November 17, 2020 NHTSA CAMPAIGN NUMBER: 20E085000

Fuel Pump May Fail and Cause Engine Stall

If the fuel pump fails, the engine can stall while driving, increasing the risk of a crash.

NHTSA Campaign Number: 20E085

Manufacturer DENSO International America, Inc.

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 1,517,721

Summary

Denso International America Inc. (Denso) is recalling certain fuel pumps. An impeller within the low pressure fuel pump may crack and deform, potentially causing the fuel pump to fail.

Remedy

Denso has notified the affected vehicle and aftermarket equipment manufacturers who may conduct recalls as necessary to replace the fuel pumps. The recall schedule will be decided by vehicle manufacturers. For DENSO-related questions, please contact DENSO NA Corporate Communications at [email protected] or 1-248-372-8261. Note: This recall is an expansion of recall 20E-026.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Manufacturer Name : DENSO International America, Inc.

Submission Date : November 24, 2021

Recall No. : 20E-085

Manufacturer Recall No. : NR

Manufacturer Information :

Manufacturer Name : DENSO International America, Inc.

Address : 24777 Denso Drive, Southfield, Michigan 48086 U.S.A

Company phone : +1 248 350 7500

Population :

Number of potentially involved : 2,483,801

Estimated percentage with defect : NR

Equipment Information :

Brand / Trade : DENSO

Model : Fuel Pump

Part No. : Various part numbers

Size : N/A

Function : Fuel supply

Descriptive Information :

The low-pressure fuel pump is located in the fuel tank and supplies fuel pressure to the fuel injection system. Production Dates : JUN 26, 2017 – SEP 24, 2019

Description of Defect :

Description of the Defect :

For Description of Defect, please see DIR filed April 24, 2020 attached to recall 20E-026.

FMVSS 1 : NR

FMVSS 2 : NR

Description of the Safety Risk :

For Description of Safety Risk please see DIR filed April 24, 2020 attached to recall 20E-026.

Description of the Cause :

For Description of Cause, please see DIR filed April 24, 2020 attached to recall 20E-026.

Identification of Any Warning that can Occur :

For Identification of Any Warning that can Occur, please see DIR filed April 24, 2020 attached to recall 20E-026.

Supplier Identification :

Component Manufacturer

Name : DENSO International America, Inc.

Address : 24777 Denso Drive, Southfield, Michigan 48086 U.S.A Country : US

Name : DENSO CORPORATION

Address : 1-1,Showa-cho,Kariya,Aichi 448-8661,Japan

Country : Japan

Chronology :

For earlier events, see Separate DENSO DIR filed April 24, 2020 attached to recall 20E-026.

June 2020 – October 2020

Additional analysis was conducted regarding the density of impellers manufactured during various periods. Because the impeller material contains three elements (resin, glass fiber, and calcium carbonate), but only one element (resin) is susceptible to swelling, only resin density was examined for this analysis. Resin density was found to more closely correlate with the occurrence of field cases than overall impeller density. The resin density findings indicated additional material lots which could contribute to the occurrence of the condition in combination with other factors.

In addition, the surface strength of impellers manufactured during various periods was examined with additional variables considered. This analysis demonstrated that a lower minimum surface strength than previously estimated could be possible.

The new resin density and surface strength information can be correlated by vehicle manufacturers with warranty data, production timing data, vehicle specific variables, and other information to determine which vehicles, if any, may be susceptible to the condition.

November 2020

Toyota filed a safety recall notice (20V-682) to cover additional Toyota vehicles that were not included in its earlier recall notices.

December 2020

Toyota amended safety recall notice (20V-682) to include additional vehicle models.

March 2021

Honda filed a safety recall notice (21V-215) to cover additional Honda vehicles that were not included in its earlier recall notices.

July 2021

Subaru filed a safety recall notice (21V-587) to cover additional Subaru vehicles that were not included in its earlier recall notices.

August 2021

Toyota filed a safety recall notice (21V-617) to cover additional Toyota vehicle model (Yaris) that was not included in its earlier recall notices. DENSO revised the population and production scope within the safety recall notice 20E-085 to account for the Yaris population.

September 2021

Subaru amended safety recall notice (21V-587) to cover additional Subaru vehicles that were not included in its earlier recall notices. DENSO revised the population within the safety recall notice 20E-085 to account for the additional population.

November 2021

Mazda made safety recall notification and implemented a safety recall (21V-875) for certain Mazda vehicles for a particular period. Additionally Chrysler (FCA US LLC) made safety recall notification and implemented a safety recall (21V-879) for certain substantially similar vehicles for a particular period. Chrysler (FCA US LLC) is not a purchaser as such term is used in this document. DENSO revised the population within the safety recall notice 20E-085 to account for the additional population.

Description of Remedy :

Description of Remedy Program :

The remedy program, if any, will be determined by vehicle manufacturers.

How Remedy Component Differs from Recalled Component :

The impeller of fuel pumps utilized for a remedy component have higher density.

Identify How/When Recall Condition was Corrected in Production :NR

Recall Schedule :

Description of Recall Schedule : The recall schedule will be decided by vehicle manufacturers.

Planned Dealer Notification Date : NR – NR

Planned Owner Notification Date : NR – NR

Purchaser Information :

The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:

Name : American Honda Motor Co., Inc.
Address : 1919 Torrance Blvd.
Torrance CA 90501-2746
Country :US
Company Phone : NR

Name : Ford Motor Company
Address : 1 American Rd,
Dearborn MI 48126
Country :US
Company Phone : 800-392-3673

Name : Mazda North American Operations
Address : 1025 Connecticut Avenue, NW
Washington DC 20036
Country :US
Company Phone : NR

Name : Mitsubishi Motors North America, Inc.
Address : 4015 Aspen Grove Dr,
Franklin TN 37067
Country :US
Company Phone : 865-441-4166

Name : Subaru of America, Inc.
Address : One Subaru Drive
Camden NJ 08103
Country :US
Company Phone : 856-488-8500

Name : Toyota Motor North America,Inc.
Address : 6565 Headquarters Drive,
Plano TX 75024
Country : US
Company Phone : 469-292-4000

Name : Magnuson Products, LLC
Address : 1990 Knoll Drive, Building A,
Ventura CA, 93003
Country : US
Company Phone : 805-642-8833

Comment section :

complementary explanation

Number of potentially involved : 2,483,801

This is the sum of the vehicle populations announced when Toyota filed safety recall notice 20V-682 and 21V-617, Honda filed safety recall notice 21V-215, Subaru filed safety recall notice 21V-587, Mazda filed safety recall notice 21V-875, and Chrysler (FCA US LLC) filed safety recall notice 21V-879.

Estimated percentage with defect : NR

DENSO is unable to provide an estimate of the percentage of vehicles to actually contain the defect. Whether the issue will lead to a vehicle stall while driving at higher speeds depends on many variables, such as the vehicle operating conditions.

Amended Defect Information Report (20E-085)

November 24, 2021

Manufacturer Name : DENSO International America, Inc.

Manufacturer Information :

Manufacturer Name : DENSO International America, Inc.

Address : 24777 Denso Drive, Southfield, Michigan 48086 U.S.A

Company phone : +1 248 350 7500

This supplements DENSO’s Amended Part 573 Report of November 24, 2021 (20E-085) concerning the fuel pump assembly issue on certain Toyota, Honda, Subaru, Mazda, and Chrysler (FCA US LLC) vehicles.

This recall affects certain vehicles equipped with specific low pressure fuel pumps with an impeller which may become deformed under certain conditions which could render the fuel pump inoperable.

DENSO sells low pressure fuel pumps of similar but not identical design and construction to other vehicle manufacturers. The vehicles of the other vehicle manufacturers possess different fuel delivery systems, engine configurations, and other variables. DENSO is cooperating with other vehicle manufacturers’ investigations. Recently Mazda made safety recall notification and implemented a safety recall 21V-875 for certain Mazda vehicles for a particular period. Additionally Chrysler (FCA US LLC) made safety recall notification and implemented a safety recall 21V-879 for certain substantially similar vehicles for a particular period. Thus, DENSO is amending its Part 573 Report for this recall (20E-085) to add the Mazda vehicles (population of 121,038) & Chrysler (FCA US LLC) vehicles (population of 1,622) to the affected population.

Number of potentially involved: Amended to: 2,483,801

Part No. :

Amended to: See attached file “Amendment 5_Part No list_20E-085”

Chronology :

Amended to add:

November 2021

Comments :

Amended to include:

Number of potentially involved: 2,483,801

Vehicle Manufacturer	Part No.
TOYOTA	195140201
TOYOTA	195140222
TOYOTA	195140249
TOYOTA	291100043
TOYOTA	291200100
TOYOTA	291200200
TOYOTA	291200202
TOYOTA	291100145
TOYOTA	AN291100146
HONDA	291100127
HONDA	291100135
HONDA	291100136
HONDA	291100138
HONDA	291100159
HONDA	291100186
HONDA	291100194
SUBARU	291100105
SUBARU	291100113
SUBARU	291100119
SUBARU	291100166
SUBARU	291100170
SUBARU	291100190
SUBARU	AF291100130
SUBARU	AF291100131
SUBARU	AF291100167
MAZDA	291100102
MAZDA	291100145
MAZDA	291100150
MAZDA	291100158
MAZDA	AN291100146