21TC03_Fuel Pump

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN 21TC03
LOW-PRESSURE FUEL PUMP
CERTAIN 2017 – 2019 HIGHLANDER HYBRID
CERTAIN 2018 – 2020 CAMRY HYBRID
CERTAIN 2019 AVALON HYBRID
CERTAIN 2019 RAV4 HYBRID
The repair quality of covered vehicles is extremely important to Toyota. All dealership
technicians performing this special service campaign 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
special service campaign 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 that have completed the above courses
to perform this campaign 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.
OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the RO.
2. Check for Campaign eligibility using TIS.
Not
Covered
No further action required.
Covered
Remove Fuel Suction
Tube Assembly from vehicle
Disassemble Fuel Suction
Tube Assembly
Install NEW fuel pump
Reassemble Fuel Suction
Tube Assembly
Reinstall Fuel Suction Tube
Assembly into vehicle
Campaign complete.
Return the vehicle to the customer.
2
I.
IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a. Compare the vehicle’s 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.
Note: TMNA warranty will not reimburse dealers for repairs completed on vehicles that are
not affected or were previously completed, even by another dealer.
II. PREPARATION
A. PARTS
Model
Part Number
04009-86531
04009-81433
Quantity
1
1
Camry Hybrid
Avalon Hybrid
04009-86325
04009-80747
04009-95106
1
1
2
KIT, PUMP, FUEL
REPLACEMENT KIT, FUEL PUMP
HOOK, REAR SEAT CUSHION LOCK SSP KIT
Rav4 Hybrid
04009-86325
04009-9510R
1
1
KIT, PUMP, FUEL
HOOK, RR SEAT LOCK, W/GKT&SEAL SSP KIT
Highlander Hybrid
Description
KIT, PUMP, FUEL
REPLACEMENT KIT, FUEL PUMP
Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be accepted on the
campaign claim.
B. TOOLS & EQUIPMENT
•
•
•
•
Standard Hand Tools
Torque Wrench
Air Blow Gun
Gas Caddy (minimum 25-gallon capacity)
C. MATERIALS
•
Brake Cleaner
3
D. CAMPAIGN TOOLS
Each dealership was provided with a Crossbar and a set of Cam Lock Retainer Jaws for
removing the Cam Lock type retainer rings when Safety Recall 20TA02 was announced. These
same jaws and crossbar will be used for the Avalon Hybrid, Camry Hybrid and Rav4 Hybrid
vehicles involved in this Special Service Campaign 21TC03.
The jaws and crossbar will be used with the dealerships existing handle set from the Fuel
Sender Lock Nut Wrench Set (09808-14031). A 1/2” breaker bar can also be used. This set of
tools will supplement the SST kit that each dealership currently has. Additional SST’s can be
purchased through the Toyota Special Service Tools (SST) website.
Campaign Tools
Cam Lock Retainer Jaws
Crossbar
Special Service Tools
Handle
Used With
09808-01010
Or suitable 1/2” breaker bar
4
E. SPECIAL SERVICE TOOLS
In the affected models, there are two different types of Fuel Pump Retainer Rings. Reference the
following chart to determine the proper SST or campaign tool for each model and retainer type.
RETAINER TYPE
Models
Highlander Hybrid
Avalon Hybrid
Camry Hybrid
Rav4 Hybrid
Bolt In
Cam Lock
Type:
SST:
No SST
Required
Fuel Sender Lock Nut Wrench Kit
(09808-14031)
Claw: 105mm Jaw Set
(09808-01070)
Crossbar
(09808-01030)
Campaign Tool:
Cam Lock Retainer Jaws
Special Notes:
Requires use of the Handle from the Fuel
Sender Lock Nut Wrench Kit, or a 1/2”
breaker bar.
5
III. BACKGROUND
The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this
were to occur, warning lights and messages may be displayed on the instrument panel, and the
engine may run rough. This will lead to the vehicle entering a failsafe driving mode in which the
vehicle can still be driven for certain distances.
IV.
SAFETY PRECAUTIONS
CAUTION:
 When installing/uninstalling the fuel system components, keep safety first in mind and carefully
observe the following instructions to avoid accidents:
a. When working on the fuel system, display a Flammable - Keep Fire Away sign.
b. Smoking is prohibited nearby.
c. Perform this work in an area where there are no sparks nearby from the operation of welders,
grinders, drills, electric motors, stoves, etc.
d. DO NOT use electrical devices nearby because they can become hot and the operation of power
switches can generate sparks.
e. DO NOT use iron or steel hammers while working, because they may generate sparks.
f. DO NOT start engines even in adjacent stalls.
g. Prepare fire extinguishers before starting any work.
h. Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or
electric fans, because their motors might generate sparks.
i. Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
j. If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use compressed
air to diffuse the fuel vapor.
k. Shop towels and other materials that have come into contact with fuel should be dried in a wellventilated area and then disposed of as appropriate.
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V.
COMPONENTS
HIGHLANDER HYBRID
Replacement items in red
No.
Part #
Quantity
1
2
3
4
04009-86531
1
04009-81433
1
Contents of Part Kit
FUEL PUMP
FUEL SUCTION TUBE GASKET
O-RING
CLIP (for fuel filter)
Quantity
Tape Color
1
1
2
1
GOLD
WHITE
Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be accepted on the
campaign claim.
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CAMRY HYBRID
AVALON HYBRID
Replacement items in red
No.
Part #
Qty
Contents of Part Kit
Qty
1
2
3
4
5
6
7
8
04009-86325
1
FUEL PUMP
FUEL SUCTION TUBE GASKET
O-RING
REAR SEAT CUSHION LOCK HOOK
O-RING
O-RING
FUEL TANK PIPE SETTING HOLDER
REAR SEAT CUSHION LOCK HOOK
1
1
2
2
1
1
1
2
04009-80747
1
04009-95106
2
Tape
Color
GOLD
RED
GREEN
WHITE
Remarks
Dispose of 1 o-ring
Dispose (not used)
Dispose (not used)
Dispose (not used)
Dispose (not used)
Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be accepted on the
campaign claim.
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RAV4 HYBRID
Replacement items in red
No.
Part #
Qty
Contents of Part Kit
Qty
1
2
3
4
04009-86325
1
04009-9510R
1
FUEL PUMP
FUEL SUCTION TUBE GASKET
REAR SEAT CUSHION LOCK HOOK
O-RING
1
1
2
1
Tape Color
Remarks
Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be accepted on the
campaign claim.
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VI.
REMOVE FUEL SUCTION TUBE ASSEMBLY
Use TIS to confirm that this vehicle is eligible for the
campaign before proceeding. Warranty will not pay
claims on ineligible vehicles.
1. CHECK FOR DTC’S
a. Using a Techstream, perform a Health Check to check for Diagnostic
Trouble Codes.
Note: This Special Service Campaign covers only the replacement of the
fuel pump and associated parts. It does not cover the diagnosis or
replacement of any other parts on the vehicle.
REMOVAL TIP: FUEL LEVEL
If the fuel level inside the fuel tank is above the specified level, fuel may overflow from the fuel
tank during the removal of the fuel suction tube assembly. Confirm the fuel level in the vehicle is
below the specified level before proceeding. If necessary, drain fuel from the tank.
Model
FUEL LEVEL RECOMMENDATIONS
Slightly below the F line on the
1/3 or less
fuel level gauge or less
Highlander Hybrid
Camry Hybrid
Avalon Hybrid
Rav4 Hybrid
Note: If fuel needs to be removed from the tank, be sure to recover it into an approved fuel
recovery system. Suitable systems are available from the Toyota Approved Dealer Equipment
website.
10
REMOVAL TIP: CAM LOCK RETAINER TOOL
An updated set of Cam Lock Claws and Support Columns was supplied to each dealership for the
20TA02 Safety Recall. The configuration of the retainer engagement sections of the claws have been
modified from the SST that is referenced in the repair manual. The NEW claws have an improved
design that enables a firm attachment to the retainer. In addition, 2 support columns are provided which
will support the retainer more securely during installation and removal. Be sure to assemble and use
the tools using the following procedures:
Campaign Tool Cam Lock Set:
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REMOVAL TIP: CAM LOCK RETAINER TOOL (cont.)
Lightly tighten the adjuster
Fully tighten the 4 bolts
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REMOVAL TIP: RAV4 HYBRID REAR SEAT REMOVAL
When removing the lower seat cushion on the Rav4 Hybrid, it’s very critical to follow the Repair
Manual procedure. This procedure details the correct location of the lifting points. If the lower
seat cushion is attempted to be removed by lifting at a point other than detailed, the seat frame
may be damaged.
REMOVAL PROCEDURE
1. Place your hand in the position beside the hook as shown in the illustration and lift the front
seat cushion assembly. This will detach the cushion wire on the front of rear seat cushion
without damage to the structure.
SEAT: REAR SEAT ASSEMBLY: REMOVAL; 2019 - 2021 MY RAV4 HV (RM100000001FE25)
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REMOVAL PROCEDURE: HIGHLANDER HYBRID FUEL TANK
FUEL TANK REMOVAL (Highlander Hybrid Only): The parts in the illustration below are not
necessary to be removed when the fuel tank is removed and re-installed.
*1
*3
V-BANK COVER SUB-ASSEMBLY
NO. 2 ENGINE UNDER COVER
*2
*4
*5
NO. 3 FRONT FLOOR HEAT INSULATOR
*6
*7
FRONT EXHAUST PIPE ASSEMBLY
*8
*9
*11
*13
*15
*17
HEATED OXYGEN SENSOR (for Bank 1)
TAIL EXHAUST PIPE ASSEMBLY
HEATER WATER HOSE
COMPRESSION SPRING
EXHAUST PIPE SUPPORT
*10
*12
*14
*16
NO. 1 ENGINE UNDER COVER
FRONT FLOOR COVER LH
CENTER EXHAUST PIPE ASSEMBLY (TWC:
Rear Catalyst)
FRONT NO. 3 EXHAUST PIPE SUBASSEMBLY
HEATER COVER
HEATED OXYGEN SENSOR (for Bank 2)
EXHAUST PIPE SUPPORT BRACKET
GASKET
Non-reusable part
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REMOVAL PROCEDURE: HIGHLANDER HYBRID FUEL TANK (cont.)
FUEL TANK REMOVAL (Highlander Hybrid Only): It is not necessary to complete steps #18 #24 of the fuel tank removal repair manual procedure on TIS.
REMOVAL TIP: TUBE ASSY REMOVAL
1)
2)
Slightly raise the fuel suction tube assembly during
this operation to make sure that the sender gauge
does not interfere with the inside of tank.
Pull up the fuel suction tube assembly to the
position indicated in the illustration. Pull portion (A)
by hand to swing the lower part of fuel suction tube
assembly downward, and then remove the fuel
suction tube assembly from the tank.
• DO NOT bend the arm of fuel sender
gauge assembly.
• DO NOT damage the wire harness at
edges of service hole when removing
the fuel suction tube assembly.
REMOVAL TIP: FUEL LEVEL SENDER
When removing and reinstalling the Fuel Level Sender from the fuel tank, take extra care with the
arm of the fuel sender. It can be easily bent. Additionally, do not touch the electric circuit of the
sender assembly.
Do not touch the electric
circuit of the fuel sender
gauge.
Do not deform the arm of the
fuel sender gauge.
15
2. REMOVE FUEL SUCTION TUBE ASSEMBLY FROM VEHICLE
a. Click the link below to access the repair manual instructions on TIS for removing the fuel
suction tube assembly from the vehicle.
REMOVE FUEL TUBE ASSY.
Highlander Hybrid
Camry Hybrid
2017
2018
Avalon Hybrid
2019
Rav4 Hybrid
2019
2018
2019
2019
2020
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VII.
DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
DISASSEMBLY TIP: FOLLOW THE REPAIR MANUAL
The Part’s Kit contains the necessary O-Rings for reassembly, if the Repair Manual procedure is
followed. If the pump components are disassembled in a manor other than as detailed in the
Repair Manual, the Parts Kit may not contain the necessary O-Rings for proper reassembly.
Please follow the procedures in the Repair Manual to ensure the correct O-Rings are available.
Example of Proper Disassembly:
Repair Manual: Using a
screwdriver (*a) with its tip wrapped
in protective tape, remove the jet
pump from the No. 1 fuel sub-tank.
Tube still attached
Jet pump properly removed from
the No.1 fuel sub-tank.
Replacement O-Ring will be
installed in this location
Example of Incorrect Disassembly:
Tube incorrectly removed
from jet pump
Replacement O-ring is the
incorrect size
Replacement O-Ring is NOT
provided for this location
DO NOT disconnect the tube
from the jet pump
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DISASSEMBLY TIP: MAIN VALVE AND REGULATOR
When replacing the fuel pump, it is not necessary to remove the Fuel Main Valve or Fuel
Pressure Regulator. These O-Rings are NOT included in the parts kit.
DISASSEMBLY TIP: FUEL FILTER
The fuel filter is required to be reused. Be careful with the tabs when removing the filter from the
original fuel pump as to not overextend them. When installing the filter on the NEW Fuel Pump,
be sure that the clips have engaged properly.
DISASSEMBLY TIPS: O-RING REMOVAL
During disassembly, the O-Ring may remain in the fuel pump housing. Be sure the inspect the
housing after removing the fuel pump and remove the O-Ring if necessary.
18
1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Click the link below to access the repair manual instructions on TIS for disassembling the
fuel suction tube assembly.
DISASSEMBLY
Highlander Hybrid
Camry Hybrid
2017
2018
Avalon Hybrid
2019
Rav4 Hybrid
2019
2018
2019
2019
2020
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.
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VIII.
REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
REASSEMBLY TIPS: O-RINGS
The part kits may come with O-Rings of different sizes. They are very difficult to tell apart
visually. To identify the different size O-Rings, they will be wrapped in individual plastic bags with
a piece of COLORED TAPE sealing it. The COLOR OF THE TAPE will identify the O-Ring size.
REFER TO THE COMPONENT DIAGRAMS TO DETERMINE THE CORRECT O-RING, as
identified by the tape color.
REASSEMBLY TIPS: FUEL TUBE
When assembling the upper and lower sections of the fuel pump assembly, be certain to correctly
align the upper and lower sections as to not twist the fuel tube.
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REASSEMBLY TIPS: FUEL FILTER INSTALLATION
When assembling the fuel filter retainer to pump housing on some models, there is a possibility
that the main valve will unseat itself from the housing. Be sure to inspect the complete assembly
for the following issues:
• Crack in the retainer
• Claws are properly engaged
• O-Ring is properly seated
• No gap between the housing and main valve
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1. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY WITH NEW FUEL PUMP
a. Follow the TIS Repair Manual instructions to reassemble the Fuel Suction Tube Assembly
with a NEW Fuel Pump.
Refer to the Component diagrams at the beginning of
these Technical Instructions to confirm the location
of each replacement part.
Example Procedure:
• Remove the original O-Ring, Spacer and
Fuel Filter from the original Fuel Pump.
• Discard the original O-Ring and Fuel
Pump, saving the Spacer and Fuel Filter.
• Install the original Spacer onto the NEW
Fuel Pump.
• Install the NEW O-Ring onto the NEW Fuel
Pump. Refer to the Component Diagram to
determine to proper O-Ring, as identified
by the colored tape on the bag.
• Apply a small amount of engine oil to the
NEW O-Ring to assure correct installation
into the Tube Assembly.
• Install the original Fuel Filter onto the NEW
Fuel Pump.
HINT:
•
Refer to the Components diagrams to
The reused filter may be discolored.
review the other NEW parts to install.
• Apply engine oil to the NEW O-ring before assembly to assure correct installation
into the Fuel Suction Tube.
Note: Fuel Pump O-Ring installation is critical to this repair. A visual inspection of
the final assembly will confirm the correct installation.
22
2. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Click the link below to access the repair manual instructions on TIS for reassembling the fuel
suction tube assembly.
REASSEMBLY
IX.
Highlander Hybrid
Camry Hybrid
2017
2018
Avalon Hybrid
2019
Rav4 Hybrid
2019
2018
2019
2019
2020
INSTALL FUEL SUCTION TUBE ASSEMBLY
1. INSTALL THE FUEL SUCTION TUBE ASSEMBLY INTO VEHICLE
a. Click the link below to access the repair manual instructions on TIS for installing the fuel
suction tube assembly into the vehicle.
Refer to the Component diagrams at the beginning of these
Technical Instructions to confirm the location of each
replacement part.
INSTALLATION
Highlander Hybrid
2017
2018
2019
Camry Hybrid
2018
2019
2020
Avalon Hybrid
2019
Rav4 Hybrid
2019
2. INSTALL REMOVED FUEL
a. If fuel was removed from the tank prior to disassembly, reinstall the originally recovered fuel
into the tank.
3. CHECK FOR DTC’S
a. Using a Techstream, perform a Health Check to check for
Diagnostic Trouble Codes.
Note: This Special Service Campaign covers only the replacement of the
fuel pump and associated parts. It does not cover the diagnosis or
replacement of any other parts on the vehicle.
23
◄ VERIFY REPAIR QUALITY ►
•
•
•
•
•
X.
Confirm that all parts listed in the Components Diagrams have been properly installed on
the vehicle
Confirm no fuel leaks from vehicle
Confirm any fuel drained from the vehicle has been reinstalled
Confirm no DTC’s are present
Test drive to confirm normal operation while under load
APPENDIX
A. PARTS DISPOSAL
In accordance with Federal law, please make sure all 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.
CAMPAIGN DESIGNATION DECODER
19TA01
19
T
A
01
Year Campaign
is Launched
Vehicle Make
Field Action Category and Phase
Field Action Sequence
A = Safety Recall Remedy
B = Safety Recall Interim
C = Special Service Campaign
D = Limited Service Campaign
E = Customer Support Program
F = Emissions Recall
01 = 1st Field Action of the year
02 = 2nd Field Action of the year
03 = 3rd Field Action of the year
19 = 2019
20 = 2020
21 = 2021
22 = 2022
23 = 2023
Etc...
T = Toyota
L = Lexus
(May use other characters in unique
cases)
(The sequence is unique for each
Field Action category)
(May use other characters in
unique cases)
Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1 st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021
24