owners manual 2023 4runner filetype:pdf - Google Search
IMPORTANT UPDATE TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 20TA02 VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED 2018 2019 Sequoia 2018 2020 Tundra 2018 2020 Corolla 2018 2019 Tacoma 2019 Corolla Hatchback 2018 2020 Camry 2014 FJ Cruiser 2018 2019 Highlander 2014 2015 Land Cruiser 2018 2020 Avalon 2014 2015 4Runner 2017 2020 Sienna** 2019 RAV4 (Japan Produced) 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. 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 ELearning 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. I. OPERATION FLOW CHART Verify Vehicle Eligibility 1. Confirm vehicle VIN matches the RO. 2. Check for Campaign eligibility using TIS. Covered Check the Campaign Status of the VIN to determine if Remedy is available Remedy Available SIENNA ONLY: Does this vehicle have floorboard modifications for a wheelchair ramp or lift? NO Remove Fuel Suction Tube Assembly from vehicle Not Covered ..Remedy Not.. Available No further action required. 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 ..YES.. Refer to the Sienna Mobility Vehicle Technical Instructions Disassemble Fuel Suction Tube Assembly Install NEW fuel pump Reassemble Fuel Suction Tube Assembly Reinstall Fuel Suction Tube Assembly into vehicle Campaign complete. Return the vehicle to the customer. 2 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? ..Remedy Available.. ..Remedy NOT Available.. Continue to Section III. PREPARATION on p.4 DO NOT PROCEED!! Check the VIN again at a later date for Remedy availability. 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? ..NO.. Continue to Section III. PREPARATION on p.4 .. YES.. Use the Sienna Mobility Vehicle Technical Instructions 3 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 Cam Lock Retainer Jaws Special Service Tools Handle Crossbar Used With Campaign Tools Retainer Ring Pliers 09808-01010 Or suitable 1/2" breaker bar Qty 2: These pliers were shipped to each dealership in early February 2021. 4 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. Type: Bolt In RETAINER TYPE 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) Campaign Tool: Cam Lock Retainer Jaws Aftermarket alternative: CTA Tools 1044 Fuel Tank Lid Wrench Special Notes: Avalon (2018) Models Requires use of the Handle from the Fuel Sender Lock Nut Wrench Kit, or a 1/2" breaker bar. Avalon (2019) Camry RAV4 Corolla (2020) Corolla Hatchback This tool is available from Autopart.com Or contact CTA Tools at info@ctatools.com for purchasing inquiries 4Runner Sequoia Tundra FJ Cruiser Sienna Tacoma Corolla (2018-2019) Land Cruiser Additional SST's can be purchased from the Toyota Special Service Tools (SST) website Highlander 5 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. 6 VI. COMPONENTS 4Runner Replacement Items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 FUEL PUMP GAUGE RETAINER Quantity 1 1 1 1 Tape Color Remarks Yellow 15.2mm 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. 7 AVALON 2018 Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 O-RING 5 O-RING 6 O-RING 7 FUEL TANK PIPE SETTING HOLDER 8 REAR SEAT CUSHION LOCK HOOK Quantity 1 1 1 1 1 1 2 Tape Color Remarks Yellow Red Sky Blue Green White 15.2mm Not used Not used Not used Not used 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. 8 AVALON 2019 - 2020 Replacement items in red No. Contents of Part Kit's Quantity 1 FUEL PUMP 1 2 FUEL SUCTION TUBE SET GASKET 1 3 O-RING 2* 4 REAR SEAT CUSHION LOCK HOOK (included in the gasket kit) 2 5 O-RING 1 6 O-RING 1 7 FUEL TANK PIPE SETTING HOLDER 1 8 REAR SEAT CUSHION LOCK HOOK (part # 04009-95106) 2 *only 1 O-Ring will be used. Discard the 2nd O-Ring. Tape Color Remarks Gold Red Green White 15.2mm Not used Not used Not used Not used 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 CAMRY 2GR-FSE 3.5 Replacement items in red No. Contents of Part Kit's Quantity 1 FUEL PUMP 1 2 FUEL SUCTION TUBE SET GASKET 1 3 O-RING 2* 4 REAR SEAT CUSHION LOCK HOOK (included in the gasket kit) 2 5 O-RING 1 6 O-RING 1 7 FUEL TANK PIPE SETTING HOLDER 1 8 REAR SEAT CUSHION LOCK HOOK (part # 04009-95106) 2 *only 1 O-Ring will be used. Discard the 2nd O-Ring. Tape Color Gold Red Green White Remarks 15.2mm Not used Not used Not used Not used 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 A25A-FSE 2.5 (VIN JTN) Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 REAR SEAT CUSHION LOCK HOOK (included in the gasket kit) 5 O-RING 6 O-RING 7 FUEL TANK PIPE SETTING HOLDER Quantity 1 1 2 2 1 1 1 Tape Color Remarks Gold Red Green White 15.2mm Not used Not used Not used 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 CAMRY A25A-FSE 2.5 (VIN 4T1) Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 REAR SEAT CUSHION LOCK HOOK (included in the gasket kit) 5 O-RING 6 O-RING 7 FUEL TANK PIPE SETTING HOLDER 8 REAR SEAT CUSHION LOCK HOOK (part # 04009-95106) Quantity 1 1 2 2 1 1 1 2 Tape Color Remarks Gold Red Green White 15.2mm Not used Not used Not used Not used 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. 12 COROLLA (2020) COROLLA HATCHBACK 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 2 5 O-RING 1 Red Not Used 6 O-RING 1 Green Not Used 7 FUEL PIPE SETTING HOLDER 1 White Not Used *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. 13 COROLLA (2018-2019) Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 O-RING 3 FUEL SUCTION TUBE SET GASKET 4 FUEL PUMP GAUGE RETAINER 5 REAR SEAT CUSHION LOCK HOOK 6 FUEL PIPE SETTING HOLDER Quantity 1 1 1 1 2 1 Tape Color Remarks (not labeled) 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. 14 FJ CRUISER Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 FUEL PUMP GAUGE RETAINER Quantity 1 1 1 1 Tape Color Yellow Remarks 15.2mm 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. 15 HIGHLANDER Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 FUEL PUMP GAUGE RETAINER 4 FUEL TANK PIPE SETTING HOLDER 5 O RING Quantity 1 1 1 1 1 Tape Color (not labeled) Remarks 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. 16 LANDCRUISER Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 FUEL PUMP GAUAGE RETAINER 5 TUBE JOINT CLIPS Quantity 1 1 1 1 16 Tape Color Remarks Yellow 15.2mm 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. 17 RAV4 Replacement items in red No. Contents of Part Kit's Quantity 1 FUEL PUMP 1 2 FUEL SUCTION TUBE SET GASKET 1 3 O-RING 2* 4 REAR SEAT CUSHION LOCK HOOK 2 5 O-RING 1 6 O-RING 1 7 FUEL PIPE SETTING HOLDER 1 *only 1 O-Ring will be used. Discard the 2nd O-Ring. Tape Color Remarks Gold Red Green White 15.2mm 13.2mm Dispose Dispose 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. 18 SIENNA Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 FUEL PUMP GAUGE RETAINER 4 O-RING 5 FUEL TANK PIPE SETTING HOLDER 6 EXHASUT PIPE GASKET (2WD) 7 EXHASUT PIPE GASKET (2WD) 8 EXHASUT PIPE GASKET (2WD) 9 FLANGE BOLT (2WD) 10 DRAIN PLUG GASKET (4WD) Quantity 1 1 1 1 1 1 1 1 2 3 Tape Color (not labeled) Remarks 16.4mm 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. 19 SEQUOIA TUNDRA Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 FUEL PUMP GAUGE RETAINER 4 O-RING Quantity 1 1 1 1 Tape Color Remarks (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. 20 TACOMA 2TR-FE 2.7 Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 FUEL PUMP GAUGE RETAINER 5 O-RING Quantity 1 1 1 1 1 Tape Color Remarks Yellow 15.2mm (not used) 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 21 TACOMA 2GR-FKS 3.5 Replacement items in red No. Contents of Part Kit's 1 FUEL PUMP 2 FUEL SUCTION TUBE SET GASKET 3 O-RING 4 FUEL PUMP GAUGE RETAINER Quantity 1 1 1 1 Tape Color Remarks Yellow 15.2mm 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. 22 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. Model 4Runner Avalon Camry Corolla Corolla Hatchback FJ Cruiser Highlander Tacoma Land Cruiser Less than full FUEL LEVEL RECOMMENDATIONS 3/4 or less 1/3 or less Empty Sequoia Tundra RAV4 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. 23 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. 24 REMOVAL TIP: COROLLA RETAINER RING REMOVAL Option #1 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) 25 REMOVAL TIP: COROLLA RETAINER RING REMOVAL Option #1 (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. 26 REMOVAL TIP: RETAINER RING REMOVAL Option #2 In early February 2021, each dealership was sent two (2) pairs of Retainer Ring Plier's. These tools can be used in place of the wedge-shaped pry bar detailed above on the Corolla ,and other models so equipped, that are experiencing excessive adhesion between the Plastic Retainer Ring and Fuel Tube assemblies. REMOVAL PROCEDURE 1. Using the pliers provided, release the adhesion between the Retaining Ring and the Fuel Tube Assembly around the entire circumference. 2. Using the SST, loosen the Retainer Ring. 27 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: 28 REMOVAL TIP: CAM LOCK RETAINER TOOL (cont.) Lightly tighten the adjuster Fully tighten the 4 bolts 29 REMOVAL 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. REMOVAL TIP: FUEL LEVEL SENDER When removing and reinstalling the Fuel Level Sender from the fuel tank, take extra care with the arm of the fuel sender. It can be easily bent. Additionally, do not touch the electric circuit of the sender assembly. Do not touch the electric circuit of the fuel sender gauge. Do not deform the arm of the fuel sender gauge. 30 REMOVAL TIP: RAV4 REAR SEAT REMOVAL When removing the lower seat cushion on the RAV4, it's very critical to follow the Repair Manual procedure. This procedure details the correct location of the lifting points. If the lower seat cushion is attempted to be removed by lifting at a point other than detailed, the Styrofoam backing will be damaged. REMOVAL PROCEDURE 1. Place your hand in the position beside the hook as shown in the illustration and lift the front seat cushion assembly. This will detach the cushion wire on the front of rear seat cushion without damage to the structure. SEAT: REAR SEAT ASSEMBLY: REMOVAL; 2019 - 2021 MY RAV4 (RM100000001FE25) 31 REMOVAL 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 *3 ROPE HOOK *5 DECK TRIM SIDE SERVICE HOLE COVER *7 DECK TRIM POCKET COVER *9 FRONT DECK SIDE TRIM COVER LH *11 REAR FLOOR FINISH PLATE *2 REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH *4 REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH *6 NO. 1 LUGGAGE COMPARTMENT TRIM HOOK *8 REAR DOOR OPENING TRIM WEATHERSTRIP LH *10 DECK TRIM SIDE PANEL ASSEMBLY LH - - 32 REMOVAL PROCEDURE: HIGHLANDER (cont.) *A w/o Rear Automatic Air Conditioning System *1 REAR DOOR OPENING TRIM WEATHERSTRIP RH *3 NO. 1 LUGGAGE COMPARTMENT TRIM HOOK *5 COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR *7 REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH *9 NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY *11 REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH *13 DECK TRIM SIDE BELT HOLE COVER RH *B w/ Rear Automatic Air Conditioning System *2 DECK TRIM SIDE PANEL ASSEMBLY RH *4 SIDE TRIM COVER RH *6 DECK TRIM POCKET COVER *8 NO. 1 DECK SIDE TRIM COVER *10 ROPE HOOK *12 FRONT DECK SIDE TRIM COVER RH - - 33 REMOVAL 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. 34 REMOVAL TIP: TUBE ASSY REMOVAL 1) Slightly raise the fuel suction tube assembly during this operation to make sure that the sender gauge does not interfere with the inside of tank. 2) Pull up the fuel suction tube assembly to the position indicated in the illustration. Pull portion (A) by hand to swing the lower part of fuel suction tube assembly downward, and then remove the fuel suction tube assembly from the tank. · DO NOT bend the arm of fuel sender gauge assembly. · DO NOT damage the wire harness at edges of service hole when removing the fuel suction tube assembly. 2. REMOVE FUEL TUBE ASSEMBLY FROM VEHICLE a. Follow the Repair Manual instructions to remove the Fuel Tube Assembly from the vehicle. Tundra 1UR-FE 4.6 Sequoia Camry A25A-FKS 2.5 Tacoma 2GR-FKS 3.5 Tacoma 2TR-FE 2.7 Corolla Hatchback FJ Cruiser REMOVE FUEL TUBE ASSY. 2018 2018 2018 2018 2019 2019 2019 2019 Sienna** Tundra 3UR-FE 5.7 Camry 2GR-FKS 3.5 Highlander*** 2017 2018 2018 2017 2018 2019 2019 2018 2019 2020 2020 2019 2020 2018 2019 Avalon 2018 2019 2020 2019 Corolla 2018 2019 2020 2014 4Runner 2014 2015 RAV4 2019 Land Cruiser 2014 2015 **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 30-32. 35 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 36 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. DISASSEMBLY TIPS: O-RING REMOVAL During disassembly, the O-Ring may remain in the fuel pump housing. Be sure the inspect the housing after removing the fuel pump and remove the O-Ring if necessary. 37 1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY a. Follow the Repair Manual instructions to disassemble the Fuel Suction Tube Assembly. Tundra 1UR-FE 4.6 Sequoia Camry A25A-FKS 2.5 Tacoma 2GR-FKS 3.5 Tacoma 2TR-FE 2.7 Corolla Hatchback FJ Cruiser 2018 2018 2018 2018 2018 2019 2014 DISASSEMBLE 2019 2019 2019 2019 Sienna Tundra 3UR-FE 5.7 Camry 2GR-FKS 3.5 Highlander 2017 2018 2018 2017 2019 Avalon 2018 Corolla 2018 4Runner 2014 2018 2019 2019 2018 2019 2020 2020 2019 2020 2019 2020 2019 2020 2015 RAV4 2019 Land Cruiser 2014 2015 2. CLEAN SUB TANK ASSEMBLY a. Using brake cleaner, clean the sub-tank assembly. 38 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. REASSEMBLY TIPS: FUEL TUBE When assembling the upper and lower sections of the fuel pump assembly, be certain to correctly align the upper and lower sections as to not twist the fuel tube. 39 REASSEMBLY TIPS: FUEL FILTER INSTALLATION When assembling the fuel filter retainer to pump housing on some models, there is a possibility that the main valve will unseat itself from the housing. Be sure to inspect the complete assembly for the following issues: · Crack in the retainer · Claws are properly engaged · O-Ring is properly seated · No gap between the housing and main valve 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. 40 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: · 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 HINT: The reused filter may be discolored. 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. Note: Fuel Pump O-Ring installation is critical to this repair. A visual inspection of the final assembly will confirm the correct installation. 41 3. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY b. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly. Tundra 1UR-FE 4.6 Sequoia Camry A25A-FKS 2.5 Tacoma 2GR-FKS 3.5 Tacoma 2TR-FE 2.7 Corolla Hatchback FJ Cruiser RAV4 2018 2018 2018 2018 2018 2019 2014 2019 REASSEMBLE 2019 2019 2019 2019 Sienna Tundra 3UR-FE 5.7 Camry 2GR-FKS 3.5 Highlander 2017 2018 2018 2017 2019 Avalon 2018 Corolla 2018 4Runner Land Cruiser 2014 2014 2018 2019 2019 2018 2019 2020 2020 2019 2020 2019 2020 2019 2015 2015 2020 42 X. INSTALL FUEL TUBE ASSEMBLY INSTALLATION TIP: PLASTIC RETAINER 43 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. Tundra 1UR-FE 4.6 Sequoia Camry A25A-FKS 2.5 Tacoma 2GR-FKS 3.5 Tacoma 2TR-FE 2.7 Corolla Hatchback FJ Cruiser RAV4 2018 2018 2018 2018 2018 2019 2014 2019 INSTALLATION 2019 2019 2019 2019 Sienna Tundra 3UR-FE 5.7 Camry 2GR-FKS 3.5 Highlander 2017 2018 2018 2017 2019 Avalon 2018 Corolla 4Runner Land Cruiser 2018 2014 2014 2018 2019 2019 2018 2019 2020 2020 2019 2020 2019 2020 2019 2015 2015 2020 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 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. 44 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 19TA01 19 T A 01 Year Campaign is Launched Vehicle Make Field Action Category and Phase Field Action Sequence 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc... T = Toyota L = Lexus 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) 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) 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 45Microsoft Word 2016