER FRONT SEAT ASSEMBLY 

   For powered seats, set the seat position forward to allow rear seat track bolts to be accessible for mounting to jig assembly in the following steps.

   1. Remove the passenger front seat following the repair manual steps:
      • Highlander (Steps   4 -  9  only) 
      • RAV4 (Manual) (Steps 1-  10 (f) only) 
      • RAV4 (Power) (Steps   5 -  10 (f) only) 
      • Sienna HV (Steps   3 -  8 (a)(4) only) 
2. PREPARE THE JIG ASSEMBLY 
   1. Identify the correct rear bolt and front alignment pinhole combination to match the seat frame type being mounted to the jig.

   HINT:

   Be sure to position the jig in a safe location clear of any moving vehicles or machinery.

3. INSTALL SEAT ASSEMBLY TO THE JIG 
   1. Place the passenger front seat assembly onto the jig and secure it using the 2 provided bolts, nuts, and washers through the rear seat track mounting holes.

      Torque: 27 N*m (20 ft.*lbf) 

      NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
   2. Ensure seat is properly secured to the jig.
4. DISCONNECT THE OCS CONNECTORS 
   1. Disconnect the front and rear OCS connectors.
      NOTE: Be sure to disconnect both front and rear OCS connectors before lifting up the seat track in the following steps.
5. REMOVE LEFT REAR SEAT TRACK INTERFERENCE NUT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the rear interference seat track nut using the SST 12mm Torque Adapter in either the 100mm or 150mm setting, with a 6" extension and ratcheting wrench.
   2. Remove the interference nut sleeve and place it in a safe location for later use.
6. REMOVE LEFT REAR SEAT TRACK NUT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the rear seat track nut using the SST 14mm Torque Adapter in either the 100mm or 150mm setting, with a 6" extension and ratcheting wrench.
   NOTE: Be sure to confirm that the rear seat track nut is being removed, not the rear OCS nut.
7. REMOVE LEFT FRONT SEAT TRACK NUT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the front seat track nut using the SST 14mm Torque Adapter in either the 100mm or 150mm setting, with a 6" extension and ratcheting wrench.

   HINT:

   For powered seats only  , disconnect the front power seat motor connector to allow the removal and installation of the front seat track bolt.

8. INSTALL A 3.5-4.5" SPACER BETWEEN THE LOWER SEAT TRACK RAIL AND THE UPPER TRACK ASSEMBLY 

   HINT:

   Be sure to use a foam block, tape roll, wood block, or similar to provide enough space to access the front and rear OCS assembly nuts.

   DO NOT exceed 4.5" of space when inserting tape roll. Damage may occur if this is not followed

9. REMOVE OCS(s) 

   DO NOT loosen any nuts other than the ones instructed.

   1. Using a ratcheting or box wrench, remove the front and/or rear OCS, as instructed by the mobile inspection app.
10. INSTALL NEW OCS(s) TO THE SEAT TRACK ASSEMBLY 
    NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
    1. If necessary, install the NEW  rear OCS to the seat track assembly.
       NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

       Torque: 25 N*m (18.5 ft.*lbf) 

    2. If necessary, install the NEW  front OCS assembly to the seat track assembly.
       NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

       Torque: 25 N*m (18.5 ft.*lbf) 

    3. Remove the spacer and place the upper seat assembly back onto the seat track assembly.
11. PREPARE INTERFERENCE SLEEVE 
    1. Prepare the interference sleeve for installation by using masking tape. Cut approximately 20mm (3/4") of tape and wrap the interference sleeve 2 times  , ensuring no wrinkles or creases exist.

       HINT:

       This will ensure that no contact between the sleeve and seat track assembly exists during the installation of the left side seat track nuts.

    2. Temporarily insert the interference sleeve onto the stud.
12. CALCULATE TORQUE SPECIFICATION FOR SEAT TRACK NUTS 
    1. Use the following formula to calculate the torque specification:
       NOTE: The applied torque changes when using the SST adapter. The calculation below will determine the new applied torque specification required for installing the seat track nuts.

       HINT:

       • The measurement that needs to be performed manually is the Torque Wrench Length  in millimeters (See illustration above). This is due to the varying sizes of torque wrenches available for use.
       • The SST adapter is set to allow for 100mm or 150mm in length (choose either length based on need and enter it into the calculation).
       • An extension can be used along with the SST adapter. The extension does not affect the calculated torque specification.
    2. Calculation  :
       • New Torque Value = (A/(A+B)) * Original Torque Value

         A = Torque wrench length (mm) (wrench drive centerline to handgrip centerline)

         B = SST adapter length being used (100mm or 150mm)

         Original Torque Value = 37 N*m 

         HINT: Example  :

         If  :

         A = *270mm *(variable based on your torque wrench size)

         B = *100mm *(fixed value for this SST)

         Original Torque Value = 37 N*m

         Then  :

         New Torque Value = (270/(270+100)) * 37 =

         (270/370) * 37 =

         0.730 * 37 = 27

         (Example) New Torque Value = 27 N*m (20 ft.*lbf) 

13. INSTALL THE LEFT SIDE SEAT TRACK BOLTS 

    The interference sleeve MUST NOT touch the seat frame on any side during the following steps.  Confirm that the interference sleeve is free to spin after the torquing of each nut.  If at any point the interference sleeve is no longer free to spin, the left side seat track nuts need to be removed, the seat track adjusted, and the nuts reinstalled.

    1. Re-install the rear seat track nut and check to ensure interference sleeve is still free to spin. If interference sleeve is not free to spin (making contact with the seat frame), loosen the rear seat track nut, adjust the seat assembly, and repeat this step.

       Original Torque Value: 37 N*m (27.5 ft.*lbf) 

       NOTE: The torque adapter MUST remain inline (parallel) with the torque wrench handle while torquing nuts. If torque wrench adapter is not parallel with the torque wrench handle while torquing, the effective length of the tool will be altered, causing torque calculations to be inaccurate.
    2. Re-install the front seat track nut following the same process as the previous step.

       Original Torque Value: 37 N*m (27.5 ft.*lbf) 

    3. Remove the tape from the interference sleeve and reinstall it to the stud.
    4. Re-install the interference sleeve nut.

       Original Torque Value: 25 N*m (18 ft.*lbf) 

    5. Confirm the status of the interference sleeve using a flashlight to shine light in the top side of the interference sleeve.

    HINT:

    If no interference exists between the lower seat frame and the spacer, the light can be seen all around. If there is interference, the light cannot be seen.

    Does the interference sleeve touch the seat track on any side? 

    NG  : Remove the left side seat track bolts and repeat the installation steps.

    OK  : Proceed to step 14  .

14. RECONNECT BOTH FRONT AND REAR OCS CONNECTORS. 
    NOTE: (Power Seat Only) Reinstall the power seat motor connector removed in the previous step.
15. REMOVE THE SEAT ASSEMBLY FROM THE JIG 
    1. Remove the 2 nuts and then remove the seat assembly from the jig.
16. REINSTALL PASSENGER FRONT SEAT 
    1. Install the passenger front seat following the repair manual steps:
       • Highlander 
       • RAV4 (Manual) 
       • RAV4 (Power) 
       • Sienna HV 
    2. Continue to Zero Point Calibration section VIII.

VIII. CALIBRATION AND CONFIRMATION

1. PERFORM ZERO POINT CALIBRATION 

   Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS/OCCUPANT CLASSIFICATION SYSTEM/INITIALIZATION.

   • Highlander 
   • RAV4 
   • Sienna HV 
2. PERFORM OCCUPANT CLASSIFICATION SYSTEM - DATA LIST/ACTIVE TEST 
   1. Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS: OCCUPANT CLASSIFICATION SYSTEM: DATA LIST/ACTIVE TEST.
      • Highlander 
      • RAV4 
      • Sienna HV 
   2. For 4-way seat  :

      Confirm that the Total Weight Information  value is within ±3.70 lbs  at each confirmation point.

      HINT: Refer to the chart above for reference.

      1. With the seat in the lowest and forward most position, move the seat to the rear most position  and confirm the "Total Weight Information" value in the data list.
      2. Move the seat to the forward most position  and confirm the "Total Weight Information" value in the data list.

      Do all the confirmation point values fall within the target range value? 

      YES  - Proceed to Step 3  .

      NO  - STOP  and contact FTS to report findings.

   3. For 6-way and 8-way seats  :

      Confirm that the Total Weight Information  value is within ±4.80 lbs  at each confirmation point.

      HINT: Refer to the chart above for reference.

      1. With the seat in the lowest and forward most position, move the seat to the rear most position  and confirm the "Total Weight Information" value in the data list.
      2. Move the seat to the rear upper position  and confirm the "Total Weight Information" value in the data list.
      3. Move the seat to the front upper position  and confirm the "Total Weight Information" value in the data list.
      4. Move the seat to the front lower position  and confirm the "Total Weight Information" value in the data list.

      Do all the confirmation point values fall within the target range value? 

      YES  - Proceed to Step 3  .

      NO  - STOP  and contact FTS to report findings.

3. PERFORM FINAL CONFIRMATION CHECK 

   Sit on the passenger front seat and confirm if the airbag light changes from "OFF"  to "ON"  .

   Does the passenger airbag indicator light switch to ON? 

   YES  - Campaign complete.

   NO  - Perform zero point calibration again and recheck.

   VERIFY REPAIR QUALITY  

   • Confirm all bolts are properly torqued. 
   • Confirm all seat track bolts and wire harness connectors are installed correctly. 
   • Confirm no DTCs present after repair. 

IX. APPENDIX

B. CAMPAIGN DESIGNATION DECODER

Examples:

19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019

20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020

21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

I. OPERATION FLOW CHART

II. IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY 
   1. Compare the vehicle's VIN to the VIN listed on the Repair Order to ensure they match.
   2. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign and that it has not already been completed.

III. PREPARATION

A. TOOLS AND EQUIPMENT

TOOLS INFORMATION

Standard Hand Tools	Techstream/GTS+	T50 "TORX" Socket
Torque Wrench	Flashlight	Masking Tape
Inspection Application	Protective Cover	Seat Jig Assembly
3.5-4.5" Spacer (foam block, wood block or equivalent)	SST 12mm Torque Adapter (50mm Long)	Paint Marker
6" 3/8 Extension	SST 14mm Torque Adapter (50mm Long)

NOTE:

• Recall SST: Seat Jig Assembly (This was shipped to your dealer at Phase 1 Remedy Launch). 
• It is critical that the seat jig assembly is used during sensor replacement, so the seat tracks remain square and do not become misaligned. Seat track out of alignment will impact the occupant detection weight readings by the ECU. 

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

1. UNBOLT THE PASSANGER FRONT SEAT AND CONFIRM OCS SERIAL NUMBERS
   1. Install the mobile inspection app on your device using the QR code or by clicking on the links below:

      Apple: Click Here 

      Android: Click Here 

      DO NOT disconnect any seat harness connectors at this time.

   2. Take note of the passenger seat position, so seat can be returned to this position later.
   3. Place the passenger front seat in the following positions before unbolting:
      • Recline Angle - Upright Position
      • Front Tilt Height - Highest Position
      • Seat Lifter Height - Highest Position
   4. Using a T50 "TORX" socket, unbolt the 4 passenger seat bolts.

      Lean the passenger front seat back to view the underside of the seat 

2. IDENTIFY THE FRONT AND REAR OCS ASSEMBLY SERIAL NUMBERS 
   1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
   2. Log into the QA - Dealer Inspection Application.
   3. Select the appropriate campaign: "23TA15/23LA03".
   4. Follow the instructions in the application to scan the front and rear OCS serial numbers.

      Do the front and/or rear OCS units require replacement? 

      YES  : Front and/or rear OCS require replacement; proceed to Section VII  .

      NO  : Proceed to step 3  .

   If the first 5 digits of the OCS serial number are illegible, the sensor must be replaced.

   NOTE: In the event that the application cannot successfully scan the vinyl VIN certification label due to its compromised condition or if it is missing, please reach out to the Quality Compliance team at quality_compliance@toyota.com  . Include a photograph of the damaged VIN label, if applicable, as well as the VIN label located beneath the windshield in your correspondence.
3. REINSTALL PASSENGER FRONT SEAT 
   1. Install the passenger front seat following the repair manual steps:
      • Corolla 
   NOTE: Be sure to tighten the bolts in the order shown in the repair manual.
4. RESTORE FRONT PASSENGER SEAT TO ORIGINAL POSITION 
5. CAMPAIGN COMPLETE 

VII. REPLACE FRONT AND/OR REAR OCS ASSEMBLIES

HINT:

Perform this procedure only when OCS replacement has been determined in the previous section.

1. REMOVE PASSENGER FRONT SEAT ASSEMBLY 
   1. Remove the passenger front seat following the repair manual steps:
      • Corolla (Steps   3 -  8  only) 
2. PREPARE THE JIG ASSEMBLY 
   1. Identify the correct rear bolt and front alignment pinhole combination to match the seat frame type being mounted to the jig.

   HINT:

   Be sure to position the jig in a safe location clear of any moving vehicles or machinery.

3. INSTALL SEAT ASSEMBLY TO THE JIG 
   1. Place the passenger front seat assembly onto the jig and secure it using the 2 provided bolts and washers through the rear seat track mounting holes.

      Torque: 27 N*m (20 ft.*lbf) 

      NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
   2. Ensure seat is properly secured to the jig.
4. REMOVE THE PASSENGER SIDE FRONT SEAT CUSHION SHIELD 
   1. Remove the passenger side front seat cushion shield following the repair manual instructions:
      • Corolla (Step   12  (a-d) only) 
5. DISCONNECT THE OCS CONNECTORS 
   1. Disconnect the front and rear OCS connectors.
   NOTE: Be sure to disconnect both front and rear OCS connectors before lifting up the seat track in the following steps.
6. REMOVE LEFT REAR SEAT TRACK INTERFERENCE NUT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the rear interference seat track nut using a 12mm 2" (50mm) Torque Adapter with a 6" extension and ratcheting wrench.
   2. Remove the interference nut sleeve and place it in a safe location for later use.
7. REMOVE LEFT REAR SEAT TRACK BOLT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the rear seat track nut using a 14mm 2" (50mm) Torque Adapter with a 6" extension and ratcheting wrench.
8. REMOVE LEFT FRONT SEAT TRACK NUT 

   DO NOT loosen any nuts other than the ones instructed.

   1. Loosen and remove the front seat track nut using a 14mm 2" (50mm) Torque Adapter with a 6" extension and ratcheting wrench.
9. REMOVE THE RIGHT SIDE SEAT TRACK NUTS 
   1. Use a paint maker to circle the circumference of each of the right side seat track nuts.

      HINT: This mark will be used to properly align the seat track during reassembly.

   2. Remove both nuts.
10. LIFT UP AND REMOVE UPPER SEAT FRAME ASSEMBLY 

    Make sure both OCS connectors are disconnected before removing the seat assembly.

    1. Lift up and remove the upper seat assembly and place it in a safe location.
11. REMOVE OCS ASSEMBLIES 

    DO NOT loosen any nuts other than the ones instructed.

    1. Remove the front and/or rear OCS assemblies, as required by the mobile app inspection results.
12. INSTALL NEW OCS ASSEMBLIES TO THE SEAT TRACK ASSEMBLY 
    NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
    1. If necessary, install the NEW  rear OCS assembly to the seat track assembly.
       NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

       Torque: 25 N*m (18.5 ft.*lbf) 

    2. If necessary, install the NEW  front OCS assembly to the seat track assembly.
       NOTE: When installing, be sure to use your thumb to gently push on the left corner of each sensor to seat the NEW OCS properly.

       Torque: 25 N*m (18.5 ft.*lbf) 

    3. Place the upper seat assembly back onto the seat track assembly.
13. REINSTALL RIGHT SIDE SEAT TRACK ASSEMBLY 
    1. Reinstall the right side seat track nuts, ensuring that the nuts are centered in the paint mark circle.

       Torque: 25 N*m (18 ft.*lbf) 

14. PREPARE INTERFERENCE SLEEVE 
    1. Prepare the interference sleeve for installation by using masking tape. Cut approximately 20mm (3/4") of tape and wrap the interference sleeve 2 times  , ensuring no wrinkles or creases exist.

       HINT:

       This will ensure that no contact between the sleeve and seat track assembly exists during the installation of the left side seat track nuts.

    2. Temporarily insert the interference sleeve onto the stud.
15. CALCULATE TORQUE SPECIFICATION FOR SEAT TRACK NUTS 
    1. Use the following formula to calculate the torque specification:
       NOTE: The applied torque changes when using the SST adapter. The calculation below will determine the new applied torque specification required for installing the seat track nuts.

       HINT:

       • The measurement that needs to be performed manually is the Torque Wrench Length  in millimeters (See illustration above). This is due to the varying sizes of torque wrenches available for use.
       • The SST adapter is set to allow for 50mm in length.
       • An extension can be used along with the SST adapter. The extension does not affect the calculated torque specification.
    2. Calculation  :
       • New Torque Value = (A/(A+B)) * Original Torque Value

         A = Torque wrench length (mm) (wrench drive centerline to handgrip centerline)

         B = SST adapter length being used (50mm)

       Original Torque Value = 37 N*m 

       HINT: Example  :

       If  :

       A = 270mm *(variable based on your torque wrench size)

       B = 50mm *(fixed value for this SST)

       Original Torque Value = 37 N*m

       Then  :

       New Torque Value = (270/(270+50)) * 37 =

       (270/320) * 37 =

       0.843 * 37 = 31

       New Torque Value = 31 N*m (23 ft.*lbf) 

16. INSTALL THE LEFT SIDE SEAT TRACK BOLTS 

    The interference sleeve MUST not touch the seat frame on any side during the following steps.  Confirm that the interference sleeve is free to spin after the torquing of each nut.  If at any point the interference sleeve is no longer free to spin, the left side seat track nuts need to be removed, the seat track adjusted, and the nuts reinstalled.

    1. Re-install the left side rear seat track nut and check to ensure interference sleeve is still free to spin. If interference sleeve is not free to spin (making contact with the seat frame), loosen the rear seat track nut, adjust the seat assembly, and repeat this step

       Original Torque Value: 37 N*m (27.5 ft.*lbf) 

       NOTE: The torque adapter MUST remain inline (parallel) with the torque wrench handle while torquing nuts. If torque wrench adapter is not parallel with the torque wrench handle while torquing, the effective length of the tool will be altered, causing torque calculations to be inaccurate.
    2. Re-install the left side front seat track nut following the same process as the previous step.

       Original Torque Value: 37 N*m (27.5 ft.*lbf) 

    3. Remove the tape from the interference sleeve and reinstall it to the stud.
    4. Re-install the interference sleeve nut.

       Original Torque Value: 25 N*m (18 ft.*lbf) 

    1. Confirm the status of the interference sleeve using a flashlight to shine light in the top side of the interference sleeve.

       HINT:

       If no interference exists between the lower seat frame and the spacer, the light can be seen all around. If there is interference, the light cannot be seen.

       Does the interference sleeve touch the seat track on any side? 

       NG  : Remove the left side seat track bolts and repeat the installation steps.

       OK  : Proceed to step 17  .

17. RECONNECT BOTH FRONT AND REAR OCS CONNECTORS. 
18. INSTALL THE PASSENGER SIDE FRONT SEAT CUSHION SHIELD 
    1. Install the passenger side front seat cushion shield following the repair manual instructions:
       • Corolla (Step 37(b) - 39(b) only) 
19. REMOVE THE SEAT ASSEMBLY FROM THE JIG 
    1. Remove the 2 nuts and then remove the seat assembly from the jig.
20. REINSTALL PASSENGER FRONT SEAT 
    1. Install the passenger front seat following the repair manual steps:
       • Corolla 
    2. Continue to Zero Point Calibration section VIII. 

VIII. CALIBRATION AND CONFIRMATION

1. PERFORM ZERO POINT CALIBRATION 
   1. Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS/OCCUPANT CLASSIFICATION SYSTEM/INITIALIZATION.
      • Corolla 
2. PERFORM OCCUPANT CLASSIFICATION SYSTEM - DATA LIST/ACTIVE TEST 
   1. Refer to the Repair Manual for instructions on Vehicle Interior/SUPPLEMENTAL RESTRAINT SYSTEMS: OCCUPANT CLASSIFICATION SYSTEM: DATA LIST/ACTIVE TEST.
      • Corolla 
      • Corolla HV 
   2. For 4-way seat  :

      Confirm that the Total Weight Information  value is within ±3.70 lbs  at each confirmation point.

      HINT: Refer to the chart above for reference.

      1. With the seat in the lowest and forward most position, move the seat to the rear most position  and confirm the "Total Weight Information" value in the data list.
      2. Move the seat to the forward most position  and confirm the "Total Weight Information" value in the data list.

   Do all the confirmation point values fall within the target range value? 

   YES  - Proceed to Step 3  .

   NO - STOP  and contact FTS to report findings.

3. CONFIRM PASSENGER AIRBAG INDICATOR LIGHT OPERATION 
   1. Sit on the passenger front seat and confirm if the airbag light changes from "OFF" to "ON".

      Does the passenger airbag indicator light switch to ON? 

      YES  - Campaign complete.

      NO  - Perform zero point calibration again and recheck.

VERIFY REPAIR QUALITY  

• Confirm all bolts are properly torqued. 
• Confirm all seat track bolts and wire harness connectors are installed correctly. 
• Confirm no DTCs present after repair. 

IX. APPENDIX

B. CAMPAIGN DESIGNATION DECODER

Examples:

19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019

20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020

21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021