2011 Toyota Prius Problems

Excessive voltage in the Intelligent Power Module (IPM) within the inverter may cause the hybrid system to shut down, causing the vehicle to stall while being driven. If the hybrid system shuts down unexpectedly, it can increase the risk of a crash.

Fix: Toyota will notify owners, and dealers will update the software for the motor/generator control electronic control unit (ECU) and the hybrid control ECU as necessary, free of charge. Note: The software updates in this recall are needed even if the vehicle had the software previously updated under recalls 14V-053 or 15V-449.

A weld in the curtain shield air bag inflator may crack causing one or both portions of the inflator to eject into the passenger cabin. If either portion of the curtain shield air bag inflator ejects into the passenger cabin, there is an increased risk of injury to vehicle occupants.

Fix: Toyota will notify owners, and dealers will install retention brackets to the curtain shield air bags, free of charge.

The electrical wiring in the seat heaters may be damaged when the seat cushion is compressed. If damaged, the copper strand heating element may short circuit, increasing the risk of a fire.

Fix: SET will notify owners, and dealers will disconnect the seat heaters, free of charge, and refund the purchase price of the seat heater accessory.

The affected vehicles may experience compression of the seat cushion which may damage the seat heater wiring. Damage to the seat heater wiring could cause the wires to short, increasing the risk of the seat burning and causing personal injury to the occupant.

Fix: SET will notify owners, and dealers will disconnect the heaters with copper strand heating elements and refund the purchase price of the seat heater accessory, free of charge.

In the affected vehicles, the Intelligent Power Module (IPM) inside the inverter module (a component of the hybrid system) contains transistors that may become damaged from high operating temperatures. If this occurs, various warning lamps will be illuminated on the instrument panel and the vehicle will have reduced power allowing it to only drive a short distance. The vehicle may enter a fail-safe/limp-home mode that limits the drivability of the vehicle. The hybrid system could also shut down completely resulting in a vehicle stall, increasing the risk of a crash.

Fix: Toyota will notify owners and dealers will update the software for both the motor/generator control electronic control unit (ECU) and the hybrid control ECU, free of charge. If an owner experiences a failure of the inverter before the vehicle receives updated software, the dealer will repair or replace the inverter assembly with a new one at no charge.

During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed. If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.

Fix: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary.