2005 Toyota Avalon

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                         PK5A489J14 
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.

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, 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.

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.

On certain vehicles, the steering yoke may not have been welded to the steering shaft during assembly.  Separation of the yoke and the steering shaft would result in a loss of steering control.  Correction: Dealers will inspect and, if necessary, replace the steering column assembly.