02
5
ar

FUEL INLET HOUSING

y

LIMITED SERVICE CAMPAIGN 22TD02

7,
2

TECHNICAL INSTRUCTIONS

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Fe
b

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CERTAIN 2021 MODEL YEAR HIGHLANDER
CERTAIN 2021 MODEL YEAR HIGHLANDER HYBRID

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d

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

22

TD

02

Ex

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.

1
Submitted to NHTSA on 03/07/2025

OPERATION FLOW CHART

No further action required

Not Covered

7,
2

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

02
5

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.

Covered

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Remediate organic growth

on

No Organic Growth

Organic Growth
Identified

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b

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

y

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

22

TD

02

Ex

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Campaign complete.
Return the vehicle to the customer.

2
Submitted to NHTSA on 03/07/2025

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.

02
5

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
Qty

3M 08405
(Flexiclear body seam sealer)

1

Illustration

Remark

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y

Part Description

7,
2

A. PARTS

• Rubber Gloves

• Shop cloth/paper towels

22

TD

02

Ex

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B. MATERIALS AND SUPPLIES
• Mirror
• Protective Glasses

on

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Order from auto-parts
store or online retailer.

3
Submitted to NHTSA on 03/07/2025

BACKGROUND

02
5

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.

22

TD

02

Ex

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on

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y

7,
2

SEALANT APPLICATION AREA DIAGRAM

4
Submitted to NHTSA on 03/07/2025

BEFORE CUSTOMER ARRIVES AT THE DEALER

7,
2

02
5

APPLYING SEALER

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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

ru

BEFORE YOU RETURN VEHICLE TO CUSTOMER

Fe
b

The vehicle needs to remain dry for 24 hours after you return it to the customer to ensure proper sealer
hardening.

on

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.

pi
re
d

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.
OPEN FUEL LID DOOR

22

TD

02

Ex

1.

5
Submitted to NHTSA on 03/07/2025

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.

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

22

TD

02

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on

3.

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y

7,
2

02
5

2.

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.

6
Submitted to NHTSA on 03/07/2025

4.

APPLYING SEALER
The sealer needs approximately 1 hour to
solidify.

02
5

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
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.

Fe
b

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.

22

TD

02

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d)

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y

7,
2

a)

7