IMPORTANT UPDATE
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA02
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
| 2018 – 2019 Sequoia | 2018 – 2019 Camry | 2018 – 2019 Avalon |
| 2018 – 2019 Tundra | 2014 FJ Cruiser | 2014 – 2015 4Runner |
| 2018 – 2019 Corolla | 2018 – 2019 Highlander | 2017 – 2019 Sienna** |
| 2018 – 2019 Tacoma | 2014 – 2015 Land Cruiser |
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs.
**Sienna Mobility Vehicles
Sienna’s that have floorboard modifications, such as a wheelchair ramp or lift, for mobility use will be featured in separate instructions. Please reference the 20TA02 Sienna Mobility Vehicle Technical Instructions for details.
Update 10/22/2020: Land Cruiser repair procedure has been added
Update 9/30/2020: Tacoma repair procedure has been added
Update 9/3/2020: Highlander repair procedure has been updated p. 23-26
Update 8/7/2020: Instructions added for rear seat removal on Highlander p. 22
Update 7/29/2020: Details updated for Sienna Mobility Vehicles p. 3
Update 7/10/2020: Instructions provided for Corolla Retainer Ring Removal p.18-19
Update 7/1/2020: Sienna, 2015 4Runner and 2018 Avalon have been added Update 6/25/2020: Corolla and Highlander have been added
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-
Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this recall repair are required to currently hold at least one of the following certification levels:
- Certified (any specialty)
- Expert (any specialty)
- Master
- Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times.
PREPARATION
PARTS
Because of the extensive list of parts for the numerous models affected by this Safety Recall, a website has been created to detail the required parts for each vehicle. Reference the following website for a detailed parts list for each specific VIN:
To log into the website:
- Enter your dealer code in the Dealer Code field.
- Enter XXXXX (5 Capital X’s) for the Password.
Note: Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
TOOLS & EQUIPMENT
- Standard Hand Tools
- Torque Wrench
- Air Blow gun
- Gas Caddy (minimum 25 gallon capacity)
MATERIALS
- Brake Cleaner
CAMPAIGN TOOLS
Prior to the launch of this Campaign, each dealership will receive a Crossbar and a set of Cam Lock Retainer Jaws for removing the Cam Lock type retainer rings. These jaws will be used with the dealerships existing Handle set from the Fuel Sender Lock Nut Wrench Set (09808-14031). A 1/2” breaker bar can also be used. This set of tools will supplement the SST kit that each dealership currently has. The Campaign tools were sent directly to the dealership’s Service Manager. Additional SST’s can be purchased through the Toyota Special Service Tools (SST) website.
In the affected models, there are three different types of Fuel Pump Retainer Rings. Reference the following chart to determine the proper SST or campaign tool for each model and retainer type.
BACKGROUND
The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights and messages may be displayed on the instrument panel, and the engine may run rough. This may result in a vehicle stall, and the vehicle may be unable to be restarted. If a vehicle stall occurs while driving at higher speeds, this could increase the risk of a crash.
SAFETY PRECAUTIONS
CAUTION:
- When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid accidents:
- When working on the fuel system, display a Flammable – Keep Fire Away sign.
- Smoking is prohibited nearby.
- Perform this work in an area where there are no sparks nearby from the operation of welders, grinders, drills, electric motors, stoves, etc.
- DO NOT use electrical devices nearby because they can become hot and the operation of power switches can generate sparks.
- DO NOT use iron or steel hammers while working, because they may generate sparks.
- DO NOT start engines even in adjacent stalls.
- Prepare fire extinguishers before starting any work.
- Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks.
- Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
- If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use compressed air to diffuse the fuel vapor.
- Shop towels and other materials that have come into contact with fuel should be dried in a well ventilated area and then disposed of as appropriate.
IMPORTANT UPDATE
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA02
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
2018 – 2019 Sequoia
2018 – 2019 Camry
2018 – 2019 Avalon
2018 – 2019 Tundra
2014 FJ Cruiser
2014 – 2015 4Runner
2018 – 2019 Corolla
2018 – 2019 Highlander
2017 – 2019 Sienna**
2018 – 2019 Tacoma
2014 – 2015 Land Cruiser
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs.
**Sienna Mobility Vehicles
Sienna’s that have floorboard modifications, such as a wheelchair ramp or lift, for mobility use will be featured in separate instructions. Please reference the 20TA02 Sienna Mobility Vehicle Technical Instructions for details.
Update 10/22/2020: Land Cruiser repair procedure has been added
Update 9/30/2020: Tacoma repair procedure has been added
Update 9/3/2020: Highlander repair procedure has been updated p. 23-26
Update 8/7/2020: Instructions added for rear seat removal on Highlander p. 22
Update 7/29/2020: Details updated for Sienna Mobility Vehicles p. 3
Update 7/10/2020: Instructions provided for Corolla Retainer Ring Removal p.18-19
Update 7/1/2020: Sienna, 2015 4Runner and 2018 Avalon have been added
Update 6/25/2020: Corolla and Highlander have been added
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this recall repair are required to currently hold at least one of the following certification levels:
• Certified (any specialty)
• Expert (any specialty)
• Master
• Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times.
2
I. OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the RO.
2. Check for Campaign eligibility using TIS.
No further action required.
Not
Covered
Covered
Campaign complete.
Return the vehicle to the customer.
Remove Fuel Suction
Tube Assembly from vehicle
Disassemble Fuel Suction
Tube Assembly
Install NEW fuel pump
Reassemble Fuel Suction
Tube Assembly
Reinstall Fuel Suction Tube
Assembly into vehicle
Check the Campaign Status of the VIN to
determine if Remedy is available
Remedy Available
The Remedy for this vehicle
is not available at this time.
Refer to the Toyota Dealer
Letter for Remedy Launch
timing for this model.
20TA02 Dealer Letter
..Remedy Not..
Available
SIENNA ONLY: Does this vehicle have
floorboard modifications for a wheelchair
ramp or lift?
NO
Refer to the Sienna Mobility Vehicle
..YES.. Technical Instructions
3
II. IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a. Compare the vehicle’s VIN to the VIN listed on the Repair Order to ensure they match.
b. Check the TIS Vehicle Inquiry System or Service Lane to verify this vehicle is eligible for
Safety Recall 20TA02.
c. Determine the Campaign Status for Safety Recall 20TA02.
What is the Campaign Status of
Safety Recall 20TA02 for this vehicle?
DO NOT PROCEED!! Check the
VIN again at a later date for
Remedy availability.
Continue to Section III.
PREPARATION on p.4
..Remedy Available.. ..Remedy NOT Available..
DO NOT PROCEED with these instructions if the
Campaign Status shows Remedy Not Available!
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on
each VIN in TIS before starting any repairs. Launch timing specific to each model is
available in the 20TA02 Dealer Letter.
Note: Warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were
previously completed, even by another dealer. In addition, warranty claims will not be processed for vehicles that
are not yet eligible for the remedy.
2. CHECK FOR FLOORBOARD MODIFICATIONS (SIENNA ONLY)
a. Inspect the vehicle to determine if modifications have been made to the floorboard of the
vehicle to accommodate a ramp or lift for wheelchair use. Such modifications typically
require the relocation and/or modification of the fuel tank. If the fuel tank has not been
modified or relocated, it will not be necessary to use the Sienna Mobility Vehicle Technical
Instructions.
Does this Sienna have floorboard
modifications for a ramp or lift?
Use the Sienna Mobility Vehicle
Technical Instructions
Continue to Section III.
PREPARATION on p.4
..NO.. .. YES..
4
III. PREPARATION
A. PARTS
Because of the extensive list of parts for the numerous models affected by this Safety Recall, a website has been created to detail the required parts for each vehicle. Reference the following website for a detailed parts list for each specific VIN:
https://20ta02.imagespm.info
To log into the website:
a. Enter your dealer code in the Dealer Code field.
b. Enter XXXXX (5 Capital X’s) for the Password.
Note: Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
B. TOOLS & EQUIPMENT
• Standard Hand Tools
• Torque Wrench
• Air Blow gun
• Gas Caddy (minimum 25 gallon capacity)
C. MATERIALS
• Brake Cleaner
D. CAMPAIGN TOOLS
Prior to the launch of this Campaign, each dealership will receive a Crossbar and a set of Cam Lock Retainer Jaws for removing the Cam Lock type retainer rings. These jaws will be used with the dealerships existing Handle set from the Fuel Sender Lock Nut Wrench Set (09808-14031). A 1/2” breaker bar can also be used. This set of tools will supplement the SST kit that each dealership currently has. The Campaign tools were sent directly to the dealership’s Service Manager. Additional SST’s can be purchased through the Toyota Special Service Tools (SST) website.
Campaign Tools
Special Service Tools
Cam Lock Retainer Jaws
Handle
09808-01010
Or suitable 1/2” breaker bar
Crossbar
Used With
5
C. Special Service Tools
In the affected models, there are three different types of Fuel Pump Retainer Rings. Reference the following chart to determine the proper SST or campaign tool for each model and retainer type.
RETAINER TYPE
Type:
Bolt In
Cam Lock
Plastic Ring
Plastic Ring
w/ Holding Tool
SST:
No SST
Required
Fuel Sender Lock Nut Wrench Kit
(09808-14031)
Claw: 105mm Jaw Set
(09808-01070)
Crossbar
(09808-01030)
Fuel Sender Lock Nut Wrench Kit (09808-14031)
Option 1: Claw: 50mm Jaw Set
(09808-01040)
Option 2: Claw: Sliding jaw
(09808-01080)
Crossbar
(09808-01030)
Fuel Pump Retainer Tool (*e) (09808-14040)
Fuel Pump Holding Tool (*d) (09808-14050)
Special Notes:
Campaign Tool:
Cam Lock Retainer Jaws
Requires use of the Handle from the Fuel Sender Lock Nut Wrench Kit, or a 1/2” breaker bar.
Aftermarket alternative:
CTA Tools 1044
Fuel Tank Lid Wrench
This tool is available from Autopart.com
Or contact CTA Tools at
[email protected] for purchasing inquiries
Additional SST’s can be purchased from the Toyota Special Service Tools (SST) website
Models
Avalon (2018)
Avalon (2019)
4Runner
Highlander
Camry
Sequoia
Tundra
FJ Cruiser
Corolla
Sienna
Tacoma
Land Cruiser
6
IV. BACKGROUND
The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights and messages may be displayed on the instrument panel, and the engine may run rough. This may result in a vehicle stall, and the vehicle may be unable to be restarted. If a vehicle stall occurs while driving at higher speeds, this could increase the risk of a crash.
V. SAFETY PRECAUTIONS
CAUTION:
When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid accidents:
a. When working on the fuel system, display a Flammable – Keep Fire Away sign.
b. Smoking is prohibited nearby.
c. Perform this work in an area where there are no sparks nearby from the operation of welders, grinders, drills, electric motors, stoves, etc.
d. DO NOT use electrical devices nearby because they can become hot and the operation of power switches can generate sparks.
e. DO NOT use iron or steel hammers while working, because they may generate sparks.
f. DO NOT start engines even in adjacent stalls.
g. Prepare fire extinguishers before starting any work.
h. Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks.
i. Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
j. If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use compressed air to diffuse the fuel vapor.
k. Shop towels and other materials that have come into contact with fuel should be dried in a well-ventilated area and then disposed of as appropriate.
7
VI. COMPONENTS
4Runner
Replacement Items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm
4
FUEL PUMP GAUGE RETAINER
1
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
8
AVALON 2018
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm
4
O-RING
1
Red
Not used
5
O-RING
Sky Blue
Not used
6
O-RING
1
Green
Not used
7
FUEL TANK PIPE SETTING HOLDER
1
White
Not used
8
REAR SEAT CUSHION LOCK HOOK
2
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
9
AVALON 2019
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
2*
Gold
15.2mm
4
REAR SEAT CUSHION LOCK HOOK (included in the gasket kit)
2
Not used
5
O-RING
1
Red
Not used
6
O-RING
1
Green
Not used
7
FUEL TANK PIPE SETTING HOLDER
1
White
Not used
8
REAR SEAT CUSHION LOCK HOOK (part # 04009-95106)
2
*only 1 O-Ring will be used. Discard the 2nd O-Ring.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
10
CAMRY
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
2*
Gold
15.2mm
4
REAR SEAT CUSHION LOCK HOOK (included in the gasket kit)
2
Not used
5
O-RING
1
Red
Not used
6
O-RING
1
Green
Not used
7
FUEL TANK PIPE SETTING HOLDER
1
White
Not used
8
REAR SEAT CUSHION LOCK HOOK (part # 04009-95106)
2
*only 1 O-Ring will be used. Discard the 2nd O-Ring.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
11
COROLLA
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
O-RING
1
(not labeled)
13.2mm
3
FUEL SUCTION TUBE SET GASKET
1
4
FUEL PUMP GAUGE RETAINER
1
5
REAR SEAT CUSHION LOCK HOOK
2
6
FUEL PIPE SETTING HOLDER
1
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
12
FJ CRUISER
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm
4
FUEL PUMP GAUGE RETAINER
1
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
13
HIGHLANDER
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
FUEL PUMP GAUGE RETAINER
1
4
FUEL TANK PIPE SETTING HOLDER
1
5
O RING
1
(not labeled)
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
14
LANDCRUISER
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm
4
FUEL PUMP GAUAGE RETAINER
1
5
TUBE JOINT CLIPS
16
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
15
SIENNA
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
FUEL PUMP GAUGE RETAINER
1
4
O-RING
1
(not labeled)
5
FUEL TANK PIPE SETTING HOLDER
1
6
EXHASUT PIPE GASKET (2WD)
1
16.4mm
7
EXHASUT PIPE GASKET (2WD)
1
8
EXHASUT PIPE GASKET (2WD)
1
9
FLANGE BOLT (2WD)
2
10
DRAIN PLUG GASKET (4WD)
3
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
Sienna Mobility Vehicles
Sienna’s that have floorboard modifications, such as a wheelchair ramp or lift, for mobility use will be featured in separate instructions. Please reference the Sienna Mobility Vehicle Technical Instructions for details.
16
SEQUOIA
TUNDRA
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
FUEL PUMP GAUGE RETAINER
1
4
O-RING
1
(not labeled)
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
17
TACOMA
2TR-FE 2.7
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm (not used)
4
FUEL PUMP GAUGE RETAINER
1
5
O-RING
1
13.2mm
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
Note: Some items in the Fuel Pump Replacement Kit will not be used
18
TACOMA
2GR-FKS 3.5
Replacement items in red
No. Contents of Part Kit’s Quantity Tape Color Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
O-RING
1
Yellow
15.2mm
4
FUEL PUMP GAUGE RETAINER
1
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
19
VII. REMOVE FUEL TUBE ASSEMBLY
Use TIS to confirm that this vehicle is eligible for the campaign before proceeding (p. 3). Warranty will not pay claims on ineligible vehicles.
1. CHECK FOR DTC’S
a. Using a Techstream, perform a Health Check to check for Diagnostic Trouble Codes.
Note: This Safety Recall covers only the replacement of the fuel pump and associated parts. It does not cover the diagnosis or replacement of any other parts on the vehicle.
REMOVAL TIP: FUEL LEVEL
If the fuel level inside the fuel tank is above the specified level, fuel may overflow from the fuel tank during the removal of the fuel suction tube assembly. Confirm the fuel level in the vehicle is below the specified level before proceeding. If necessary, drain fuel from the tank.
FUEL LEVEL RECOMMENDATIONS
Model
Less than full
3/4 or less
Empty
4Runner
Avalon
Camry
Corolla
FJ Cruiser
Highlander
Tacoma
Land Cruiser
Sequoia
Tundra
Sienna
Note: If fuel needs to be removed from the tank, be sure to recover it into an approved fuel recovery system. Suitable systems are available from the Toyota Approved Dealer Equipment website.
20
REMOVAL TIP: PLASTIC RING RETAINERS
If removing the Plastic Ring type retainers, cut the 4 internal claws to prevent the Fuel Tube assembly from rotating during removal. This could cause damage to the fuel level sender, fuel tank, or fuel tube assembly.
REMOVAL TIP: TUBE ASSY ALIGNMENT
For vehicles with the plastic retainer rings, place matchmarks on both the Fuel Tube Assembly and the fuel tank. During disassembly, confirm that the Fuel Tube Assembly does not rotate. During reassembly, this will aid in aligning the locating tabs for proper installation.
21
REMOVAL TIP: COROLLA RETAINER RING REMOVAL
Corolla models have been identified to experience breakage of the Fuel Tube Assembly during disassembly. In order to prevent damage to the Fuel Tube Assembly during removal, perform the procedure detailed in the following steps.
Example of Damaged Fuel
Tube Assembly
The damage during disassembly is caused by adhesion, or “sticking”, of the Retainer Ring and the Fuel Tube Assembly. When the Retainer Ring is rotated on the stationary Fuel Tube assembly, the portions that are “stuck” together are under a very high load and may break off.
(continued next page)
22
REMOVAL TIP: COROLLA RETAINER RING REMOVAL (cont.)
It will be necessary to separate the bond between the Retainer Ring and Fuel Tube Assembly before starting to remove the Retainer Ring. An effective method to separate this bond is the insert a wedge-shaped tool between the two pieces.
Tool selection is critical for this procedure. The tool needs to be able to slide flat across the surface of the Fuel Tube Assembly without digging into the Fuel Tube Assembly and causing damage. The tool tip also needs to have a wedge shape so that it can push upward on the Retainer Ring. The handle needs to be angled from tip to provide clearance of the electrical and fuel line connections. Metal trim tools and small pry bars are good examples of tools that work well. A screwdriver will not be acceptable.
REMOVAL PROCEDURE
1. Using the proper tool as described above, place the tool at the junction between the Retainer Ring and the Fuel Tube Assembly.
2. Using a small hammer, gently tap inward on the tool to force the Retainer Ring to flex enough the create the separation between the two pieces.
3. Gently rotate the tool upward a small amount to confirm the separation.
4. Remove the tool from under the Retainer Ring.
5. Continue this same process at 8 to 10 additional points around the Retainer Ring.
6. Remove the Retainer Ring using the appropriate tools.
7. Inspect the top of the Fuel Tube Assembly for cracking or damage on both sides. Do not reuse the Fuel Tube Assembly if it is damaged.
Example Video of Retainer Ring Separation
Break-away Torque of Retainer Ring: Corolla’s built at the Canada assembly plant (Vin: 2T) have been identified to require a very large amount of force (200+ ft.lbs) to remove the Retainer Ring. The Mississippi built vehicles (VIN: 5Y) generally require much lower amounts of force. When removing the retainer rings on the Canada-built vehicles, it may be necessary to have one person stabilize the tool on the top of the Retainer Ring while a second person uses a breaker bar to loosen the Retainer Ring.
23
REMOVAL TIP: CAM LOCK RETAINER TOOL
An updated set of Cam Lock Claws and Support Columns are being supplied to each dealership for this campaign. The configuration of the retainer engagement sections of the claws have been modified from the SST that is referenced in the repair manual. The NEW claws have an improved design that enables a firm attachment to the retainer. In addition, 2 support columns are provided which will support the retainer more securely during installation and removal. Be sure to assemble and use the tools using the following procedures:
Campaign Tool Cam Lock Set:
24
REMOVAL TIP: CAM LOCK RETAINER TOOL (cont.)
Lightly tighten the adjuster
Fully tighten the 4 bolts
25
DISASSEMBLY TIP: HIGHLANDER REAR SEATS
When removing and reinstalling the Highlander 2nd row seats, do not use an impact on the seat retaining bolts. Only use hand tools. The use of an impact may cause the welded nuts on the inside of the floorboard channel to break free of the sheet metal, causing an extensive repair. Be sure to properly torque the bolts during reassembly.
2. REMOVE FUEL TUBE ASSEMBLY FROM VEHICLE
a. Follow the Repair Manual instructions to remove the Fuel Tube Assembly from the vehicle.
REMOVE FUEL TUBE ASSY.
Tundra
1UR-FE 4.6
2018
2019
Sienna**
2017 2018 2019
Tundra
3UR-FE 5.7
2018
2019
Highlander***
2018 2019
Sequoia
2018
2019
Avalon
2018 2019
Camry
2018
2019
4Runner
2014
2015
Corolla
2018
2019
Land Cruiser
2014
2015
Tacoma
2GR-FKS 3.5
2018
2019
FJ Cruiser
2014
Tacoma
2TR-FE 2.7
2018
2019
**Sienna Mobility Vehicles
Sienna’s that have floorboard modifications, such as a wheelchair ramp or lift, for mobility use will be featured in separate instructions. Please reference the Sienna Mobility Vehicle Technical Instructions for details.
***Highlander
The repair procedure is modified from the Repair Manual. Follow the instructions as detailed on pages 23-25
26
DISASSEMBLY PROCEDURE: HIGHLANDER
To access the Fuel Tube Assembly on the Highlander, it is not necessary to remove many of the interior Side Panel components as detailed in the Repair Manual. The following diagrams will detail the parts that are NOT NECESSARY to remove.
*1
NO. 2 DECK SIDE TRIM COVER
*2
REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH
*3
ROPE HOOK
*4
REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH
*5
DECK TRIM SIDE SERVICE HOLE COVER
*6
NO. 1 LUGGAGE COMPARTMENT TRIM HOOK
*7
DECK TRIM POCKET COVER
*8
REAR DOOR OPENING TRIM WEATHERSTRIP LH
*9
FRONT DECK SIDE TRIM COVER LH
*10
DECK TRIM SIDE PANEL ASSEMBLY LH
*11
REAR FLOOR FINISH PLATE
–
–
27
DISASSEMBLY PROCEDURE: HIGHLANDER (cont.)
*A
w/o Rear Automatic Air Conditioning System
*B
w/ Rear Automatic Air Conditioning System
*1
REAR DOOR OPENING TRIM WEATHERSTRIP RH
*2
DECK TRIM SIDE PANEL ASSEMBLY RH
*3
NO. 1 LUGGAGE COMPARTMENT TRIM HOOK
*4
SIDE TRIM COVER RH
*5
COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR
*6
DECK TRIM POCKET COVER
*7
REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH
*8
NO. 1 DECK SIDE TRIM COVER
*9
NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY
*10
ROPE HOOK
*11
REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH
*12
FRONT DECK SIDE TRIM COVER RH
*13
DECK TRIM SIDE BELT HOLE COVER RH
–
–
28
DISASSEMBLY PROCEDURE: HIGHLANDER (cont.)
To access the Fuel Tube Assembly, use the following steps to fold the carpet:
1. FOLD CARPET FOR FUEL TUBE ACCESS
a. Pull out the front floor carpet from the inside of deck trim side panel as shown in the illustration.
Note: Use the same procedures for LH and RH sides.
b. w/ Rear Seat Heater only: Push out the harness from the opening of front floor carpet. (Use the same procedures for the LH side and RH side.)
c. Gently fold the carpet rearward
d. Remove the rear floor silencer pad No.2.
29
VIII. DISASSEMBLY OF FUEL TUBE
DISASSEMBLY TIP: FOLLOW THE REPAIR MANUAL
The Part’s Kit contains the necessary O-Rings for reassembly, if the Repair Manual procedure is followed. If the pump components are disassembled in a manor other than as detailed in the Repair Manual, the Parts Kit may not contain the necessary O-Rings for proper reassembly. Please follow the procedures in the Repair Manual to ensure the correct O-Rings are available.
Example of Proper Disassembly:
Repair Manual: Using a screwdriver (*a) with its tip wrapped in protective tape, remove the jet pump from the No. 1 fuel sub-tank.
Tube still attached
Jet pump properly removed from
the No.1 fuel sub-tank.
Replacement O-Ring will be
installed in this location
Example of Incorrect Disassembly:
Tube incorrectly removed from jet pump
Replacement O-ring is the incorrect size
DO NOT disconnect the tube from the jet pump
Replacement O-Ring is NOT provided for this location
30
DISASSEMBLY TIP: MAIN VALVE AND REGULATOR
When replacing the fuel pump, it is not necessary to remove the Fuel Main Valve or Fuel Pressure Regulator. These O-Rings are NOT included in the parts kit.
DISASSEMBLY TIPS: FUEL FILTER
Many of the models will require the fuel filter to be reused. Be careful with the tabs when removing the filter from the original fuel pump as to not overextend them. When installing the filter on the NEW Fuel Pump, be sure that the clips have engaged properly.
1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Follow the Repair Manual instructions to disassemble the Fuel Suction Tube Assembly.
DISASSEMBLE
Tundra
1UR-FE 4.6
2018
2019
Sienna
2017 2018 2019
Tundra
3UR-FE 5.7
2018
2019
Highlander
2018 2019
Sequoia
2018
2019
Avalon
2018 2019
Camry
2018
2019
4Runner
2014
2015
Corolla
2018
2019
Land Cruiser
2014
2015
Tacoma
2GR-FKS 3.5
2018
2019
FJ Cruiser
2014
Tacoma
2TR-FE 2.7
2018
2019
31
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.
IX. REASSEMBLE FUEL TUBE ASSEMBLY
REASSEMBLY TIPS: O-RINGS
The part kits may come with O-Rings of different sizes. They are very difficult to tell apart visually. To identify the different size O-Rings, they will be wrapped in individual plastic bags with a piece of COLORED TAPE sealing it. The COLOR OF THE TAPE will identify the O-Ring size. REFER TO THE COMPONENT DIAGRAMS TO DETERMINE TO CORRECT O-RING, as identified by the tape color.
2. CONFIRM PARTS
a. Using the part lookup website, input the VIN number to confirm that you have the proper parts for this vehicle:
https://20ta02.imagespm.info
To log into the website:
a. Enter your dealer code in the Dealer Code field.
b. Enter XXXXX (5 Capital X’s) for the Password.
32
3. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY WITH NEW FUEL PUMP
a. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly with a NEW Fuel Pump.
Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
Example Procedure:
HINT:
The reused filter may be discolored.
• Remove the original O-Ring, Spacer and Fuel Filter from the original Fuel Pump.
• Discard the original O-Ring and Fuel Pump, saving the Spacer and Fuel Filter.
• Install the original Spacer onto the NEW Fuel Pump.
• Install the NEW O-Ring onto the NEW Fuel Pump. Refer to the Component Diagram to determine to proper O-Ring, as identified by the colored tape on the bag.
• Apply a small amount of engine oil to the NEW O-Ring to assure correct installation into the Tube Assembly.
• Install the original Fuel Filter onto the NEW Fuel Pump.
• Refer to the Components diagrams to review the other NEW parts to install.
• Apply engine oil to the NEW O-ring before assembly to assure correct installation into the Fuel Suction Tube.
4. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
b. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly.
REASSEMBLE
Tundra
1UR-FE 4.6
2018
2019
Sienna
2017 2018 2019
Tundra
3UR-FE 5.7
2018
2019
Highlander
2018 2019
Sequoia
2018
2019
Avalon
2018 2019
Camry
2018
2019
4Runner
2014
2015
Corolla
2018
2019
Land Cruiser
2014
2015
Tacoma
2GR-FKS 3.5
2018
2019
FJ Cruiser
2014
Tacoma
2TR-FE 2.7
2018
2019
33
X. INSTALL FUEL TUBE ASSEMBLY
INSTALLATION TIP: PLASTIC RETAINER
34
1. INSTALL THE FUEL SUCTION TUBE ASSEMBLY INTO VEHICLE
a. Follow the Repair Manual instructions to reinstall the Fuel Suction Tube into the vehicle.
Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
INSTALLATION
Tundra
1UR-FE 4.6
2018
2019
Sienna
2017 2018 2019
Tundra
3UR-FE 5.7
2018
2019
Highlander
2018 2019
Sequoia
2018
2019
Avalon
2018 2019
Camry
2018
2019
4Runner
2014
2015
Corolla
2018
2019
Land Cruiser
2014
2015
Tacoma
2GR-FKS 3.5
2018
2019
FJ Cruiser
2014
Tacoma
2TR-FE 2.7
2018
2019
2. INSTALL REMOVED FUEL
a. If fuel was removed from the tank prior to disassembly, reinstall the originally recovered fuel into the tank.
3. CHECK FOR DTC’S
e. Using a Techstream, perform a Health Check to check for Diagnostic Trouble Codes.
Note: This Safety Recall covers only the replacement of the fuel pump and associated parts. It does not cover the diagnosis or replacement of any other parts on the vehicle.
◄ VERIFY REPAIR QUALITY ►
• Confirm no fuel leaks from vehicle
• Confirm any fuel drained from the vehicle has been reinstalled
• Test drive to confirm normal operation while under load
• Confirm no DTC’s are present
• Confirm that all parts listed in the Components Diagrams have been properly installed on the vehicle.
35
19
19 = 2019
20 = 2020
21 = 2021
22 = 2022
23 = 2023
Etc…
Year Campaign
is Launched
19TA01
T
T = Toyota
L = Lexus
Vehicle Make
A
A = Safety Recall Remedy
B = Safety Recall Interim
C = Special Service Campaign
D = Limited Service Campaign
E = Customer Support Program
F = Emissions Recall
(May use other characters in unique
cases)
Field Action Category and Phase
01
01 = 1st Field Action of the year
02 = 2nd Field Action of the year
03 = 3rd Field Action of the year
(The sequence is unique for each
Field Action category)
(May use other characters in
unique cases)
Field Action Sequence
Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in
2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched
in 2021
XI. APPENDIX
A. PARTS DISPOSAL
In accordance with Federal law, please make sure all recalled parts (original parts)
removed from the vehicle are disposed of in a manner in which they will not be reused,
unless requested for parts recovery return.
B. CAMPAIGN DESIGNATION DECORDER
Remedy Instructions and TSB
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Last update on 2021-01-22 / Affiliate links / Images from Amazon Product Advertising API
Last update on 2021-01-22 / Affiliate links / Images from Amazon Product Advertising API
