2020 Toyota Highlander

I am having fuel pump issues and my VIN was excluded from the recall from Toyota for similar issues. Toyota’s low-pressure fuel pump recall (originally announced Jan 2020, expanded multiple times through Jan 2025) covers vehicles across several model years, where a defective impeller made from inadequate resin material could swell and cause fuel starvation and sudden stalling. Highlander is mentioned as included for selected model years in some recall summaries

Fuel gauge is inaccurate, leading to potential safety issues. The fuel gauge does not show as full, when the car is refueled, and likewise shows as empty when there is enough fuel to drive hundreds of miles. This has led to situations where the fuel light is on, and car is indicating no remaining miles left, but there is plenty of fuel. Toyota knows there is a problem. I started a Lemon Law claim with the Washington State Attorney's General office and notified Toyota. They have offered to replace my vehicle, which is currently in process.

Since purchasing this vehicle I began to notice that the fuel gauge is inaccurate. This issue is sporadic. Often after filling the gas tank completely, the gauge will only register as 3/4 full. Like wise, it is inaccurate when the tank gets low, showing that there is 1/4 tank, when in fact it is nearly empty. The "remaining miles" indicator that displays is likewise inaccurate and often the low fuel indicator light comes on when it shouldn't, and doesn't display when it should. I have had it to the deal 4 times now for repair. Initially they told me nothing was wrong, then indicated that a software update was necessary. When that didn't fix it, I returned the vehicle and they indicated an instrument panel sensor chip needed to be replaced. I waited a month for that to happen and it didn't fix the issue. I then opened a trouble incident with Toyota USA and after several weeks received a call back from the dealer indicating this is a known (presumably still developing) issue and has something to do with a faulty gas tank that causes the readings to be inaccurate. The dealer indicated that they know this will require the gas tank to be replaced but that they don't have parts to do this and will contact me at some point in the future. This is a serious safety issue, as it could lead to the vehicle running out of gas while driving, without any indication that the fuel is low. The only way to have any certainty regarding the fuel level is to do a calculation each time you drive based on the estimated fuel economy and # of miles driven since the last fill up.

In my 2020 Highlander I approached a stop sign at a "T" intersection behind 4 other cars. After stopping and looking to see road was clear of oncoming traffic, I pulled out and started my left turn. As I was turning into my lane the car engine turned OFF and the steering wheel was LOCKED in the left position. There was no power for the brakes, which left me jamming on the brake pedal as hard as I could only slowing the car slightly. The steering wheel was LOCKED LEFT and I thought I was going to break it trying to force it back. With no ability to move the steering wheel or brake, I braced myself as the Highlander continued turning in the left direction into the other lane. The result was a head on collision with a Mini Cooper, both cars totaled, and injuring both myself and the other driver. Highlander was investigated by forensic company in the employ of the insurance company, but they could not find any error in the cars CDR (Crash Data Retrieval) system.

EACH TIME I FILL UP THE CAR WITH GAS I AM UNABLE TO FILL THE TANK TO ITS LISTED CAPACITY. THE VEHICLE HAS A 17 GALLON TANK, BUT WHEN THE VEHICLE IS NEAR EMPTY (1-2 GALLONS REMAINING) I CAN PUMP IN ONLY 12-13 GALLONS OF GAS. THIS GREATLY IMPACTS THE RANGE OF THE VEHICLE. THE DATE SHOWN BELOW IS MY MOST RECENT FILL-UP, BUT IT HAS HAPPENED EACH TIME I FILL UP. I HAVE REPORTED THIS TO MY TOYOTA DEALER.

THE VEHICLE IS SOLD AS HAVING A 17 GALLON FUEL TANK. I'VE DRIVEN THE VEHICLE FOR 5000 PLUS MILES NOW. I HAVE NEVER BEEN ABLE TO GET MORE THAN 13 GALLONS OF FUEL INTO THE TANK. I HAVE WAITED UNTIL THE GAGE SAID THERE WAS ONLY 12 MILE UNTIL EMPTY. STILL COULD ONLY FILL UP WITH ON 13 GALLONS OF FUEL. THE GAGE SAY'S IT'S FULL. I HAVE MADE THE TOYOTA DEALERSHIP AWARE OF THE ISSUE. BUT THEY SAID THERE WAS NOTHING ON THEIR SYSTEM ABOUT A RECALL OR NEEDED REPAIR. IF THE VEHICLE IS ADVERTISED AS HAVING A 17 GALLON TANK I SHOULD BE ABLE TO USE THAT WHALE 17 GALLONS OF FUEL. INSTEAD I CAN ONLY FILL UP TO 13 GALLONS.

VEHICLE WILL NOT START WITHOUT A JUMP AFTER 3-5 HOURS. THE BATTERY STAYS CHARGED LESS THAN ONE DAY, BUT TYPICALLY STARTS AGAIN WITHOUT A JUMP IF DRIVEN AGAIN WITHIN A 3-5 HOUR PERIOD. THE VEHICLE STAYS RUNNING ONCE JUMPED. DEALER SERVICE DEPARTMENT INDICATES A SOFTWARE UPDATE MAY BE REQUIRED. THIS HAS HAPPENED SINCE PURCHASE ON JUNE 7, 2020. DATE BELOW IS THE MOST RECENT DATE IT OCCURRED.

2020 TOYOTA HIGHLANDER HYBRID AWD. WHEN FILLING FROM ALMOST EMPTY (PER LOW FUEL WARNING LIGHT AND DISTANCE TO EMPTY READING ALMOST 0), TANK ONLY ACCEPTS ~12.5 GALLONS BEFORE GAS STATION FUEL NOZZLE AUTO CLICKS OFF. THE FUEL GAGE AT THIS POINT INDICATES THAT THE VEHICLE IS ~7/8 FILLED. THE OWNERS MANUAL WARNS ABOUT NOT ATTEMPTING TO FILL AFTER THE FUEL NOZZLE AUTOMATICALLY CLICKS OFF. BEING UNABLE TO FILL TANK MAY LEAD TO OWNERS ATTEMPTING TO OVERFILL TANKS AND COULD RESULT IN INADVERTENTLY SPILLING FUEL WHICH POSES A SAFETY RISK AND AN ENVIRONMENTAL DAMAGE RISK. IT CAN ALSO LEAD TO MORE EMISSIONS. A SIMILAR PROBLEM EXISTS WITH 2019/2020 TOYOTA RAV4 PER NHTSA RECORDS, TOYOTA HAS PROPOSED A FIX FOR THIS VEHICLE BUT HAS STATED THAT NO OTHER MODELS ARE AFFECTED BY THIS ISSUE. THE PROBLEM DESCRIBED ABOVE IS ALMOST IDENTICAL WITH THE EXCEPTION THAT THE VEHICLES HAVE DIFFERENT FUEL TANK CAPACITIES. TOYOTA HAS INDICATED THAT THIS IS "NORMAL".