2008 Toyota RAV4 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, the rear wheel suspension link arms could separate. This could result in loss of vehicle control and cause a crash resulting in injury and/or damage to property. Correction: Dealers will replace both suspension link arms and encase them in epoxy to prevent future improper servicing. Note: This recall supersedes recall 2013327. As part of the previous recall, dealers were to inspect the suspension arms for corrosion, replace them depending on their condition, and encase them in epoxy. Only vehicles which did not receive replacement of both suspension arms through the previous recall will need to be repaired under this campaign.

A failure of this component (suspension) 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, in the event of a severe frontal collision, there is a possibility that the webbing of the seat belt in both second-row outboard seating positions could contact a portion of the metal seat cushion frame, become cut, and separate. If this occurs, the seat belt may not properly restrain the occupant, which could increase the risk of injury. Correction: Dealers will install plastic protectors on the seat cushion frame in both second-row outboard seating positions.

A failure of this component (seats and restraints) 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 some vehicles, if the rear wheel alignment toe adjustment locking nuts are improperly tightened when an alignment is performed in the field, backlash may develop in the threaded portion of the suspension arm (shaft and turnbuckle), followed by the formation of rust. If this occurs, threads may wear, causing the arm to separate which could result in loss of vehicle control. Correction: Dealers will inspect the suspension arm threads for corrosion. If corrosion is found, the arm(s) will be replaced. If no corrosion is found, an epoxy sealer will be applied to the suspension arm to inhibit corrosion. Note: This recall supersedes recall 2012253. Vehicles that were repaired under the previous campaign will also need to be repaired under this campaign.

A failure of this component (suspension) 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).

This recall was replaced by Transport Canada recall no. 2013-327. On some vehicles, if the rear wheel alignment toe adjustment locking nuts are improperly tightened when an alignment is performed in the field, backlash may develop in the threaded portion of the suspension arm (shaft and turnbuckle), followed by the formation of rust. If this occurs, threads may wear, causing the arm to separate which could result in loss of vehicle control. Correction: Dealers will inspect the arms and verify the tightening torque of the lock nuts, or replace the arms, as necessary.

A failure of this component (suspension) 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 roll angle sensors in the airbag sensor assembly could fail. If one of the roll angle sensors malfunctions, the airbag warning lamp will illuminate, the roll detection system will be suspended, and the curtain shield airbag will not deploy during a roll-over crash (where deployment is warranted), thereby increasing the risk of personal injuries to the seat occupant. The airbag system, however, will continue to detect frontal and lateral impacts and, in those instances, will function as designed. If both roll angle sensors fail nearly simultaneously after starting the vehicle, the curtain shield airbag and the seatbelt pretensioner could inadvertently deploy. Inadvertent curtain shield airbag deployment in a non-impact situation may cause damage to the surrounding vehicle environment and create expensive vehicle repair, including replacement of the curtain shield airbag module and the airbag electronic control unit. In some instances, inadvertent deployment could cause minor injuries to vehicle occupants. Correction: Dealers will replace the airbag sensor 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 accelerator pedal may become stuck in the wide open position due to an unsecured or incompatible driver's floor mat. A fully depressed accelerator pedal may result in very high vehicle speeds and make it difficult to slow or stop the vehicle. This could result in a crash causing property damage and/or personal injury. Correction: Dealers will modify or replace the accelerator pedal. Note: This is an expansion of recall 2009290 for vehicles not previously included in the campaign.

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).