T-SB-0018-19

February 15, 2019

Knocking Noise From Fuel Tank Area
Service
Category

Engine/Hybrid System

Section

Fuel System

Market USA

Applicability
YEAR(S)

MODEL(S)

2017 - 2019

Highlander

ADDITIONAL INFORMATION

Introduction

Some 2017 – 2019 model year Highlander vehicles may exhibit a knocking noise from the fuel
tank area at idle, vehicle stationary, with a full tank of gasoline. Follow the Repair Procedure in
this bulletin to address this condition.

Warranty Information
OP CODE

DESCRIPTION

TIME

OFP

T1

T2

EG1824

Install Valve Assembly, Charcoal Canister Plate
and R & R Fuel Tank Protector

1.0

77404-0E050

91

52

APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
 For California specification vehicles sold, registered, and operated in California, Connecticut,
Delaware, Maine, Maryland, Massachusetts, New Jersey, New York, Oregon, Pennsylvania,
Rhode Island, Vermont, and Washington, warranty is in effect for 36 months or 50,000 miles,
whichever occurs first, from the vehicle’s in-service date.


© 2019 Toyota Motor Sales, USA

Page 1 of 8

T-SB-0018-19

February 15, 2019

Page 2 of 8

Knocking Noise From Fuel Tank Area
Parts Information
PART NUMBER

PART NAME

QTY

Protector Sub-assy, Fuel Tank

1

17451-0D140

Gasket, Exhaust Pipe, Center

1

90917-A6001

Gasket, Exhaust Pipe

1

PREVIOUS

NEW

77606-0E040
77606-0E050

77606-48160

N/A

77720-48060

Valve Assy, Fuel Outlet

1

N/A

77743-48020

Plate, Charcoal Canister, No. 1

1

Required Tools & Equipment
REQUIRED TOOLS & MATERIAL

PART NUMBER

QTY

Nitto Tape

360UL

1

NOTE
Nitto Tape is located in the unusual interior noise (UIN) kit (PN 08231-00801), which is stocked by most
dealers. Check the kit first before ordering.

Repair Procedure

1. Confirm the condition exists.
Does the vehicle exhibit a knocking noise from the fuel tank area at idle, vehicle stationary,
with a full tank of gasoline?
 YES — Continue to step 2.


NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.

© 2019 Toyota Motor Sales, USA

T-SB-0018-19

February 15, 2019

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Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

2. Confirm if the vehicle has the NEW pulsation damper valve assembly installed.
NOTE
The NEW part can be identified by the addition of a bracket and valve assembly attached to the
charcoal canister.

Does the vehicle have the NEW pulsation damper valve assembly installed?
 YES — This bulletin does NOT apply. Continue diagnosis using the


applicable Repair Manual.
NO — Continue to step 3.

Figure 1. Without Pulsation Damper Valve
Assembly Installed

Figure 2. With Pulsation Damper Valve
Assembly Installed

© 2019 Toyota Motor Sales, USA

T-SB-0018-19

February 15, 2019

Page 4 of 8

Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

3. Install the NEW pulsation damper valve assembly.
A. Remove the tail exhaust pipe assembly and the charcoal canister protector.
Refer to TIS, applicable model and model year Repair Manual:
 2017 – 2019 Highlander:
Engine/Hybrid System – Emission Control – “2GR-FKS Emission Control:
Canister: Removal”

B. Remove the front center floor cover and the No. 1 fuel tank protector sub-assembly.
Refer to TIS, applicable model and model year Repair Manual:
 2017 – 2019 Highlander:
Engine/Hybrid System – Fuel System – “2GR-FKS Fuel: Fuel Tank: Removal”

C. Disconnect the fuel tank vent hose sub-assembly.
Refer to TIS, applicable model and model year Repair Manual:
 2017 – 2019 Highlander:
Engine/Hybrid System – Emission Control – “2GR-FKS Emission Control:
Canister: Removal”
D. To provide adequate clearance to the
NEW bracket, trim the NEW pulsation
damper valve as shown.

Figure 3.

© 2019 Toyota Motor Sales, USA

T-SB-0018-19

February 15, 2019

Page 5 of 8

Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

E. Ensure clearance between the valve and bracket BEFORE proceeding to the next step.
F. Install the NEW bracket to the
charcoal canister.
(1) Remove the nut from the front of
the charcoal canister.
(2) Install the bracket on the stud.
(3) Tighten the nut and valve assembly
plate into place.

Figure 4.

Torque: 5.5 N*m (56 kgf*cm,
49 in*lbf)

G. Install the NEW pulsation damper valve
assembly onto the NEW bracket.
Push both retaining clips of valve
assembly through the two holes on the
bracket.

Figure 5.

© 2019 Toyota Motor Sales, USA

T-SB-0018-19

February 15, 2019

Page 6 of 8

Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

H. Connect the NEW pulsation damper
valve assembly to the charcoal canister.

Figure 6.

I.

Figure 7.

Cut the two reflect sleeves as shown.

1

1

© 2019 Toyota Motor Sales, USA

Cut Location

T-SB-0018-19

February 15, 2019

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Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

J. Wrap the two reflect sleeves around each of the vent tube connections and tape them
into place as shown in Figures 8 and 9.
Figure 8.

Figure 9.
1

3

2

4

1

5

1

1

RH

2

Up

3

Reflect Sleeve

4

Vent Tube

5

Nitto Tape

K. Using the zip ties supplied, tie the NEW
pulsation damper valve assembly to the
purge line as shown by doubling the zip
ties together for each location.

Reflect Sleeve

Figure 10. Zip-Tie Locations

NOTE
Double or connect the zip ties to provide
adequate length to secure assembly.

© 2019 Toyota Motor Sales, USA

T-SB-0018-19

February 15, 2019

Page 8 of 8

Knocking Noise From Fuel Tank Area
Repair Procedure (continued)

L. Trim the excess zip-tie tail between 3 mm – 5 mm.
M. Install the No. 1 fuel tank protector sub-assembly and the front center floor cover.
Refer to TIS, applicable model and model year Repair Manual:
 2017 – 2019 Highlander:
Engine/Hybrid System – Fuel System – “2GR-FKS Fuel: Fuel Tank: Installation”
N. Install the charcoal canister protector and the tail exhaust pipe assembly.
Refer to TIS, applicable model and model year Repair Manual:
 2017 – 2019 Highlander:
Engine/Hybrid System – Emission Control – “2GR-FKS Emission Control:
Canister: Installation”
O. Make sure the vehicle has a full tank of gasoline and start the engine.

P. At idle, vehicle stationary, confirm the knocking noise is no longer present.

© 2019 Toyota Motor Sales, USA