Toyota Highlander Hybrid Fuel System Problems

Fuel System complaints by model year

Which parts fail

• Inverter
  63

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  99%
• 25k–50k
  66%
• 50k–75k
  1414%
• 75k–100k
  1010%
• 100k–150k
  4444%
• 150k+
  1616%

What owners report

The Hybrid inverter failed when accelerating from a red light. A loud clunk was heard and the car would not move forward. The engine was still running but car would not accelerate and had to be pushed out of the road. "check Hybrid system" warning flashed. Car was towed to a dealer who confirmed that it was not covered by the warranty at 9 years, 117K miles (warranty is 8 years, 110K miles). The previous recalls for the Hybrid inverter had been completed ~3 years ago and so the recall also would not cover the repair. The quoted cost of the repair is ~$11K.

The inverter failed and the car stalled on a busy freeway (I-5) during a dark, rainy evening. The car could not make it all the way to the side of the shoulder and stopped partially blocking a lane. It was extremely dangerous and the driver, my wife, was lucky not to be injured.

Tl* the contact owns a 2009 Toyota Highlander Hybrid. While driving 30 MPH, the contact heard a clunking noise coming from the front end of the vehicle. The vehicle lost power and failed to accelerate or restart. The vehicle was towed to the dealer. The dealer immediately noticed that the vehicle seemed to consume abnormal quantities of oil. The vehicle had an oil change a month and a half prior to the failure and the oil meter measured one quart of engine oil left in the vehicle. The dealer was unable to diagnose the failure. Several months later, the contact received notification of NHTSA campaign number: 13V396000 (Hybrid propulsion system). After the recall repair was performed, the failure recurred. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 125,000. The VIN was not available.

Takata recall- when fuiling from the pump, nuzzles keep shuting off itself like the tank is already full. Its been happening recently. At the same time, check break system by deler start appering. It takes 3 to 4 push to start the car after this error message. Sometimes it takes longer and especially it happens in the morning. Took to deler but they did not find a code to check but this is still happening.

Vehicle Hybrid/engine shut off while driving. Various warning lights lit up including vsc, Hybrid system, and check engine. I was forced to change lanes with the car off but moving at about 40 MPH and pull over on a side street. I as able to restart the vehicle and continue my drive. The following day, even though the check engine light and all warnings had cleared, the car turned off again while I was driving and breaking at a red light. The car failed to properly restart after this second incident. The vehicle was towed to a Toyota dealership which specified that the issue is the Hybrid inverter. The vehicle only has about 81,000 miles and according to Toyota a recall had already been performed on the intelligent power module for the inverter in 2014.

Tl* the contact owns a 2008 Toyota Highlander Hybrid. While driving approximately 45 MPH, the vehicle stalled and the slip, brake, and master warning lights illuminated. The vehicle restarted after twenty five minutes. The failure recurred on the initial start up on two separate occasions. The vehicle was taken to the dealer, but they could not diagnose the cause of the failure. The mechanic was unable to duplicate or locate the failure. Recently, the vehicle was towed to the dealer for a second diagnostic. The VIN was not included in NHTSA campaign number: 13V396000 (Hybrid propulsion system). The manufacturer was not notified of the failure. The approximate failure mileage was 90,000.

While entering into a driveway at a very slow speed, I stepped on the brake to slow down further. But instead of braking, the car lunged forward. I felt I was not in control of the vehicle. I continued to hit the brakes, but the vehicle continued to go forward. It slammed into the car that was parked in the driveway and caused major damage. It also shoved the car into their garage, split the frame in half and ripped off brick from their home. The surface was slippery with wet leaves and there was a slight incline going up the driveway, but I just had brand new top of the line winter tires put on and I was probably only going 5 MPH. It did not make any sense. From reading the forums on line, I believe this is a major defect with the Hybrid and Toyota is not doing anything about it. They need to do a recall. Lives are at stake. Thank god no one was hurt, but it could have been fatal.

The gas tank fell partially off and dragged on the road. I was driving on city streets, turning right at 5 MPH when I heard a loud pop/snap sound and then a terrible sound of something dragging under the car. Fortunately, I could pull over and stop within 50 feet. The gas tank was not damaged significantly (it passed a pressure test at the dealership). The gas tank is attached with two straps, fore and aft. The right sides of both straps snapped very close to where the straps are bolted to the main body in a place that could not have possibly been damaged. The flat bed truck driver who delivered the vehicle to berkeley Toyota noted that there were no signs that the vehicle had been abused in any way. He also argued that had this happened on the freeway at high speed, it could have been quite dangerous.

Related recalls (1)

NHTSA investigations