In January 2020, Toyota issued a recall for 3.34 million vehicles in the US due to a potential stalling issue. What initially seemed like a simple fix for the brand quickly turned into a five-alarm fire. The company also faced a class-action lawsuit from owners in federal court in May 2020. The plaintiffs alleged their Toyota vehicles were stalling on busy roads, creating dangerous situations.
After two years of litigation, the case was settled in December 2022, but that didn’t end the problem that initiated the safety campaigns. In January 2025, the company expanded the recall of Toyota and Lexus vehicles for the same engine-stalling issue, then again in April 2026.
In total, Toyota has recalled over 5.8 million vehicles globally since the issue first arose in 2020. The problem, however, was not a mystery. Denso, a Tier-1 supplier to automakers such as Toyota (Denso’s largest shareholder), Honda, General Motors, Ford, Stellantis, and Nissan, discovered a defect in its fuel pumps and alerted the National Highway Traffic Safety Administration (NHTSA) to the problem. Six years and hundreds of millions of dollars later, vehicles with potentially failing Denso fuel pumps are still being added to the list.
Denso Fuel Pump Manufacturing Defect
Nissan fuel pump assembly diagram. (Source: Nissan)
Denso builds an in-tank low-pressure pump that sends fuel from the gas tank through the fuel lines to the engine. The pump has an impeller that spins, creating the constant pressure required to draw fuel from the tank and into the lines. However, the company discovered a flaw in its impeller, which it said was manufactured with an insufficient resin density, causing it to absorb fuel, deform, and create excessive running resistance. Normally, when the car’s computer detects this issue, it triggers warning lights on the dashboard and causes the engine to run rough or stall.
The recall, however, is one of the more interesting ones since it does not stem from an investigation launched by the NHTSA. Denso made first contact with the organization, outlining the issue and listing which vehicles were potentially at risk.
Since Denso supplies these fuel pumps to multiple automakers, other brands affected include Honda, Acura, Subaru, and Mazda, all of which have either reported similar issues stemming from low-pressure fuel pumps or active recalls on models to resolve the issue. The majority of vehicles affected, however, are Toyota and Lexus models.
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Class Action Lawsuit Against Toyota
2016 Toyota RAV4 finished in white with black interiorToyota
Owners of the affected Toyota models filed a lawsuit against the automaker in May 2020, four months after the original recall for defective fuel pumps was opened. The case was litigated in federal court and settled two years later, in December 2022.
The original complaint alleged that Toyota and Denso knew of the defect and continued to produce and sell products without warning consumers, thereby providing grounds for a lawsuit against Toyota Motor Corporation, Toyota Motor North America, and Denso International America. The settlement was valued between $212 million and $288 million, with a separate $28.5 million cash fund reserved for plaintiffs in the case to cover legal fees and other incentives, according to the settlement agreement.
The settlement fund was an agreement made by Toyota to provide warranty repair benefits, which were valued accordingly. The settlement also included a 15-year warranty extension for the fuel pumps and reimbursed owners who paid for repairs on their own. Toyota and Denso denied that the vehicles were defective, that they violated any laws, or that they could be held legally liable.
The Recall Expanded in 2025, then Again in 2026
2019 Lexus GS F White Front Angle w/ Shore BackdropLexus
As of January 2025, the list of Toyota and Lexus vehicles potentially affected was outlined by Toyota as follows:
- 2013-2015 Lexus LS 460, GS 350
- 2014 Toyota FJ Cruiser, Lexus ISF
- 2014-2015 Toyota 4Runner, Land Cruiser; Lexus GX 460, IS 350, LX 570
- 2015 Lexus NX 200t, RC 350
- 2017 Lexus IS 200t, RC 200t, GS 200t
- 2017-2019 Toyota Highlander; Lexus GS 350
- 2017-2020 Toyota Sienna and Lexus RX 350
- 2017-2020 Toyota Tacoma
- 2018-2019 Toyota 4Runner, Land Cruiser; Lexus GS 300, GX 460, IS 300, IS 350, LS 500h, LX 570, NX 300, RC 300, RC 350
- 2018-2020 Toyota Avalon, Camry, Corolla, Sequoia, Tundra; Lexus ES 350, LC 500, LC 500h, LS 500, RX350L
- 2019 Toyota Corolla Hatchback and Lexus UX 200
- 2019-2020 Toyota RAV4
In April 2026, Toyota expanded the list of models to include Lexus RC models built between 2015-2022, Lexus GS models built between 2016-2020, and the 2022 Lexus IS. Owners were to be notified by mail, with letters scheduled to be sent out on June 8, 2026. To check on recalls issued by a manufacturer, visit the manufacturer’s site or enter your vehicle’s VIN on the NHTSA’s website to find out if your vehicle needs to be repaired.
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Denso Addresses Quality Issues
Front 3/4 view of the 2011 – 2012 Toyota SiennaToyota
A statement issued by Denso blames the fuel pump’s defect on the impeller’s lower resin density, which ultimately causes the impeller to deform and lead to engine issues. “This was a specific quality issue that was caused by specific factors in the manufacturing process of the recalled fuel pumps,” read the statement. “This issue could not be foreseen with the available technical knowledge at that time, and it took a considerable amount of time to finally identify the root causes.”
The statement, relayed as a message from then-Chief Quality Officer Yasuhiko Yamazaki, in the company’s 2024 integrated report, outlined the company’s focus on resolving the issue and its commitment to quality. Globally, the recall has affected approximately 6 million Toyota and Lexus vehicles, as well as an unknown number of other vehicles from other brands that use Denso as a supplier.
Widespread Parts Sharing Has Caused Problems Before
2011-2013 Hyundai Equus All Airbags DeployedHyundai
The largest recall to plague the automotive industry is the ongoing Takata Airbag recall, an issue which has spanned nearly 25 years since the first reported incidents. Over 100 million vehicles globally have been recalled for defective airbags that could spew metal shrapnel into the cabin upon inflation of the airbags, a critical hazard that has resulted in 27 deaths and over 400 injuries in the US.
The second-largest recall was initiated in 2014 and quickly became the largest single-manufacturer recall in history. General Motors was responsible for rectifying faulty ignition systems in nearly 30 million vehicles, resulting in $4.1 billion in fines and repair costs. The ignition switch defect disables safety features like airbags and power brake assist when it fails, which resulted in the deaths of 124 people.
Toyota’s recall of more than 6 million vehicles for faulty fuel pumps is critical, but not to the same extent as on-board safety mechanisms causing more harm than good. The resulting engine stalling or sputtering as a result of the impeller restricting the flow of fuel to the engine at inopportune times is a major traffic safety issue.
How Manufacturers Respond to Defects
NHTSA Website Recall CheckerNHTSA
There are two ways recalls can be issued for automobiles. Either the manufacturer can voluntarily recall models it thinks could have issues pertaining to safety and emissions, or the federal government can force automakers to open or expand recalls after investigations led by the NHTSA or Environmental Protection Agency (EPA) prompt further action.
To resolve issues, the new age of software-defined vehicles permits automakers new ways to fix many problems by issuing over-the-air updates to connected vehicles. When parked, a vehicle’s computer can automatically download the updated software to patch a variety of issues. If the issue is related to a mechanical component, owners are notified by the automaker, usually by mail, if their vehicle is part of a recall and given instructions to contact their dealer for repairs.
To find out if your vehicle is part of an ongoing recall, visit the NHTSA’s website and enter your vehicle’s identification number (VIN) or license plate to look up any associated recalls. CarBuzz also provides comprehensive reporting on all recalls issued, keeping you up-to-date on all information regarding the safety of your vehicle.
Sources: Toyota, Denso, Hagens Berman, Paultan, Consumer Reports, Motley Rice, Car Talk
