When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
bbqsoup: there will probably be a long service backlog with as many vehicles which are affected. We are still one ahead on recalls.... although you got an extra one with your '10 :-)
"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 contain an impeller that could deform due to excessive fuel absorption. Although the cause is unknown, if impeller deformation occurs, the impeller may interfere with the fuel pump body, and this 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, Toyota 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, Toyota 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, Toyota began an investigation to identify factors potentially contributing to cracking.
September 2019 – December 2019 As part of the investigation, Toyota 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. Toyota 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 Toyota 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 Toyota 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, Toyota 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.
As of January 7, 2020, based on a diligent review of records, Toyota’s best engineering judgment is that there are 66 Toyota Field Technical Reports and 2,571 warranty claims that have been received from U.S. sources that relate to the fuel pump failure investigated in this chronology and which were considered in the decision to submit this report.January 9, 2020
While continuing its investigation into the cause of impeller swelling, Toyota 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
Toyota filed a Part 573 report.
January – mid February 2020
As observed in Toyota’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.
Toyota 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, Toyota 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, Toyota 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, Toyota 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), Toyota 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, Toyota decided to amend recall 20V-012.
As of March 4, 2020, based on a diligent review of records, Toyota’s best engineering judgment is that there are 81 Toyota Field Technical Reports and 3,225 warranty claims that have been received from U.S. sources that relate to the fuel pump failure investigated in this chronology and which were considered in the decision to submit this report.
Description of Corrective Repair Action:
All known owners of the affected Toyota and Lexus vehicles will be notified by first class mail to return their vehicles to a Toyota or Lexus dealer. Dealers will replace the 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.
Just spoke to my dealer, my 2014GX is on the list and wait for the parts for the fuel pump recall. Expecting the mail notice in few weeks. After six years trouble free, I guess to have a new fuel pump is a good thing.
My 2015 Luxury isn’t included, per the VIN lookup site... bummer, I had to go in for a 60k service anyway, and wouldn’t mind a new fuel pump. Oh well, one less thing for them to mess up.
Hello All,
I am a new owner of a 2019 Lexus ES350 which I purchased used 2 weeks ago from a non-Lexus dealer and this is my first post. I was aware of a recall however, it wasn't until after my purchase that there was no repair or one in site any time soon. I ended up calling the Lexus customer service line and asked about the recall. After being told "it could be awhile" 3-6 months for a fix, I was told if you don't feel comfortable driving the car, Lexus will pay for a rental until there is a fix. I said, so Lexus will provide me with a rental for as long as it takes to fix my car? Yes sir! Long story short, my almost new 2019 ES350 is now sitting comfortably in my garage until a repair is made. So, if anyone wants a rental until there is a fix, go to your local dealer and ask, If your car is part of the recall, it's that simple.
Hi-
has anyone got a rental from the dealer for this recall? How’d it work? Loaner or a rental from a rental agency? I’d rather not get something smaller than a gx. Or atleast something comparable.. curious on other experiences. Thanks.
Hi emg2919,
I live in S. Fl and have a loaner. I just called my dealer and they filled out the paperwork and sent Enterprise to pick me up. I could select any car they had available. Signed some papers and I was on my way. Very simple, took about 2 hours to complete the entire process.
Called my dealer, they told me it would be early fall before the parts are available. They said: "don't let the fuel quantity get low", also the problem seems to be related to high humidity, hot climates. They offered no rental car.
Called my dealer, they told me it would be early fall before the parts are available. They said: "don't let the fuel quantity get low", also the problem seems to be related to high humidity, hot climates. They offered no rental car.
Hi Statman,
I don't think your dealer would offer, but you can request and I don't believe they have a choice but to give you a rental if you request one.. That would be a lawsuit waiting to happen. Lexus customer support told me if I wasn't comfortable driving my car they would provide a rental until my car was fixed. I am certain, this would pertain to anyone.
03-06-20 | 01:49 PM
