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Highlander T24 2.4L Turbo - Surging, hesitation and general tuning issues.

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17K views 44 replies 24 participants last post by  mrs hudson  
#1 ·
I know this has been discussed here, so please feel to merge. Not looking to duplicate, but present the issue and my (hopefully temporary) solution

Fellow turbo owners, if you’ve experienced surging at low rpm, hesitation at start (I see this the most) or at any speed with light throttle application, hesitation to shift, bucking, ect. I’m 95% sure it’s all tuning related. I’ve experienced all of these in a way over the past few months and 6700 miles and I’m able to almost reproduce it at a whim so long as traffic allows. I think I have enough data from my travels as I will present below, to prove this and hope a TSB is issued, or Toyota to rescind the 87 octane requirement and modify it to 91 octane+ (Spoiler: that’s the problem and the solution).

This is going to be a long post, so apologies in advance

To start, please for the love of god don’t comment anything about the 2GR 3.5L V6. It’s gone. Toyota is moving on to this being it’s already in almost a dozen cars currently (or will be) within the next year or so. Now that I’ve been running 93 and the tuning is working properly, this is a far better experience than the v6 that you had to rev out for the limited torque it had.

Since the start I’ve driven this HL primarily on the highway and continue to do so as it’s far larger and more comfortable then the RAV I have, so most miles on this are highway (80%/20% if I’m putting a number on it). With that being said, I also live in the hills of PA. So, I’m constantly varying power and gear requirements, which I think is why I’ve been able to reproduce these issues easily. Going up hills and applying 5-15% throttle is where my issue really is apparent with the surging, you can physically see the tach bouncing up and down in 500-800rpm increments before it either levels out, or I either let off, or apply more throttle to force a downshift. The surging also occurs at 30-60% throttle after 3500rpm, where it just won’t rev out smoothly. The other issue was on takeoff, most were claiming turbo lag, as it does in a way make sense where you step and then it takes a moment before anything happens.

Enter the dealers. Obviously, this isn’t ideal. I’ve contacted the dealer I’ve bought it from, one where it was serviced last, and another in my area that I trust. Most of them said the same, bring it in so we can see. Fair. However, one did vaguely acknowledge that he has heard of one or two others having this issue. Trying to probe this gentleman for as much as possible, we arrived at the same conclusion. Because this powertrain is essentially from the lexus application where it needed 91+, Toyota must not have tuned it well enough under certain conditions to run 87 safely, so it’s likely pulling timing or assuming poor fuel conditions, but not enough to throw a light.

Knowing this, I decided to test it myself by switching between 87 and 93 (87 and 93 are at most pumps here, 91 is rare with the in between being 89). I was in the process of moving, so I was back and forth between Scranton PA and Lancaster PA. A journey that is quite hilly and has plenty of speed variation from 35 to a posted 65 (most do 75). The many times I’ve done this doing 87, I’ve averaged between 23 and 25 on the to and from journey – weather was fairly consistent mid to high 80s, decently high humidity, AC on. On this trip, I was able to pick 3-4 locations when the shuddering would occur very predictably. So, making this trip within the last 3 weeks, I decided to run 93 from the Sunoco I usually go to. Funny enough, there was absolutely no shuddering at all. There was no hesitation at all. It revved out cleaner, with none of the aforementioned hesitation on take off, nor when revving out. The shifting predictability was perfect. Even better, my combined MPG for the same trip resulted in 27.2 and 27.8. It drives like a completely new vehicle and frankly, how I expected it to be from the start.

As for now, just based on this performance I believe that is the issue is in fact tuning related and needs to be addressed or the minimum octane requirements updated. I am worried nothing happen and I have to live with paying the extra 70-80 cents a gallon – even though they make hundreds of thousands of these vehicles a year and the T24-FKS will be in everything soon. I have a suspicion others are indeed having these concerns, but either have not reported these problems and/or Toyota is not acknowledging anything.

I had my curiosity how they were able to get 265hp and 319ft/lbs on 87 with a 11:1 compression ratio and a turbo, where Mazda had to run 2 separate power figures using 10.5:1 with 87 at 227hp/310tq or 256hp/320tq. (Other manufacturers do this also, but I’m very familiar with Mazda specifically)
As of this morning, I am back and forth with the senior technician at my local dealer for next steps. As of our latest conversation, I am going to be running this tank of 93 out and putting 87 back to see if the issues present themselves again. They would then take my vehicle for testing to reproduce (I told them as mentioned prior I can do so rather quickly) and then report findings to Toyota NA. This tech as like the others, did not hear of this issue before, but did let me know the Tundra did have a TSB for a similar condition where owners were encouraged to run 91+ until the TSB was applied, so here’s hope.

Please let me know if you have had similar issues and have tried a higher octane and what that result was.

Thanks for reading.
 
#2 ·
You shouldn’t have to use premium in a turbo designed to use regular this surge hesitation issue is an engine mapping issue that needs to be addressed by Toyota in a software flash on the ecu I’ve filed with the ntsb as my dealer says that’s just the way it is until Toyota corporate dies something about it …. NO tsb or recall as of yet
 
#3 ·
I know. But knowing that premium resolved the issues I have leads me to believe it is in fact tuning as I can definitively say to the dealer that yes, I have these issues, and yes, using a higher octane rating fixes it. Some issues I play dumb and let them figure it out (like when I had a water leak on the a pillar), but something like this where it takes time to surface and reproduce the issue plus being something a dealer can't technically fix unless corporate creates a new tune for them. I figure the more information the better
 
#4 ·
You shouldn’t have to use premium in a turbo designed to use regular this surge hesitation issue is an engine mapping issue that needs to be addressed by Toyota in a software flash on the ecu I’ve filed with the ntsb as my dealer says that’s just the way it is until Toyota corporate dies something about it …. NO tsb or recall as of yet
But if Premium makes it run better, then that means, as you said, it's a mapping issue and likely needs to be adjusted OR run higher octane gas.

I'd rather be safe and run higher octane gas to reduce knock and not run the engine lean until Toyota can, in fact, confirm their software needs an adjustment. Running the engine lean is never a good thing.
 
#5 ·
There's protections that likely would prevent any damage from happening. Regardless, that would be widespread being the vast majority of people still run 87. I'm sure they've made at least 100k of these so far, so I think it's fair to assume there's no widespread damage or catastrophic events happening. I am surprised on how little people have this issue and don't make any attempt to contact a dealer for it, let alone corporate.
 
#6 ·
There's protections that likely would prevent any damage from happening. Regardless, that would be widespread being the vast majority of people still run 87. I'm sure they've made at least 100k of these so far, so I think it's fair to assume there's no widespread damage or catastrophic events happening. I am surprised on how little people have this issue and don't make any attempt to contact a dealer for it, let alone corporate.
I'm sure there would be; how long the engine will last running lean or other issues that may rise from it, it'll be hard to say without racking more miles and seeing more data from many cars obviously.

It gives me anxiety reading anything related to turbo honestly as I had horrible experiences with other vehicles. They were more finicky even if they were running smoothly.
 
#8 ·
The Japanese really do turbos well. Toyota historically has been great with them, which is why I bought it. However, the tuning is the problem. When you use 93 it runs great, as it does in the NX and RX applications they stole it from. Which is the issue frankly. I came from mazda which gives 2 power figures on 87 and 93, which Toyota did not do here but they should. When on 93 this thing is great. Tons of power and I can easily get into the mid 20s.

Now, domestic vehicles with turbos. God no. Outside the 2.7 ecoboost and the 2.7 GM, they're all basically what you described.
 
#7 ·
...I had horrible experiences with other vehicles. They were more finicky even if they were running smoothly.
+1. I've owned 2 in my life and neither experience was good. Not sure I'd buy another even if it was the only thing available.
 
#9 ·
My wife has a 2023 Highlander Platinum that I don't drive very often, but I noticed the surge when the vehicle had around 3,500 miles. At that point, my wife didn't really notice it too much, but it really bothered me. I noticed that it was better on eco, and my wife has just kept it on eco. However, I drove it yesterday, and the surging has become horrible even in eco. I regret buying this car... an over $50k premium car feel like $20k lemon! We'll fill up with 93 on the next tank and see if that helps.
 
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#10 · (Edited)
Almost 4K on the HiHy and flawless operation with the aspirated 2.5l and the extra hp from the no lag 3 electric motors operating in tandem make up for lack of turbo boost. Combined with a single gear electronic CVT smooth as silk with no gearshifts all the way to 70+. Twenty two hp less than the turbo adn 0-60 at 7.9 sec compared to turbos 7.5 sec. Gladly take the less than 1/2 sec acceleration in trade for smooth running at 36+ mpg on 87 octane.
 
#12 ·
I started the thread on this months ago and there’s lots of people that are looking at it. It’s listed under 2023 highlander bucking and surging under acceleration. Premium fuel solved all my issues and the auto runs as intended. My Highlander not tuned properly for 87 octaine. 18.5 k miles on mine so far.
7.5k on 93 octaine. Started running premium at 11k after a poster on my thread said premium fixed the surging and bucking problems caused by 87 octaine fuel.
Some people don’t want to pay the extra money for premium but that’s what it takes until a TSB comes along
 
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#15 ·
Back in the old days my parents had a Chrysler 2.2 turbo. Even though Chrysler said 87 could be run, it always ran better on 92, every time. Toyota maybe didn’t fully test the tune for 87, but if it were my car I’d run the better gas.
.02

At at least Chevy was up front with buyers about the two turbo variants in my Malibus, Lower performance 1.5T was designed for and ran on 87 and no better on 93, but their high performance 2.0T version in my Premier trim was labeled to run best on 93 but capable of running on 87 but at a much reduced level of performance.....said so on the fuel door label

The one thing you can rely on Toyota to do was to fully test the tune for 87. And that when the turbo was tuned for safety, meeting emission standards, driveability and max hp for performance they also discovered that it was best to use slower burning hi test gasoline to maximize spark advance and valve timing for maximum induction and compression. And that in order to prevent detonation damage and meet emission standards using a faster burning 87 octane would necessitate the ECU modify (retard) ignition timing, fuel injector dwell and valve closure.

Unlike Chevy, Toyota is faced with only one new turbo engine that is to be incorporated in differing brands, models and trims and had to design its programmed operating characteristics for each accordingly, the prime requirement in development being that whatever fuel it burned has to meet '23 EPA emission standards. So, the other one thing that you can rely upon is that the marketing research disclosed that at almost a buck a gallon extra for premium fuel, that branding and promoting the new turbo 4 in a Toyota as requiring high octane fuel would hinder their competitive advantage and retard Highlander sales along with the ignition timing.

Hopefully, if possible, Toyota can come up with a simple software fix to assure smooth dependable operation in all temperatures while still meeting '23 EPA emission requirements running on 87. If not, there is always the Chevy method and a modified fuel door label is in order.
 
#17 ·
I do have an update:

I stopped running 93 around 450 miles ago. Ever since today, it's been great. No surging, little hesitation, but nothing that I can't say was normal. No issues at all. However, it was cooler out, most days I had the a/c on low or just used windows. Today it was upper 80s and high humidity. Right away, AC was working hard, had the shuddering and the hesitation. Unfortunately, my fridge died, so I had to get a trailer and tow home a new fridge (1200 lbs with trailer) and you can feel it lugging a bit.

So. I wonder if it's really nerfing everything and pulling timing to prevent knock or something with the higher heat. I'd think maybe heat soak, but within the first mile and a half, it was doing it. Maybe a possibility it's the compressor pulling too much power, or something else where it's sucking power when the compressor is on. Strange though. I will be calling the dealer Tuesday and seeing what they say.
 
#18 ·
I do have an update:

I stopped running 93 around 450 miles ago. Ever since today, it's been great. No surging, little hesitation, but nothing that I can't say was normal. No issues at all. However, it was cooler out, most days I had the a/c on low or just used windows. Today it was upper 80s and high humidity. Right away, AC was working hard, had the shuddering and the hesitation. ..................
.02
Better running is most likely due to colder air temperature more than A/C load on the crankshaft. (Read somewhere that the design of new turbo pulls air from the front of the vehicle under the plastic vanity cover to the turbo intake in an attempt to direct cooler air to the turbo intake.)

Turbo compresses incoming air to boost air/fuel charge to max h.p......... too much boost and the wastegate dumps the excess but if the turbo sucks warmer thinner air the max charge will be affected......too little boost and S.O.L. And with slower burning 87 the ECU will retard ignition and valve timing. On excessively hot days the lower density air can starve the turbo by lowering the mass of the charge, plus the parasitic load on the crank from the A/C compressor & alternator doesn't help either. Colder more dense air assures that the turbo has an excess of incoming air for max boost.

So much crap under the hood and convoluted air flow that there doesn't appear to be sufficient space to install an effective cold air intake system.
 
#22 ·
Toyota repurposed engines that were designed to run on premium fuel in their Lexus premium brand into a vehicle that they designed to run on regular fuel on the vanilla side of the house. They did not make the necessary adjustments for a smooth transition, but that will all get worked out.
Just like with Honda motor corporation the Acura or premium side of the house runs premium fuel where the vanilla side of the house, Honda runs regular fuel in most cases.
 
#23 ·
Toyota repurposed engines that were designed to run on premium fuel in their Lexus premium brand into a vehicle that they designed to run on regular fuel on the vanilla side of the house. They did not make the necessary adjustments for a smooth transition, but that will all get worked out.
Just like with Honda motor corporation the Acura or premium side of the house runs premium fuel where the vanilla side of the house, Honda runs regular fuel in most cases.
The Lexus version of the 2.4 Turbo is rated at a higher HP and torque level, 275HP and 317 Ft.Lbs. of torque. My guess is this indicates the premium fuel requirement. Why the Highlander version might also need premium, remains to be seen. That said, the response I've received from both Toyota and my dealer's MT is wearing thin. I'm going to touch base with the dealer on another unrelated Highander issue, hopefully there will be a update on this too.
 
#26 ·
To all 2023 Toyota Highlander 2.4 turbo owners:
I have stated on this site in the past that my new Highlander was surging and hesitating. I went to two Toyota dealers to resolve the issue. One Dealer stated that their resulting inspection indicated that the car is operating normally. The second Dealer said I had bad gas. Well the third was a charmer. They applied a TSB (Toyota Service Bulletin) T-S-B-0087-23 to the car's computer. All of that surging nonsense immediately went away. Also, I was told that it will get even better once the computer 'learns' my driving values. In defense of the two prior dealers, I don't know if the fix was available at the time of their inspections.
 
#41 ·
2023 Highlander Platinum - I made my second official complaint to Toyota about this problem (hesitation to shift, bucking, etc.), and mentioned "Lemon Laws." My local dealer called me within the hour to tell me that Toyota was sending one of their techs to check it out. They did the ECM update from version 896630EG5000 to 896630EG5100. It is like a different car--I am beyond happy with it now!

My wife has a 2023 Highlander Platinum that I don't drive very often, but I noticed the surge when the vehicle had around 3,500 miles. At that point, my wife didn't really notice it too much, but it really bothered me. I noticed that it was better on eco, and my wife has just kept it on eco. However, I drove it yesterday, and the surging has become horrible even in eco. I regret buying this car... an over $50k premium car feel like $20k lemon! We'll fill up with 93 on the next tank and see if that helps.
2023 Highlander Platinum - I made my second official complaint to Toyota about this problem (hesitation to shift, bucking, etc.), and mentioned "Lemon Laws." My local dealer called me within the hour to tell me that Toyota was sending one of their techs to check it out. They did the ECM update from version 896630EG5000 to 896630EG5100. It is like a different car--I am beyond happy with it now!
 
#42 ·
2023 Highlander Platinum - I made my second official complaint to Toyota about this problem (hesitation to shift, bucking, etc.), and mentioned "Lemon Laws." My local dealer called me within the hour to tell me that Toyota was sending one of their techs to check it out. They did the ECM update from version 896630EG5000 to 896630EG5100. It is like a different car--I am beyond happy with it now!
What month has your car been built?
 
#43 ·
If anyone is having this problem, just have dealer perform an ecu reflash. After I had mine done a few months back, the engine runs great. Ask for service bulletin T-SB-0087-23. It was released in November 3, 2023 and is titled (appropriately)Hesitation/Non-linear Acceleration From a Stop.