T-SB-0008-22

T-SB-0008-22
February 8, 2022
Vehicle Refueling Performance
Service
Category
Engine/Hybrid System
Section
Fuel System
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2020 - 2021
Highlander HV
Plant Code(s): S
Introduction
Some 2020 – 2021 model year Highlander Hybrid vehicles may exhibit one or more of the
following conditions:



The fuel gauge displays less than full when the fuel nozzle automatically clicks off.
The total amount of fuel dispensed while refueling is less than expected when the fuel
nozzle automatically clicks off.
The Low Fuel warning light illuminates sooner than expected.
Additionally, the distance to empty mileage displayed in the Multi-Information Display (MID) may
be less than expected. To address these concerns an updated fuel tank, fuel gauge bracket, and
fuel sender gauge assembly were developed. Follow the procedures in this bulletin to address
these conditions.
© 2021 Toyota Motor Sales, USA
Page 1 of 7
T-SB-0008-22
February 8, 2022
Page 2 of 7
Vehicle Refueling Performance
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
PRODUCTION CHANGE EFFECTIVE VIN
TMMI S1
5TDFARAH#MS012385
5TDYARAH#MS012385
5TDGARAH#MS012385
5TDZARAH#MS012385
5TDHARAH#MS012385
5TDHBRCH#MS012385
5TDLA3AH#MS012385
5TDDBRCH#MS012385
5TDEBRCH#MS069249
5TDDBRCH#MS069249
5TDXBRCH#MS069249
5TDHBRCH#MS069249
5TDLB3CH#MS069249
5TDGBRCH#MS069249
5TDBBRCH#MS069249
5TDFBRCH#MS069249
TMMI S2
5TDYARAH#MS509630
5TDGARAH#MS509630
5TDHARAH#MS509630
5TDZARAH#MS509630
5TDHARAH#MS537119
5TDDBRCH#MS509630
5TDHBRCH#MS509630
5TDXBRCH#MS537119
5TDGBRCH#MS537119
5TDHBRCH#MS537119
5TDDBRCH#MS537119
5TDBBRCH#MS537119
Highlander HV
© 2021 Toyota Motor Sales, USA
T-SB-0008-22
February 8, 2022
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Vehicle Refueling Performance
Warranty Information
OPCODE
DESCRIPTION
TIME
EG1919
R & R Fuel Sender Gauge, Fuel Gauge Bracket, and Fuel
Tank Sub-assembly
(Includes: Fuel Input Level Check, Draining Fuel Check)
2.7
Take the Vehicle to the Gas Station and Fill Until Fuel
Pump Automatically Clicks Off
0.3
Combo A
OFP
T1
T2
77001-0E160
87
13
Reimbursement for gasoline is NOT allowed on any type of warranty claim except courtesy deliveries and any applicable
SSCs. Gasoline is a customer-pay item and should not be included in a warranty claim that does not allow for such an
item. ANY claims submitted with a sublet for gasoline will be returned for correction, regardless of a DSPM authorization.
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
 Vehicles equipped with a California Certified Emission Control System that are registered and
operated in California, Arizona (2012 model year only), Connecticut (starting with
2005 model year), Delaware (starting with 2014 model year), Maine (starting with 2004 model
year), Maryland (starting with 2011 model year), Massachusetts (starting with 2004 model year),
New Hampshire (2005 – 2009 model year only), New Jersey (starting with 2005 model year),
New Mexico (2010 – 2011 model year only), New York (2004 – 2015 model year for ZEV models,
starting in 2016 model year all models), Oregon (starting with 2008 model year), Pennsylvania
(starting with 2008 model year), Rhode Island (starting with 2005 model year), Vermont (starting
with 2004 model year), and Washington (starting with 2009 model year) – California Emission
Long-term Defect Warranty is in effect for 7 years or 70,000 miles from the vehicle’s in-service
date, whichever occurs first. (Please reference Policy 4.7 for additional information.)
Parts Information
PART NUMBER
PART NAME
QTY
77001-0E161
Tank Sub-assy, Fuel
1
77173-0E020
77173-0E021
Fuel Gauge Bracket
1
83320-0E060
83320-0E061
Gage Assy, Fuel Sender
1
Gasket, Fuel Suction Tube Set
1
PREVIOUS
NEW
77001-0E160
77169-0R030
© 2021 Toyota Motor Sales, USA
T-SB-0008-22
February 8, 2022
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Vehicle Refueling Performance
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
PART NUMBER
QTY
TSADVUNIT
Techstream 2.0
TS2UNIT
ADE
1
Techstream Lite
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
 Only ONE of the Techstream units listed above is required.
 Software version 16.30.011 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
SPECIAL SERVICE TOOLS (SST) & Equipment
PART NUMBER
QTY
Fuel Sender Lock Nut Wrench Set*
09808-14031-KIT
1
*Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2021 Toyota Motor Sales, USA
T-SB-0008-22
February 8, 2022
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Vehicle Refueling Performance
Diagnostic Procedure
1. Confirm the customer has refueled the vehicle just BEFORE the inspection.
2. Confirm the condition exists.
Does the vehicle exhibit one or more of the following conditions?



The fuel gauge displays less than full when the fuel nozzle automatically clicks OFF.
The total amount of fuel dispensed while refueling is less than expected when the fuel
nozzle automatically clicks OFF.
The Low Fuel warning light illuminates sooner than expected.

YES — Continue to step 3.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
3. Connect the vehicle to Techstream.
4. Using Techstream, check the fuel input reading by using the combination meter data list.
Is the fuel input level less than 14.9 gallons?

YES — Continue to step 5.

NO — Go to step 7.
5. Take the vehicle to a gas station and refuel the vehicle with the trigger fully depressed until
the fuel nozzle automatically clicks OFF.
6. Using Techstream, check the fuel input reading by using the combination meter data list.
Is the fuel input level less than 14.9 gallons?

YES — Go to the Fuel Sender Gauge, Fuel Gauge Bracket, and Fuel Tank
Replacement section.

NO — Continue to step 7.
7. Does the customer complaint include the refueling amount being less than expected?

YES — Continue to step 8.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
8. Drain 11.5 gallons of fuel into an approved measurable container using the Techstream Fuel
Pump Active Test, which can be found by entering the following menus:
Engine – Active Test – Fuel Pump.
© 2021 Toyota Motor Sales, USA
T-SB-0008-22
February 8, 2022
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Vehicle Refueling Performance
Diagnostic Procedure (continued)
9. Follow the procedure below to perform a meter reset.
NOTE
Ensure the vehicle is on level ground BEFORE performing meter reset.
A. Use the odometer or trip button to change the meter display to odometer.
B. Turn the vehicle OFF.
C. Hold the odometer or trip button and turn the ignition to the IG-ON position
(NOT engine ON).
D. Continue holding the odometer or trip button for approximately five seconds.
The odometer mileage will flash to confirm the reset was successful.
E. Is the Low Fuel warning light illuminated?

YES — Continue to the Fuel Sender Gauge, Fuel Gauge Bracket, and Fuel Tank
Replacement section.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
NOTE
If this bulletin does NOT apply, refuel the vehicle with the drained fuel AFTER the diagnosis
is complete.
Fuel Sender Gauge, Fuel Gauge Bracket, and Fuel Tank Replacement
If a repair is necessary, the fuel sender gauge, fuel gauge bracket, AND fuel tank assembly
MUST be replaced.
NOTICE
 Do NOT damage the wire harness.
 Do NOT damage the cam lock retainers.
 When disengaging each wire harness from the clamp, disengage one wire at a time.
© 2021 Toyota Motor Sales, USA
T-SB-0008-22
February 8, 2022
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Vehicle Refueling Performance
Fuel Sender Gauge, Fuel Gauge Bracket, and Fuel Tank Replacement (continued)
1. Remove the fuel tank.
Refer to TIS, applicable model and model year Repair Manual:

2020 – 2021 Highlander HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Tank: Removal”
2. Replace the fuel sender gauge and fuel gauge bracket.
A. Remove the fuel sender gauge and fuel gauge bracket.
Refer to TIS, applicable model and model year Repair Manual:

2020 – 2021 Highlander HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Sender Gauge
Assembly: Removal”
B. Install the NEW fuel sender gauge and fuel gauge bracket onto the NEW fuel tank.
Refer to TIS, applicable model and model year Repair Manual:

2020 – 2021 Highlander HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Sender Gauge
Assembly: Installation”
3. Install the NEW fuel tank.
Refer to TIS, applicable model and model year Repair Manual:

2020 – 2021 Highlander HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Tank: Installation”
4. Put any drained fuel back into the vehicle and take the vehicle to a gas station to refuel with
the trigger fully depressed until the nozzle automatically clicks off.
5. Confirm the condition no longer exists.
© 2021 Toyota Motor Sales, USA