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NHTSA Recall 10V384000

American Government Special Collections Reference Desk

Vehicles:  Toyota Corolla, Toyota Matrix

NHTSA Recall 10V384000

NHTSA Campaign ID number : 	10V384000
	
Vehicle Make / Model: 	    	Model Year(s):
     TOYOTA / COROLLA 	    	2005-2008
     TOYOTA / MATRIX 	    	2005-2008
Manufacturer: TOYOTA MOTOR NORTH AMERICA, INC. 	Mfr's Report Date: AUG 26, 2010
NHTSA CAMPAIGN ID Number: 10V384000 	
PE09054,EA10006
NHTSA Action Number: 2 Investigations found
Component: ENGINE AND ENGINE COOLING
Potential Number of Units Affected: 1,128,659
Summary:
TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2008 COROLLA AND COROLLA MATRIX VEHICLES. THE ENGINE CONTROL MODULE (ECM) FOR THE SUBJECT MODELS EQUIPPED WITH THE 1ZZ-FE ENGINE AND TWO-WHEEL DRIVE MAY HAVE BEEN IMPROPERLY MANUFACTURED. THERE IS A POSSIBILITY THAT A CRACK MAY DEVELOP AT CERTAIN SOLDER POINTS OR ON VARISTORS ON THE CIRCUIT BOARD.
Consequence:
THERE ARE A VARIETY OF WARNINGS AND CONSEQUENCES ASSOCIATED WITH THE DEFECT. THE ENGINE WARNING LAMP COULD BE ILLUMINATED, HARSH SHIFTING COULD RESULT, THE ENGINE MAY NOT START, OR THE ENGINE COULD SHUT OFF WHILE THE VEHICLE IS BEING DRIVEN. AN ENGINE SHUTOFF WHILE THE VEHICLE IS BEING DRIVEN INCREASES THE RISK OF A CRASH.
Remedy:
DEALERS WILL INSPECT THE PRODUCTION NUMBER OF THE ECM AND REPLACE THE ECM IF NECESSARY. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. TOYOTA WILL MAIL AN INTERIM OWNER NOTIFICATION THE MIDDLE OF SEPTEMBER 2010 TO ADVISE OWNERS OF THIS DEFECT AND RECALL. THIS INTERIM NOTIFICATION WILL INFORM OWNERS THAT THEY WILL RECEIVE A FUTURE NOTIFICATION WHEN PARTS BECOME AVAILABLE TO HAVE THE FREE REMEDY PERFORMED ON THEIR VEHICLE. THE SAFETY RECALL BEGAN ON NOVEMBER 29, 2010. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
Notes:
OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .


Engine Stalling
NHTSA ID: PE09054
Dated opened: November 30, 2009

On November 30, 2009, the Office of Defects Investigation (ODI) opened a preliminary evaluation (PE09-054) to investigate alleged engine stalling, while driving in model year (MY) 2006 Toyota Corolla and Corolla Matrix vehicles . In its response to ODI's information request submitted on March 2, 2010, Toyota indicated that it had identified two possible causes of production defects of the engine control units (ECU) used in the MY 2005 through 2007 Corolla and Matrix vehicles equipped with the 1ZZ-FE engine.

Failure mode A1 - BGA ball failure caused by improperly cured conformal coating applied to ECU circuit boards. This can cause cracks to form in the soldered joints of some components. Failure mode A2 - Varistor over heating; a glass coating is created on the surface of the Varistor during its production process. In case of an insufficient coating, a crack can occur in the surface of the glass coating. When ions are charged in the plating electrolytes after the glass coating process, the plating electrolytes can penetrate into the Varistor through the glass crack then an electrical short occurs. With respect to these failures, if the condition arises, it can potentially lead to one or more of the following: MIL on, engine stall or engine no start, harsh shifting.

Of the approximately 155,000 warranty and extended warranty claims Toyota has analyzed the projected 5 year failure rate of the ECU associated with an engine stall is 0.8%.

This investigation has been upgraded to an Engineering Analysis (EA10-006) to further assess the scope, frequency and safety risks associated with the identified defects.

Engine Stall
NHTSA ID: EA10006
Dated opened: August 18, 2010

On August 26, 2010, Toyota submitted a Defect Information Report to the National Highway Traffic Safety Administration (NHTSA) regarding problems with Engine Control Modules that could result in engine stall while driving in certain model year (MY) 2005 through 2008 Toyota Corolla, Corolla Matrix and Pontiac Vibe vehicles equipped with the 1ZZ-FE engine and two-wheel drive and manufactured between April 19, 2004 and January 2, 2008. Toyota's report indicated that cracks may develop at certain solder point or on varistors on the ECMs. According to Toyota, such cracks generally resulted in engine warning lamp illumination, harsh shifting or engine no-start. In some cases, if the cracking occurs on particular solder points or varistors, the engine could stop while the vehicle is being driven. Toyota will notify owners of subject vehicles that they should return their vehicles to a Toyota or Pontiac dealer. Dealers will be instructed to inspect the production number of the ECM for each vehicle and replace the ECM if necessary.

On November 30, 2009, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE09-054) to investigate alleged engine stall while driving in model year (MY) 2006 Toyota Corolla and Corolla Matrix vehicles. In its response to ODI's information request, submitted on March 2, 2010, Toyota indicated that it had identified two possible conditions with ECMs used in MY 2005 through 2007 Toyota Corolla and Matrix vehicles: 1) cracks forming between the IC and the board caused by an improperly cured conformal coating applied to the circuit boards after the soldering process is completed; and 2) cracks occurring in a variable resistor (varistor) due to overheating. During the manufacturing process a glass coating is created on the surface of the varistor.

Between March and August 2010, Toyota began collecting ECMs from the field to further investigate failure modes that may result in engine stall. Toyota also conducted durability testing on ECMs collected from in-use vehicles to assess whether the problems may be a continuing trend. In addition, they conducted durability testing in order to assess whether this problem was a continuing trend. Toyota found that 4 of 32 collected ECMs malfunctioned after thermal shock testing. Toyota also confirmed that cracking could develop at solder points on the ECM circuit board that could lead to engine stall while driving and that this trend was likely to continue.

The manufacturer failure data in this resume is limited to MY 2005 through 2007 Toyota Corolla and Corolla Matrix vehicles. Based on Toyota's recall, this Engineering analysis has been closed.

Documents

DateDocument Name & DetailsDocuments
publication 26 August 20102005-2008 Toyota Corolla/Matrix Part 572, Defect Information Report
To: Daniel C. Smith, National Highway Traffic Safety Administration
From: Chris Santucci, Toyota Motor North America, Inc.
NHTSA Recall 10V384000

PDF
- 280KB - 4 pages
publication 26 August 2010ENGINE STALLING
To: Chris Santucci, Toyota Motor North America, Inc.
From: Jennifer Timian, National Highway Traffic Safety Administration
NHTSA Recall 10V384000

PDF
- 32KB - 4 pages
publication 26 August 2010Voluntary Safety Recall - Preliminary Notification
Filing of Defect Information Report, Engine Control Module (ECM) for Certain 2005 through 2008 Toyota Corolla and Corolla Matrix Models Equipped with a 1ZZ-FE Engine and Two Wheel Drive
Toyota Customer Services
NHTSA Recall 10V384000

PDF
- 777KB - 12 pages
publication September 2010Certain 2005 through 2008 Toyota Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL NOTICE (Interim Notice)
Toyota
NHTSA Recall 10V384000

PDF
- 17KB - 1 page
publication September 2010Owner Letter Mailing Schedule 10V-384
Toyota
NHTSA Recall 10V384000

PDF
- 10KB - 1 page
publication November 2010Certain 2005 through 2008 Toyota Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL NOTICE (Interim Notice)
Toyota
NHTSA Recall 10V384000

PDF
- 136KB - 1 page
publication 29 November 2010Toyota Safety Recall 10V-384
To: Delia Lopez, National Highway Traffic Safety Administration
From: George Morino, Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 447KB - 19 pages
publication 29 November 2010Toyota Safety Recall 10V-384
To: Delia Lopez, National Highway Traffic Safety Administration
From: George Morino, Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 281KB - 2 pages
publication 9 December 2010Safety Recall – A0J Dealer Ordering Criteria – Revision 1.1 Certain 2005 through 2008 Toyota Corolla and Corolla Matrix Vehicles Equipped with 1ZZ-FE Electronic Control Module (ECM)
Toyota
NHTSA Recall 10V384000

PDF
- 322KB - 2 pages
publication 5 January 2011Safety Recall – A0J Dealer Ordering Criteria – Revision 2.1 Certain 2005 through 2008 Toyota Corolla and Corolla Matrix Vehicles Equipped with 1ZZ-FE – Electronic Control Module (ECM)
Toyota
NHTSA Recall 10V384000

PDF
- 314KB - 1 page
publication 12 January 2011Quarterly Report - December 31, 2010
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 87KB - 2 pages
publication 31 January 2011Safety Recall – A0J Certain 2005 through 2008 Toyota Corolla and Corolla Matrix Vehicles Equipped with 1ZZ-FE Electronic Control Module (ECM)
Remedy Procedure – Phase 2 (2007 – 2008 model year)
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 510KB - 17 pages
publication 6 April 2011Quarterly Report - March 31, 2011
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 433KB - 2 pages
publication 11 July 2011Quarterly Report - June 30, 2011
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 73KB - 2 pages
publication 12 July 2011Toyota Safety Recalls 09V-388, 10V-023, 10V-160, 10V-176, 10V-345, 10V-346, 10V-384 and 10V499 Dealer Notification Letter for Owner Follow-Up Notice
To: Delia Lopez, National Highway Traffic Safety Administration
From: George Morino, Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 184KB - 4 pages
publication 20 July 2011Certain 2005 through 2008 Toyota Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL FOLLOW-UP NOTICE (Replacement Parts Available)
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 169KB - 2 pages
publication 9 August 2011Owner Renotification of Non-Completed Safety Recalls and Service Campaigns
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 370KB - 2 pages
publication 12 August 2011Certain 2005 through 2008 Toyota Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL FOLLOW-UP NOTICE (Replacement Parts Available)
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 41KB - 1 page
publication 11 October 2011Quarterly Report - September 30, 2011
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 42KB - 2 pages
publication 30 November 2011Owner Renotification of Non-Completed Safety Recalls and Service Campaigns
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 440KB - 2 pages
publication 9 December 2011Certain 2005 through 2008 Toyota Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL FOLLOW-UP NOTICE (Replacement Parts Available)
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 940KB - 1 page
publication 26 January 2012Quarterly Report - December 31, 2011
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 150KB - 2 pages
publication April 2012Quarterly Report - March 31, 2012
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 31KB - 2 pages
publication 21 May 2012Certain 2005 through 2008 Corolla and Matrix Vehicles Engine Control Module (ECM)
SAFETY RECALL FOLLOW-UP NOTICE (Replacement Parts Available)
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 323KB - 1 page
publication 28 June 2012Owner Renotification of Non-Completed Safety Recalls and Service Campaigns
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 589KB - 3 pages
publication 29 November 2012Toyota Safety Recall 10V-384 Dealer Notification Letter for Owner Follow-Up Notice
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 996KB - 6 pages
publication 7 December 2012Toyota Safety Recall 10V-384 Follow-Up Owner Notification Letter
Toyota Motor Sales, U.S.A., Inc.
NHTSA Recall 10V384000

PDF
- 930KB - 3 pages


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