Dive Brief:
- Toyota Motor North America has recalled over 94,000 electric vehicles for HVAC system faults, including some electrical compressor failures, causing the defroster and defogger system to become inoperative, which can lead to condensation on the windows and reduced visibility, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include model year 2023-2025 Toyota bZ4X SUV, Lexus RZ and Subaru Solterra EV built through June. An estimated 100% of the recalled vehicles have the defect.
- Dealers will update the HVAC system’s electronic control module control software and replace any defective electric air conditioning compressors if needed, free of charge. Owner notification letters are expected to be mailed on Oct. 20.
Dive Insight:
All of the recalled EVs are equipped with HVAC systems that control the windshield defroster function. However, this issue only affects vehicles equipped with an HVAC electronic control unit, also referred to as an amplifier assembly, running “specific software from the specific supplier,” the recall report states. The ECU for the HVAC system was sourced from Tier 1 supplier Denso Corp.
Unlike a traditional internal combustion engine vehicle that uses a belt-driven air conditioning compressor, the recalled EVs use an electric compressor, which is controlled by software.
According to the report, the problem is caused by the programming of the HVAC control ECU software, causing the system to enter a “fail-safe mode” under certain conditions that interrupts the heater function and impacts the vehicles’ defroster function. In colder temperatures, the performance of the defroster will be reduced, which can lead to frost, ice or fog buildup on the windshield that can reduce driver visibility. Toyota is currently working on a software remedy.
Other Toyota or Lexus models sold in the U.S. are equipped with a different HVAC software version and are not part of the recall.
The recall is Toyota’s 7th of 2025, and follows a May recall of 443K Tundra pickups for rear tail light malfunctions.
