2009 Toyota Camry Hybrid

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

On June 25, 2014, Toyota initiated a Warranty Enhancement Program (ZE1) to extend warranty coverage for the brake actuator assembly and skid control ECU/brake pedal stroke sensor in certain MY 2007 to 2011 Toyota Camry hybrid vehicles. Toyota's program covers repairs related to two conditions:internal malfunctions of the Brake Actuator assembly; and overly sensitive monitoring logic for the Brake Pedal Stroke Sensor.Primary coverage provides warranty enhancement until November 30, 2015, with no mileage limitation.After the primary coverage period ends, secondary coverage is provided for 10 years or 150,000 miles from the date of first use, whichever occurs first.In addition, on July 10, 2014, Toyota initiated Limited Service Campaign E0U to replace the Brake Reservoir Tank in MY 2007 through 2011 Toyota Camry hybrid vehicles.The LSC will be available until June 30, 2017, and will only be available at an authorized Toyota dealer.ODI's analysis of failure data determined that the majority of records were related to the Brake Actuator condition, which appeared to be the causal component in 734 complaints/field reports and 864 warranty claims.The Brake Pedal Stroke Sensor (80 reports/189 claims) and Brake Reservoir Tank (91 reports/44 claims) conditions were identified in far fewer records.Analysis of the failure data indicate that each condition provides warning prior to any reduction in power assisted braking, with less than 10 percent of all reports and claims involving diagnostic codes or complaint narratives indicating increased braking effort or reduced brake effectiveness.In addition, most of the incidents in which reduced braking assist appears to have occurred involved operation in a reduced assist mode and not a sudden, complete loss of power assisted braking.ODI assessed reduced assist mode in a subjective driving evaluation which indicated that the brake system provided normal and harddeceleration capability with reasonable increases in pedal effort.Less than one percent of reports and claims analyzed by ODI included evidence indicating a complete loss of power assisted braking occurred and this mode requires operation for a significant period of time with multiple audible and visual warnings.Repair expense was cited in many of the complaints reviewed by ODI, especially those related to the Brake Actuator, which had repair costs exceeding $3,000 according to some complaints.High repair cost appears to have been a factor in the only crash identified by ODI for the fault conditions identified by Toyota, which involved a Brake Actuator failure that was diagnosed but the owner declined repair approximately eight months prior to the reported crash incident.This preliminary evaluation is closed.The closing of this investigation does not constitute a finding that a safety-related defect does not exist.For additional information regarding this investigation, including analysis of the Brake Actuator, Brake Pedal Stroke Sensor, and Brake Reservoir Tank fault conditions and failure experience, see Attachment A to this closing resume.

On October 10, 2012, Toyota initiated a safety recall of approximately 2.5 million U.S. vehicles involving the following models and model years:2007-2009 Camry and Camry Hybrid, 2009 Corolla and Corolla Matrix, 2008 Highlander and Highlander Hybrid, 2007-2009 RAV4, 2008-2009 Scion xB and xD, 2008-2009 Sequoia, 2007-2008 Tundra, 2007-2008 Yaris, and 2009 Pontiac Vibe.See NHTSA recall number 12V-491 for more details, including the affected vehicle manufacture dates for each vehicle model.Note that only early-production 2009 model year vehicles are included in the recall.Toyota and GM dealers will inspect the power window master switch (PWMS) assemblies and apply a specialized grease that inhibits heat build-up.The circuit board in the PWMS may be replaced with a new one if notchy or sticking feeling is observed during the inspection.The failure report summary above shows counts for the vehicles identified at the start of this Engineering Analysis, specifically the approximately 1.4 million vehicles that share an identical PWMS assembly design including, model year 2007-2009 Camry, Camry Hybrid, RAV4, and Yaris built from September 2006 through August 2008, as well as all 2008 Highlander Hybrid.Toyota subsequently identified approximately one million additional vehicles that have a slightly different PWMS design but contain the same defect condition.Note that the totals for complaints and fires shown above may include duplicative reports (between ODI and manufacturer reports).This Engineering Analysis is closed.See attached report for additional information.The ODI reports cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10323848, 10360414, 10392622, 10394453, 10411328, 10429983, 10436663, 10446699, 10447416, 10447417, 10447419, 10447444, 10447515, 10447845, 10447947, 10449270, 10450133, 10450568, 10450606, 10450641, 10451821, 10455540, 10455614, 10456353, 10456438, 10457854, 10457955, 10459730, 10460166, 10460691, 10461220, 10462140, 10462200, 10462247, 10462404, 10462705, 10462761, 10464451, 10464769, 10465421, 10466279, 10466667, 10468126, 10468265, 10475230, 10470313, 10470684, 10471551, 10471824, 10472336, 10472910, 10473753, 10473967, 10473969, 10476921, 10477469, 10478563 and 10478657.

ODI has identified certain Toyota vehicles experiencing a higher rate of fire and thermal event incidents among all Toyota vehicles that use the same power window master switch design.They include a total of approximately 1.4 million model year (MY) 2007 through 2009 Camry, Camry Hybrid, RAV4 and Yaris vehicles built from approximately September 2006 through August 2008, as well as all MY 2008 Highlander Hybrid vehicles.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-006) to further study the alleged defect and its consequences.The ODI reports cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10461220, 10460691, 10460166, 10459730, 10457955, 10457854, 10456438, 10456353, 10455614, 10455540, 10451821, 10450641, 10450606, 10450568, 10450133, 10449270, 10447947, 10447845, 10447515, 10447444, 10447419, 10447417, 10447416, 10446699, 10436663, 10429983, 10411328, 10407290, 10394453, 10392622, 10360414, 10323848.

The contact owns a 2009 Toyota Camry Hybrid. The contact’s wife stated while driving approximately 30 MPH, the VSC and ABS warning lights illuminated. The vehicle was taken to an independent mechanic and was diagnosed with needing the brake master cylinder replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The contact also filed a complaint with the manufacturer. The failure mileage was approximately 154,000.

NHTSA ID

11438335

Incident

Oct 22, 2021

Mileage

154,000 mi

The contact owns a 2009 Toyota Camry Hybrid. The contact stated while driving 10 MPH, she smelled a burning odor and she saw smoke in the vehicle. The contact stated she also felt heat on her back. The contact stated as she continued to drive, the seat became increasingly warmer. There were no warning lights illuminated. The contact stated that she parked and exited the vehicle. The contact stated the seat then cooled down. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The contact stated that the failure had been reoccurring while driving and while the vehicle was parked. The dealer was notified of the failure and advised the contact that her VIN was not included in the recall for NHTSA Campaign Number: 16V396000 (SEATS). The manufacturer was notified of the failure and advised as the dealer. A case was opened. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 168,000

NHTSA ID

11434555

Incident

Sep 18, 2021

Mileage

168,000 mi

The contact owns a 2009 Toyota Camry Hybrid. The contact stated that while driving and depressing the brake pedal, the vehicle would not immediately stop, causing the stopping distance to become extended. The vehicle was taken to an independent mechanic who diagnosed that the ABS module was faulty and needed to be replaced. The vehicle was not repaired. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The failure mileage was approximately 130,000.

NHTSA ID

11425992

Incident

Jun 15, 2021

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2009 TOYOTA CAMRY HYBRID. THE CONTACT STATED WHILE OPERATING THE VEHICLE, THE ABS, VSC, AND CHECK BRAKE SYSTEM WARNING LIGHTS ILLUMINATED AND THE VEHICLE WOULD NOT IMMEDIATELY STOP WHILE DEPRESSING THE BRAKE PEDAL. THE CAUSE OF THE FAILURE WAS NOT YET DETERMINED. THE LOCAL DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 131,000.

NHTSA ID

11408106

Incident

Apr 1, 2021

Mileage

131,000 mi

MY DASHBOARD IS MELTING, SINCE IT IS MELTING IT IS CAUSING THE DASHBOARD TO BE REALLY SHINEY, WHICH IS CAUSING A HUGE REFLECTION ON MY WINDSHIELD, WHICH IS MAKING IT HARD TO SEE OUT. THE DASHBOARD IS ALSO REALLY STICKY FROM MELTING, AND IM ALSO CONCERNED ABOUT THE AIRBAGS BECAUSE OF THIS.

NHTSA ID

11233757

Incident

Jul 22, 2019

Mileage

105,000 mi

RE: TSB-L-SB-0144-11 STICKY/MELTING DASHBOARD THE CAR IS 6 MONTHS BEYOND THE DATE OF THE WARRANTY ENHANCEMENT PERIOD. SINCE THE CONDITION OF SHINY STICKINESS OF THE DASHBOARD DID NOT COME TO MY ATTENTION UNTIL AFTER THE ENHANCEMENT PERIOD, I BELIEVE THAT I AM NEVERTHELESS ENTITLED TO THE REPAIR OF THE DASHBOARD BY TOYOTA AND THAT COVERAGE SHOULD BE ALSO EXTENDED TO THE REPLACEMENT OF CERTAIN ANCILLARY PARTS RELATED TO THE REPLACEMENT THAT MIGHT BE DAMAGED AS A RESULT OF THE WARRANTY REPAIR. THERE IS NO VALID REASON THAT THE WARRANTY ENHANCEMENT SHOULD HAVE EXPIRED AS THIS CONDITION IS DANGEROUS AND NEEDS TO BE CORRECTED ON ALL AFFECTED VEHICLES REGARDLESS OF AN ARBITRARY PERIOD SET BY TOYOTA. *JS

NHTSA ID

11231368

Incident

Jul 11, 2019

Mileage

47,000 mi

MELTING DASHBOARD AND DRIVER'S SIDE VISOR DOES NOT STAY UP. THE MELTING DASH CAUSES A GLARE ON THE WINDSHIELD CAUSING VISIBILITY TO BE OBSTUCTED. I WAS TOLD THAT I MISSED THE WARRANTY PERIOD BUT HAVE NEVER BEEN SENT ANYTHING ABOUT THIS PROBLEM.

NHTSA ID

11230204

Incident

Jul 1, 2019

Mileage

100,120 mi

TL* THE CONTACT OWNS A 2009 TOYOTA CAMRY HYBRID. WHILE DRIVING 45 MPH AND DEPRESSING THE BRAKE PEDAL, THE VEHICLE FAILED TO STOP. THE CONTACT SHIFTED INTO LOW GEAR AND WAS ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD. IN ADDITION, THE ABS, TRACTION CONTROL, AND BRAKE WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 137,000.

NHTSA ID

11209020

Incident

May 13, 2019

Mileage

137,000 mi

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

Some 2005 – 2026 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.