Prius

Defect

Due to incorrect programming the hybrid vehicle ECU can incorrectly determine that the validation signal is erroneous for the shifter position

Remedy

Reprogram the Hybrid ECU.

Defect

The pre-crash brake assist function can be delayed.

Remedy

Reprogram the Brake booster assembly with master cylinder ECU.

Defect

Under certain circumstances the hybrid unit may shut down and cause loss of motive power.

Remedy

Reprogram the Power Management ECU.

Defect

An improper assembly of the electrical contacts in the reminder switch for the driver seat belt

Remedy

Replace driver side seat inner belt.

Defect

An electrical short circuit in the combination meter could occur.

Remedy

Inspect and replace the meter circuit plate based on the inspection result

Defect

Incorrectly installed covers could prevent the seat-mounted side air bag from deploying properly.

Remedy

Inspect the covers installed on the front seats and replace any incorrectly installed covers

Defect

An electrical connection within the motor may cause the brake booster pump to stop operating

Remedy

Inspect and replace the brake booster pump assembly if necessary.

Defect

The vehicle may not enter a failsafe driving mode as intended.

Remedy

Reprogram the Power Management ECU.

Defect

The vehicle may not enter a failsafe driving mode as intended.

Remedy

Reprogram the Power Management ECU.

Defect

Due to assembly variation a portion of the engine wire harness could contact the cover.Should the insulation wear and the core wires become exposed there is an increased risk of a vehicle fire.

Remedy

Inspect the engine wire harness and repair or replace it if necessary.

Defect

The hybrid system of the subject vehicles includes an inverter assembly which contains a capacitor that may not have been properly bolted to the inverter housing. In this condition the terminal of the capacitor could be damaged by vibration during normal vehicle operation.

Remedy

On affected vehicles replace the invertor assembly

Defect

The Electric Vehicle (EV) fuse which may malfunction if the vehicle isrepeatedly operated by the electric motor under high-load driving conditions such as during a long hill climb. If the fuse malfunctions warning lights and warning messages will illuminate. In some cases the vehicle can be driven but with reduced power. In other cases the hybrid system could shut down resulting in the loss of motive power.

Remedy

On affected vehicles replace the fuse.

Defect

The passenger air bag inflator may have been incorrectly manufactured/assembled. This may allow leakage of compressed gas and partial inflation of the airbag without a deployment command.

Remedy

Replace passenger airbag unit.

Defect

The subject vehicles are equipped with a foot-operated parking brake system containing a parking brake cable and a crank lever which upon activation transmit the force of the parking brake pedal to the brake caliper piston. Over time during normal operation of the vehicle the cable could disengage at the pedal end causing the parking brake to become inoperative.

Remedy

Recall the vehicles that are likely to be affected to fit retaining clips for the cable.

Defect

The vehicles are equipped with a fuel evaporative emission control unit (canister) assembled to the fuel tank. There is a possibility that a crack could develop on the resin channel for the emission gas flow due to an improper shape of the channel edge at that location. The crack could expand over time and eventually fuel may leak from the crack when the vehicle has a full tank. Fuel or fuel vapour in the presence of an ignition source could increase the risk of a vehicle fire

Remedy

Recall the vehicles that are likely to be affected and replace the fuel suction plate sub-assembly.

Defect

On affected vehicles the curtain side air bag inflator may have a crack in a weld. If this crack propagates gas may leak and in certain conditions partially in inflate the air bag.

Remedy

On affected vehicles install retention brackets on the curtain shield air bag inflators.

Defect

The inverter assembly may overheat which will cause warning lamps to illuminate and the vehicle to enter a fail safe mode. Fail safe allows the vehicle to be driven on reduced power to a place of safety. However it is possible for the hybrid system to shut down causing the vehicle to stop which increases the risk of a collision.

Remedy

On affected vehicles reprogramme the Motor Generator and Power Management ECUs.

Defect

The inverter assembly may overheat which will cause warning lamps to illuminate and the vehicle to enter a fail safe mode. Fail safe allows the vehicle to be driven on reduced power to a place of safety. However it is possible for the hybrid system to shut down causing the vehicle to stop which increases the risk of a collision.

Remedy

On affected vehicles reprogramme the Motor Generator and Power Management ECUs.

Defect

In certain circumstances components within the inverter assembly may overheat which can lead to the selection of: fail safe mode where the vehicle can still drive with reduced power for a certain distance or in the worst case the drive systems shut down and the vehicle stop.

Remedy

Recall the vehicles that are likely to be affected to reprogramme the Motor Generator E.C.U. and Power Management Control E.C.U.

Defect

The subject vehicles are equipped with brake pressure accumulators consisting of a metal plunger containing brake fluid encased in a metal housing. The plunger is designed with metal pleated bellows to allow for motion. Nitrogen gas is sealed between the plunger and housing. It is possible that a fatigue crack could develop in the bellows due to vertical vibration of the plunger while driving. If this occurs nitrogen gas could leak into the brake fluid and gradually cause the brake pedal stroke to become longer resulting in decreased hydraulic pressure which could result in increased stopping distance.

Remedy

Recall the vehicles that are likely to be affected to first check which type of brake booster is fitted and if the at risk type is fitted; replace the brake booster assembly with an improved one.

Defect

The subject vehicles are equipped with brake pressure accumulators consisting of a metal plunger containing brake fluid encased in a metal housing. The plunger is designed with metal pleated bellows to allow for motion. Nitrogen gas is sealed between the plunger and housing. It is possible that a fatigue crack could develop in the bellows due to vertical vibration of the plunger while driving. If this occurs nitrogen gas could leak into the brake fluid and gradually cause the brake pedal stroke to become longer resulting in decreased hydraulic pressure which could result in increased stopping distance.

Remedy

Recall the vehicles that are likely to be affected to first check which type of brake booster is fitted and if the at risk type is fitted; replace the brake booster assembly with an improved one.

Defect

In the Hybrid system of the subject vehicles there is an electrically driven water pump assembly that circulates coolant through the hybrid components. It is possible the coil wire of the electric motor installed in the water pump may have been scratched during the coiling manufacturing process at the supplier. In this condition the coil wire may corrode at the scratched portion and in some cases break. If this occurs the water pump could stop working leading to illumination of various warning lights in the instrument panel. In some cases a short circuit occurs between adjacent coil wires resulting in a blown fuse for the electric power supply circuit. This will cause the hybrid system to stop while the vehicle is being driven which increases the risk of an accident.

Remedy

Replace the HV Electric Water Pump

Defect

It is possible that the splines of the extension shaft on vehicles equipped with Electric Motor assisted Power Steering (EMPS) may not have received the correct hardness treatment. This can cause the spline to distort and wear and eventually result in loss of steering.

Remedy

Recall affected vehicles check and if necessary replace the shaft.

Defect

In the Hybrid system of the subject vehicles there is an electrically driven water pump assembly that circulates coolant through the hybrid components. It is possible the coil wire of the electric motor installed in the water pump may have been scratched during the coiling manufacturing process at the supplier. In this condition the coil wire may corrode at the scratched portion and in some cases break. If this occurs the water pump could stop working leading to illumination of various warning lights in the instrument panel. In some cases a short circuit occurs between adjacent coil wires resulting in a blown fuse for the electric power supply circuit. This will cause the hybrid system to stop while the vehicle is being driven which increases the risk of an accident.

Remedy

Replace the HV Electric Water Pump

Defect

In the Hybrid system of the subject vehicles there is an electrically driven water pump assembly that circulates coolant through the hybrid components. It is possible the coil wire of the electric motor installed in the water pump may have been scratched during the coiling manufacturing process at the supplier. In this condition the coil wire may corrode at the scratched portion and in some cases break. If this occurs the water pump could stop working leading to illumination of various warning lights in the instrument panel. In some cases a short circuit occurs between adjacent coil wires resulting in a blown fuse for the electric power supply circuit. This will cause the hybrid system to stop while the vehicle is being driven which increases the risk of an accident.

Remedy

Replace the HV Electric Water Pump

Defect

The nut that secures the pinion to the electric power steering system motor shaft may become loose if excessive force is used in full lock manoeuvrers. This could in extreme cases have an affect on the steering operation.

Remedy

Recall all affected vehicles for the replacement of the securing nut.

Defect

Due to improper moulding of the body of the crankshaft position sensor engine oil may penetrate the seal and enter the sensor wiring connector. In this condition the engine oil within the sensor's wiring connector may expand due to engine heat and could deform the sensor. In the worst case the connector may become disconnected which could cause the engine to stall while driving and restarting would not be possible.

Remedy

Recalled vehicles will have the crankshaft position sensor replaced.

Defect

It is possible that the connections at the intermediate shaft and sliding yoke of the steering column may become loose and if the symptoms are ignored steering control can be lost.

Remedy

Recall the vehicles that are likely to be affected and replace the steering intermediate shaft. In addition inspect the sliding yoke and intermediate shaft extension and replace if necessary. This recall is staggered starting with Prius and Corrolla. Avensis customer letters will be sent out over the next three months

Defect

It is possible that the connections at the intermediate shaft and sliding yoke of the steering column may become loose and if the symptoms are ignored steering control can be lost.

Remedy

Recall the vehicles that are likely to be affected and replace the steering intermediate shaft. In addition inspect the sliding yoke and intermediate shaft extension and replace if necessary. This recall is staggered starting with Prius and Corrolla. Avensis customer letters will be sent out over the next three months

Defect

Due to improper assembly of the airbag inflator used in the side airbag curtain shield airbag and knee airbag systems the subject airbags may not fully inflate during a collision resulting in an increased risk of injury to the vehicle's occupants.

Remedy

Recalled vehicles will have the subject airbags replaced.

Defect

In the stop lamp switch of subject vehicles equipped with LED stop lamps there is the possibility that silicone oxide may be generated the surface of the contact point and in consequence the resistance of the contact could increase. In this circumstance current may not flow causing the stop lamp to become inoperative.

Remedy

Recalled vehicles will have the subject switch replaced with a quality assured unit.