2008 Toyota Highlander Hybrid

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.

On certain vehicles, a control board for the Intelligent Power Module (IPM), part of the hybrid system inverter assembly, could fail while the vehicle is underway.  This could cause various warning lamps, including the malfunction indicator lamp, slip indicator lamp, brake system warning lamp, and master warning lamp, to illuminate on the instrument panel.  If this occurred, in most cases, the vehicle would enter fail-safe driving mode, resulting in reduced motive power in which the vehicle could still be driven for short distances.  In some instances, the fuse of the power supply circuit could blow, causing the hybrid system to stop functioning.  The resultant loss of vehicle propulsion, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing property damage and/or personal injury.  Correction: Dealers will inspect and, if necessary, replace the Intelligent Power Module.

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.

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.

On certain vehicles, if the Toyota optional accessory "tray-type" floor mat is not secured by the retaining hooks, or if it is placed on top of an existing floor mat, the "tray-type" floor mat could move forward and interfere with the accelerator pedal.  This could result in a crash causing property damage, personal injury or death.  Correction: The manufacturer will notify owners to remove the "tray-type" floor mat and provide instructions on how to obtain a reimbursement.