Issue:
This recall is for certain block heater kits installed on certain vehicles or sold as accessories at Toyota or Lexus dealerships.
On certain vehicles, the engine block heater cable may not have enough heat protection and could be damaged by high temperatures. If this happens, the cable could short circuit while plugged in, and cause the wiring to overheat or melt.
Note: This recall only affects the following block heater/cord part numbers:
C014003034 PK5A408J09 PU14000904
C014003151 PK5A408J13 PU14000905
C014000885 PK5A489J11 PU14000907
C014000888 PK5A489J22 PU14000909
C014000907 PK5A410H00 PU14000911
C014100904 PU14000900 PU14000913
C014100907 PU14000901 PU14003571
C014100911 PU14000902
PK5A408J05 PU14000903
Safety Risk:
Engine block heater wiring that overheats or melts could create the risk of a fire.
Corrective Actions:
Toyota recommends that you should stop using the engine block heater immediately. Toyota will notify owners by mail and instruct you to take your vehicle to a dealer to disable the engine block heater. For some vehicles, the corrective actions for this recall are under development. For others, a new engine block heater cannot be installed, and the owner will receive a refund of the purchase price of the engine block heater.
On certain vehicles, the fuel delivery pipes in the engine compartment may have been produced with particles from the anti-corrosion plating on the gasket seating surface where the fuel pressure sensor is installed. This could affect the sealing properties of the gasket seated between the pressure sensor and the pipe, potentially resulting in a fuel leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage. Correction: Dealers will replace the gasket and repair the gasket seating surface.
On certain AWD vehicles, if the floor carpet near the accelerator pedal is not reinstalled correctly following a service repair, the plastic pad embedded into the floor carpet could interfere with the operation of the accelerator pedal. If this occurs, the accelerator pedal could temporarily become stuck in a partially depressed position, rather than return to the idle position. This could result in a loss of throttle control and a crash causing property damage and/or personal injury. Correction: Dealers will modify the plastic pad.
On certain GS 300, GS 300 AWD, GS 350, IS 250, IS 250 AWD and IS 350 vehicles, the fuel pressure sensor connected to the engine fuel delivery pipe may not have been sufficiently tightened during vehicle assembly. Should the pressure sensor loosen, fuel could leak past a gasket used in the connection between the sensor and pipe, and through the threaded portion of the sensor. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury. Correction: Dealers will inspect for fuel leakage from the threaded portion of the fuel pressure sensor. If there are no signs of a fuel leak, the fuel pressure sensor will be tightened to specifications. If a fuel leak is confirmed, the gasket between the sensor and the fuel delivery pipe will be replaced, and the sensor will be tightened.
Certain vehicles use brake fluids containing polymers that act as lubricants for certain brake system components. If during vehicle maintenance, brake fluid is used that does not contain such polymers or only small amounts, part of the internal rubber seal located at the end of the brake master cylinder piston may become dry and may curl during movement of the piston. If this occurs, a small amount of the brake fluid could slowly leak from the brake master cylinder into the brake booster, resulting in illumination of the brake warning lamp. If the brake warning light has illuminated and the vehicle continues to be operated without refilling the master cylinder brake fluid reservoir, the driver will begin to notice a spongy or soft brake pedal feel and braking performance may gradually decline. This will increase the stopping distance, increasing the likelihood of a crash. Correction: Dealers will replace the brake master cylinder seal with a newly designed one.
On certain vehicles, the use of selected ethanol fuels may cause the aluminium fuel rails to corrode. This could result in plugged fuel injector(s), causing a rough engine idle and/or the illumination of the engine warning lamp. Corrosion may also cause a pinhole to develop on the fuel rail, which could result in fuel leakage. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire. Correction: Dealers will replace the fuel rails.
On certain GS 300, GS 300 AWD, IS 250, IS 250 AWD and IS 350 vehicles, incorrect fabrication process may cause the fuel lines to crack, possibly resulting in a leak. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire causing injury or death. Correction: Dealers will replace the fuel lines.
On certain GS 300, GS 300 AWD, GS 430, IS 250, IS 250 AWD and IS 350 vehicles, the front seat belt retractors may contain an inappropriately sized part for the emergency locking system. This can prevent the locking system from releasing when it is activated. If the seat belt is locked in this condition, the occupant may either not fasten the seat belt, or be inadequately restrained due to improper belt-fit thereby increasing the risk of injury. Correction: Dealers will replace the front seat belt assemblies.
This vehicle may contain inadequate side airbag inflators. The airbag inflators were produced with an insufficient amount of the heating agents which apply heat to the argon gas in the inflator. In this condition, expansion force of the gas in the inflator may be insufficient to properly inflate the airbag when the system is activated during a collision, which can increase the risk of injury. Correction: Dealer will replace the side airbag module.
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