Toyota recalls more than 100,000 Land Cruisers over fire risk
Toyota is recalling 105,794 Land Cruiser 250 SUVs in the US because a fuel system connection could come loose and cause a fire. Particularly embarrassing for the Japanese carmaker is that, despite an investigation lasting nearly two years, it has been unable to establish why the fuel line retaining clip moves out of position. To ensure safety, Toyota will now fit an additional clip to the affected connection.
Small clip, major fire risk
According to the US National Highway Traffic Safety Administration (NHTSA), the recall covers model-year 2024–2027 Toyota Land Cruiser 250 SUVs built between 29 November 2023 and 1 October 2026. Toyota launched the safety campaign on 14 October, and NHTSA published its details on 21 October.
The problem lies in a quick connector near the fuel tank that joins a plastic fuel line to a metal fuel pipe. The connector’s retainer can move upwards, potentially allowing the line to separate from the connection.
While the petrol engine is running, the fuel pump continues to supply fuel until the engine shuts down automatically. During that time, a significant amount of petrol can spill beneath the vehicle. If the fuel comes into contact with an ignition source, there is a risk of fire.
Toyota has been unable to identify the cause
Most puzzling is that Toyota’s engineers have been unable to reproduce the problem in laboratory conditions or find an obvious design flaw in the fuel line or its retaining mechanism.
During the investigation, the company inspected approximately 600 customer vehicles whose owners had not reported any problems. Engineers found a displaced retainer on just one vehicle, but the fuel line remained connected and was not leaking.
By early October, Toyota had received 64 warranty claims and 23 technical reports in the US relating to the connection.
With the precise cause still unknown, Toyota decided to recall all affected vehicles to eliminate the potential risk.
Dealers will inspect the fuel line connection and fit an additional retaining clip. Mechanics will also replace the plastic line if necessary. Toyota will cover all costs and begin notifying owners in late November.
The problem primarily affects North American hybrids
In the US market, the Land Cruiser 250 is offered exclusively with a 2.4-litre turbocharged petrol engine paired with the i-FORCE MAX hybrid system. Combined output reaches 243 kW and 630 Nm of torque. The electric motor sits between the eight-speed automatic transmission and the combustion engine.
The European Land Cruiser differs significantly. Western European models use a 2.8-litre turbodiesel with a 48 V mild-hybrid system. The diesel engine produces 151 kW and 500 Nm.
The US recall therefore does not automatically mean that Land Cruisers intended for the European market are affected by the same problem. Owners in Europe should nevertheless check their vehicle’s VIN in Toyota’s official recall database, particularly if the vehicle was imported from North America.
The problem is not limited to the US. Toyota is carrying out a similar recall in Canada, where 6,721 Land Cruisers require inspection.
The Land Cruiser has built its reputation on durability and reliability over decades. That makes it all the more striking that the safety of more than 100,000 vehicles is now being called into question by a single fuel line retainer whose behaviour the manufacturer itself cannot fully explain.
