SAFETY RECALL 20TA02 – Vehicle May Stall During Driving at Higher Speed – 2014-2020 Toyota

November 4, 2020 NHTSA CAMPAIGN NUMBER: 20V682000

Fuel Pump May Fail

If the fuel pump fails, the engine can stall while driving, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V682

Manufacturer ToyotaeBay logo Motor Engineering & Manufacturing

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 1,517,721

 

Summary

ToyotaeBay logo Motor Engineering & Manufacturing (ToyotaeBay logo) is recalling certain 2018-2019 4Runner, 2019-2020 Avalon, 2019 Corolla Hatchback, 2017-2019 Highlander, 2018-2020 Camry, 2020 Corolla, 2018-2019 Land Cruiser, 2017-2020 Tacoma, 2019-2020 RAV4, 2019-2020 Sequoia, 2017-2020 Sienna, 2019-2020 Tundra, 2018-2020 Lexus ES350, 2017 Lexus GS200t, 2017-2019 Lexus GS350, 2019 Lexus GS300, 2018-2020 Lexus LC500h, 2019-2020 Lexus LS500, 2018-2019 Lexus GX460, 2017 Lexus IS200t, 2019 Lexus IS300, 2019 Lexus IS350, 2018-2020 Lexus LC500, 2018 Lexus LS500, 2019 Lexus LS500h, 2018-2019 Lexus LX570, 2017 Lexus RC200t, 2019 Lexus RC300, RC350, 2017 and 2019-2020 Lexus RX350, 2018-2020 RX350L, 2019 Lexus UX200, 2018-2019 Lexus NX300 vehicles. The low-pressure fuel pump inside the fuel tank may fail.

 

Remedy

ToyotaeBay logo will notify owners, and dealers will replace the fuel pump assembly with an improved one, free of charge. Owners of specific models were notified that remedy parts were available starting January 21, 2021. Owners of other models will be notified as remedy parts become available. Remedy parts should be available for all affected vehicles by late March 2021. Owners may contact ToyotaeBay logo customer service at 1-888-270-9371 or Lexus customer service at 1-800-255-3987. Note: This recall is an expansion of recall 20V-012. ToyotaeBay logo’s number for this recall is 20TA02. Lexus’ number for this recall is 20LA01.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


Condition

The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights and messages may be displayed on the instrument panel, and the engine may run rough. This may result in a vehicle stall, and the vehicle may be unable to be restarted. If a vehicle stall occurs while driving at higher speeds, this could increase the risk of a crash.

 

Remedy

Any authorized ToyotaeBay logo dealer will replace the low-pressure fuel pump with an improved one FREE OF CHARGE.

 

Sienna Mobility Vehicles, ToyotaeBay logo-Authorized Conversion

Sienna vehicles that have been converted for wheelchair accessibility by a ToyotaeBay logo-authorized mobility conversion company are eligible to have the remedy performed. Refer to the Technical Instructions on TIS for the remedy procedure instructions.

  • Dealers should confirm in TIS / Service Lane if a mobility vehicle has been converted by an authorized company as shown below:
  • In rare cases, Sienna vehicles converted by an authorized company may not appear in ToyotaeBay logo’s records and; therefore, may not appear on TIS / Service lane as shown above. These vehicles should still have the remedy performed per the Technical Instructions.
  • Below is the list of companies that are authorized by ToyotaeBay logo to convert Sienna vehicles for wheelchair accessibility.
    • The Braun Corporation (BraunAbility)
    • Vantage Mobility International (VMI)

 

Sienna Mobility Vehicles, Non-ToyotaeBay logo-Authorized Conversion

Sienna vehicles that have been converted for wheelchair accessibility by a non-ToyotaeBay logo authorized mobility conversion company have undergone an unauthorized modification to the factory condition of the vehicle. These modifications may make it difficult or impossible to apply the remedy in their current condition. ToyotaeBay logo does not recommend modifying vehicles and cannot evaluate how any aftermarket, non-ToyotaeBay logo approved parts and/or modifications could affect a vehicle’s performance.

Subject to individual review by the dealer and notwithstanding ToyotaeBay logo’s recommendation, some dealers may be willing to perform the Safety Recall remedy with the vehicle in its current modified condition. If your dealership is willing to do so, the customer may be responsible for the cost of parts and/or labor not otherwise covered by ToyotaeBay logo’s Safety Recall. ToyotaeBay logo provides the specific remedy parts, differential oil (AWD-only), and covers 2.6 – 2.7 hours of dealership labor expenses. The customer is responsible to pay any additional charges for parts and/or labor which are the result of the vehicle’s non-ToyotaeBay logo-approved modifications.

ToyotaeBay logo is not responsible for later performance problems the vehicle may have that are the result of the nonToyota-approved vehicle modifications.

If the dealer decides it cannot complete the repair on a non-authorized conversion due the modifications in that case, the dealer may advise the customer that they have the option of contacting the conversion company for direction. Although the conversion company may or may not be able to provide a solution for the customer, the conversion company may, in the alternative, remove the fuel tank and fuel suction tube assembly, at the customer or conversion company’s expense. In this case, the ToyotaeBay logo dealer could then be able to install the remedy low-pressure fuel pump into the fuel suction tube assembly free-of-charge. The re-installation of the fuel suction tube assembly and fuel tank into the vehicle would need to be performed at the customer or conversion company’s expense by the conversion company in this case. 

 

Covered Vehicles

There are now approximately 2,768,500 vehicles covered by this Safety Recall. Approximately 20,750 vehicles involved in this Safety Recall were distributed to Puerto Rico. Refer to the covered vehicles summary attached near the bottom of this document for additional details on the covered vehicles.

 

Certain 2018 – 2019 model year 4Runner and 2018 – 2019 model year Land Cruiser Vehicles are Included in this Recall

Out of an abundance of caution, ToyotaeBay logo originally included certain 2018 – 2019 model year 4Runner and 2018 – 2019 model year Land Cruiser vehicles in the recall population when this recall was first initiated on January 13, 2020.   On March 4, 2020, ToyotaeBay logo amended the recall population based on its understanding of the factors necessary to cause the recall condition.  Based on information available at that time, the models in the table below were removed from the recall.

ToyotaeBay logo continued to investigate the issue and new information from the investigation indicated that the previous method for evaluating the combination of factors leading to this condition resulted in the exclusion of vehicles from the recall that should have been included.  Thus, ToyotaeBay logo further expanded the recall population on October 28, 2020 and the vehicles in the table below (previously removed in March) are included.

Owners may have received an interim letter in late February 2020; however, ToyotaeBay logo sent a subsequent letter to owners of these vehicles between late April 2020 and early May 2020 explaining that they were not involved in this recall based on the information available at that time.  ToyotaeBay logo has re-notified the owners of these vehicles to advise them that they are now involved in this recall and explained this situation.

 


Multiple Models and Model Years
Vehicle May Stall During Driving at Higher Speed
NHTSA Recall No. 20V-012

Frequently Asked Questions
Original Publication Date: June 18, 2020

 

Q1: What is the condition?

The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights and messages may be displayed on the instrument panel, and the engine may run rough. This may result in a vehicle stall, and the vehicle may be unable to be restarted. If a vehicle stall occurs while driving at higher speeds, this could increase the risk of a crash.

 

Q1a: Are there any symptoms/warnings of the condition?

Drivers may experience rough engine running, warning lights or messages on the instrument panel, engine no start, and loss of motive power.

 

Q1b: Which warning lights and messages may be displayed if the condition is present?

If the condition were to occur, the malfunction indicator lamp (MIL) shown below, may illuminate in the instrument panel cluster. In addition to the malfunction indicator lamp, other warning lamps and messages may also be displayed. The specific lamp(s) and message(s) that is/are displayed may vary depending upon the specific model of vehicle.


Note:
The malfunction indictor lamp (MIL) and other lamps and messages can be displayed for other issues unrelated to this Safety Recall.

 

Q2: What is ToyotaeBay logo going to do?

Any authorized ToyotaeBay logo dealer will replace the low-pressure fuel pump with an improved one FREE OF CHARGE.

 

Q2a: Why were additional vehicles added on December 18, 2020?

ToyotaeBay logo discovered a clerical error that resulted in certain 2019 Sequoia, 2019 Tacoma, and 2019 Tundra vehicles not being included in the October 28, 2020 amendment.

 

Q2b: Why did ToyotaeBay logo expand this recall on October 28, 2020?

ToyotaeBay logo continued to investigate the issue and new information from the investigation indicated that the previous method for evaluating the combination of factors leading to this condition resulted in the exclusion of vehicles from the recall that should have been included. Thus, ToyotaeBay logo further expanded the recall population on October 28, 2020.

 

Q2c: Why was my vehicle removed from this recall on March 4, 2020, but added back to the recall on October 28, 2020?

Out of an abundance of caution, ToyotaeBay logo originally included certain 2018 – 2019 model year 4Runner and 2018 – 2019 model year Land Cruiser vehicles in the recall population when this recall was first initiated on January 13, 2020.  On March 4, 2020, ToyotaeBay logo amended the recall population based on its understanding of the factors necessary to cause the recall condition.

Based on information available at that time, certain vehicles were removed from the recall.

ToyotaeBay logo continued to investigate the issue and new information from the investigation indicated that the previous method for evaluating the combination of factors leading to this condition resulted in the exclusion of vehicles from the recall that should have been included.  Thus, ToyotaeBay logo further expanded the recall population on October 28, 2020 and certain vehicles, that were previously removed, have been included in the recall.

 

Q3: Which and how many vehicles are covered by this Safety Recall?

When this Safety Recall was first announced on January 13, 2020, there were approximately 564,300
vehicles covered. On March 4, 2020, this Safety Recall was amended and covered a total of approximately 1,433,050 vehicles. On October 28, 2020, this Safety Recall was amended to include a total of approximately 2,760,500 vehicles. On December 18, 2020, this Safety Recall was amended to include a total of approximately 2,768,500 vehicles.

 

List of ToyotaeBay logo Models/Model Years Included as of October 28, 2020

Model NameModel YearProduction PeriodApproximate UIO
4Runner2014 – 2015Early September 2013 – Mid-February 2015112,500
4Runner2018 – 2019Late May 2018 – Early April 2019121,400
Avalon2018 – 2020Early April 2018 – Early October 201933,700
Camry2018 – 2020Mid-November 2017 – Mid-February 2019590,800
Corolla2018 – 2020Mid-October 2017 – Early July 2019371,300
Corolla Hatchback2019Mid-June 2018 – Early November 201810,300
Highlander2017 – 2019Early July 2017 – Early December 2019519,500
Land Cruiser2014– 2015Early September 2013 – Mid-March 20154,500
Land Cruiser2018 – 2019Mid-July 2018 – Early April 20192,800
RAV42019 – 2020Early October 2018 – Early October 2019187,500
Sequoia2018 – 2020Early April 2018 – Late July 201914,800
Sienna2017 – 2020Early September 2017 – Early September 2019166,300
Tacoma2017 – 2020Early September 2017 – Mid-September 2019502,450
Tundra2018 – 2020Early April 2018 – Mid-July 2019113,450
FJ Cruiser2014Early September 2013 – Early August 201417,200

 

Q3a: Are there any other Lexus/ToyotaeBay logo/ScioneBay logo vehicles covered by this Safety Recall in the U.S.?

Yes, there are approximately 587,790 total Lexus vehicles now covered by this Safety Recall. The following vehicles are covered:

• 2018 – 2020 ES 350• 2014 – 2015 IS 350• 2018 – 2019 NX 300
• 2017 GS 200t• 2018 – 2019 IS 350• 2017 RC 200t
• 2018 – 2019 GS 300• 2018 – 2020 LC 500• 2018 – 2019 RC 300
• 2013 – 2015 GS 350• 2018 – 2020 LC 500h• 2015 RC 350
• 2017 – 2019 GS 350• 2018 – 2020 LS 500• 2018 – 2019 RC 350
• 2014 – 2015 GX 460• 2018 – 2019 LS 500h• 2018 – 2020 RX 350L
• 2018 – 2019 GX 460• 2013 – 2015 LS 460• 2017 – 2020 RX 350
• 2014 IS F• 2014 – 2015 LX 570• 2019 UX 200
• 2017 IS 200t• 2018 – 2019 LX 570
• 2018 – 2019 IS 300• 2015 NX 200t

 


Q4:
How long does the repair take?

The repair will range from approximately one and one half to three and one half hours depending upon the vehicle model. Refer to the table below for the estimated repair time for each model for which the remedy is available.

ModelApproximate Repair Time
TundraOne and one half hours
Sequoia
Camry
Avalon
Corolla / Corolla Hatchback
FJ CruiserTwo hours
Tacoma
4RunnerTwo and one half hours
Sienna
Land Cruiser
HighlanderApproximately three and one half hours. If your vehicle is not equipped with engine Stop & Start system, the remedy should take approximately two and one half hours
Rav4Approximately two and one half hours. If your vehicle is not equipped with engine Stop & Start system, the remedy should take approximately one and one half hours

 

Q5: Are Sienna vehicles that have been converted for wheelchair accessibility able to have the remedy performed?

The remedy, once available, can be applied to Sienna vehicles that have been converted for wheelchair accessibility by a ToyotaeBay logo-authorized mobility conversion company. Conversion of Sienna vehicles using non-ToyotaeBay logo-approved parts and/or accessories may make is difficult or impossible for a dealer to install the remedy parts for this Safety Recall.

 

Q5a: Who are the companies that have been authorized by ToyotaeBay logo to convert Sienna vehicles for wheelchair accessibility?

Below is the list of companies that offer ToyotaeBay logo-authorized conversions for Sienna vehicles for wheelchair accessibility.

  • The Braun Corporation (BraunAbility)
  • Vantage Mobility International (VMI)

 

Q5b: What if my vehicle is converted by a non-authorized mobility conversion?

Sienna vehicles that have been converted for wheelchair accessibility by a non-ToyotaeBay logo authorized mobility conversion company have undergone an unauthorized modification to the factory condition of the vehicle. These modifications may make it difficult or impossible to apply the remedy in their current condition. ToyotaeBay logo does not recommend modifying vehicles and cannot evaluate how any aftermarket, non-ToyotaeBay logo approved parts and/or modifications could affect a vehicle’s performance.

Subject to individual review by the dealer and notwithstanding ToyotaeBay logo’s recommendation, some dealers may be willing to perform the Safety Recall remedy with the vehicle in its current modified condition. If your dealership is willing to do so, the customer may be responsible for the cost of parts and/or labor not otherwise covered by ToyotaeBay logo’s Safety Recall. ToyotaeBay logo provides the specific remedy parts, differential oil (AWD-only), and covers 2.6 – 2.7 hours of dealership labor expenses. The customer is responsible to pay any additional charges for parts and/or labor which are the result of the vehicle’s non-ToyotaeBay logo-approved modifications.

ToyotaeBay logo is not responsible for later performance problems the vehicle may have that are the result of the non-ToyotaeBay logo-approved vehicle modifications.

 

Q6: What if I previously paid for repairs related to this Safety Recall?

Reimbursement consideration instructions will be provided in the owner letter.

 

Q7: How does ToyotaeBay logo obtain my mailing information?

ToyotaeBay logo uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q8: What if I have additional questions or concerns?

If you have additional questions or concerns, please contact the ToyotaeBay logo Brand Engagement Center at 1-888-270-9371 Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 


TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA02
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED

Vehicle May Stall During Driving At Higher Speed – 2014-2020 Toyota

 

 


TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA02
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
2017 – 2020 SIENNA MOBILITY VEHICLES

Vehicle May Stall During Driving At Higher Speed – 2017-2020 Toyota Sienna Mobility Vehicles

 

 


 

Description of Problem:

The subject vehicles are equipped with a low-pressure fuel pump, located in the fuel tank, that supplies fuel pressure to the fuel injection system.  These fuel pumps may include impellers which have been manufactured with lower density.  If these impellers are also (1) of a type with lower surface strength or (2) of a different type but were exposed to production solvent drying for longer periods of time, higher levels of surface cracking may occur.  In this condition, excessive fuel absorption may occur, resulting in increased impeller deformation.  In some cases, the impeller may deform to a point that creates sufficient interference with the fuel pump body to cause the fuel pump to become inoperative.  An inoperative fuel pump due to these conditions could result in illumination of check engine and master warning indicators, rough engine running, engine no start and/or vehicle stall while driving at low speed.  However, in rare instances, vehicle stall could occur while driving at higher speeds, increasing the risk of a crash.

 

Chronology of Principal Events:

 

June 2019 – August 2019

In early June 2019, ToyotaeBay logo observed an increase in field reports related to the low pressure fuel pumps produced by the supplier.  These reports indicated that customers alleged rough engine running, engine no start, and/or loss of motive power while driving at low speed (less than 20 mph) and occurred more commonly in areas of the southern U.S. with hotter climates.

 

In mid-June, ToyotaeBay logo began an investigation, including the recovery of failed parts from the field.  The supplier began inspection and analysis of the recovered parts and identified impeller deformation inside the fuel pump assembly due to more fuel absorption into the impeller material, with signs of binding/interference between the pump impeller and the pump casing/cover.  A further analysis of failed impellers was conducted, and it was confirmed that the failed impellers had a lower density.  Generally, impellers with lower density are more susceptible to fuel absorption.

 

As part of ongoing parts analysis, an additional observation was made of cracking to the impeller surface.  To understand the relationship between surface cracks and pump failure, ToyotaeBay logo began an investigation to identify factors potentially contributing to cracking.

 

September 2019 – December 2019

As part of the investigation, ToyotaeBay logo hypothesized that solvent used during the manufacturing process was a factor in fuel pump impeller cracking and began duplication testing.  During the testing, cracks occurred on the surface of the impellers as the solvent dried over time.  However, the duplication test could not match impeller crack that was observed in the parts recovered from the field.

 

ToyotaeBay logo also conducted vehicle testing to understand potential failure modes of incidents identified in the field.  Starting with a review of operation parameters to support duplication, recovered failed parts were installed in a ToyotaeBay logo fleet vehicle.  After confirming that no DTC was initially present, the vehicle was parked for a period of time and then started; low fuel pressure was detected.  Shortly thereafter, the check engine light and master warning were displayed.  The vehicle was then driven until a rough running condition/loss of power became noticeable, and vehicle speed was gradually reduced until low speed engine stall occurred.  The vehicle returned to normal operation immediately after restarting it.

 

This evaluation suggested that this issue occurs at lower speeds, but ToyotaeBay logo continued to investigate whether this condition could lead to a loss of motive power at higher speeds.  As part of this investigation, a manual review of available freeze frame data from all field incidents was done.  Based on a detailed analysis of these data, three alleged cases were identified where loss of motive power occurred at higher speed (>20mph).

 

January 9, 2020

While continuing its investigation into the cause of impeller swelling, ToyotaeBay logo could not rule out the possibility of loss of motive power at higher speeds in the subject vehicles.  Therefore, the decision was made to conduct a voluntary safety recall campaign.

 

January 13, 2020

ToyotaeBay logo filed a Part 573 report.

 

January – mid February 2020

As observed in ToyotaeBay logo’s earlier study of low density impellers combined with drying solvent, cracks could not be duplicated to a level observed in the recovered parts.  Thus, it was concluded that these conditions alone could not create impeller swelling and deformation which could result in sufficient impeller interference with the fuel pump body, causing the pump to become inoperative.

 

ToyotaeBay logo continued investigating whether there were other factors that could create cracks similar to those in the field recovered parts.  One factor considered was the potential for longer lead times and temperature variation during fuel pump transit to the vehicle assembly plant during which the fuel pump would be exposed to drying solvent.  Replication testing was done again with low density impellers, but with longer duration of dry solvent exposure and also temperature cycling.  As a result, cracking was observed and appeared similar to the level of cracking as the recovered parts from the field.

 

However, ToyotaeBay logo observed that some field cases involved impellers that had low density with similar cracks to other field cases, but experienced shorter lead times to the vehicle assembly plant (i.e., were not exposed to drying solvent for longer periods of time during production in the same manner as the pumps investigated above).  Thus, ToyotaeBay logo investigated a second factor, which was the surface strength of different pump impeller types.  Analyses were performed on impeller samples from the pump types that may have been produced with lower density material.  These analyses identified that the surface strength was low on one particular type.

Impellers of this type, produced with the lower density material, can experience higher levels of surface cracking even when exposed to shorter durations of solvent drying.

 

Based on the above activities, ToyotaeBay logo concluded that pumps produced with impellers of lower density that also contain either (1) a pump impeller of a type with lower surface strength or (2) a pump impeller that was exposed to production solvent drying for longer periods of time could experience the impeller cracking at a level that could lead to excessive fuel absorption and increased impeller deformation.  If impeller deformation results in sufficient interference with the fuel pump body, the fuel pump may become inoperative.

 

In parallel with the aforementioned investigation (beginning in mid-January), ToyotaeBay logo began an investigation to confirm that a fail-safe driving mode would occur in hybrid vehicles if this condition occurs.  The testing involved inducing an inoperative fuel pump condition on test vehicles.  During testing it was observed that the LS500h and LC500h could potentially experience a ready off condition instead of entering a fail-safe driving mode under specific testing circumstances.

 

Additional analysis was conducted on the hybrid system design.  This analysis compared design differences between hybrid systems used in the models being tested above.  Further refinements to the test methods were developed to understand if the initial testing reflected what could occur in the field if one of these hybrid models experienced this fuel pump condition.  Using the refined test methods, additional testing was done to cover all the hybrid models that may be equipped with a subject fuel pump.

 

Based on these results, it was determined that all hybrid vehicles equipped with the subject fuel pump, except LS500h/LC500h, would enter a fail-safe driving mode if this fuel pump condition occurs.  However, because the LS500h and LC500h vehicles use a hybrid system of a unique design that may use more electricity from the battery and use the engine less than earlier designs, there is a possibility that, under certain driving conditions, these vehicles may have a hybrid battery state of charge that would not allow the vehicle to enter a fail-safe driving mode if this fuel pump condition occurs.  Thus, it was determined that these models should be included in the recall population.

 

February 27, 2020

Based on the new information explained above, ToyotaeBay logo decided to amend recall 20V-012 [and Toyota filed its amendment on March 4, 2020].

 

March 19, 2020

ToyotaeBay logo filed an additional amendment to its Part 573 Report for recall 20V-012 to add certain Lexus GS300 and GS350 vehicles, that are equipped with the aforementioned fuel pumps, to the affected population.  ToyotaeBay logo had identified a clerical error that resulted in those vehicles not being included in the March 4, 2020 amendment.

 

April 9, 2020

ToyotaeBay logo had identified separate clerical errors that resulted in certain field reports from non-U.S. sources being included in the chronology in the March 4, 2020 amendment.  Thus, ToyotaeBay logo revised the relevant portion of Section 6, Chronology of Principal Events, in that document with the following information about the vehicles covered by this recall at this point:

“As of March 4, 2020, based on a diligent review of records, ToyotaeBay logo’s best engineering judgment is that there are 73 ToyotaeBay logo Field Technical Reports and 3,358 warranty claims that have been received from U.S. sources that relate or may relate to the fuel pump failure investigated in this chronology and which were considered in the decision to submit this report.”

 

April 2020 – September 2020

ToyotaeBay logo continued to monitor the field data and investigate whether vehicles outside the scope of recall 20V-012, that potentially received impellers of lower density, could experience the condition identified in the recall.  As a part of this effort, ToyotaeBay logo requested the supplier to continue examining the three factors (impeller density, impeller surface strength, and stress exposure through solvent drying) that can combine to create the condition in the recall.

 

The supplier first re-evaluated whether surface stress exposure could be affected by the variation in solvent amount applied on the impeller during the supplier’s manufacturing process.  As stress exposure in this case is affected by (1) the point in time the applied solvent has been absorbed by the impeller and begins drying, and (2) the rate at which the solvent dries, the supplier conducted a test where different levels of solvent were applied to the impeller and the impeller weight change was measured over time.  Based on the observed weight change over time, the supplier determined that (1) the point at which solvent absorption ends and solvent drying begins is not earlier than previously estimated; and (2) the rate at which solvent dries is not higher than previously estimated.  Thus, because the previously estimated drying time and drying rates were appropriate, the supplier determined that its previous estimates about the level of potential surface stress exposures were also appropriate and conveyed these results to ToyotaeBay logo.

 

In addition, the supplier re-evaluated its prior estimates about the potential levels of density in the affected impellers.  Because the impeller material contains three elements (resin, glass fiber, and calcium carbonate), but only one element (the resin) is susceptible to swelling, the supplier examined whether considering only the density of the resin is more appropriate.    Thus, the supplier developed a method to measure resin density by assessing the production variation of the amount of resin, glass fiber, and calcium carbonate between each impeller lot that could have used material of lower density.  Then the supplier conducted testing to quantify the content of glass fiber and calcium carbonate in representative impellers from each lot, which was then used to calculate the resin density.  Based on this methodology, it was determined that the resin density had a higher correlation to the occurrence of field cases confirmed through part recovery as compared to overall density.

 

The supplier also re-evaluated its prior measurements of the surface strength for the affected impeller types.  From this activity, the supplier observed that some test pieces previously used to assess surface strength had rougher surfaces due to the process used to cut the samples for testing.  Thus, the supplier evaluated whether the existence of a rough surface on the test pieces could affect the accuracy of the measurement.  The supplier then collected available impellers to re-test and confirm the prior measurements of minimum surface strength.  The results of these tests found that the potential range of surface strength measurements could be wider than previously measured and that a lower minimum surface strength than previously estimated could be possible.

 

September 2020 – October 2020

The supplier then conducted a simulation to estimate a minimum resin density threshold for each fuel pump type/lot, taking into account the existing information on solvent drying stress exposure and the latest information on each pump type’s surface strength.  This minimum resin density was then compared with resin density distribution of all affected impeller lots, and as a result, an additional pump type and additional suspect lots not included in the 20V-012 recall scope were identified.

 

October 22, 2020

ToyotaeBay logo decided to amend the vehicle population involved in recall 20V-012, as the previous method for evaluating the combination of factors leading to this condition resulted in the exclusion of vehicles from the recall that should have been included.

 

As of October 11, 2020, ToyotaeBay logo’s best engineering judgment is that there are 103 ToyotaeBay logo Field Technical Reports and 3,522 warranty claims that have been received regarding the newly identified vehicles included in this amendment from U.S. sources that relate or may relate to the fuel pump failure investigated in this chronology and which were considered in the decision to amend this report.

 

Description of Corrective Repair Action:

For all involved vehicles, ToyotaeBay logo and Lexus dealers will replace the fuel pump assembly with an improved one.

 


65 Affected Products

Vehicles

MAKEMODELYEAR
LEXUSES3502018-2020
LEXUSGS 200T2017
LEXUSGS 3502017-2019
LEXUSGS3002019
LEXUSGX4602018-2019
LEXUSIS 3002019
LEXUSIS 3502019
LEXUSIS200T2017
LEXUSLC5002018-2020
LEXUSLC500H2018-2020
LEXUSLS5002018-2020
LEXUSLS500 H2019
LEXUSLX5702018-2019
LEXUSNX3002018-2019
LEXUSRC 200T2017
LEXUSRC 3002019
LEXUSRC 3502019
LEXUSRX3502017, 2019-2020
LEXUSRX350L2018-2020
LEXUSUX2002019
TOYOTAeBay logo4RUNNER2018-2019
TOYOTAeBay logoAVALON2019-2020
TOYOTAeBay logoCAMRY2018-2020
TOYOTAeBay logoCOROLLA2020
TOYOTAeBay logoCOROLLA HATCHBACK2019
TOYOTAeBay logoHIGHLANDER2017-2019
TOYOTAeBay logoLAND CRUISER2018-2019
TOYOTAeBay logoRAV42019-2020
TOYOTAeBay logoSEQUOIA2019-2020
TOYOTAeBay logoSIENNA2017-2020
TOYOTAeBay logoTACOMA2017-2020
TOYOTAeBay logoTUNDRA2019-2020

 


65 Associated Documents

Manufacturer Notices(to Dealers,etc) – ToyotaeBay logo DATE July 1, 2021 TOPIC Technician qualifications to perform this recall have been updated

RCMN-20V682-3348.pdf 1477.205KB

 


Manufacturer Notices(to Dealers,etc) – Lexus – ToyotaeBay logo DATE July 1, 2021 TOPIC Technician qualifications to perform this recall have been updated

RCMN-20V682-0709.pdf 1423.007KB

 


Manufacturer Notices(to Dealers,etc) – LEXUS DATE March 31, 2021 TOPIC • The remedy for Phase 11 vehicles is now available • Loaner Vehicle Reimbursement Procedure section has been updated

RCMN-20V682-0148.pdf 1395.791KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE April 22, 2021 TOPIC • Loaner Vehicle Reimbursement Procedure section has been updated

RCMN-20V682-9923.pdf 1430.722KB

 


Remedy Instructions and TSB

RCRIT-20V682-6245.pdf 2807.997KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-20V682-7302.pdf 1092.62KB

 


Manufacturer Notices(to Dealers,etc) – ToyotaeBay logo DATE TOPIC January 13, 2021 • Estimated Remedy Availability Timing has been updated for Highlander, RAV4 (Japan Prod), Camry (Japan Prod), Corolla and Corolla Hatchback • Owner Letter Mailing Date section has been updated • Loaner Vehicle Reimbursement Procedure section has been updated

RCMN-20V682-7095.pdf 1490.064KB

 


Remedy Instructions and TSB

RCRIT-20V682-4910.pdf 4302.106KB

 


Remedy Instructions and TSB

RCRIT-20V682-4730.pdf 1120.264KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE TOPIC January 13, 2021 • The remedy for Phase 6 vehicles is now available • Vehicles from Phase 10 have been consolidated to Phase 8 under Estimated Remedy Availability Timing table • Owner Letter Mailing Date section has been updated • Loaner Vehicle Reimbursement Procedure section has been updated

RCMN-20V682-3732.pdf 1516.98KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE TOPIC January 13, 2021 • The remedy for Phase 6 vehicles is now available • Vehicles from Phase 10 have been consolidated to Phase 8 under Estimated Remedy Availability Timing table • Owner Letter Mailing Date section has been updated • Loaner Vehicle Reimbursement Procedure section has been updated • Estimated Remedy Availability Timing has been updated for UX 200

RCMN-20V682-0178.pdf 1469.412KB

 


Manufacturer Notices(to Dealers,etc) – Lexus December 11, 2020 • Estimated Remedy Availability Timing has been updated for vehicles added October 28, 2020 • The NHTSA recall no. applicable to the vehicles added October 28, 2020 has been added • The Owner Letter Mailing Date section of the Dealer Letter has been updated

RCMN-20V682-7883.pdf 1451.114KB

 


Manufacturer Notices(to Dealers,etc) – December 11, 2020 Estimated Remedy Availability Timing has been updated for the vehicles added on October 28, 2020 • The NHTSA recall no. applicable to the vehicles added on October 28, 2020 has been added • The Owner Letter Mailing Date section of the Dealer Letter has been updated

RCMN-20V682-1731.pdf 2057.209KB

 


ISSUED Owner Notification Letter(Part 577) – 24051_Lexus_20LA01_Exp_Rem

RCONL-20V682-7178.pdf 849.785KB

 


Manufacturer Notices(to Dealers,etc) – ToyotaeBay logo DATE March 18, 2021 TOPIC • The remedy for Phase 10 vehicles is now available

RCMN-20V682-2731.pdf 1548.897KB

 


Remedy Instructions and TSB

RCRIT-20V682-1962.pdf 4778.906KB

 


Manufacturer Notices(to Dealers,etc) – LEXUS DATE March 18, 2021 TOPIC • The remedy for Phase 9 vehicles is now available

RCMN-20V682-7106.pdf 1474.193KB

 


Remedy Instructions and TSB

RCRIT-20V682-0817.pdf 3193.381KB

 


Manufacturer Notices(to Dealers,etc) – DATE: February 12, 2021 TOPIC: Estimated Remedy Availability Timing has been updated for LX 570 and 2019 NX 300

RCMN-20V682-3234.pdf 1472.588KB

 


ISSUED Owner Notification Letter(Part 577) – 24054_Toy_20TA02_Cross-Mdl

RCONL-20V682-3044.pdf 1097.281KB

 


Remedy Instructions and TSB

RCRIT-20V682-1599.pdf 4647.801KB

 


Remedy Instructions and TSB

RCRIT-20V682-2725.pdf 4685.944KB

 


Remedy Instructions and TSB

RCRIT-20V682-9458.pdf 1554.102KB

 


Remedy Instructions and TSB

RCRIT-20V682-9184.pdf 4301.918KB

 


Remedy Instructions and TSB

RCRIT-20V682-9813.pdf 2966.006KB

 


Remedy Instructions and TSB

RCRIT-20V682-4200.pdf 4763.81KB

 


Remedy Instructions and TSB

RCRIT-20V682-0563.pdf 3184.035KB

 


Remedy Instructions and TSB

RCRIT-20V682-9878.pdf 3002.65KB

 


Remedy Instructions and TSB

RCRIT-20V682-9159.pdf 4473.643KB

 


Remedy Instructions and TSB

RCRIT-20V682-9492.pdf 4171.558KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE February 18, 2021 TOPIC • The remedy for Phase 7 vehicles is now available • Estimated Remedy Availability Timing has been updated for Sequoia and Tundra

RCMN-20V682-2309.pdf 1649.567KB

 


December 18, 2020 AMENDED DEFECT INFORMATION REPORT (20V-012, 20V-682)

RMISC-20V682-4179.pdf 17.119KB

 


Manufacturer Notices(to Dealers,etc) – DATE: December 18, 2020 TOPIC: Toyota has added approximately 8,000 vehicles to this Recall.

RCMN-20V682-3433.pdf 1491.431KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE February 18, 2021 TOPIC • The remedy for Phase 7 vehicles is now available

RCMN-20V682-0948.pdf 1473.251KB

 


Manufacturer Notices(to Dealers,etc) – LEXUS DATE February 25, 2021 TOPIC • The remedy for Phase 8 vehicles is now available

RCMN-20V682-4544.pdf 1486.427KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE March 25, 2021 TOPIC • The remedy for Phase 10 vehicles is now available

RCMN-20V682-6265.pdf 1491.423KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE March 25, 2021 TOPIC • The remedy for Phase 11 vehicles is now available • Estimated Remedy Availability Timing has been updated for 4Runner

RCMN-20V682-3239.pdf 1542.576KB

 


Manufacturer Notices(to Dealers,etc) – TOYOTA DATE February 25, 2021 TOPIC • The remedy for Phase 8 vehicles is now available

RCMN-20V682-5011.pdf 1558.689KB

 


Manufacturer Notices(to Dealers,etc) – DATE: February 12, 2021 TOPIC: • Estimated Remedy Availability Timing has been updated for Land Cruiser and 2018-2020 Sienna (FWD) • Owner Letter Mailing Date Section has been updated

RCMN-20V682-8021.pdf 1553.778KB

 


ISSUED Owner Notification Letter(Part 577) – 24054_Toy_20TA02_P181920

RCONL-20V682-1144.pdf 1101.267KB

 


ISSUED Interim Owner Notification Letter(Part 577) – 24006_Toy_20TB02_Exp_Int

RIONL-20V682-8780.pdf 1092.62KB

 


Remedy Instructions and TSB

RCRIT-20V682-1800.pdf 4026.309KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE TOPIC January 28, 2021 • The remedy for phase 6 vehicles is now available • Owner Letter Mailing Date Section has been updated

RCMN-20V682-7359.pdf 1493.87KB

 


ISSUED Interim Owner Notification Letter(Part 577) – 24007_Lexus_20LB01_Exp_Int

RIONL-20V682-8862.pdf 845.714KB

 


ISSUED Interim Owner Notification Letter(Part 577) – 24006_Toy_20TB02_ExpU_Int

RIONL-20V682-8913.pdf 1093.252KB

 


ISSUED Interim Owner Notification Letter(Part 577) – 24007_Lexus_20LB01_ExpU_Int

RIONL-20V682-5302.pdf 848.858KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE March 11, 2021 TOPIC • The remedy for Phase 9 vehicles is now available • Estimated Remedy Availability Timing has been updated for 2017 Sienna (FWD) and RAV4 (USA Built)

RCMN-20V682-9495.pdf 1560.268KB

 


Manufacturer Notices(to Dealers,etc) – Lexus DATE TOPIC January 28, 2021 • 2019 – 2020 ES 350 (Japan Built) vehicles are included in Phase 6 remedy

RCMN-20V682-4456.pdf 1471KB

 


Remedy Instructions and TSB

RCRIT-20V682-9927.pdf 4792.641KB

 


Remedy Instructions and TSB

RCRIT-20V682-6035.pdf 3264.308KB

 


Remedy Instructions and TSB

RCRIT-20V682-7500.pdf 3274.1KB

 


Recall Quarterly Report #2, 2021-2

RCLQRT-20V682-4324.PDF 211.268KB

 


Manufacturer Notices(to Dealers,etc) – October 28, 2020 • Toyota has added approximately 1,327,800 vehicles to this Recall.

RCMN-20V682-5899.pdf 1298.068KB

 


Defect Notice 573 Report

RCLRPT-20V682-3280.PDF 253.096KB

 


Recall Acknowledgement

RCAK-20V682-2302.pdf 350.5KB

 


Manufacturer Notices(to Dealers,etc) – October 28, 2020 • Toyota has added approximately 1,327,800 vehicles to this Recall.

RCMN-20V682-8202.pdf 1343.067KB

 


Manufacturer Notices(to Dealers,etc) – October 28, 2020 • Toyota has added approximately 1,327,800 vehicles to this Recall.

RCMN-20V682-0847.pdf 1487.701KB

 


Recall Acknowledgement

RCAK-20V682-2302.pdf 244.92KB

 


November 4, 2020 Re: Amendment to Toyota and Lexus Safety Recall 20V-012

RMISC-20V682-0794.pdf 302.721KB

 


Manufacturer Notices(to Dealers,etc) – October 28, 2020 Lexus has added approximately 190,000 vehicles to this Recall

RCMN-20V682-3302.pdf 1249.442KB

 


Manufacturer Notices(to Dealers,etc) – DATE April 8, 2021 TOPIC • The remedy for Phase 12 vehicles is now available

RCMN-20V682-3463.pdf 1550.345KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE April 15, 2021 TOPIC • The remedy for Phase 13 vehicle is now available • Loaner Vehicle Reimbursement Procedure section has been updated

RCMN-20V682-0703.pdf 1465.805KB

 


Remedy Instructions and TSB

RCRIT-20V682-5129.pdf 2572.251KB

 


Recall Quarterly Report #1, 2021-1

RCLQRT-20V682-3062.PDF 211.269KB

 


Recall Quarterly Report #3, 2021-3

RCLQRT-20V682-9317.PDF 211.361KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V682&docType=RCL

 


 

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MAXODYNE® FTC Decarbonizer Ultimate Fuel Catalyst 1 Gal (3.78 L)
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SLIP 2000 Carbon Killer - 15 oz.
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  • The true fuel catalyst - harness every particle of energy in the fuel. Restore engine power and fuel economy
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Vesicur Yeap Herbnifique 3-In-1 Decarboxylator & Oil Infuser & Gummy Maker Machine With Mixing Function, Tincture Maker, Herbal Recipe Book Included (Black)
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