Safety Recall 20LA01 Vehicle May Stall During Driving At Higher Speed – 2017-2019 Toyota Sienna Mobility Vehicles

SEOCONTENT-START

IMPORTANT UPDATE
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA02
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
2017 – 2019 SIENNA MOBILITY VEHICLES
These instructions are only for 20TA02 Sienna vehicles that have been converted
for mobility use by an authorized mobility conversion company. All other models are detailed in separate instructions.
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
MOBILITY VEHICLE ELIGIBILITY
Are Sienna vehicles that have been converted for wheelchair accessibility able to have the remedy performed?
Only vehicles that are converted for wheelchair accessibility by a Toyota-authorized mobility conversion company are compatible with the remedy.
Who are the authorized mobility conversion companies?
Below is the list of companies that are authorized by Toyota to convert Sienna vehicles for wheelchair accessibility.
o The Braun Corporation (BraunAbility)
o Vantage Mobility International (VMI)
What if a vehicle is converted by a non-authorized mobility conversion company?
Sienna vehicles that have been converted for wheelchair accessibility by a non-Toyota authorized mobility conversion company have undergone an unauthorized modification to the factory condition of the vehicle. These vehicles may be incompatible with the remedy in their current modified condition. Toyota does not recommend modifying vehicles and cannot evaluate how any aftermarket, non-Toyota approved parts and/or modifications could affect a vehicle’s performance.
Notwithstanding Toyota’s recommendation, some dealers may be willing to perform the Safety Recall remedy with the vehicle in its current modified condition. If your dealership is willing to do so, the customer may be responsible for the cost of parts and/or labor not otherwise covered by Toyota’s Safety Recall. Toyota provides the specific remedy parts, differential oil (AWD-only), and covers 2.6 – 2.7 hours of dealership labor expenses. The customer is responsible to pay any additional charges for parts and/or labor which are the result of the vehicle’s non-Toyota-approved modifications.
Toyota is not responsible for later performance problems the vehicle may have that are the result of the non-Toyota-approved vehicle modifications.
3
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
Does this vehicle have floorboard
modifications for a wheelchair ramp or lift?
YES
Refer to the non-mobility
..NO.. 20TA02 Technical Instructions
Is this a Toyota-approved conversion?
YES
Is the dealer willing to complete the
replacement of the fuel pump on this
non-authorized conversion?
YES NO
..NO..
Refer to page #2 and #6 for
customer s options
Is this vehicle a Sienna?
YES
..NO..
4
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 Step #2
CONFIRM MODEL 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. CONFIRM MODEL
a. Confirm that this vehicle is a Sienna.
Is this vehicle a Sienna?
Use the non-mobility
20TA02 Technical Instructions
Continue to Step #3 on p.5
..YES.. ..NO..
5
3. CHECK FOR FLOORBOARD & FUEL TANK MODIFICATIONS
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, use the non-mobility 20TA02 Technical Instructions.
Does this Sienna have floorboard modifications for a ramp or
lift that required modifications to the fuel tank or it s location?
Use the non-mobility
20TA02 Technical Instructions
Continue to Step 4 on p.5
..YES.. .. NO..
4. CHECK TIS MEMO FIELD FOR TOYOTA-APPROVED CONVERSION
a. Check the Memo field in TIS to determine if the modifications on this vehicle were completed
by a Toyota-authorized conversion company.
TIS Campaign Search:
Does TIS indicate that this vehicle has been converted
by a Toyota-authorized Mobility company?
Continue to Step 4
on page 6
Continue to Section III.
PREPARATION on p.7
..YES.. .. NO..
Note: In rare cases, Sienna vehicles converted by an authorized company may not appear in
Toyota’s records and; therefore, may not appear on TIS / Service lane as shown above. These
vehicles should still have this remedy performed per the Technical Instructions.
Authorized Conversion Companies:
• The Braun Corporation (BraunAbility)
• Vantage Mobility International (VMI)
To determine the brand of conversion on mobility vans, the conversion companies usually
apply their logos to the sides and rear hatch. It’s also common to find stickers applied inside
the driver’s door jamb. If there are no visual indicators on the vehicle to identify the
conversion company, ask the vehicle owner if they have the information available.
6
5. NON-APPROVED CONVERSION
Sienna vehicles that have been converted for wheelchair accessibility by a non-Toyota
authorized mobility conversion company have undergone an unauthorized modification to the
factory condition of the vehicle. These vehicles may be incompatible with the remedy in their
current modified condition. Toyota does not recommend modifying vehicles and cannot
evaluate how any aftermarket, non-Toyota approved parts and/or modifications could affect a
vehicle’s performance.
Subject to individual review by the dealer and notwithstanding Toyota’s recommendation, some
dealers may be willing to perform the Safety Recall remedy with the vehicle in its current
modified condition. If your dealership is willing to do so, the customer may be responsible for
the cost of parts and/or labor not otherwise covered by Toyota’s Safety Recall. Toyota provides
the specific remedy parts, differential oil (AWD-only), and covers 2.6 – 2.7 hours of dealership
labor expenses. The customer is responsible to pay any additional charges for parts and/or
labor which are the result of the vehicle’s non-Toyota-approved modifications.
Toyota is not responsible for later performance problems the vehicle may have that are the
result of the non-Toyota-approved vehicle modifications.
Because the modifications to this vehicle are unknown to Toyota, there will be no repair
instructions available. If the dealer decides to proceed with the repair, it will up to the
technician to determine the best method to remove the fuel tank and replace the fuel pump.
Torque values for reinstallation will need to be determined by contacting the conversion
company.
If the dealer decides it cannot complete the repair on a non-authorized conversion due the
modifications in that case, the dealer may advise the customer that they have the option of
contacting the conversion company for direction. Although the conversion company may or
may not be able to provide a solution for the customer, the conversion company may, in the
alternative, remove the fuel tank and fuel suction tube assembly, at the customer or conversion
company’s expense. In this case, the Toyota dealer could then be able to install the remedy
low-pressure fuel pump into the fuel suction tube assembly free-of-charge. The re-installation of
the fuel suction tube assembly and fuel tank into the vehicle would need to be performed at the
customer or conversion company’s expense by the conversion company in this case.
If upon inspection it’s determined that this vehicle does not use a Toyota fuel pump, as
originally designed, email the Quality Compliance Depart (quality_compliance@toyota.com) for
further instructions.
After reviewing this information, is the Dealer willing
to perform the Remedy Repair on this non Toyota-approved
mobility conversion?
Advise customer of their
options as detailed in these
instructions
Continue to Section III.
PREPARATION on p.7
..YES.. .. NO..
7
III. PREPARATION
A. PARTS
Because of the extensive list of parts for this model, a website has been created to detail the required parts. 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
8
C. Special Service Tools
Sienna vehicles that have been modified by Toyota-authorized conversion companies could have the following Retainer Ring types. Vehicles that have been modified by non-authorized companies may have different types of Fuel Pump Housing Retainers.
RETAINER TYPE
Type:
Bolt In
Plastic Ring
SST:
No SST
Required
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)
Special Notes:
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
Brands
Braun Rear Entry
Braun Side Entry
VMI
9
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.
10
VI. COMPONENTS
Example Only. Modifications performed on Mobility Vehicles may be different than indicated.
Replacement items in red
Note: Due to the variances in design of fuel tanks in mobility vehicles, this diagram should be only be used as a guide.
The actual installation method of the Fuel Tube Assemblies may differ from original equipment.
No. Contents of Part Kit’s Quantity Remarks
1
FUEL PUMP
1
2
FUEL SUCTION TUBE SET GASKET
1
3
FUEL PUMP GAUGE RETAINER
1
4
O-RING
1
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.
11
VII. REMOVE FUEL TUBE ASSEMBLY
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 tank and fuel suction tube assembly. Confirm the fuel tank in Sienna Mobility Vehicles has been completely drained before proceeding.
FUEL LEVEL RECOMMENDATIONS
Sienna Mobility Vehicle
Drain Fuel Tank
Note: Be sure to recover all fuel into an approved fuel recovery system. Suitable systems are available from the Toyota Approved Dealer Equipment website.
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.
12
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.
2. REMOVE FUEL TUBE ASSEMBLY FROM VEHICLE
Because of fuel tank modifications to mobility vehicles, the removal and installation procedure will be different that the Repair Manual instructions indicate. Reference the following links for details regarding the Toyota-authorized conversions:
Toyota-authorized Conversion Details:
BraunAbility
Vantage Mobility International (VMI)
Non-authorized Mobility Conversions:
Because the modifications to this vehicle are unknown to Toyota, there will be no repair instructions available. It will up to the technician to determine the best method to remove the fuel tank and replace the fuel pump. Torque values for reinstallation will need to be determined by contacting the conversion company.
13
VIII. DISASSEMBLE FUEL TUBE ASSEMBLY
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
14
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
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 FUEL TUBE
Sienna
2017 2018 2019
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.
15
IX. REASSEMBLE FUEL TUBE ASSEMBLY
1. 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.
2. 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.
3. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
b. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly.
REASSEMBLE FUEL TUBE
Sienna
2017 2018 2019
16
X. INSTALL FUEL TUBE ASSEMBLY
INSTALLATION TIP: PLASTIC RETAINER (if used)
17
1. INSTALL THE FUEL SUCTION TUBE AND TANK INTO VEHICLE
Because of fuel tank modifications to mobility vehicles, the removal and installation procedure will be different that the Repair Manual instructions indicate. If working on a Toyota-authorized conversion, use the disassembly instructions (p. 12) in reverse order.
If working on a non-authorized conversion, there will be no repair instructions available. Torque values for reinstallation will need to be determined by contacting the conversion company.
Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
2. INSTALL REMOVED FUEL
a. Reinstall the originally recovered fuel into the tank.
3. 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.
◄ 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.
18
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

SEOCONTENT-END