2021 Toyota Highlander

On July 25, 2026, while driving my 2021 Toyota Highlander Hybrid at high speeds on the freeway, the vehicle experienced a sudden loss of drive power accompanied by a check engine light and a severe hybrid system error warning. The failure occurred without any prior warning or degradation in performance, forcing an immediate emergency maneuver through traffic to reach the shoulder. The vehicle was towed to Toyota of El Cajon for diagnostic evaluation. The dealership service invoice details the following findings: - Primary Failure: Primary fuel injector failure (direct injection system). - Diagnostic Behavior: The engine experienced severe cylinder misfires under load at freeway speeds when the direct injectors were commanded on. - System Impact: Engine misfires triggered a hard safety shutdown of the hybrid system, immediately cutting motive power to the wheels. - Repair Executed: Replacement of the failed fuel injector assembly Safety Concern: A primary fuel injector failure at highway speeds causes an instantaneous engine misfire under load, which immediately triggers a hard hybrid drive system shutdown. Cutting motive power suddenly in heavy traffic without advance warning creates an extreme hazard for rear-end collisions. I am requesting NHTSA document and investigate this failure mode and its automated system shutdown logic.

This appears to be a fuel pump or something with the fuel issue on a 2021 Toyota Highlander L series. While driving it would stop and switch off at stop lights and stop sign. The codes that come up have to do with fuel being lean. However this also affects the braking system and causes it to be very hard to steer with this issue. The problem I have is that it cuts off without even you knowing what's happening and I was almost rear-ended twice. My car is now sitting outside unable to start. It doesn't even have 85,000 miles on it with all these issues. I believe it also said something about my transmission but unsure because the codes were flashing off and on.

*Component/System:** The **Fuel Pump / Fuel Delivery System** failed. The vehicle and the replaced spark plugs/coils are available for inspection upon request. **Safety Risk:** The vehicle **stalls abruptly while in motion (at speed)**, causing an immediate loss of motive power in traffic. This creates an extreme risk of rear-end collisions and leaves the driver stranded in active lanes of travel. The vehicle must be shifted to park, turned off, and restarted to temporarily "reset" the system, which is life-threatening in high-speed or heavy-traffic environments. **Confirmation/Reproduction:** The problem has been confirmed by an **independent service center**. Initial diagnostic codes led to the replacement of spark plugs and ignition coils; however, the stalling persisted. Subsequent diagnostic testing specifically identified the fuel pump as the point of failure, consistent with symptoms of known Toyota fuel pump recalls. **Inspections:** The vehicle has been inspected by an **independent mechanic**. It has not yet been inspected by Toyota corporate, the police, or insurance representatives, as no crash has occurred yet—though the risk is imminent. **Warning Symptoms:** The Check Engine light illuminated on January 21, February 21, Febuary 26, March 6 and March 10. Prior to the first total stall, the vehicle exhibited brief hesitations during acceleration. There were no specific "Fuel Pump" warnings on the dashboard; the vehicle simply loses power without a countdown or secondary safety mode (Limp Mode).

While driving westbound on I-8 at approximately 70 MPH in the left lane, a warning message suddenly appeared on my dashboard stating that a malfunction in the hybrid system had been detected. Immediately after the alert, the vehicle lost power and stopped accelerating. I was forced to quickly maneuver across multiple lanes of traffic and barely made it to the narrow right shoulder. Because I had been traveling in the left lane at highway speed, the situation was extremely dangerous, and I was fortunate not to be rear-ended. The vehicle was undrivable and had to be towed to a mechanic. Upon inspection, the cause was identified as a faulty fuel pump, which triggered the hybrid system malfunction and sudden loss of power. The vehicle has only 44,000 miles, making this premature failure especially concerning. Toyota currently has possession of the vehicle but is refusing to cover the repair. Notably, there was a recall issued for fuel pump failures causing similar issues in 2020 model-year vehicles. Given the identical nature of the failure, I believe this indicates an ongoing fuel pump defect that has not been fully resolved.

Entering the freeway a mile from home the car would not properly excellerate, only reachind 40 mph before exiting the freeway in favor backroads to my appointment. Shaking back and forth while driving, exacerbated when braking and coming to stop, I needed to put the car into neutral to calm down the shaking while waiting for the light to change. I just went through experiencing a brake failure and reporting of that to this Agency and now see another of many defects associated with the 2020-2022 Toyota Highlanders and Siennas Toyota is not addressing through Recalls as they should be, and further frustrated this Agency has or chooses to have no means by which to enforce Toyota's responsibility to the public

Yesterday, as I do a couple times a month, I went to switch parking places, putting my 2021 Toyota Highlander where my 2007 Mazda was parked, in order to drive it and keep the battery from dying. After starting both cars I first moved the Mazda to make room for the Toyota. As I was slowly steering the Toyota at (idle speed) into the now vacant parking spot, the car accelerated on it's own, prompting me to hit the brakes, but to no avail. The car jumped the curb hitting, knocking over and and damaging a large ceramic planter and small tree in my neighbor's yard. My split second reaction upon having no brakes and a run away car was to push it out of drive, which ended up putting the car into reverse, causing a harsh jolt, followed by the car accelerating again on it's own, in reverse towards another neighbor's garage. I live in a condo complex, so all of this took place within about 30 feet of forward/backward/forward motion. My second split second decision (with no brakes) to avoid smashing into the garage was throwing it back into drive, which sent it accelerating back towards the parking place again. This time I had the presence of mind to push the power button on the dash, allowing me to barely come to stop before jumping the curb again. Whole thing lasted about 15 seconds. I had an appointment to attend, so after a brief conversation explaining to my (now outside) neighbor what happened, I left in the older car. Returning later in the day I found damage to the front of my Toyota and wonder if my transmission is damaged as well. I'm reimbursing my neighbor today. I've not attempted to drive the Toyota since, and am seeking your advice on how best to proceed, whether I should initiate contact with Toyota regarding this incident, or is that something you should initiate? Please advise. Thank you.

While depressing the brake pedal the vehicle continues to accelerate before finally slowing to a stop. This happens on bumpy road surfaces as well as level road surfaces. There were no warning lights, alarms or messages prior to or during the failure. This issue started around 35,000 mileage and has progressively gotten worse to current day. (Current mileage as of 1/29/2024 is 54,346.) This issue would cause the vehicle to potentially rear end a vehicle you are following or propel the vehicle into an intersection typically controlled by a traffic signal or device. Local dealer has said there is nothing wrong as they could not replicate the issue.

On July 19, the car was parked and refused to start. Tried Jump start and the gas was at more than half a tank. The car would operate for 30 seconds, stutter and then stop. On July 20, took the car to ED MARTIN TOYOTA in Noblesville, IN. They could not diagnose the issue. Replaced Fuel Pump system. Evaluated all electrical and no issues observed. Escalated to TOYOTA Regional Engineering to teoubleshoot. The car is still in the shop with no root-cause. If the car was in motion and this issue would have occured, could have resulted in a serious accident.

Impossible to completely fill the gas tank on the Highlander Hybrid. 17+ gallon tank, yet car will accept at most 12-13 gallons of fuel. Fuel gauge reads between 3/4 and 7/8 full after each fill-up. This issue has persisted since the vehicle was new. Multiple requests to the dealer to fix this problem are largely ignored with them telling me that they aren't aware of any issues, research suggests that many other owners are experiencing the same problem.