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

WARNING: This page is about the Highlander Hybrid LE, 2.5L Eng VIN A, which is a different variant/trim than selected.
Publication date: 2024-09-26
Reference number: 23TA15

SAFETY RECALL 23TA15 (REMEDY NOTICE) - MULTIPLE MODELS AND MODEL YEARS - PASSENGER AIRBAG MAY NOT DEPLOY

SAFETY RECALL 23TA15 (REMEDY NOTICE) - MULTIPLE MODELS AND MODEL YEARS - PASSENGER AIRBAG MAY NOT DEPLOY

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 23TA15, Date of Issue:  September 26, 2024
TOYOTA: See Chart Below
COPYRIGHT: © 2018 Toyota, USA License Agreement TMS1002

SERVICE INFORMATION

IMPORTANT UPDATE  

The attached Dealer Letter has been updated. Refer to the details below. 

DATE TOPIC
12/09/2024 Updated Phase Table in Dealer Letter and FAQ

The most recent update in the attached Dealer Letter will be highlighted with a red box. 

Please review this notification with your staff to assure that all relevant personnel have been briefed regarding this subject.

Thank you for your cooperation.

Toyota Motor Sales, USA, Inc.

6565 Headquarters Drive

Plano, TX 75024

(469) 292-4000

Original Publication Date: September 26, 2024

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

COVERED VEHICLES

Model/Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2020-2021 Avalon Early July 2020 - Late April 2021 9,100 0
2020-2021Avalon HV Early July 2020 - Early May 2021 5,800 0
2020-2022 Camry Early July 2020 - Early November 2023 202,500 0
2020-2022 Camry HV Early July 2020 - Late September 2021 27,100 0
2020-2021 Corolla Late May 2020 - early March 2021 92,700 0
2020-2021 Highlander Late May 2020 - Late September 2021 134,900 0
2020-2021 Highlander HV Early June 2020 - Late September 2021 58,100 0
2020-2021 RAV4 Early June 2020 - Late May 2021 249,800 0
2020-2021 RAV4 HV Early June 2020 - Mid-November 2021 76,800 0
2021 Sienna HV Mid-October 2020 - Late March 2021 35,300 0
G16810858
 STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY. 
Refer to Dealer Inventory Procedures section for more details. 
G16810859

On December 20, 2023 Toyota 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 the models described in the table above.

CONDITION

The subject vehicles have Occupant Classification System (OCS) sensors in the front passenger seat that could have been improperly manufactured, causing a short circuit. This would not allow the airbag system to properly classify the occupant's weight, and certain front passenger airbags may not deploy as designed in certain crashes, increasing the risk of injury.

REMEDY

Toyota dealers will inspect the OCS sensors and, if necessary, replace them FREE OF CHARGE.  Please note that as part of the remedy repair, technicians will be required to use a mobile inspection application.

In order to make the best use of available parts while mitigating risk to Toyota's customers, Toyota is employing a phased remedy implementation, starting with the most humid states first, based on the vehicle's state of registration at time of phase one launch  . This is because, while OCS sensor failure is rare, it is more likely to occur in more humid areas first.

Important Note:  The dates specified in this table are estimates and are subject to change.

APPLICABLE VEHICLES

Phase Model Years Models Location Approximate Total Vehicles Estimated Remedy Launch Timing
1 All involved Model Years All involved Models Rental Agencies, U.S. Terr., Ak, FL, LA, MS, HI, IA, MI, IN, ME, VT, AL 183,700 Remedy Available Now
2 All involved Model Years All involved Models WI, OH, RI, WA, GA, MA, AR, DE 125,100
3 All involved Model Years All involved Models IL, ND, NY, NC, MN 110,900 Fbruary 2025
4 All involved Model Years All involved Models NH, KY, WV, PA, TN, CT 76,400 April 2025
5 All involved Model Years All involved Models MO, SC, MD, D.C., VA, OR, NJ 109,900 June 2025
6 All involved Model Years All involved Models SD, NE, KS 10,100 August 2025
7 All involved Model Years All involved Models TX, OK, ID 98,700 September 2025
8 All involved Model Years All involved Models CA, MT, WY, CO, UT, NM, AZ, NV 177,100 January 2026

CAMPAIGN PHASE INTERPRETATION

Campaigns may be launched in phases due to many factors, such as: the nature of the repair, parts availability, etc. It is important that each VIN is confirmed using TIS to determine if the vehicle is in the remedy or interim phase. Only perform the repair that is available for the specific VIN. If a remedy repair is performed on an interim phase vehicle, the claim will be subject to debit. 

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STATUS IDENTIFICATION 

  1. Campaign Description: 23TA15 Remedy
  2. Campaign Status: Remedy Available
    • This vehicle is eligible to have the remedy performed. 
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STATUS IDENTIFICATION 

  1. Campaign Description: 23TB15 Interim
  2. Campaign Status: Remedy Not Available
    • This vehicle is in the interim phase; the remedy CANNOT be performed at this time. 

COVERED VEHICLES

There are approximately 892,000 vehicles covered by this Safety Recall. Approximately 2,100 vehicles involved in this Safety Recall were distributed to Puerto Rico.

OWNER LETTER MAILING DATE

Phase 1 Customer Mailing October 2024
Phase 2 Customer Mailing January 2025

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 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 - 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.

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 (Non SET and GST dealers: https://dealerdaily.toyota.com/  ). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

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.

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 (Non SET and GST dealers: 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. 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 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 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.

PARTS INFORMATION

Part Number Part Description Quantity
04003-60106 SENSOR SUB-ASSY, WEIGHT DETECTOR, FR 1
04003-60206 SENSOR SUB-ASSY, WEIGHT DETECTOR, RR 1

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.

WARRANTY REIMBURSEMENT PROCEDURES

Warranty Reimbursement Procedure 

G16810862
WARRANTY REIMBURSEMENT PROCEDURES

Op Code Description Flat Rate Hours
23TA15R1 OCS Inspection Only 0.4
23TA15R2 OCS Inspection + OCS
Replacement For 1 or Both
Sensors - RAV4, Sienna,
Highlander		 1.5
23TA15R3 OCS Inspection + OCS
Replacement For 1 or Both
Sensors - Corolla		 1.6
23TA15R4 OCS Inspection + OCS
Replacement For 1 or Both
Sensors - Camry, Avalon		 1.4

CAMPAIGN DESIGNATION/PHASE DECODER

G16810863

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

Please review this entire package with your Service and Parts staff to familiarize them with the proper step-by-step procedures required to implement this Safety Recall. 

Thank you for your cooperation.

TOYOTA MOTOR SALES, U.S.A., INC.

SAFETY RECALL 23TA15

SAFETY RECALL 23TA15 (Remedy Notice) 

Multiple Models and Model Years 

Passenger Airbag May Not Deploy 

Frequently Asked Questions 

Original Publication Date: September 26, 2024 

Q1: What is the condition? 

A1: The subject vehicles have Occupant Classification System (OCS) sensors in the front passenger seat that could have been improperly manufactured, causing a short circuit. This would not allow the airbag system to properly classify the occupant's weight, and certain front passenger airbags may not deploy as designed in certain crashes, increasing the risk of injury.

Q2: Are there any warnings that this condition exists? 

A2:  Yes, the SRS warning light and the "Passenger Airbag OFF" light will be illuminated, and a multi-information display message will be displayed.

Q3: What is Toyota going to do? 

A3: Toyota will inspect the OCS sensors and, if necessary, replace them FREE OF CHARGE  .

Q4: When will the remedy become available? 

A4: In order to make the best use of available parts while mitigating risk to Toyota's customers, Toyota is employing a phased remedy implementation, starting with the most humid states first, based on the vehicle's state of registration at time of phase one launch  . This is because, while OCS sensor failure is rare, it is more likely to occur in more humid areas first.

APPLICABLE MODELS AND YEARS

Phase Model Years Model Location Approximate Total Vehicles Estimated Remedy Launch Timing
1 All involved Model Years All involved Models Rental Agencies, U.S. Terr., Ak, FL, LA, MS, HI, IA, MI, IN, ME, VT, AL 183,700 Remedy Available Now
2 All involved Model Years All involved Models WI, OH, RI, WA, GA, MA, AR, DE 125,100
3 All involved Model Years All involved Models IL, ND, NY, NC, MN 110,900 February 2025
4 All Involved Model Years All Involved Models NH, KY, WV, PA, TN, CT 76,400 April 2025
5 All Involved Model Years All Involved Models MO, SC, MD, D.C., VA, OR, NJ 109,900 June 2025
6 All Involved Model Years All Involved Models SD, NE, KS 10,100 August 2025
7 All Involved Model Years All Involved Models TX, OK, ID 98,700 September 2025
8 All Involved Model Years All Involved Models CA, MT, WY, CO, UT, NM, AZ, NV 177,100 January 2026

Q4a: How did Toyota decide which states should go first in the phase launch schedule? 

A4a: Based on available data, Toyota has determined there is a correlation between higher OCS sensor failure rates and higher humidity areas. The best way to minimize the number of customers who may experience an actual OCS sensor failure is to prioritize vehicles with the highest likelihood of failing by making the remedy available to vehicles in states with the highest average annual humidity first.

Q4b: What if I move to a different state before the remedy becomes available for my vehicle? 

A4b: Your vehicle's phase will be determined prior to Phase 1 launch, based on the state of the vehicle's registration. Once a vehicle is assigned a phase, that phase will not be changed due to vehicle movement between states.

Q5: Which and how many vehicles are covered by this Safety Recall? 

A5: There are approximately 892,000 vehicles covered by this Safety Recall.

APPLICABLE MODELS AND YEARS

Model Years Model Production Period Approximate Total Vehicles
2020-2021 Avalon Early July 2020 - Late April 2021 9,100
2020-2021 Avalon HV Early July 2020 - Early May 2021 5,800
2020-2022 Camry Early July 2020 - Early November 2023 202,500
2020-2022 Camry HV Early July 2020 - Late September 2021 27,100
2020-2021 Corolla Late May 2020 - early March 2021 92,700
2020-2021 Highlander Late May 2020 - Late September 2021 134,900
2020-2021 Highlander HV Early June 2020 - Late September 2021 58,100
2020-2021 RAV4 Early June 2020 - Late May 2021 249,800
2020-2021 RAV4 HV Early June 2020 - Mid November 2021 76,800
2021 Sienna HV Mid October 2020 - Late March 2021 35,300

Q5a: Are there any other Toyota/Lexus vehicles covered by this Safety Recall in the U.S.? 

A5a: Yes, there are certain Lexus 2021 ES250, 2020-2022 ES300H, 2020-2021 ES350, 2020-2021 RX450H, 2020-2021 RX350 vehicles covered by this Safety Recall.

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 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.

TECHNICAL INSTRUCTIONS

FOR 

SAFETY RECALL 23TA15 

PASSENGER AIRBAG MAY NOT DEPLOY 

CERTAIN 2020-2022 AVALON, AVALON HV, CAMRY, CAMRY HV VEHICLES 

Updated 12/09/2024 - Updated inspection app download 

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: 

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. 

I. OPERATION FLOW CHART

G16810864

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.
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

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. 
G16810865
B. PARTS
PARTS INFORMATION

Part Number Part Description Quantity
04003-60106 SENSOR SUB-ASSY, WEIGHT DETECTOR, FR As needed
04003-60206 SENSOR SUB-ASSY, WEIGHT DETECTOR, RR As needed

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

G16810866

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

NOTE: Manual seat track assembly will follow the same inspection instructions.
  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 

      G16810867
      G16810868
      		 DO NOT disconnect any seat harness connectors at this time.
      G16810869
    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
      G16810870
      G16810871
    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. 

      G16810872
  2. IDENTIFY THE FRONT AND REAR OCS SERIAL NUMBERS 
    1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
      G16810873
      G16810874
      G16810875
      G16810876
    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  .

    G16810877
    		 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 
    G16810878
    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

NOTE: Manual seat track assembly will follow the same repair instructions.

HINT: 

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

G16810879
  1. REMOVE PASSENGER FRONT SEAT ASSEMBLY 
    G16810880
    		 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.

    G16810881
  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) 

      G16810882
      NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
      G16810883
    2. Ensure seat is properly secured to the jig.
      G16810884
  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.
    G16810885
  5. REMOVE LEFT SIDE SEAT TRACK NUTS 
    G16810886
    		 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.
    G16810887
    G16810888
  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.

    G16810889
    G16810890
    		 DO NOT exceed 4.5" of space when inserting tape roll. Damage may occur if this is not followed. 
  7. REMOVE OCS(S) 
    G16810891
    G16810892
    		 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.
    G16810893
  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.
    G16810894
    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) 

      G16810895
    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) 

    G16810896
    1. Remove the spacer and place the upper seat assembly back onto the seat track assembly.
      G16810897
    2. Re-install the rear seat track nut.

      Torque: 47 N*m (35 ft.*lbf) 

      G16810898
    3. Re-install the front seat track nut.

      Torque: 47 N*m (35 ft.*lbf) 

      G16810899
    4. Reconnect both front and rear OCS connectors.
      G16810900
    5. Remove the 2 mounting nuts securing the seat assembly to the jig and remove the seat assembly from the jig.
    G16810901
  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  .
    G16810902

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 
    G16810903
    G16810904
    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

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 DECODER
G16810905

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

TECHNICAL INSTRUCTIONS

FOR 

SAFETY RECALL 23TA15 

PASSENGER AIRBAG MAY NOT DEPLOY 

CERTAIN 2020-2022 HIGHLANDER, HIGHLANDER HV, RAV4, RAV4 HV, SIENNA HV VEHICLES 

Updated 12/09/2024 - Updated inspection app download information 

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: 

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. 

I. OPERATION FLOW CHART

G16810906

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.
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

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. 
G16810907
B. PARTS
PARTS INFORMATION

Part Number Part Description Quantity
04003-60106 SENSOR SUB-ASSY, WEIGHT DETECTOR, FR As Needed
04003-60206 SENSOR SUB-ASSY, WEIGHT DETECTOR, RR As Needed

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

G16810908

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

NOTE: Manual seat track assembly will follow the same inspection instructions.
  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 

      G16810909
      G16810910
      		 DO NOT disconnect any seat harness connectors at this time
      G16810911
    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
      G16810912
      G16810913
    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. 

    G16810914
  2. IDENTIFY THE FRONT AND REAR OCS ASSEMBLY SERIAL NUMBERS 
    1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
      G16810915
      G16810916
    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  .

    G16810918
    		 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.
    G16810917
  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 
    G16810919

VII. REPLACE FRONT AND/OR REAR OCS ASSEMBLIES

HINT:

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

G16810920
  1. REMOVE PASSENGER FRONT SEAT ASSEMBLY 
    G16810921
    		 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.

    G16810922
  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.
      G16810923
      G16810924
    2. Ensure seat is properly secured to the jig.
      G16810925
  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.
      G16810926
  5. REMOVE LEFT REAR SEAT TRACK INTERFERENCE NUT 
    G16810927
    G16810928
    		 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.
      G16810929
    2. Remove the interference nut sleeve and place it in a safe location for later use.
      G16810930
  6. REMOVE LEFT REAR SEAT TRACK NUT 
    G16810931
    G16810932
    		 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.
    G16810933
  7. REMOVE LEFT FRONT SEAT TRACK NUT 
    G16810934
    G16810935
    		 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.
    G16810936

    HINT:

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

    G16810937
  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.

    G16810939
    		 DO NOT exceed 4.5" of space when inserting tape roll. Damage may occur if this is not followed 
    G16810938
  9. REMOVE OCS(s) 
    G16810940
    G16810941
    		 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.
    G16810942
  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.
    G16810943
    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) 

      G16810944
    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) 

      G16810945
    3. Remove the spacer and place the upper seat assembly back onto the seat track assembly.
      G16810946
  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.

      G16810947
    2. Temporarily insert the interference sleeve onto the stud.
      G16810948
  12. CALCULATE TORQUE SPECIFICATION FOR SEAT TRACK NUTS 
    G16810949
    G16810950
    G16810951
    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 
    G16810952
    • 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.
      G16810953
    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) 

      G16810954
    3. Remove the tape from the interference sleeve and reinstall it to the stud.
      G16810955
    4. Re-install the interference sleeve nut.

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

      G16810956
    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  .

    G16810957
    G16810958
  14. RECONNECT BOTH FRONT AND REAR OCS CONNECTORS. 
    G16810959
    NOTE: (Power Seat Only) Reinstall the power seat motor connector removed in the previous step.
    G16810960
  15. REMOVE THE SEAT ASSEMBLY FROM THE JIG 
    1. Remove the 2 nuts and then remove the seat assembly from the jig.
    G16810961
  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.
    G16810962

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 
    G16810963
    G16810964
    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

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 DECODER
G16810965

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

TECHNICAL INSTRUCTIONS

FOR 

SAFETY RECALL 23TA15 

PASSENGER AIRBAG MAY NOT DEPLOY 

CERTAIN 2020-2021 COROLLA VEHICLES 

Updated 12/09/2024 - Updated inspection app download information 

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: 

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. 

I. OPERATION FLOW CHART

G16810966

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.
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

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. 
G16810531
B. PARTS
PARTS INFORMATION

Part Number Part Description Quantity
04003-60106 SENSOR SUB-ASSY, WEIGHT DETECTOR, FR As Needed
04003-60206 SENSOR SUB-ASSY, WEIGHT DETECTOR, RR As Needed

IV. WORK PROCEDURE TABLE OF CONTENTS

-

V. BACKGROUND

G16810967

VI. INSPECT FRONT AND REAR OCS SERIAL NUMBERS

NOTE: Manual seat track assembly will follow the same inspection instructions.
  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 

      G16810968
      G16810969
      		 DO NOT disconnect any seat harness connectors at this time.
      G16810970
    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
      G16810971
      G16810972
    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 

      G16810973
  2. IDENTIFY THE FRONT AND REAR OCS ASSEMBLY SERIAL NUMBERS 
    1. Viewing from underneath the seat, locate and identify the front and rear OCSs.
      G16810974
      G16810975
    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  .

    G16810976
    G16810977
    		 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 
    G16810978

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) 
    G16810979
  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.

    G16810980
  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) 

      G16810981
      NOTE: Wear protective gloves. Sharp areas on the seat track parts may injure your hands.
      G16810982
    2. Ensure seat is properly secured to the jig.
      G16810983
  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) 
    G16810984
  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.
    G16810985
    G16810986
  6. REMOVE LEFT REAR SEAT TRACK INTERFERENCE NUT 
    G16810988
    		 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.
      G16810987
      G16810989
    2. Remove the interference nut sleeve and place it in a safe location for later use.
      G16810990
  7. REMOVE LEFT REAR SEAT TRACK BOLT 
    G16810992
    		 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.
      G16810991
      G16810993
  8. REMOVE LEFT FRONT SEAT TRACK NUT 
    G16810995
    		 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.
    G16810994
    G16810996
  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.
      G16810997

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

      G16810998
    2. Remove both nuts.
      G16810999
  10. LIFT UP AND REMOVE UPPER SEAT FRAME ASSEMBLY 
    G16811001
    		 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.
      G16811000
      G16811002
  11. REMOVE OCS ASSEMBLIES 
    G16811004
    		 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.
      G16811003
      G16811005
  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.
    G16811006
    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) 

      G16811007
    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.
      G16811008

      Torque: 25 N*m (18.5 ft.*lbf) 

    3. Place the upper seat assembly back onto the seat track assembly.
      G16811009
  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) 

      G16811010
      G16811011
  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.

      G16811012
    2. Temporarily insert the interference sleeve onto the stud.
      G16811013
  15. CALCULATE TORQUE SPECIFICATION FOR SEAT TRACK NUTS 
    G16811014
    G16811015
    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 
    G16811016
    • 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.
      G16811017
    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) 

      G16811018
    3. Remove the tape from the interference sleeve and reinstall it to the stud.
      G16811019
    4. Re-install the interference sleeve nut.

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

      G16811020
    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  .

    G16811021
    G16811022
  17. RECONNECT BOTH FRONT AND REAR OCS CONNECTORS. 
    G16811023
  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) 
    G16811024
  19. REMOVE THE SEAT ASSEMBLY FROM THE JIG 
    1. Remove the 2 nuts and then remove the seat assembly from the jig.
    G16811025
  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. 
    G16811026

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 
    G16811027
    G16811028
    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

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 DECODER
G16811029

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

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