Toyota Highlander Hybrid Recalls

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Two of the main control modules for the hybrid drive system are the Inverter Module and the Intelligent Power Module (IPM), which is located inside the Invertor Module. The IPM can operate at temperatures high enough to damage its electrical solder connections. Damaged solder joints can result in illumination of warning lights, various drivability concerns, and possible stalling of the hybrid drive system. Dealers will replace the IPM on affected vehicles to correct this concern.

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Vehicles have a tire size/weight rating label to inform owners of the carrying capacity of their vehicle. These models are being recalled because the incorrect vehicle weight rating is shown on the information label. This could result in vehicle and tire overloading, increasing the risk of tire failure. Owners will be provided an updated vehicle weight label to correct this concern.

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Vehicles that have had accessories added to the seats such as seat heaters, seat covers or DVD headrests may not have the occupant sensor system of the passenger seat calibrated properly. This can affect passenger air bag operation in a crash. Dealers will test the sensitivity of the occupant detection sensors and recalibrate them as necessary free of charge to resolve the concern.

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Toyota and General Motors are recalling certain models because the power window master switch assembly in some of these vehicles was built using a less precise process for lubricating the internal components of the switch assembly. Irregularities in this lubrication process may cause the power window master switch assemblies to malfunction and overheat. This could result in the switch melting or possibly catching fire. Dealers will inspect and repair or replace the master window switch as necessary.

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The amount of adhesive applied between the inner and outer parts of the crankshaft pulley may be inadequate. If this is the case, the outer ring may become misaligned and/or not properly rotate with the inner ring, causing an abnormal noise and/or illumination of the Check Engine Light. In some cases, the power steering belt could come off resulting in a loss of power steering assist, increasing the risk of a crash. Dealers will inspect the crankshaft pulley and replace it if necessary.

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A module inside the hybrid drive inverter module may contain inadequately soldered transistors. These solder joints could fail under high electrical loads, resulting in illumination of various dashboard warning lights, drivability concerns, and/or engine stalling. If the vehicle were to stop unexpectedly, this would increase the risk of a crash. Owners will be notified in July 2011 if their vehicle is involved in this recall. They will received a second notice when parts become available. Dealers will inspect the hybrid inverter module production number to determine if the inverter contains the suspect transistors. They will replace any affected modules.

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One or both sensors designed to detect vehicle roll angle may fail, resulting in illumination of the airbag waring light and suspension of the roll detection system. If both sensors were to fail under certain conditions, the curtain shield airbag and seat belt pretensioner could be inadvertently activated. Inadvertent activation of airbag components can result in injury to vehicle occupants. Dealers will replace the airbag sensor assembly with a new one containing improved roll rate sensors. This recall is scheduled to begin during May 2011.

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The floor carpet cover may interfere with the accelerator pedal if its forward retention clip is not installed properly. As a result, the throttle can become stuck in a partially open position, increasing the risk of a crash. Dealers will replace the carpet cover with a newly designed one. No owner notification schedule has been provided at this time.

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These vehicle were sold without the required load carrying captivity modification label. Dealers will mail the corrected label to vehicle owners. Owners have the option of requesting that the dealer install the label. This recall is expected to begin on May 27, 2010.

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Toyota is recalling certain 2008-2010 Highlander, and 2009-2010 Corolla, Venza, and Matrix models because an unsecured or incompatible floor mat may cause the accelerator pedal to get stuck in the wide open position. This can cause high vehicle speeds and may make the vehicle difficult to stop, which can lead to a crash. Toyota will modify or replace the accelerators on the affected vehicles.

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