2005-2024 Toyota Musty Odor from Water Intrusion TSB

Some 2005-2024 Toyota vehicles may develop a musty odor inside the cabin if they have experienced water intrusion. This condition can be unpleasant and indicates the presence of moisture and potentially organic growth within the vehicle's interior. Toyota Technical Service Bulletin T-SB-0055-24 outlines a comprehensive dealer-performed remediation process to address this issue, including the Toyota Camry musty odor problem.

Important Warnings

This service bulletin includes several critical warnings for both technicians and owners:

• The procedures in this bulletin are NOT applicable to vehicles that have undergone severe freshwater or saltwater intrusion, such as those submerged in floods or storms. These situations require different remediation methods.
• This bulletin is NOT applicable for general HVAC odor concerns. It specifically addresses odors caused by water intrusion.
• BEFORE beginning any remediation, the source of the water intrusion MUST be identified and repaired. The bulletin does NOT apply if the water leak has not been found and fixed.
• Always use proper Personal Protective Equipment (PPE) as per current EPA guidelines, including N95 respirators, safety goggles, and protective gloves.
• Soft parts with absorbent qualities (e.g., floor mats, carpet, insulated pads, dash panel insulator assembly) that have come into contact with moisture MUST be removed and replaced with NEW parts. These parts should NOT be reused.
• If the dash panel insulator assembly is affected by water contact, it MUST be removed and replaced with a NEW part BEFORE remediation. Do NOT attempt to cut out affected areas or treat the existing dash panel insulator assembly.
• If equipped, HV or EV batteries must be removed prior to servicing or cleaning areas where they are present or exposed. Refer to TIS, applicable model and model year Repair Manual and follow ALL recommended safety procedures for HV and EV battery handling.
• A cabin air filter should NOT be installed in the HVAC system during the remediation process. A NEW high-performance charcoal filter should only be installed AFTER the entire remediation is complete.
• Door panels and the headliner can typically remain installed UNLESS they show evidence of water contact.

Symptoms

The primary symptom addressed by this bulletin is the presence of a musty odor within the vehicle's interior. This odor is a direct result of water intrusion, which can lead to the growth of organic matter and staining on interior components.

Diagnosis and Trigger Conditions

The musty odor is triggered by water intrusion into the vehicle's interior. Diagnosis involves a thorough inspection to identify the source of the water leak and assess the extent of moisture contact, staining, and organic matter growth on soft and hard interior parts. Technicians must inspect the entire interior floorboard areas, including under seats and trim panels, as well as the dash panel insulator assembly on both driver and passenger sides.

Required Tools and Parts

Successful odor remediation requires specific tools, materials, and replacement parts:

Personal Protective Equipment (PPE):

• 3M™ (or equivalent) N95 Certified (or higher) NIOSH Approved Respirator
• Safety Goggles/Eye Protection
• Protective Gloves

Tools & Materials:

• 3M™ Quat Disinfectant Cleaner Concentrate 5 (Quantity: 1)
• Heavy Duty Cleaner (e.g., Spray Nine or Similar) (Quantity: 1)
• Pump Spray Bottle (Quantity: 1)
• Scrub Brush (Quantity: 1)
• Painter's Tape (Quantity: 1)
• Ozone Machine (or Equivalent) (Part Number: RBO521011, Quantity: 1)

Replacement Parts:

• High Performance Charcoal Filter (Quantity: 1)
• Insulator Assy., Dash Panel (Quantity: 1, if affected)

Note that specific part numbers for the charcoal filter and dash panel insulator assembly will vary by vehicle model/model year and should be referenced in the Parts Catalog.

Repair Procedure Summary

The odor remediation process is comprehensive and dealer-performed, involving several stages:

1. Preparation: Technicians begin by applying two layers of blue painter's tape to all door opening thresholds (door sills, B and C pillars) to protect painted surfaces during interior component removal and reinstallation. This is illustrated in Figure 1 of the bulletin.
2. Inspection and Disassembly: All parts surrounding the source of the water leak are removed for a thorough inspection. This includes seat assemblies (front, rear, second, and third row if applicable) and lower trim panels (scuff plates, kick panels, pillar garnishes). The entire interior floorboard is inspected for organic matter growth or staining (Figures 2, 3, 4). The dash panel insulator assembly is also inspected on both sides (Figure 5). If the dash panel insulator assembly is affected, it must be removed and replaced before remediation. The cabin air filter is removed and discarded, and a new one will be installed only after the entire process is complete (Figure 6). HV or EV batteries must be safely removed if present in affected areas. Figure 7 shows a disassembled vehicle ready for cleaning.
3. Cleaning: Loose debris is removed from the floor pan. A heavy-duty cleaner (like Spray Nine) is used to spray and scrub the floor pan and other hard components that will not be replaced, removing stains. Then, a diluted 3M™ Quat Disinfectant product is sprayed to visibly wet the floor pan and other affected components, allowing it to soak for at least 30 minutes. After soaking, the vehicle is thoroughly wiped dry to ensure all moisture is removed.
4. Reassembly: The vehicle interior is reassembled using treated hard parts and new soft parts (e.g., floor mats, carpet, insulated pads, and the dash panel insulator assembly if replaced). A NEW high-performance charcoal filter is installed in the HVAC system. Normal vehicle operation is confirmed, and any Diagnostic Trouble Codes (DTCs) are cleared.
5. Ozone Treatment: After reassembly, the vehicle's A/C is turned ON in recirculation mode. An ozone machine (RBO521011) is run for 1 hour. Following this, the machine is turned off, and the vehicle is aired out for 2 hours.

Warranty Information

This odor remediation repair is covered under the Toyota Basic Warranty. The warranty is valid for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Warranty application is strictly limited to the specified condition described in this bulletin.

For warranty claims, the following information applies:

• Operation Code (OP CODE): 743991 (Odor Remediation (Dealer Performed))
• Time: Labor times should be aggregated using the Electronic Flat Rate Manual, considering overlapping labor. Additional documentation may be required per Warranty Policies 4.21 and 8.14.
• Original Failed Part (OFP): This should be the part number of the component that caused the water intrusion. If no specific part number is available (e.g., a seam seal leak), the part number of a related component should be used.
• T1 Code: 66
• T2 Code: The appropriate T2 code must be identified.
• Sublet Type: ZZ (for repairs sublet to a body shop, as per Warranty Policy 8.22).

Owner Action

If you experience a Toyota Camry musty odor or a similar musty smell in your 2005-2024 Toyota vehicle, it is recommended to visit your authorized Toyota dealer. They will perform the necessary inspection to identify the source of any water intrusion and carry out the odor remediation process as outlined in T-SB-0055-24. This repair is covered under your vehicle's basic warranty, provided it is within the 36-month or 36,000-mile term.

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Source: NHTSA ID: 10255562, T-SB-0055-24