2009 Toyota Corolla Recall

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 PK5A489J14 PK5A408J05 PU14000903

Engine block heater wiring that overheats or melts could create the risk of a fire.

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, long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, could eventually degrade the propellant contained in the passenger frontal airbag. This could cause the airbag to deploy with more force than normal. As a result, if the vehicle were involved in a collision that warrants airbag deployment, fragments could be propelled toward vehicle occupants, and the airbag assembly could be damaged, preventing proper function. These issues could increase the risk of injury. Correction: Depending on the vehicle model, dealers will either replace the passenger frontal airbag inflator, or replace the airbag assembly. Note: Canadian climate results in the propellant degrading slowly. The recall is being conducted as a precaution to address future risk, and is expected to replace airbag inflators before their function would be affected.

A failure of this component (airbag) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, inconsistent application of grease during the manufacturing process could cause the driver's side power window master switch to stick or become inoperative due to electrical contact point wear. This could cause debris to accumulate between the contact points, potentially resulting in an electrical short circuit. If a short circuit occurs, the switch assembly may overheat, produce smoke, melt and/or potentially lead to a fire causing injury and/or property damage. Correction: Dealers will inspect the driver's power window master switch and apply a specialized grease that inhibits heat build-up, or replace the power window master switch circuit board, as necessary. Note: This is an expansion of recall 2012-338.

A failure of this component (electrical) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, electrical circuitry in the steering wheel assembly may become damaged. As a result, the driver's airbag may not function as intended, causing the instrument panel airbag warning lamp to illuminate. Failure of the driver's airbag to deploy during a crash (where deployment is warranted) could increase the risk of injury to the seat occupant. Correction: Dealers will replace the spiral cable assembly.

A failure of this component (airbag) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the trunk lid may begin to close after it has been opened. Contributing factors may include the trunk lid being in the partially open position, windy conditions, the vehicle being parked on an incline, or weight (such as snow or ice) acting on the trunk lid. As a result, interaction could occur between a person and the trunk lid, which could lead to minor injury. Correction: Owners who are dissatisfied with the performance of their vehicle’s trunk lid may have the trunk springs replaced under special warranty coverage.

A failure of this component (structure) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, due to improperly applied grease, the driver's side power window master switch could stick or become inoperative. If attempts are made to lubricate the switch, the switch assembly could overheat and melt. A melting switch may produce smoke and potentially lead to a fire causing property damage and/or personal injury. Correction: Dealers will inspect the driver's power window master switch and apply a specialized grease that inhibits heat build-up, or replace the power window master switch circuit board, as necessary.

A failure of this component (electrical) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, accelerator pedal movement may become rough, slow to return, or the pedal may stick in a depressed position. This could result in a loss of throttle control and a vehicle crash, causing property damage, personal injury or death. Correction: Dealers will install a steel reinforcement bar to the accelerator pedal assembly. With this reinforcement in place, the excess friction that can cause the pedal to stick is eliminated.

A failure of this component (other) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the accelerator pedal may become stuck in the wide open position due to an unsecured or incompatible driver's floor mat. A stuck open accelerator pedal may result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death. Correction: Dealers will reconfigure the shape of the accelerator pedal. Certain models will also have the shape of the floor underneath the accelerator pedal modified and/or a brake override system installed.

A failure of this component (other) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, when driven in extremely low ambient temperatures, the intake manifold suction port for the brake vacuum can become blocked due to the freezing of condensation emanating from Positive Crankcase Ventilation (PCV). Should the suction port become blocked, vacuum assist to the brakes would be insufficient and the increased pedal pressure required could lead to an increase in vehicle stopping distance. Extended stopping distances may result in a vehicle crash causing property damage, personal injury or death. Correction: Dealers will install a newly designed intake air connector which will relocate the brake system vacuum port.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).