TECHNICAL INSTRUCTIONS
LIMITED SERVICE CAMPAIGN 22TD02
FUEL INLET HOUSING
CERTAIN 2021 MODEL YEAR HIGHLANDER
CERTAIN 2021 MODEL YEAR HIGHLANDER HYBRID

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this repair are required to successfully complete the most current version of the E-Learning
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 have completed
all of the following courses:
T623 – Electrical Circuit Diagnosis
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.

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OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps
as outlined in the full technical instructions to confirm the campaign is completed correctly.

Verify Vehicle Eligibility
1. Confirm vehicle VIN matches RO
2. Check Vehicle Inquiry System for
campaign eligibility

No further action required

Not Covered

Covered
Apply body sealer to the mating
surface of the panels of the fuel inlet
housing and side member

After applying body sealer, remove
interior panels behind 3 rd row seat to
check for organic growth

Organic Growth
Identified

Remediate organic growth
No Organic Growth

Campaign complete.
Return the vehicle to the customer.

2

IDENTIFICATION OF AFFECTED VEHICLES
1.

CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a) Compare the vehicles VIN to the VIN listed on the Repair Order to ensure they match.
b) Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and that it has not
already been completed.
NOTICE:
TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or
were previously completed, even by another dealer.

PREPARATION
A. PARTS
Part Description

Qty

3M 08405
(Flexiclear body seam sealer)

1

B. MATERIALS AND SUPPLIES
• Mirror
• Protective Glasses

Illustration

• Rubber Gloves

Remark

Order from auto-parts
store or online retailer.

• Shop cloth/paper towels

3

BACKGROUND
The involved vehicles are equipped with a fuel inlet housing which may allow water to leak into the interior of the
vehicle through the seal between the fuel inlet housing and the vehicle body. If this occurs, customers may notice
water in the interior area of the vehicle, behind the third-row seat.

SEALANT APPLICATION AREA DIAGRAM

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APPLYING SEALER

BEFORE CUSTOMER ARRIVES AT THE DEALER
The vehicle needs to be dry when it arrives at your dealer to ensure proper sealer hardening.
• The customer should not bring the vehicle to your dealer if its presently raining, or if rain is forecasted to
occur in the next 24 hours
• Reschedule the customer’s appointment in the event of rainy weather
• The customer should not wash the vehicle (or otherwise get it wet) before bringing it to the dealer
BEFORE YOU RETURN VEHICLE TO CUSTOMER
The vehicle needs to remain dry for 24 hours after you return it to the customer to ensure proper sealer
hardening.
After retuning the vehicle, advise the customer not to drive the vehicle in the rain, wash the vehicle, or get the
vehicle wet within 24 hours after the you return the vehicle.
NOTICE:
The quality of sealer application is ensured when operating temperature is 40°F - 100°F (4°C - 38°C).
Confirm the work space meets this condition. If the condition is not met, the quality of sealer
application will be affected.
1.

OPEN FUEL LID DOOR

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2.

LOCATE SEALER VOID USING A MIRROR
c) Use a mirror to locate void in sealer on the bottom left corner of the fuel lid door opening.
NOTICE:
Sealer must be applied on the entire void area up to the existing sealer making sure there is no gaps
in sealer.

3.

CLEAN AND DEGREASE THE SEALER APPLICATION
POSITION
a) Wear protective glasses.

b)

Using compressed air, remove foreign matter and water
from the sealer application area.
NOTICE:
Clean before applying sealant and make sure there is
no foreign matter on the surface. Foreign matter may
reduce quality of seal and cause water leak.
HINT:
Use shop cloths to keep foreign matter and water from
scattering.
c) Degrease the sealer application area.
d) Once again using compressed air, remove foreign matter
and water from the sealer application area.

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4.

APPLYING SEALER
The sealer needs approximately 1 hour to
solidify.
DO NOT return the vehicle to the customer,
move the vehicle, or let water contact the
sealer until the sealer is dry (1 hour from
application

d)

a)

Wear rubber gloves.

b)
c)

Pick up sealer tube with and remove cap.
Use left hand to squeeze a dime size amount of sealer onto
right index finger.

Apply sealer in several steps to the gap of the body panels from the fuel lid door hinge to the existing
sealer.
NOTICE:
Be careful to only apply sealer in the voided area.

e)

Push the applied sealer into the gap of the body panels as
shown in the illustration.
NOTICE:
Fill entire void with sealer, there should be no gaps in
sealer.

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h)

f)

Once again, apply sealer in several steps onto the applied
sealer as shown in the illustration.

g)

Use a finger to spread the sealer evenly as shown in the
illustration.
NOTICE:
Be careful not to press down the sealer.

Use a mirror to confirm if void area is completely covered with sealer. Repeat steps until void is completely
covered with sealer.
NOTICE:
• After application of sealant, no gaps should be present in sealant application area.
• Sealer must be applied on the entire void area up to the existing sealer making sure there is no
gaps in sealer.

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5.

REMOVE EXCESS SEALER
a) Remove any excess sealer in the visible area inside and
surrounding the fuel door opening.
b) Wait for the sealer to dry for about an hour.

After application of sealant, the sealant should not be visible
without using a mirror. For instance, when filling the vehicle
with fuel.

The sealer needs approximately 1 hour to solidify.
DO NOT return the vehicle to the customer, move the vehicle, or let water contact the sealer
until the sealer is dry (1 hour from application)
After returning the vehicle to the customer, inform them that the vehicle must remain dry for
24 hours. The customer should not drive the vehicle in the rain, wash the vehicle, get the
vehicle wet etc.. within 24 hours after the remedy is performed

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ORGANIC GROWTH INSPECTION
1.

ORANIC GROWTH INSPECTION
NOTICE:
You may inspect for organic growth while the sealer is
drying.
a)

Remove the parts in the order shown below.
(1) DECK BOARD ASSEMBLY
(2) NO. 3 DECK BOARD SUB-ASSEMBLY (w/o Woofer)
(3) TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)
(4) BATTERY SERVICE HOLE COVER
(5) REAR DECK FLOOR BOX
(6) DECK SIDE TRIM BOX LH (w/o Woofer)

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b)

Inspect the recessed area near the fuel filler inlet for the presence of organic growth
Organic Growth Inspection Area

Check thoroughly in this
area for organic growth

Examples of Organic growth

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c)

Inspect the remainder of the area for the presence of organic growth
Organic Growth Inspection Areas

Check the seat fabric for
organic growth

Check the jute padding
for organic growth

Check the factory-applied LASD (liquid
applied sound deadening) for organic growth

Examples of Organic growth
Fabric

Jute Padding

LASD

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Result

OK
NG

Judgment
NO Organic Growth
FOUND

Action

Campaign completed, proceed to page 14

Organic Growth
FOUND

Remediate mold, follow instructions below

REMEDIATE ORGANIC GROWTH (If Necessary)
1. INITIATE ORGANIC GROWTH REMEDATION PROCEDURES
Prepare the vehicle for organic growth remediation by following the instructions in T-SB-0094-21. Start with
the disassembly procedure on Page 7 of 20. Key steps are shown below. Remember to follow the SERVPRO
service request procedures in the T-SB.
a.
b.
c.
d.

Disassembly procedure – guidelines for interior component removal
Liquid Applied Sound Deadener (LASD) Removal Procedure
Preparation for SERVPRO Remediation
SERVPRO Remediation Service Request

2. POST REMEDIATION STEPS
a.
b.

Application of Urethane Seam Sealer (If removed during LASD removal)
Installation of Floor Silencer Sheeting in place of LASD. Replacement Silencer Sheeting part
number details below.

Part Number
58651-22H91
58651-22H92
c.

Description
Silencer Sheeting (3.0 mm thickness)
Silencer Sheeting (1.5 mm thickness)

Maximum Quantity
2
2

Interior Reassembly Procedure A. Re-install vehicle interior, replacing organic growth
damaged components as necessary.

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REASSEMBLE VEHICLE
a)

2.

Install the parts in the order shown below.
(1) DECK SIDE TRIM BOX LH (w/o Woofer)
(2) REAR DECK FLOOR BOX
(3) BATTERY SERVICE HOLE COVER
(4) TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)
(5) NO. 3 DECK BOARD SUB-ASSEMBLY (w/o Woofer)
(6) DECK BOARD ASSEMBLY

CLOSE FUEL LID DOOR
The sealer needs approximately 1 hour to solidify.
DO NOT return the vehicle to the customer, move the vehicle, or let water contact the sealer
until the sealer is dry (1 hour from application).

-

◄ VERIFY REPAIR QUALITY ►
Confirm no DTCs
Confirm all fasteners torqued to specification

APPENDIX
A. CAMPAIGN DESIGNATION DECODER

B. CAMPAIGN PARTS DISPOSAL
As required by Federal Regulations, please make sure all campaign 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.

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