Canada - Fuel System - Engine Compartment Ticking Noises

Bulletin
TSB2215R

Issue Date
2005-03-21

Market
Canada

Title
FUEL INJECTOR TICKING" NOISE

Component
ENGINE MECHANICAL

Models
'01 - '05 Highlander (V6)

TSB REVISION NOTICE:
- December 01, 2005: OPN has been changed under Warranty Information.
- June 30, 2005: A new section, "Component Identification," has been added; a note has been added to step 2 of the Repair Procedure, and two images clarified (Figures 2 and 6).
The previous TSB should be discarded.

INTRODUCTION:
Some customers with 2001 - 2005 model year Highlander vehicles with V6 engines may complain of a "ticking" noise from the engine compartment when the engine is idling. An updated fuel main tube has been made available, and a second fuel pressure pulsation damper has been added to improve this condition.

APPLICABLE VEHICLES:
- 2001 - 2005 model year Highlander vehicles equipped with V6 engines produced BEFORE the Production Change Effective VINs shown below.






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:






WARRANTY INFORMATION:






REQUIRED SSTs:






COMPONENT IDENTIFICATION:

REPAIR PROCEDURE:

CAUTION:
- Do not smoke or work near an open flame when working on the fuel system.
- Keep gasoline away from rubber or leather parts.
- Wear safety goggles while working with fuel system under pressure.
- Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
- Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.

1. Discharge fuel system pressure.






A. Remove Circuit Opening Relay from Relay Block No. 1 located to the left of the Instrument Panel Junction Block behind the left lower finish panel.
B. Start the engine. After the engine has stalled, turn the ignition switch OFF.
C. Reinstall the Circuit Opening Relay.
D. Disconnect negative (-) battery cable.

2. Disconnect fuel pipe sub assembly No. 1.






NOTE:
- Ensure that the removed bolt and washers are discarded.
- Refer to the "Component Identification" section to ensure the correct bolt and washers are removed and damper is installed.






A. Disconnect the fuel pipe clamp No. 1 from the connector.
B. Check if there is any dirt or mud on the pipe and around the connector before disconnecting the fuel line. Clean if necessary.






C. Disconnect the connector from the hose while pinching portion "A" with your fingers as shown in the illustration.
D. If the connector and pipe are stuck, pinch the fuel pipe, push and pull the connector by hand to disconnect them. Do not use any tools.
E. Drain the fuel that remains inside fuel pipe sub-assembly No. 1.
F. Place a tray under the vehicle or point of disconnection, if needed, to catch any fuel that may spill.






G. Protect the disconnected fuel lines from debris by covering with a vinyl or plastic bag.
H. Remove original pulsation damper from rear fuel rail.






I. Remove and discard remaining bolt holding fuel pipe sub-assembly No. 1 to front fuel rail.

3. Install the new Fuel Pipe Sub-assembly No. 1 onto the vehicle.
4. Install both the original pulsation damper and the new (additional) damper with new fuel pipe hose gaskets as shown, and torque to the following specifications.

Torque: 33 N-m (24 ft-lbf, 331 kgf-cm)

Check for fuel leaks.
A. Reconnect the negative battery terminal.
B. Connect the Toyota Diagnostic Tester.
C. Turn the ignition switch to the "ON" position (do NOT start engine).
D. Turn the Diagnostic Tester ON.
E. Select "1. DIAGNOSIS" on the Diagnostic Tester.
F. Select "2. ENHANCED"OBD II.
G. Select "3. ACTIVE TEST."
H. Select "FUEL PUMP/SPD."
I. Turn on the fuel pump with Active Test by pressing the right arrow on the Diagnostic Tester.
J. Check for fuel leaks.
K. Check and clear any DTCs that may have been set while performing the repair.

6. Once confirmed that no leaks are present, take vehicle on a test drive to ensure any air trapped in the pulsation dampers has been purged.
7. Repair is complete.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.