NHTSA ID Number: 10182947
Manufacturer Communication Number: SET-TSB-16-006Re
TSB/Document Date: 2020-11-23
Summary
The hood release cable grommet may have been damaged during the installation of onboard vacuum or 2n1 LED fog & DRL lights on certain 2015-16 Highlander vehicles.
Apply silicone around
edges of grommet
Fig. 19
Note: If vehicle is also equipped with SV1000 onboard vacuum, proceed to Section C
prior to Reassembly.
VEHICLE REASSEMBLY (FOR 2N1 FOG DRL LIGHT)
25. Install lower instrument panel finish
panel sub-assembly.
Fig. 20
26. Install no. 1 instrument panel under
cover sub-assembly.
27. Install cowl side trim sub-assembly
LH.
28. Install front door scuff plate LH.
Fig. 20
Southeast Toyota
Distributors, LLC
December 9, 2016
SET Accessory Highlander water intrusion (Cont.)
29. Install front fender liner LH.
Fig. 21
30. Install front fender wheel opening
molding sub-assembly LH.
TIS INFO
Fig. 21
31. Install left front tire.
32. Reconnect negative battery terminal.
Repair complete for vehicles with LD4000/LD4010 Fog and DRL light vehicles.
Proceed to next section if vehicle is also equipped with SV1000 onboard
vacuum.
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December 9, 2016
SET Accessory Highlander water intrusion (Cont.)
SECTION C: SV1000 Onboard Vacuum
A.
ONBOARD VACUUM HARNESS REMOVAL
1. Disconnect negative battery terminal.
2. Remove left front tire.
Fig. 22
3. Remove front fender wheel
opening molding sub-assembly
LH.
4. Remove front fender liner LH.
TIS INFO
Fig. 22
5. Remove front door scuff plate LH.
6. Remove cowl side trim subassembly LH.
TIS INFO
7. Remove no. 1 instrument panel
under cover sub-assembly.
8. Remove lower instrument panel
finish panel sub-assembly.
TIS INFO
Fig. 23
9. Locate DRL module behind left
side of lower instrument panel
finish panel sub-assembly.
Fig. 23
Southeast Toyota Distributors, LLC
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
10. Remove vacuum hose panel.
11. Remove hose assembly by
unthreading nut on hose end onto
hose attachment point inside hose
storage cavity.
Vacuum hose panel
12. Remove vacuum canister panel and
canister assembly.
Fig. 24
Fig. 24
Canister
panel
13. Remove 8mm screw in the hose
storage compartment (Fig. 25) and 3
10mm bolts in the vacuum canister
compartment (Fig. 26) holding on
board vacuum to quarter panel trim
panel as shown in illustration.
Fig. 25
Fig. 26
14. Tilt vacuum inward and disconnect
the electrical connector.
Fig. 27
Fig. 27
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
15. Tilt vacuum inward and disconnect
secondary fuel door release cable
from fuel door solenoid.
Fig. 28
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction.
Fig. 28
16. Remove the wire retainer on the back
of the harness power connector by
prying clips away from housing body
and sliding back.
Fig. 29
Fig. 29
17. Insert narrow flat blade screwdriver
into mating end of connector, just
under the top terminal. Apply
pressure down and pull back on the
top wire from the back of the housing.
Fig. 30
Fig. 30
18. Fully remove the top wire from the
connector housing.
Fig.31
19. Use Electrical tape to protect terminal
during procedure.
Fig. 31
Note: Onboard vacuum power wire is connected to B+ and has 12V at all times. Battery
cable must be disconnected to prevent damage.
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
20. Remove LH rear quarter panel trim.
Fig. 32
TIS INFO
Fig. 32
21. Locate vacuum power harness
behind left rear quarter panel interior
trim routed along factory harness. Cut
all cable ties securing harness.
Fig. 33
Fig. 33
22. Remove Vacumm power harness by pulling through the hood release cable
grommet.
B.
HOOD RELEASE CABLE REPLACEMENT
23. Per TIS instructions remove Hood release cable with grommet.
TIS INFO
24. Per TIS instructions install new Hood release cable with grommet.
TIS INFO
Note: If vehicle is also equipped with LD4010 fog and DRL 2m1 light, refer to section B
before completely installing the Hood Release cable grommet.
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
C.
REVISED VACUUM POWER HARNESS ROUTING
•
OVERVIEW- The harness will run
down the back of the wheel well.
Then routed on to the inside of the
body seam to a body plug in the
driver’s side floor board. Once
inside the vehicle the harness is to
be routed the driver’s side of the
vehicle to its original location.
Vacuum harness is not to be
routed through hood release cable
grommet. Fig. 34
Fig. 34
25. Loosen underbody splash shields
behind left front tire.
Fig. 35
Fig. 35
26. Route harness down back of wheel
well and to the inside of the body
seam.
Fig. 36
Seam
Fig. 36
Harness
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
27. Route harness above frame support.
Fig. 37
Fig. 37
Support
28. Locate and temporarily remove floor
pan plug above support.
Fig. 38
Fig. 38
29. Make a cut in the center of body plug
by folding and using side cuts or
equivalent to make an incision in
center of plug.
Fig. 39
Fig. 39
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
30. Route Harness through body plug as
shown. Pull harness through body
plug.
Fig. 40
Fig. 40
31. Push Harness into body through body
plug hole.
Fig. 41
Fig. 41
TIP: Mechanics wire or fish tool may be
helpful in routing wire under floor
insulation.
32. Locate the harness in the driver’s
floor pan under carpet. Pull harness
into vehicle.
Fig. 42
Harness
Fig. 42
33. Route Harness with factory harness
along left side of vehicle to rear
quarter on board vacuum location.
Fig. 43
Fig. 43
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
D.
VEHICLE REASSEMBLY (FOR ONBOARD VACUUM)
34. Route the harness up through the
inner structure of the driver's side
quarter panel, using 2 cable ties to
secure to the existing harness.
Continue routing the harness up over
the wheel well, following the path of
the existing harness. There will be
extra harness length, so from the
point marked by the red arrow, keep 3
feet of harness length for finishing the
run. Attach a cable tie at the locations
of the red and white arrows and
tighten. The length of harness left
over should be bunched up and
secured between the areas marked
by the two yellow arrows, which will
be the two cable ties used to secure
each end of the bunched harness to
the existing harness. Fig 44
Fig. 44
35. Remove electrical tape from routed
wire terminal. Connect positive wire
back into wiring harness connector terminal is polarized and will only
latch in when inserted correctly. Pull
back on wire once inserted to test
connection. Replace wire retainer on
back of connector
Fig. 45
Fig. 45
36. Install Left rear quarter panel trim.
TIS INFO
Fig. 46
Fig. 46
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
TIP: Before proceeding with assembly,
locate the manual fuel door release and
electrical connector in the left rear interior
trim panel. Fig. 47 Locate cable tab on
manual release where cable is to be
attached.
Fig. 47
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction
prior to assembly.
37. Position vacuum in rear of vehicle as
pictured. Reconnect electrical
connector.
Fig. 48
Fig. 48
38. Slide vacuum towards panel and forward (Fig. 49) allowing access to route cable
from rear of unit to manual release (Fig. 50).
Fig. 49
Fig. 50
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SET Accessory Highlander water intrusion (Cont.)
39. Affix cable loop to tab on manual fuel
door release lever.
Fig. 51
Note: If vacuum is not equipped with
secondary fuel door release cable see
SET-TSB-16-005 for additional instruction
prior to assembly.
Fig. 51
40. Properly position on board vacuum in
it’s mounting position.
Fig. 52
•
Verify operation of fuel door
release by pulling release cable
•
Temporarily connect negative
battery terminal and verify
operation of vacuum by pressing
the power button.
Fig. 52
41. Install vacuum assembly with 10mm
socket and ratchet using hardware
provided to mounting holes on
bracket.
Fig. 53
Fig. 53
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December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
42. Install self tapping screw in hole
inside hose storage cavity. Tighten
with 8mm socket.
Fig. 54
Fig. 54
43. Install hose assembly by threading nut on hose end onto hose attachment point
inside hose storage cavity. Press power button again to test vacuum air path
connections - suction should be felt at end of hose assembly. Turn vacuum off
using power button.
Southeast Toyota Distributors, LLC
December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
44. Insert hose assembly into hose
storage cavity following steps shown.
Fig. 55
Fig. 55
45. Install hose storage and vacuum canister compartment panels.
46. Install lower instrument panel finish
panel sub-assembly.
Fig. 56
47. Install no. 1 instrument panel under
cover sub-assembly.
48. Install cowl side trim sub-assembly
LH.
49. Install front door scuff plate LH.
Fig. 56
Southeast Toyota Distributors, LLC
December 9, 2016
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SET Accessory Highlander water intrusion (Cont.)
50. Seat body plug in floor panel and seal
with 3M silicone or equivalent.
•
Apply silicone between
harness and body plug.
•
Ensure incision made to
body plug is completely
sealed.
Fig. 57
Apply
Sealant
Fig. 57
51. Install and secure underbody splash
shields.
Fig. 58
Fig. 58
52. Install front fender liner LH.
Fig. 59
53. Install front fender wheel opening
molding sub-assembly LH.
TIS INFO
Fig. 59
54. Install left front tire.
55. Reconnect negative battery terminal.
Southeast Toyota Distributors, LLC
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TSB/Document ID: SET-TSB-16-006Re
Replacement Service Bulletin Number:
MFR Communication Date: 2017-01-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
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