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.

11/11/2016

SET -TSB-16-006
Category:

Vehicle Exterior

Section:

Door/Latch

Highlander water intrusion
grommet damaged during accessory installation
Applicability
INSTALLED ACCESSORY INFORMATION
ACCESSORY
DESCRIPTION
CODE
KIT PART NUMBER

YEAR(S)

MODEL(S)

2016

Highlander

Onboard Vacuum

SV1000

2016

Highlander

LED Fog Light & DRL 2n1

LD4000 or
LD4010

00016-48017-01
00016-48017-02
00016-48017-04
00016-00081
00016-48011

**This Publication does not apply to Vehicles Equipped with an accessory from the factory or Systems added by
other manufacturers.

Introduction
Southeast Toyota (SET) offers onboard vacuum and LED fog & DRL 2n1 Light
accessories as port or dealer installed options. The hood release cable grommet may be
damaged during the installation of onboard vacuum cleaner or LED fog & DRL 2n1 light
on 2016 Highlander vehicles. Should the hood release cable grommet be damaged
water intrusion may occur during heavy rains. This Bulletin addresses the inspection
and repair procedures for water intrusion concerns on vehicles equipped with SET
accessories: onboard vacuum and/or LED fog & DLR light.
Work Flow Overview

Determine Installed Accessories
LED Fog Light / DRL 2n1
LD4000 or LD4010 ONLY
Inspect for water leak or
damaged hood release
cable grommet

OK

NG

1.
2.

Replace Hood Release
Cable
Reroute 2n1 light harness

Onboard Vacuum
SV1000 ONLY

1.
2.

Replace Hood Release
Cable
Reroute Onboard Vacuum
harness

BOTH Onboard Vacuum and LED
Fog Light / DRL 2n1
LD4010 and SV1000
1.
2.
3.

Replace Hood Release
Cable
Reroute Onboard Vacuum
Harness
Reroute 2n1 light harness

Repair Complete

1

November 11, 2016

2

SET Accessory Highlander water intrusion (Cont.)
Warranty Information
For Dealers located in the Southeast Region, Florida, Georgia, Alabama, South Carolina, or
North Carolina, Submit Warranty claim utilizing the information below.
Accessory

OP CODE

DESCRIPTION

TIME

OFP

T1

T2

LD4000 or
INSGRO
Inspect Grommet
1.2
00016-SPECL 99 99
LD4010
LD4000 or
RRHRC1
R&R Hood Release Cable with 2n1 harness
1.4
00016-SPECL 99 99
LD4010
SV1000
RRHRC2
R&R Hood Release Cable with Vacuum harness
2.4
00016-SPECL 99 99
LD4010 and
R&R Hood Release Cable with 2n1 and Vacuum
RRHRC3
2.6
00016-SPECL 99 99
SV1000
harness
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, press 5 then 4 or email [email protected] for claim payment instructions.

Parts Information
PART NUMBER

DISCRIPTION

53630-0E050

Cable Assembly, Hood Lock Control (as needed)

Southeast Toyota Distributors, LLC

November 11, 2016

3

SET Accessory Highlander water intrusion (Cont.)
SECTION A: Inspection

Verify Vehicle is equipped with SET accessory.
•

Port installed Onboard Vacuum
(Fig. 1) can be identified by
“SV1000” option code appearing
in TIS VIN inquiry vehicle
accessory codes.

•

Port installed LED Fog Light & DRL
2n1 (Fig.2) can be identified by
“LD4000” or “LD4010” option code
appearing in TIS VIN inquiry vehicle
accessory codes.

•

Dealer installed units can be
identified by reviewing service
history for 00016-48017-0X.

•

Dealer installed units can be
identified by reviewing service
history for 00016-00081 or
00016-48011

Fig. 1

Fig. 2

•

Vehicle equipped with LED Fog Light & DRL 2n1 LD4000 or LD4010 ONLY.
 Proceed to step 1 starting on page 4.

•

Vehicle equipped with Onboard Vacuum SV1000 ONLY.
 Perform repairs as listed in Section C starting on page 12.

•

Vehicle equipped with BOTH LED Fog Light & DRL 2n1 LD4000 or LD4010
AND Onboard Vacuum SV1000.
 Perform repairs as listed in Section B starting on page 6 and Section C
starting on page 12.

•

Vehicle is not equipped with SET accessories listed
 This TSB does not apply

Southeast Toyota Distributors, LLC

November 11, 2016

4

SET Accessory Highlander water intrusion (Cont.)
Inspect for water intrusion and grommet condition.
1. Remove front door scuff plate
LH and cowl side trim subassembly.

Fig. 3

Fig. 3

2. Pull carpeting away from floor
board in area behind parking
brake pedal.
Fig. 4

Fig. 4
3. Check Driver’s floor board for dampness.
A. Feel insulation
under carpet

Fig. 5a

B. Feel insulation under
foam pad.

Fig. 5b

C. Check insulation on
bulkhead

Fig. 5c

Note: If uncertain of water intrusion, perform water leak test while monitoring the area
behind the parking brake in the area of the hood release cable grommet.

Southeast Toyota Distributors, LLC

November 11, 2016

5

SET Accessory Highlander water intrusion (Cont.)
4. Remove left front tire.

Fig. 6
5. Remove front fender wheel
opening molding sub-assembly
LH.

6. Remove front fender liner LH.
Fig. 6

7. Inspect the hood release cable
grommet. Grommet should be:

Fig. 7
Fig. 7
•

Correctly positioned in
fender well.

•

Not ripped or torn.

•

Sealed with silicon.

 If water intrusion is detected or Grommet is damaged proceed to Section B
starting on page 6 for repair instructions.
 If Water intrusion is not found and the grommet is not damaged, inspection
is complete. No repairs required.

Southeast Toyota Distributors, LLC

November 11, 2016

SET Accessory Highlander water intrusion (Cont.)
SECTION B: LD4000 or LD4010 LED Fog Light & DRL 2n1

A.

LED FOG LIGHT & DRL 2N1 HARNESS REMOVAL.
1. Disconnect negative battery terminal.
2. Remove left front tire.
Fig. 5
3. Remove front fender wheel
opening molding sub-assembly
LH.
4. Remove front fender liner LH.
TIS INFO
Fig. 5

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. 6

9. Locate DRL module behind left
side of lower instrument panel
finish panel sub-assembly.

Fig. 6

Southeast Toyota Distributors, LLC

6

November 11, 2016

7

SET Accessory Highlander water intrusion (Cont.)
10. Disconnect DRL harness from
module.

Fig. 7

Fig 7

11. Disassemble harness connectors.
a. Locate the plastic terminal
locking tab in the connector
housing.

Fig. 8

Fig 8

b. Using a terminal release tool,
disengage locking tab from
terminal to release from
connector body.
Fig. 9
Fig. 9
c. With locking tab disengaged,
lightly pull wire with terminal
from rear of connector body.
Fig. 10

Fig. 10
12. Cut all cable ties retaining excess accessory harness under dash.
13. Remove accessory harness through hood release cable grommet.

Southeast Toyota Distributors, LLC

November 11, 2016

8

SET Accessory Highlander water intrusion (Cont.)

Note: If this vehicle is also equipped with onboard Vacuum. Remove Onboard Vacuum
harness as outlined in Section C starting on page 13, step 10, before continuing.
B.

HOOD RELEASE CABLE REPLACEMENT
14. Per TIS instructions remove Hood release cable with grommet.
TIS INFO
15. Per TIS instructions install new Hood release cable with grommet.
TIS INFO
Note: See next steps before completely installing the Hood Release cable grommet.

C.

LED FOG LIGHT & DRL 2N1 HARNESS REVISED INSTALLATION PRIOR TO
INSTALLING HOOD RELEASE CABLE GROMMET INTO BODY.
16. Make a ¼ inch long incision in the
hood release cable grommet in the
area shown.
Fig. 11

Fig. 11
17. Route accessory wiring harness
through grommet. One Terminal at a
time.

Fig. 12

Fig 12
Note: Do not damage new hood release
cable grommet.

18. Pull harness through grommet. Do
not let existing electrical tape or
harness conduit to pass through
grommet.

Fig. 13

STOP

Southeast Toyota Distributors, LLC

November 11, 2016

9

SET Accessory Highlander water intrusion (Cont.)

19. Make a small loop in accessory wire
harness and wire tie to hood release
cable.
Fig. 14

Fig. 14
20. Push Hood Release cable into
position. Ensure grommet is flush
against bulkhead.

Fig. 15

Fig. 15

21. Extra harness can be pulled to the
front of the wheel well and secured
near left front fog light housing.

Fig. 16

Fig. 16

22. Reassemble connectors under dash.
Note: Connectors have polarity
markings. Push terminals into
connector as shown. Fig. 17
•
•

Red wire goes to “+”
connector cavity.
Black wire goes to “-”
connector cavity.

Southeast Toyota Distributors, LLC

Fig. 17

November 11, 2016

10

SET Accessory Highlander water intrusion (Cont.)
23. Connect accessory harness to DRL
module. Fig. 18

Fig. 18

24. Seal Grommet with 3M silicone or
equivalent. Fig. 19

D.

•

Apply silicone between
harness and release cable.

•

Ensure incision made to
grommet is completely
sealed.

•

Apply silicone around