SAFETY RECALL 21TA05 – Vehicle May Stall During Driving at Higher Speeds – 2019-2020 Toyota Yaris

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August 6, 2021 NHTSA CAMPAIGN NUMBER: 21V617000

Fuel Pump May Fail and Cause Engine Stall

A fuel pump failure may cause an engine stall, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V617

Manufacturer Toyota Motor Engineering & Manufacturing

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 31,307

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2019-2020 Yaris, Yaris Hatchback, and Yaris Sedan vehicles. An impeller within the low-pressure fuel pump may crack and deform, potentially causing the fuel pump to fail.

 

Remedy

Dealers will replace the low-pressure fuel pump assembly, free of charge. Owner notification letters were mailed December 30, 2021. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s numbers for this recall are 21TB05 and 21TA05.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


SAFETY RECALL 21TA05

Certain 2019 – 2020 Model Year Yaris Sedan
Certain 2020 Model Year Yaris Hatchback & Yaris R
Vehicle May Stall During Driving at Higher Speeds
NHTSA Recall No. 21V-617

 

Model Years / Model Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2019 – 2020 Yaris Sedan Early October 2018 – Early February 2020 25,700 0
2020 Yaris Hatchback / Yaris R Early August 2019 – Late January 2020 5,600 0

 

On August 6, 2021, based on Mazda’s investigation into this issue, Toyota filed a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2019 – 2020 model year Yaris Sedan, 2020 model year Yaris Hatchback and Yaris R vehicles.

 

Condition

The subject vehicles were designed and manufactured by Mazda.  According to Mazda, the subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights may be displayed on the instrument cluster, and the engine may run rough. This may result in a vehicle stall, and/or 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

Toyota is currently preparing the remedy for this issue.  When the remedy is available, authorized Toyota dealers will replace the low-pressure fuel pump with an improved one FREE OF CHARGE. At this time, Toyota estimates the remedy can be available in the fourth quarter of 2021.

 

Covered Vehicles

There are approximately 31,300 vehicles covered by this Safety Recall. Approximately 8,000 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will notify owners by early October 2021.

Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

Pre-Owned Vehicles in Dealer Inventory

Toyota typically requests that dealers NOT deliver any pre-owned vehicles in dealer inventory that are covered by a Safety Recall unless the defect has been remedied. In this case, until remedy parts are available, delivery of a pre-owned vehicle is acceptable if disclosed to the customer that the vehicle is involved in this Safety Recall and that the remedy is currently being prepared by Toyota.

Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Ed Hellwig (469) 292-1165 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Customer Reimbursement

Reimbursement consideration instructions will be included in the owner letter.

 


TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 21TA05
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEEDS
CERTAIN 2019 – 2020 MODEL YEAR YARIS SEDAN
CERTAIN 2020 MODEL YEAR YARIS HATCHBACK & YARIS R

TECHNICAL INSTRUCTIONS SAFETY RECALL 21TA05 – Vehicle May Stall During Driving At Higher Speeds – 2019-2020 Toyota Yaris

 

TECHNICAL INSTRUCTIONS SAFETY RECALL 21TA05 – Vehicle May Stall During Driving At Higher Speeds – 2019-2020 Toyota Yaris

 


Frequently Asked Questions

Original Publication Date: August 6, 2021

 

Q1:What is the condition?

The subject vehicles were designed and manufactured by Mazda.  According to Mazda, the subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights may be displayed on the instrument cluster, and the engine may run rough. This may result in a vehicle stall, and/or 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 on the instrument cluster, engine no start, and/or 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 check engine light shown below, may illuminate in the instrument panel cluster. In addition to the check engine light, other warning lights may also be displayed.

 

Q2:What is Toyota going to do?

Toyota is currently preparing the remedy. When the remedy becomes available, any authorized Toyota dealer will replace the low-pressure fuel pump with an improved one FREE OF CHARGE.

 

Q3: When will the remedy become available?

Toyota is currently preparing the parts and repair instructions for the remedy. At this time, Toyota estimates that the remedy can be available in the fourth quarter 2021.

 

Q4: Which and how many vehicles are covered by this Safety Recall?

There are approximately 31,300 vehicles covered by this Safety Recall.

Model Name Model Year Production Period Approximate Vehicles
Yaris Sedan 2019 – 2020 Early October 2018 – Early February 2020 25,700
Yaris Hatchback / Yaris R 2020 Early August 2019 – Late January 2020 5,600

 

Q4a:Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.?A4a:No, there are no other Lexus/Toyota/Scion vehicles covered by this Safety Recall.

 

Q5: What if I previously paid for repairs related to this Safety Recall?

Reimbursement consideration instructions will be provided in the owner letter.

 

Q6: How does Toyota obtain my mailing information?

Toyota 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.

 

Q7: What if I have additional questions or concerns?

If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

 


August 6, 2021

 

DEFECT INFORMATION REPORT

 

  1. Vehicle Manufacturer Name:

Mazda de Mexico Vehicle Operation
Av. Hiroshima 1000, Complejo Industrial Salamanca, C.P.
36875, Salamanca, Gto

 

Affiliated U.S. Sales Company:

Toyota Motor North America, Inc. [“TMNA”]
6565 Headquarters Drive, Plano, TX 75024

 

Manufacturer of Fuel Pump Assembly

DENSO CORPORATION
1-1, Showa-cho, Kariya-city, Aichi-pref., 448-8661, Japan

Phone: +81-566-25-5511

 

DENSO International America, Inc.
24777 Denso Drive, Southfield, Michigan 48086 U.S.A. Phone: +1-248-350-7500
Country of Origin: Japan and U.S.A.

 

  1. Identification of Involved Vehicles and Affected Components:

Based on production records, we have determined the involved vehicle population as in the table below.

Make/Car Line Model Year Manufacturer Production Period
Toyota / Yaris

Hatchback, Yaris Sedan, Yaris R

2019-2020 Mazda de Mexico Vehicle Operation October 4, 2018 through February 6, 2020

 

Applicability Part Number Part Name Component Description
MY2019-2020 Toyota Yaris Hatchback, Yaris Sedan, Yaris R 23221-WB002 Low Pressure Fuel Pump Fuel Pump
MY2019-2020 Toyota Yaris Hatchback, Yaris Sedan, Yaris R 77020-WB001 Fuel Suction w/Pump & Gage Tube Assy Fuel Pump Assembly

Note:

(1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S.

(2) Based on Toyota’s current understanding of the condition from Mazda, this recall applies to certain vehicles with specific low-pressure fuel pumps supplied by Denso, containing impellers produced during specific periods under specific circumstances.  These vehicles contain fuel pumps that were produced with impellers of lower density and contain a pump impeller that was exposed to production solvent drying for longer periods of time, which may deform when exposed to higher levels of ambient environmental temperatures. Vehicles with fuel pumps that were not produced under the aforementioned conditions are not included at this time.

 

  1. Total Number of Vehicles Potentially Involved:

Toyota Yaris Hatchback, Yaris Sedan, Yaris R : 31,307

 

  1. Percentage of Vehicles Estimated to Actually Contain the Defect:

Unknown.  Toyota is unable to provide an estimate of the percentage of vehicles to actually contain the defect.  Whether the issue in each case will lead to a vehicle stall while driving at higher speeds depends on many variables, such as the specific production condition of fuel pump impeller and vehicle operating conditions such as the level of ambient environmental temperatures.

 

  1. 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 were exposed to production solvent drying for longer periods of time and higher levels of ambient environmental temperatures, 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.

 

  1. Chronology of Principal Events:

March – November 2020:

 

Mazda, which is responsible for the vehicle’s design and manufacture, began an investigation into low-pressure fuel pump failures in the field.  (Although the supplier was Denso, it was later learned that the fuel pump design was different than those in other Toyota models.)  Toyota did not have access to the design information; therefore, to support Mazda’s investigation, at the end of March, Toyota began providing Mazda with fuel pumps recovered from the field.  Initially, three recovered fuel pumps were sent to Mazda.

 

Mazda reported that, for one of the fuel pumps it had received, the impeller was deforming due to low material density and extended drying time of solvent used in testing.  Mazda also hypothesized that variation in field usage, such as environmental temperature in different regions and fuel type used by customers, could be additional contributors to impeller deformation.

 

Mazda then investigated nine additional fuel pumps that had been recovered from the field.  Eight of these pumps had impeller deformation, while the ninth pump was contaminated by outside influences, and its failure was unrelated to impeller deformation.

 

Later, Mazda found four additional fuel pumps with impeller deformation. Throughout this time, Toyota continued to recover field parts to support Mazda’s investigation.

 

December 2020 – July 2021:

Based on the recovered field parts and other investigation actions conducted by Mazda, Mazda reported that, for the fuel pumps in the subject vehicles, exposure to higher environmental temperatures appeared to be a factor.  Based on this information, Mazda considered the temperature exposure for the subject vehicles in different markets and continued to investigate the specifics of how this factor, when combined with the other factors that had been previously identified as relevant (lower density impellers and longer exposure to solvent drying) could lead to sufficient interference between the impeller and the fuel pump body to cause the fuel pump to become inoperative.  Denso conducted heat cycle testing to understand how environmental temperature influenced impeller deformation. Test results demonstrated that impeller deformation accelerates with higher temperature.  In addition, to support Mazda’s further investigation, Toyota provided field data to Mazda for different North American markets.

 

August 4, 2021:

Based on the investigation by Mazda, it was determined that, if these impellers, which were manufactured with lower density, were exposed to production solvent drying for longer periods of time and higher levels of ambient environmental temperatures, 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.

 

As of July 29, 2021, Toyota’s best engineering judgment is that there are a total of 123 Field Technical Reports, 37 of which were confirmed (received between March 13, 2020 and July 29, 2021), and 1,432 warranty claims, 62 of which were confirmed (received between April 15, 2019 and July 29, 2021), that have been received from U.S. sources that relate or may relate to the subject fuel pump failures.  The majority of reports and claims were for illumination of check engine and master warning indicators and engine no start cases.

 

  1. Description of Corrective Repair Action:

For all involved vehicles, Toyota dealers will replace the low-pressure fuel pump assembly with an improved one.

 

Reimbursement Plan for pre-notification remedies

The owner letter will instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement pursuant to Toyota’s General Reimbursement Plan.

 

  1. Recall Schedule:

Notifications to owners of the affected vehicles will occur by October 5, 2021.  A copy of the draft owner notification will be submitted as soon as it is available.

 

  1. Distributor/Dealer Notification Schedule:

Notifications to distributors/dealers will be sent on August 6, 2021.  Copies of dealer communications will be submitted as they are issued.

 

  1. Manufacturer’s Campaign Number:

[Interim / Remedy] 21TB05 / 21TA05

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
TOYOTA YARIS 2019-2020

 


11 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-21V617-8421.pdf 369.121KB

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Remedy Instructions and TSB

RCRIT-21V617-4260.pdf 2217.061KB

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Manufacturer Notices(to Dealers,etc) – TOYTOA DATE 10/27/2021 TOPIC Additional Interim Rental Opcode available

RCMN-21V617-1123.pdf 368.745KB

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Defect Notice 573 Report

RCLRPT-21V617-3402.PDF 214.35KB

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August 6, 2021 DEFECT INFORMATION REPORT

RMISC-21V617-5658.pdf 197.42KB

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Manufacturer Notices(to Dealers,etc) – Toyota Date: August 6, 2021 SAFETY RECALL 21TA05 (Interim Notice 21TB05)

RCMN-21V617-3711.pdf 212.82KB

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Recall Acknowledgement

RCAK-21V617-4709.pdf 645.181KB

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Manufacturer Notices(to Dealers,etc) – Toyota DATE 9/15/2021 TOPIC Interim Rental Opcodes now available NHTSA Recall No. has been added

RCMN-21V617-1471.pdf 434.969KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V617-8546.PDF 211.155KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V617-3881.pdf 1160.64KB

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Recall 573 Report-Amendment 1

RCLRPT-21V617-7180.PDF 214.489KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V617&docType=RCL

 


 

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