Toyota recalls more than 1.1 million vehicles due to faulty airbags that do not deploy properly

Toyota said the recall includes 2020-2022 vehicles and many models, including Toyota Avalon, Camry, Corolla, RAV4, Highlander, Sienna Hybrid, Lexus ES250, ES300H, ES350, RX350 models.

Of the more than 1.1 million affected vehicles, one million are in the US. The rest are in other markets, but details are unclear.

The fault could cause the Occupant Classification System (OCS) sensors to fail. OCS typically includes a weight sensor located under the seat, a seat belt tension sensor to determine whether the seat is occupied by a child wearing a seat belt or simply placing a heavy object on the seat.

When analyzing the data, a light will appear on the dashboard to let the driver know whether the passenger airbag is on or off. The airbag is also controlled to deploy at maximum or moderate speed depending on the size of the occupant.

If the seat is determined to be occupied by a child, a light adult, or simply a heavy object, the airbag will not deploy in the event of a collision. Because for children, deploying an airbag at a speed of about 320 km/h can be more dangerous than not deploying at all. The "air bomb" can lead to deaths or head, neck, and spinal injuries caused by the airbag, for most children.

However, the OCS sensor short circuit causes the system to malfunction, and poses a risk of not deploying as designed in the event of an accident.

Dealers will inspect and, if necessary, replace the faulty sensors. The Japanese automaker plans to begin notifying owners of the recalled vehicles in February 2024.

In July 2022, Toyota also had to recall 3,500 RAV4s in the US because collisions between components could cause the OCS sensor to not accurately detect passengers in the front seat.

Frontal airbags have helped save more than 50,000 lives in the United States over the past 30 years, according to the National Highway Traffic Safety Administration (NHTSA).

The new sensors work better because older airbags tend to deploy with the same force on everyone, causing some injury and, in rare cases, even death to children or small adults, as well as unbelted passengers sitting too close to the airbag.