T-CP-N04-0144-W_

TOYOTA
Toyota Motor Sales, U.S.A., Inc.
19001 S. WESTERN AVE.
P.O. BOX 2991
TORRANCE, CA 90509–2991
(310)618–4000
(310)618–7800 Fax
September 14, 1992
TO:
ALL TOYOTA DEALERS, SERVICE AND PARTS MANAGERS
SUBJECT:
SPECIAL SERVICE CAMPAIGN - N04 (1987 - 1990 TERCEL HEADLAMP BULB)
Toyota will initiate a Special Service Campaign to inform certain Tercel owners of the need to use
only Koito brand replacement headlamp bulbs. The original equipment headlamp bulbs in these
vehicles were all Koito brand. The use of any brand of bulb other than Koito can cause the
headlamp to fail to meet all of the photometric requirements of the Federal Motor Vehicle Standard
No. 108.
Owners will be supplied with caution labels and asked to install them on the headlamp housings.
Owners who have previously replaced headlamp bulbs will be asked to bring their vehicle to a dealer
for inspection and, if necessary, replacement with a Koito brand bulb. Any headlamp bulb of the involved vehicles that is burnt out now or in the future will be replaced free of charge with a Koito
brand bulb.
Please assist any involved Tercel owner by inspecting and replacing any non-Koito or burned out
headlamp bulb with the correct Koito bulb. If an owner has not installed the caution labels on each
headlamp housing, please do so for them. An initial supply of these labels is enclosed with this information package. Should you require additional labels, they can be ordered by calling (310)
783-5596. In addition, please install caution labels and Koito headlamp bulbs as necessary in any
vehicles currently in your stock.
1.
Owner Notification Letter Mailing Date
September 28, 1992 (copy attached)
2.
Identification of Involved Vehicles
VIN
Model
Model
Year
Toyota
Tercel
1987 1990
NOTE:
VDS
EL31D
EL31F
EL31G
EL31H
EL31M
EL32D
EL32F
EL32G
EL32H
EL33F
EL33M
EL34F
VIS
Production
Period
0000001-0581253
7/86 - 8/90
Although the involved vehicles are within the above VIN ranges, not all vehicles in
these ranges were imported into the U.S.
Page 2
SSC N04
Should you be contacted by the owner of an involved vehicle who has not yet received a notification,
please verify eligibility by referring to the VIN range and perform the inspection, caution label
installation, and if necessary, bulb replacement.
3.
Repair Procedures
Refer to the attached Technical Instructions.
4.
Parts Ordering
Part No.
5.
Description
Ordering Procedure
90981-13032
Bulb
Normal stocking
81126-16370
Caution Label
To order, contact:
[email protected]
Reimbursement Procedures
Submit Special Service Campaign claims following the procedures described in the Toyota
Warranty Policy & Procedures Manual.
The operation codes to be used for this campaign are as follows:
SSC #
N04
*
NOTE:
Op. Code
Description
Flate Rate Hour
250101
Inspect headlamp bulb/install
labels.*
0.3 hrs./vehicle
250102
Inspect headlamp bulbs/install
labels.* Replace one headlamp bulb.
(Includes adjust headlamp aiming.)
0.5 hrs./vehicle
250103
Inspect headlamp bulbs/install
labels.* Replace two headlamp bulbs.
(Includes adjust headlamp aiming.)
0.6 hrs./vehicle
250106
Customer reimbursement for previous
bulb replacement.
actual expense
(enter in
sublet)
Label installation only necessary if they have not been installed by owner.
The above operation codes include 0.1 flate rate hour for administrative expenses.
Page 3
SSC N04
6.
Customer Reimbursements
Please reimburse any owners who have previously paid to have a headlamp
bulb replaced.
-
Enter the reimbursement charges as a CR sublet type.
Use the customer’s invoice number as the sublet invoice number.
Enter the reimbursement amount in the sublet amount column.
Provide a brief description of the reason for the reimbursement.
Use the customer reimbursement operation code number 250106.
Please review this entire package with your Service and Parts staff to familiarize them with the
proper step-by-step procedure and implement this Special Service Campaign to ensure customer
satisfaction.
Thank you for your cooperation.
TOYOTA MOTOR SALES, U.S.A., INC.
Enclosures
SPECIAL SERVICE CAMPAIGN NOTICE-SSC N04
Dear Toyota Customer:
This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
The office of Vehicle Safety Compliance of the National Highway Traffic Safety Administration (“NHTSA”) believes that 1987 through 1990 Toyota Tercels may fail to conform to Federal Motor Vehicle Safety Standard (“FMVSS” or “Standard”) 108, if replacement headlamp bulbs other
than Koito brand bulbs are installed. Investigation indicates that there may be intereference within the headlamp housing when replacement
bulbs other than those manufactured by Koito are installed. This interference may cause a mis-positioning of the bulb filament and result in the
headlamp’s not meeting all of the photometric requirements of the Standard.
Toyota Original equipment headlamp bulbs were all manufactured by Koito and are therefore not subject to the interference.
Toyota has agreed to conduct a recall of these vehicles pursuant to the National Traffic and Motor Vehicle Safety Act.
A modification program has been developed to address this condition at no cost to you.
What is the


condition?
What will
When non-Koito brand replacement bulbs are installed, the headlamp may not meet all of the photometric
requirements of FMVSS 108.


Toyota do?
Toyota dealers will provide a new replacement Koito brand bulb at no charge if a non-Koito brand bulb
is now installed or should a headlamp bulb burn out in the future.
What should 1.
Place one of the enclosed “caution labels” on each headlamp housing as
you do?
illustrated below.
2.
Use only Koito brand headlamp bulbs for replacement.
3.
In the case of either of the following contact a Toyota dealer as soon as possible for a free exchange new
Koito brand bulb:
(a)
If a non-Koito brand headlamp bulb is not installed, or
(b)
If a headlamp bulb should burn out in the future.
The replacement labor time is approximately 15-30 minutes. However, it may be
necessary to wait longer depending upon the dealer’s work schedule.
If you have sold or traded your vehicle, please fill out the attached prepaid postcard
and return it to us.
What if you


Please contact your dealer or Toyota Customer Assistance Center at 1-800-331-4331. If you believe
have other
that your dealer or Toyota has failed to remedy the defect within a
questions?
reasonable time, you may submit a complaint to the Administrator, National
Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, D.C.
20590 or call the toll free Auto Safety Hotline at 800-424-9393 (Washington D.C.
area residents may call 426-0123).
Sincerely,
TOYOTA MOTOR SALES, U.S.A., INC.
CORPORATE SERVICE DEPARTMENT
TECHNICAL INSTRUCTIONS
I.
PROCEDURES:
Confirm that vehicle is in affected VIN range.
Yes
No
Confirm headlight bulb manufacturer:
(1) Remove both headlight bulbs.
Caution:
The bulb remains hot immediately after the headlights are turned off,
so take care not to burn yourself on the bulb.
(2) Confirm maker of headlight bulb.
Is the bulb manufactured by KOITO?
No
Yes
Replace the bulb with one
made by KOITO.
(Part No. 90981-13032)
(1) Reinstall the bulb.
(2) If the CAUTION LABELS have not
been affixed, attach them to the
specified location.

 Wipe both headlights
clean with a dry cloth.

 Remove the backing from the
CAUTION LABEL.

 Attach the CAUTION LABEL
as shown in the illustration.
If the CAUTION LABELS have
not been affixed, attach them to
the specified location.

 Wipe both headlights clean
with a dry cloth.

 Remove the backing from the
CAUTION LABEL.

 Attach the CAUTION LABEL
as shown in the illustration.
Adjust aiming of headlight
beam.
Finished
II. HEADLIGHT BULB REMOVAL, INSPECTION AND INSTALLATION PROCEDURE
1.
Turn off the headlight switch.
2.
Open the hood and unplug the
connector while depressing the
lock release.
3.
Turn the bulb retaining ring
counter-clockwise and take out
the bulb.
CAUTION:


The bulb remains hot
immediately after the
headlights are turned off, so
take care not to burn yourself
on the bulb.
4.
Confirm the manufacturer of the
headlight bulb. If the bulb is not
manufactured by KOITO, replace
the bulb with one made by KOITO.
5.
Reinstall the original or
replacement KOITO bulb and the
bulb retaining ring.
Insert the connector.
NOTE:


Do not touch the bulb glass
with your bare hands. If you
do, clean the glass with
alcohol and a clean rag.


Make sure the connector is
fully locked.


Repeat the procedure with the
other bulb.


If bulb is replaced, adjust
aiming of the headlight beam.
III. LOCATION OF CAUTION LABEL
1. If the CAUTION LABELS have not been affixed in the correct location,
attach them to the specified location indicated below:






Wipe the area on top of both headlights clean with a dry cloth.
Remove the backing from the CAUTION LABEL.
Attach the CAUTION LABEL as shown in the illustration below.