Fuel Pump Recall

[TommyG]

cb1111, thanks for the info on the fuel pump recall.

This pdf (the second one) was the kind of failure info I was looking for.

https://static.nhtsa.gov/odi/rcl/2020/RMISC-20V012-4705.pdf

 

[Space King]

Hmmm.... according to the documents posted by cb1111, Toyota engineers still haven't determined the root cause of the failure.

What's happening is that cracks are forming in the fuel pump's impeller. This allows it to absorb more fuel than intended, causing it to swell and subsequently bind in the pump housing. They thought it may have been caused by a solvent used in manufacturing, however they weren't able to able to replicate the cracking precisely.

I'm not sure what plastic Denso is using to make the impellers out of, my guess would be PPS. I'd like to take one apart and find out. Part of my gig is doing post-mortem failure analysis as well as FFMEA (functional failure mode and effect analysis, before you ask), so I live for this sort of thing.

I'll be watching this space.

 

[cb1111]

Hmmm.... according to the documents posted by cb1111, Toyota engineers still haven't determined the root cause of the failure.

What's happening is that cracks are forming in the fuel pump's impeller. This allows it to absorb more fuel than intended, causing it to swell and subsequently bind in the pump housing. They thought it may have been caused by a solvent used in manufacturing, however they weren't able to able to replicate the cracking precisely.

I'm not sure what plastic Denso is using to make the impellers out of, my guess would be PPS. I'd like to take one apart and find out. Part of my gig is doing post-mortem failure analysis as well as FFMEA (functional failure mode and effect analysis, before you ask), so I live for this sort of thing.

I'll be watching this space.

But they somehow have narrowed down the time period of the affected units. Accordingly, they must know that Denso was using some sort of different material (or a different factory) during that time period.

I suspect that this recall will expand.

I'll see what I can find out at the office next week.

 

[Space King]

But they somehow have narrowed down the time period of the affected units. Accordingly, they must know that Denso was using some sort of different material (or a different factory) during that time period.

I suspect that this recall will expand.

I'll see what I can find out at the office next week.

It's hard to say.
For the sake of discussion let's assume that the impeller material is PPS plastic. You make PPS by mixing sodium sulfide, PDB and NMP solvent. You heat it to a specific temperature, add your glass or mineral reinforcement element, and while it's still in it's viscous state, you inject it into a heated mold. Wait for the crosslinking magic to happen, and presto! You got an impeller.

OK, so basically your critical manufacturing elements are materials, temperature and duration. A problem with materials can easily be tracked down through basic m&p (materials and process) practices. Denso knows who they got their materials from along with dates, batch and lot numbers... etc. So narrowing down the scope of potentially bad units is relatively trivial. What's harder to track down is if the failure is on the process side. For example a bad temp sensor in a mold could be causing parts to over or under cure. That could be a nightmare, because you don't know how long the equipment has been running in an out of tolerance condition. Even if Denso has policies to calibrate the equipment before each run, there's always the potential for a lazy operator to just pencil whip the checklist.

Anyway, I'm sure you'll keep us posted if you find anything.

 

[medium.rare.pepe]

So looks like more models/years were added to the recall.
Toyota is conducting a safety recall involving certain Toyota and Lexus vehicles - Toyota USA Newsroom

2013-2015 Model Year Lexus LS 460;
2013-2014 Model Year Lexus GS 350;
2014 Model Year Toyota FJ Cruiser, Lexus IS-F;
2014-2015 Model Year Toyota 4Runner, Land Cruiser; Lexus GX 460, IS 350, LX 570;
2015 Model Year Lexus NX 200t, RC 350;
2017 Model Year Lexus IS 200t, RC 200t;
2017-2019 Model Year Toyota Sienna; Lexus RX 350;
2018 Model Year Lexus GS 300;
2018-2019 Model Year Toyota Avalon, Camry, Corolla, Highlander, Sequoia, Tacoma, Tundra; Lexus ES 350, GS 350, IS 300, IS 350, LC 500, LC 500h, LS 500, LS 500h, RC 300, RC 350, RX 350L.

Also guys who got the original notice check your VIN again.
My 2019 is no longer listed as part of the recall arty:

 

[Blazephantom]

So looks like more models/years were added to the recall.
Toyota is conducting a safety recall involving certain Toyota and Lexus vehicles - Toyota USA Newsroom

2013-2015 Model Year Lexus LS 460;
2013-2014 Model Year Lexus GS 350;
2014 Model Year Toyota FJ Cruiser, Lexus IS-F;
2014-2015 Model Year Toyota 4Runner, Land Cruiser; Lexus GX 460, IS 350, LX 570;
2015 Model Year Lexus NX 200t, RC 350;
2017 Model Year Lexus IS 200t, RC 200t;
2017-2019 Model Year Toyota Sienna; Lexus RX 350;
2018 Model Year Lexus GS 300;
2018-2019 Model Year Toyota Avalon, Camry, Corolla, Highlander, Sequoia, Tacoma, Tundra; Lexus ES 350, GS 350, IS 300, IS 350, LC 500, LC 500h, LS 500, LS 500h, RC 300, RC 350, RX 350L.

Also guys who got the original notice check your VIN again.
My 2019 is no longer listed as part of the recall arty:

My 2019 4Runner is no longer on the recall list.

 

[alphabeast]

So looks like more models/years were added to the recall.
Toyota is conducting a safety recall involving certain Toyota and Lexus vehicles - Toyota USA Newsroom

2013-2015 Model Year Lexus LS 460;
2013-2014 Model Year Lexus GS 350;
2014 Model Year Toyota FJ Cruiser, Lexus IS-F;
2014-2015 Model Year Toyota 4Runner, Land Cruiser; Lexus GX 460, IS 350, LX 570;
2015 Model Year Lexus NX 200t, RC 350;
2017 Model Year Lexus IS 200t, RC 200t;
2017-2019 Model Year Toyota Sienna; Lexus RX 350;
2018 Model Year Lexus GS 300;
2018-2019 Model Year Toyota Avalon, Camry, Corolla, Highlander, Sequoia, Tacoma, Tundra; Lexus ES 350, GS 350, IS 300, IS 350, LC 500, LC 500h, LS 500, LS 500h, RC 300, RC 350, RX 350L.

Also guys who got the original notice check your VIN again.
My 2019 is no longer listed as part of the recall arty:

I'm excited to be on the list now. I was starting to feel left out.

 

[Mass 4runner]

My early build '19 is off the list now. One less thing to worry about

 

[ProfessorP]

My January 2019 build T4R is no longer on the recall list as well. Back when this thread first started it was listed on the NHTSA site, but no info was available on the Toyota site. Now both sites list zero recalls for my VIN.

 

[AGS92]

Same here--my 2019 has also been removed from the recall. :dancin:

 

[Moose568]

Yesterday, my 2019 was listed on the CarFax Car Care app as a recall but was not listed today.

 

[Blue 4ever Runner]

Mine is off the list too. YES!!

 

[Robertoice]

Just dropped my 2019 SR5 for her first service 5k service. I went in assuming I’d dodged a bullet with a later build date considering I bought my runner right as 2020s had been released. I was rudely awoken when the service rep told me I was a part of the recall. He told me all he knows is they are still working on it and they’d call me once he knew more. Thankfully I knew what the recall was for cause he acted like he knew nothing about it and hadn’t been informed. I guess at this point all I can do is wait and pray I don’t stall out :/

 

[Blue 4ever Runner]

Just dropped my 2019 SR5 for her first service 5k service. I went in assuming I’d dodged a bullet with a later build date considering I bought my runner right as 2020s had been released. I was rudely awoken when the service rep told me I was a part of the recall. He told me all he knows is they are still working on it and they’d call me once he knew more. Thankfully I knew what the recall was for cause he acted like he knew nothing about it and hadn’t been informed. I guess at this point all I can do is wait and pray I don’t stall out :/

I think that's all any of us can do. Wait and see. The build date on my 2019 SR5 is 12/18. Originally on the recall list and now not. Will it go back on the list? Who the hell knows.

 

[-E5J-]

Also, no longer on the list

Initially received the letter from Toyota Corporate stating mine was part of the recall, but to essentially stand by while they figured it out, as well as a fix... And that Toyota would be in touch as soon as they had more information for me.

After checking Lookup Safety Recalls & Service Campaigns today, it seems I'm no longer on the recall list...

So apparently, they are narrowing it down and slowing eliminating VINs from the recall.

Not sure if its the exact manufacturing date, however upon looking up the VIN on Vehicle Specification | Toyota Owners it indicates "Date of First Use October 11, 2018" with an "Order Date" of 08/2018.

Interestingly, it also indicates that the TRD PRO Package was "Factory" installed. There is an option for it to be listed as either "Factory" or "Port" installed, however mine says "Factory." Maybe they all say that though.

I'm sure it's not a factor, but thought I'd mention it.

 

[Sp00ner]

Initially received the letter from Toyota Corporate stating mine was part of the recall, but to essentially stand by while they figured it out, as well as a fix... And that Toyota would be in touch as soon as they had more information for me.

I got the same letter, just showed up like a week ago or so.

 

[-E5J-]

Found the "order date" where are you guys finding a build date?

Check out this site... Vehicle Specification | Toyota Owners

It shows your "Order Date" as well as "Date of First Use" which I assume may be close to the actual build date.

For instance, mine indicates an Order Date of 08/2018, but a "Date of First Use" as "October 11, 2018."

 

[-E5J-]

They're used synonymously. There's no way to derive the actual day/time of manufacture without some serious insider information.

This site:

Vehicle Specification | Toyota Owners

...differentiates between "Order Date" and "Date of First Use."

 

[-E5J-]

I got the same letter, just showed up like a week ago or so.

Double check the official Toyota Recall website Lookup Safety Recalls & Service Campaigns and the Check for Recalls: Vehicle, Car Seat, Tire, Equipment | NHTSA site to confirm... You may no longer be listed...

Found out today that I was no longer on the list...

 

[Sky]

Well great- Toyota just added an additional 1.1 million vehicles to the fuel pump recall.......