NHTSA ID Number: 11016779
Manufacturer Communication Number: 22TD02
TSB/Document Date: 2025-04-08
Summary
TECHNICAL INSTRUCTIONS LIMITED SERVICE CAMPAIGN 22TD02 FUEL INLET HOUSING CERTAIN 2021 MODEL YEAR HIGHLANDER CERTAIN 2021 MODEL YEAR HIGHLANDER HYBRID
Submitted to NHTSA on 03/07/2025
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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Submitted to NHTSA on 03/07/2025
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.
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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)
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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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Submitted to NHTSA on 03/07/2025
ORGANIC GROWTH INSPECTION
1.
ORANIC GROWTH INSPECTION
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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NOTICE:
You may inspect for organic growth while the sealer is
drying.
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Submitted to NHTSA on 03/07/2025
b)
Inspect the recessed area near the fuel filler inlet for the presence of organic growth
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Organic Growth Inspection Area
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Check thoroughly in this
area for organic growth
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Examples of Organic growth
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Submitted to NHTSA on 03/07/2025
c)
Inspect the remainder of the area for the presence of organic growth
Organic Growth Inspection Areas
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Check the seat fabric for
organic growth
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Check the jute padding
for organic growth
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Check the factory-applied LASD (liquid
applied sound deadening) for organic growth
Examples of Organic growth
Jute Padding
LASD
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Fabric
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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
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REMEDIATE ORGANIC GROWTH (If Necessary)
1. INITIATE ORGANIC GROWTH REMEDATION PROCEDURES
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Disassembly procedure – guidelines for interior component removal
Liquid Applied Sound Deadener (LASD) Removal Procedure
Preparation for SERVPRO Remediation
SERVPRO Remediation Service Request
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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.
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.
Maximum Quantity
2
2
Interior Reassembly Procedure A. Re-install vehicle interior, replacing organic growth
damaged components as necessary.
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Description
Silencer Sheeting (3.0 mm thickness)
Silencer Sheeting (1.5 mm thickness)
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Part Number
58651-22H91
58651-22H92
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2. POST REMEDIATION STEPS
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Submitted to NHTSA on 03/07/2025
REASSEMBLE VEHICLE
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
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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).
APPENDIX
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◄ VERIFY REPAIR QUALITY ►
Confirm no DTCs
Confirm all fasteners torqued to specification
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A. CAMPAIGN DESIGNATION DECODER
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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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Submitted to NHTSA on 03/07/2025
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TSB/Document ID: 22TD02
Replacement Service Bulletin Number:
MFR Communication Date: 2025-02-07
MFR Internal Campaign ID/Software Version: 22TD02
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
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