2021 Toyota Highlander Fuel system Problems

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.

NHTSA ID

11753720

Incident

Jul 25, 2026

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.

NHTSA ID

11731434

Incident

Mar 30, 2026

*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).

NHTSA ID

11723230

Incident

Jan 21, 2026

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.

NHTSA ID

11721649

Incident

Mar 1, 2026

My gas tank does not fill up to 17 gallons like it claimed it would when I purchased the vehicle, It also keeps automatically shutting off after filling up a little bit 8-10 gallons and it is not full, I have to hold the handle and fuel manually and constantly worried its going to over fill.

NHTSA ID

11701016

Incident

Nov 21, 2025

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

NHTSA ID

11683905

Incident

Aug 8, 2025

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.

NHTSA ID

11666931

Incident

Jun 13, 2025

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.

NHTSA ID

11568711

Incident

Jan 29, 2024

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.

NHTSA ID

11475898

Incident

Jul 19, 2022

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.

NHTSA ID

11454480

Incident

Feb 28, 2022

SINCE I HAVE OWNED THE 2021 HIGHLANDER, THE LOW FUEL WARNING LIGHT DOES NOT COME ON UNTIL NEARLY EMPTY. THIS HAS BEEN AN ISSUE SINCE DAY ONE. MY LAST TOYOTA THE LOW FUEL LIGHT TYPICALLY ILLUMINATED ON THE DASH AROUND 35 MILES DTE. I WAS RELIEVED TO SEE TOYOTA ISSUED A SPECIAL SERVICE CAMPAIGN (21TC05) ACKNOWLEDGING THE ISSUE... BUT IT DID NOTHING TO FIX THE PROBLEM!! I HAD THE REPROGAM SERVICE PERFORMED AND STILL, THE LIGHT AND DTE DID NOT IMPROVE OR CHANGE. THE LOW FUEL LIGHT DOES NOT COME ON UNTIL ABOUT 10 MILES DTE. AND I ONLY GET 16 MPG, SO THIS IS VERY LITTLE WARNING ESPECIALLY IF TRAVELING OR GAS STATIONS ARE NOT AVAILABLE IN A REASONABLE DISTANCE. BACK TO THE DRAWING BOARD TOYOTA!

NHTSA ID

11454109

Incident

Dec 18, 2020

My concern has to do with an inability to completely fill the gas tank in my 2021Toyota Highlander Hybrid XLE (AWD), and the gas tank capacity has worsened over time. I purchased the vehicle new from a Toyota dealer in Maryland in April 2021. Initially, I could fill the gas tank to almost full per the gas gauge. Over time, the amount of gas the tank can hold has decreased. As of early 2022, I can only fill the tank to just above 3/4 full per the gas gauge. Please note that when filling the tank at a gas station, I always stop filling when the gas pump shutoff switch activates (1st click) - I never "top off" the tank. It is certainly annoying to not get anywhere close to advertised range of the vehicle (the vehicle display shows a range just over 400 miles/tank versus an expected 600+ miles). However, my main concern is safety-related - I don’t trust my fuel gauge and fuel monitoring system, and as a result I fill the tank whenever I approach 1/2 full per the gas gauge. This is so I don't inadvertently run out of fuel. In Sept 2021, I took my vehicle to the Toyota dealer where I purchased it to report this fuel tank issue. The dealer's service department "verified [customer's] concern that the fuel pup clicks off before gas tank was full." The dealer also "created a TAS Case #xxx and with the information give was informed there is an active investigation by Toyota on this concern and there is no repair available at this time." Since then, the dealer has not reported anything new from Toyota USA (they said "we'll hear about any fix the day before you do.."). I called Toyota USA last Fall and also got no indication on an impeding fix. Bottom line - Toyota USA has been silent on the matter, although there is certainly lots of online chatter from other owners and mention of a lawsuit against Toyota. I am wondering if this issue is similar to what was noted (and finally fixed?) for Toyota's late model RAV4 hybrid vehicles.

NHTSA ID

11450021

Incident

Apr 30, 2021

CAN NOT FILL IN A FULL TANK OF GAS. AT MOST THE CAR TAKES 13 GALLONS, WHERE AS THE TANK CAPACITY IS 17, WHICH IS 4 GALLONS SHORTER AND GIVES 140 MILES SHORTER RANGE (CALC ACCORDING TO EPA RATING). 140 MILES IS A HUGE DIFFERENCE. EVEN IF YOU FILL MORE THAN 13 GALLONS, THE RANGE STAYS AT 423 MILES AND DOESN`T INCREASE.

NHTSA ID

11448081

Incident

Mar 14, 2021

Advertisement say make 35 mpg Is lie Car make 16 to 24 mpg ave not more than that I decide buy this car for save gas, and spend more that any v6, Toyota still a lot money and fake advertisement, and also the dealer charge $3,000 more of the price because they say there are not cars, I paid $ 55,000 + taxes super expensive car for lie at the costumers. I went to service to the dealer and they said, that it is not they problem, the car is like that, I hope you can help to return or change the car

NHTSA ID

11441873

Incident

Nov 25, 2021

Regarding brakes: There is an inconsistent involuntary brake pressure release occurring when slowing down via braking where the brakes let loose for about a second before applying again. This occurs with no change in pressure applied to the brake pedal. This is a dangerous situation, especially if in emergency braking situation. This has occurred multiple times over the 16k miles that it's been driven, but more recently. There is no consistency on the speeds it occurs at either. Regarding fuel: We are unable to fill fuel tank completely due to poor venting in gas tank, which could lead to spilled gas similar to overfill, causing a hazard. This vehicle has a 17.1 gallon fuel tank but we are only able to get 12-13 gallons upon fill-up at empty. Both of these issues have been reported to our local Toyota dealership, with no resolution.

NHTSA ID

11440891

Incident

Nov 17, 2021

I have a 2021 FWD Highlander Hybrid, running in ECO mode with just over 5K miles. I just had this problem happen this afternoon. Pulling into a parking spot at the grocery store. I was going pretty slow, almost stopped, and then the car engine revs and lurches forward. Thank goodness I had my foot on the brake, otherwise the car would of jumped the curb/parking block. Also, happened to me previously coming out of our neighborhood on to a busy street. I'm stopping at the stop sign, going pretty slow, and then all of a sudden the car engine revs and lurches forward. Quite frankly I consider this a huge safety concern. If my foot was not already on the brake the car would of moved forward into on coming traffic The car was just in for its 5K mile service at the Toyota Dealership, and there are no warning lamps or messages displayed when the problem occurs

NHTSA ID

11434865

Incident

Sep 29, 2021

Toyota claims that the 2021 Highlander Hybrid had a fuel tank capacity of 17.1 however I am not able to fill my gas tank to this level. At most I am only getting about 12-13 gallon. This issue seems very similar to the Rav 4 one. We need a fix asap.

NHTSA ID

11433475

Incident

Sep 18, 2021

I recently purchased new 2021 Toyota Highlander Hybrid Platinum AWD. The deciding factor was the range of 598 miles per fill-up on the advertised 17.1 gallon tank size. However the reality after many fillips is only about 14 gallons for maximum of 420 miiles range. I’ve gone to different gas stations in area and none of them would allow me to pump any further gas in than about 14 gallons. When I googled this issue I found that it is a very common issue among all owners of hybrid highlanders yet Toyota customer service won’t acknowledge this known and heavily reported issue. This is especially annoying when that range is the singular reason I decided to buy this brand/model over other brand/models I was comparing against. Please investigate this issue and make Toyota fix this issue through factory recall. Reference the 2019 Toyota Rav-4 Hybrid which also has this issue that Toyota has finally acknowledged and beginning to fix.

NHTSA ID

11427329

Incident

Aug 1, 2021

Upon attempting to engage the brakes, it was found that they did not work. Immediately thereafter, the car began an uncommanded full acceleration. The insurance company has totaled the car. Our safety as occupants was obviously at serious risk. The driver chose to take the car off the road rather than jeopardize the lives of others on the same road. The car plowed through boulders and trees, coming to rest upside down wedged between an earthen berm and a tree......suspended about 2 feet above the ground. There were no warnings prior to the incident. The car has been inspected by the insurance company, and has been authorized for inspection by the manufacturer. There were no serious injuries as a result of the accident. We were VERY lucky! Uncommanded acceleration without any control is a frightening event any time....but definitely in the vicinity of other vehicles full of families.

NHTSA ID

11419420

Incident

May 14, 2021

HIGHLANDER HAS SAME ISSUE AS THE 2019-2020 TOYOTA RAV4 FUEL ISSUE IDENTIFIED BY THE NHTSA: VEHICLE FUEL GAUGES DISPLAYING LESS THAN FULL AND/OR TOTAL FUEL DISPENSED IS LESS THAN EXPECTED, WHEN THE FUEL NOZZLE AUTOMATICALLY CLICKS OFF. NOTED THE 'DISTANCE TO EMPTY' SHOWN ON THE MULTI-INFORMATION DISPLAY IS LESS THAN EXPECTED. WHILE DRIVING, VEHICLE ABRUPTLY COMES CLOSE TO SHUTTING OFF BECAUSE GAUGES ARE INACCURATE. VEHICLE CANNOT BE DRIVEN TO THE FULL CAPACITY OF THE STATED RANGE. GAS TANK IS 17.1 GALLONS BUT VEHICLE CANNOT TAKE MORE THAN 12-13 GALLONS FROM EMPTY.

NHTSA ID

11414525

Incident

Apr 29, 2021

Mileage

1,700 mi

I REPORTED MY GAS TANK NOT FILLING PAST 12.9 GALLONS OF GASOLINE ON NUMEROUS FILL UPS ON MY NEW 2021 HIGHLANDER HYBRID PLATINUM TO TOYOTA SERVICE DEPARTMENT. THE HIGHLANDER ON INVOICE SAYS IT'S A 17 GALLON TANK CAPACITY. TOYOTA SERVICE DEPART REFILLED MY EMPTY TANK TO12.6 GALLONS VERIFYING MY COMPLAINT. THE SERVICE ADVISOR INFORMED ME THEY NOTIFIED TOYOTA AND TOYOTA RESPONDED IN SAYING THEY ARE AWARE OF THE ISSUE AND THERE'S NOTHING TODO. THE TOYOTA SERVICE ADVISOR INFORM ME UNTIL THERE IS ENOUGH COMPLAINTS THEN TOYOTA WOULD ISSUE A RECALL

NHTSA ID

11414311

Incident

Apr 21, 2021

Mileage

23 mi

I BOUGHT MY 2021 TOYOTA HIGHLANDER XLE AWD FROM TOYOTA OF DALLAS ON 4/11/21. I HAVE HAD NOTHING BUT TROUBLE FROM THE FUEL GUAGE / DISTANCE TO EMPTY SYSTEM. FROM SHOWING FULL WHEN THE TANK IS NOT FULL TO REFUSING TO CHANGE FROM FULL EVEN AFTER DRIVING OVER 100 MILES, I HAVE BECOME VERY DISTURBED BY THIS VEHICLE. I AM UNABLE TO GET TOYOTA AND THE DEALERSHIP TO RESPOND TO ME AFTER SEVERAL ATTEMPTS. MY CAR IS CURRENTLY SITTING IN THE GARAGE SHOWING A FULL TANK AFTER DRIVING 169 MILES AFTER REFUELLING! WHAT IN THE WORLD IS GOING ON? SOMEONE PLEASE KINDLY HELP. [XXX]. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11408677

Incident

Apr 11, 2021

Mileage

600 mi

CAN NOT FILL IN A FULL TANK OF GAS. AT MOST THE CAR TAKES 13 GALLONS, WHERE AS THE TANK CAPACITY IS 17, WHICH IS 4 GALLONS SHORTER AND GIVES 140 MILES SHORTER RANGE (CALC ACCORDING TO EPA RATING). 140 MILES IS A HUGE DIFFERENCE. EVEN IF YOU FILL MORE THAN 13 GALLONS, THE RANGE STAYS AT 423 MILES AND DOESN`T INCREASE.

NHTSA ID

11407715

Incident

Mar 15, 2021

TOYOTA MANUAL SPEC AND WEBSITE ADVERTISE THE TANK CAPACITY IS 17.1 GALLONS. HOWEVER, I CAN ONLY FILL TOP OFF AROUND 12.5-13 GALLONS WHICH MISLEADS TO CUSTOMERS. THE PROBLEM IS THAT I DON'T KNOW WHETHER THE GAUGE IS INCORRECT (SHOWING FULL TOO EARLY) OR THE TANK IS OUT OF SHAPE WHICH I CAN'T FILL TO 17.1 GALLONS. THIS CAN CAUSE UNWANTED SITUATION WHERE PEOPLE THINK THEY CAN GO COUPLE EXTRA HUNDRED MILES BEFORE IT GOES EMPTY OR PEOPLE CONTINUE FORCING TO PUMP MORE GAS AFTER 12.5 GALLONS DUE TO 17.1 GALLONS CAPACITY. THE TOYOTA APP ALSO GIVES THE RANGE AROUND 420 MILES WHICH IS AN ESTIMATE FOR MPG OF TANK CAPACITY AROUND 12 GALLONS. IT IS HARD TO KNOW WHETHER MY CAR GOT ISSUE OR COMPANY FAULTY ADVERTISES THE TANK CAPACITY (LONG RANGE PER FILL) TO ATTRACT CUSTOMERS. I WOULD LOVE TO KNOW WHAT'S GOING ON SO I CAN USE IT PROPERLY.

NHTSA ID

11407513

Incident

Apr 9, 2021

GAS TANK ONLY HOLDS 12.5 - 13 GALLONS WITH A RANGE OF 425-450 AT MOST WHEREAS TOYOTA CLAIMS IN THEIR ADVERTISING AND SPECS THAT THE TANK HOLD 17.1 GALLONS AND THE CAR HAS A RANGE OF 598 MILES. I CONFIRMED WITH TOYOTA THAT THIS IS OFF SPECIFICATION AND THEY SAID THE TANK WILL ONLY TAKE 14 GALLONS AND THE RANGE WILL DECIDE ITSELF. I USE THE CAR FOR LONG TRIPS, BOUGHT IT FOR THE TANK SIZE AND RANGE AND AM CONCERNED I AM GOING TO RUN OUT.

NHTSA ID

11407136

Incident

Apr 1, 2021

Mileage

1,903 mi