ATTENTION: This Technical Service
Bulletin was issued by Southeast Toyota
Distributors, LLC.
For Toyota Dealers located within the Southeast
Region: Please refer to SET Dealer Daily to obtain
instructions on how to order parts and submit a warranty
claim (If applicable).
For Lexus Dealers or Toyota Dealers NOT located in
Florida, Georgia, Alabama, South Carolina or North
Carolina: For Repair Authorization, Parts Ordering, and
Warranty Claims please contact Southeast Toyota
Distributors Warranty Claims Department:

(888)851-2722
Press 5, then Press 4 for Out of Region SET Repairs

[email protected]
Thank you for your continued support.

9/9/2016

SET -TSB-16-005
Category:

Vehicle Exterior

Section:

Door/Hatch

2016 Highlander On Board Vacuum
Secondary Manual Fuel Door Release Access
Applicability
YEAR(S)

2016

MODEL(S)

Highlander

INSTALLED ACCESSORY INFORMATION
DESCRIPTION

ACCESSORY CODE

KIT PART NUMBER

SV1000

00016-48017-01,
00016-48017-02,
00016-48017-03

ON BOARD VACUUM
CLEANER

**This Publication does not apply to Vehicles Equipped with an On Board Vacuum Cleaner Systems added by other
manufacturers.

Introduction
The 2016 Toyota Highlander is equipped with a primary electronic fuel door release system and a
secondary mechanical release (located in the inside left quarter panel) to be used if the electronic
fuel door switch becomes inoperable. 2016 Highlanders with the SET accessory on board
vacuum system do not provide access to the secondary manual fuel door release lever. This
TSB outlines the process and procedures required for modification of the on board vacuum to
allow access to the secondary manual fuel door release.

Warranty Information
For Dealers located in the Southeast Region, Florida, Georgia, Alabama, South Carolina, or North
Carolina, Submit Warranty claim utilizing the information below.
OP CODE

DESCRIPTION

TIME

OFP

T1

T2

VACMOD

On Board Vacuum Modification

0.8

00016-SPECL

99

99

Port Installed Option (PIO) – is in effect for 36 months or 36,000 miles from the vehicle’s in-service date, whichever
occurs first. Unless otherwise specified in vehicle VIN inquiry.
Dealer Installed Option (DIO) – is in effect for 12 months, regardless of mileage, from the date the part(s) was
installed on the vehicle or the remainder of any applicable New Vehicle Limited Warranty, whichever provides greater
coverage.
Over the Counter Sale (OCS) – is in effect for 12 months, regardless of mileage, from the date the part(s) were sold.
Labor is not warranted for over-the counter service part replacements.
If you are a dealer located outside of the Southeast Region, please contact the SET Accessory Warranty
Department at (888) 851-2722 or email [email protected] for claim payment instructions.

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September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
Parts Information
PART NUMBER

DESCRIPTION

00016-48017-50

Highlander Service Repair Parts

If you are a dealer outside of the SET region, please contact the SET accessory department at (888) 8512722 or email [email protected].

Inspection
1. Verify Vehicle is equipped with SET
accessory on board vacuum (Fig. 1)
•

Port installed units can be identified
by “SV1000” option code appearing
in TIS VIN inquiry vehicle
accessory codes

•

Dealer installed units can be
identified by reviewing service
history.

2. Remove on-board vacuum hose access panel and remove hose from storage panel.
3. Inspect hose storage compartment for manual fuel door release.
Compartment does not have manual fuel
door release. (Fig. 2)

Manual fuel door release and label located
in hose storage compartment.
(Fig. 3)

TSB applies, continue to repair

TSB does not apply. Reinstall hose and
hose storage compartment door.

Southeast Toyota Distributors, LLC

September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access

Repair
Disassembly
4. Disconnect negative battery cable
5. Remove hose assembly by unthreading nut on hose end onto hose attachment point inside
hose storage cavity.
6. Remove vacuum canister assembly and panel door covering canister area.
7. Remove 8mm screw in the hose storage
compartment (Fig. 4) and 3 10mm bolts
in the vacuum canister compartment
(Fig. 5) holding on board vacuum to
quarter panel trim panel as shown in
illustration.

Southeast Toyota Distributors, LLC

September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
8. Disconnect the electrical connector and
remove vacuum from vehicle.

Modification
9. Lay vacuum assembly face down on protective surface. Locate the bulge in the hose storage
compartment backing. Locate the screw hole in near top of the bulge. Mark location as follows:
•
•

33mm (1 5/16 in.) from screw hole down center line of bulge.
11mm (7/16 in.) to left of centerline towards front of the vehicle.
(See Fig. 7)

Southeast Toyota Distributors, LLC

September 9, 2016
2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
10. Using drill and 3/8 inch bit, drill hole in marked location (Fig. 8)

11. Insert cable into drilled hole (Fig. 9) positioning loop as shown. Fully seat grommet in hole
(Fig. 10).

Southeast Toyota Distributors, LLC

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September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
Reassembly
TIP: Before proceeding with assembly, locate the manual fuel door release and electrical
connector in the left rear interior trim panel. (Fig. 11) Locate cable tab on manual release where
cable is to be attached. (Fig. 12)

12. Position vacuum in rear of vehicle as pictured (fig. 13). Reconnect electrical connector.

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September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
13. Slide vacuum towards panel and forward (Fig. 14) allowing access to route cable from rear of
unit to manual release (Fig. 15).

14. Affix cable loop to tab on manual fuel door
release lever. (Fig. 16)

Southeast Toyota Distributors, LLC

September 9, 2016
2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
15. Properly position on board vacuum in it’s
mounting position (Fig.17).
•

Verify operation of fuel door release by
pulling release cable

•

Connect negative battery terminal and
verify operation of vacuum by pressing
the power button.

16. Place sticker in the hose storage area
compartment. (Fig. 18)

17. Install vacuum assembly with 10mm socket
and ratchet using hardware provided to
mounting holes on bracket. (Fig.19).

Southeast Toyota Distributors, LLC

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September 9, 2016

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2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access
18. Install self tapping screw in hole inside hose
storage cavity. Tighten with 8mm socket.
(Fig. 20)

19. 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.
21. Insert hose assembly into hose storage cavity
following steps shown (Fig.21).

Southeast Toyota Distributors, LLC

September 9, 2016
2016 Highlander On Board Vacuum Secondary Manual Fuel Door Release Access

22. Install hose storage compartment and vacuum canister compartment panels.

23. Locate the Vehicle Owner’s Manual. Apply
Owner’s Manual modification Sticker (Fig. 22)
on page 261.

Southeast Toyota Distributors, LLC

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