Mil On With DTCS P0087 And/Or P107A-2A At High Altitude And With High Temperatures (T-SB-0049-21 REV1)

WARNING: This page is about the Highlander Hybrid LE, 2.5L Eng VIN A, which is a different variant/trim than selected.

Publication date: 2022-12-09
Reference number: T-SB-0049-21 REV1
Supersedes refnos: T-SB-0049-21

MIL ON WITH DTCS P0087 AND/OR P107A-2A AT HIGH ALTITUDE AND WITH HIGH TEMPERATURES

TECHNICAL SERVICE BULLETIN

Reference Number(s): T-SB-0049-21 Rev1, Date of Issue: December 09, 2022

TOYOTA:	2020 - 2022 Highlander, Highlander HV; 2021 - 2022 Sienna HV
SERVICE CATEGORY:	Engine/Hybrid System
SECTION:	Fuel System
MARKET:	USA
COPYRIGHT:	© 2022 Toyota, USA License Agreement TMS1002

Superceded Bulletin(s): T-SB-0049-21, Date of Issue: June 25, 2021

APPLICABILITY

YEAR(S)	MODEL(S)	ADDITIONAL INFORMATION
2020 - 2022	Highlander, Highlander HV
2021 - 2022	Sienna HV

REVISION NOTICE

December 09, 2022 Rev1:

Applicability has been updated to include 2022 model year Highlander, Highlander Hybrid, and Sienna Hybrid vehicles.
The Production Change Information, Parts Information, and Calibration Information sections have been updated.

Any previous printed versions of this bulletin should be discarded.

INTRODUCTION

Some 2020 - 2022 Highlander and Highlander Hybrid and 2021 - 2022 Sienna Hybrid vehicles may exhibit a MIL ON condition with Diagnostic Trouble Codes (DTCs) P0087 (Fuel Rail/System Pressure - Too Low) and/or P107A2A (Fuel Rail Pressure Sensor (Low) Signal Stuck in Range) present. This condition may occur when the vehicle is operated at high altitude and high temperature; typically, above 3,300 feet (1,000 meters) and ambient temperature above 85°F (30°C). The Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM) logic has been modified to reduce the possibility of this condition occurring. Follow the Repair Procedure in this bulletin to address this condition.

PRODUCTION CHANGE INFORMATION

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown below.

PRODUCTION CHANGE INFORMATION

MODEL	PLANT	PRODUCTION CHANGE EFFECTIVE VIN
Highlander	TMMI (West)	5TDYZRAH#N127216 5TDFZRAH#N127216 5TDHZRAH#N127216 5TDGZRAH#N127216 5TDCZRAH#N127216 5TDZZRAH#N127216 5TDLZRAH#N127216 5TDJZRAH#N127216 5TDLZ3AH#N127216 5TDFZRBH#N229664 5TDDZRBH#N229664 5TDLZ3BH#N229664 5TDGZRBH#N229664 5TDHZRBH#N229664 5TDBZRBH#N229664 5TDCZRBH#N229664 5TDLZRBH#N229664 5TDJZRBH#N229664
Highlander	TMMI (East)	5TDYZRAH#N553137 5TDHZRAH#N553137 5TDGZRAH#N553137 5TDZZRAH#N553137 5TDCZRAH#N553137 5TDDZRBH#N582995 5TDHZRBH#N582995 5TDGZRBH#N582995 5TDCZRBH#N582995 5TDBZRBH#N582995
Highlander HV	TMMI (West)	5TDFARAH#N99159 5TDYARAH#N99159 5TDLA3AH#N99159 5TDGARAH#N99159 5TDAARAH#N99159 5TDHARAH#N99159 5TDZARAH#N99159 5TDEBRCH#N99159 5TDXBRCH#N99159 5TDFBRCH#N99159 5TDDBRCH#N99159 5TDLB3CH#N99159 5TDGBRCH#N99159 5TDHBRCH#N99159 5TDABRCH#N99159 5TDLC3CH#N99159 5TDBBRCH#N99159
Highlander HV	TMMI (East)	5TDYARAH#N516162 5TDAARAH#N516162 5TDGARAH#N516162 5TDHARAH#N516162 5TDZARAH#N516162 5TDDBRCH#N516162 5TDXBRCH#N516162 5TDHBRCH#N516162 5TDGBRCH#N516162 5TDABRCH#N516162 5TDBBRCH#N516162
Sienna HV	TMMI (East)	5TDGSKFC#NS68445 5TDZSKFC#NS68445 5TDESKFC#NS68445 5TDXSKFC#NS68445 5TDDSKFC#NS68445 5TDYSKFC#NS68445 5TDJSKFC#NS68445 5TDASKFC#NS68445 5TDBSKFC#NS68445 5TDKSKFC#NS68445 5TDZRKEC#NS68445 5TDERKEC#NS68445 5TDGRKEC#NS68445 5TDDRKEC#NS68445 5TDXRKEC#NS68445 5TDYRKEC#NS68445 5TDJRKEC#NS68445 5TDKRKEC#NS68445 5TDBRKEC#NS68445

WARRANTY INFORMATION

OP CODE

DESCRIPTION

TIME

OFP

800269

Reprogram Engine ECM (PCM)

0.7

89661-######⁽¹⁾

⁽¹⁾	Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired by searching for the parts in the Electronic Parts Catalog using the VIN filter.

APPLICABLE WARRANTY

This repair is covered under the Toyota Federal Warranty. This warranty is in effect for 96 months or 80,000 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.

PARTS INFORMATION

MODEL	PART NUMBER		PART NAME	QTY
MODEL	PREVIOUS	NEW	PART NAME	QTY
Highlander	89661-0EB63 89661-0EB64	89661-0EB65	Computer, Engine Control (ECM/PCM)	-
	89661-0EB72 89661-0EB73	89661-0EB74
	89661-0EB83 89661-0EB84	89661-0EB85
	89661-0EG01 89661-0EG02	89661-0EG03
	89661-0EG11 89661-0EG12	89661-0EG13
	89661-0EG21 89661-0EG22	89661-0EG23
	89661-0EK70	89661-0EK71
	89661-0EK90	89661-0EK91
Highlander HV	89661-0EC00-D 89661-0EC01	89661-0EC02
	89661-0EG30-A 89661-0EG31	89661-0EG32
	89661-0EE60	89661-0EE61
Sienna HV	89661-08650 89661-08651	89661-08652
Sienna HV	89661-08700	89661-08701
All	00451-00001-LBL		Authorized Modifications Labels	1

NOTE:

The ECM (PCM) should NOT be replaced as part of the Repair Procedure.
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through Dealer Daily - Parts - Dealer Support Materials Orders .

REQUIRED TOOLS & EQUIPMENT

REQUIRED EQUIPMENT

SUPPLIER

PART NUMBER

QTY

Techstream ADVI⁽¹⁾

ADE

TSADVUNIT

Techstream 2.0

TS2UNIT

Techstream Lite

TSLITEPDLR01

Techstream Lite (Green Cable)

TSLP2DLR01

⁽¹⁾	Essential SST.

NOTE:

Only ONE of the Techstream units listed above is required.
Software version 17.20.013 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.
Use Techstream or an approved J2534 interface to perform flash reprogramming updates.
Visit techinfo.toyota.com for more information regarding J2534 reprogramming.

PARTS INFORMATION

SPECIAL SERVICE TOOLS (SST)

PART NUMBER

QTY

Battery Diagnostic Tool⁽¹⁾

DCA-8000P T

⁽¹⁾	Essential SST.

NOTE: Additional SSTs may be ordered by calling 1-800-933-8335.

CALIBRATION INFORMATION

MODEL	MODEL YEAR	ENGINE	CALIBRATION ID
MODEL	MODEL YEAR	ENGINE	PREVIOUS	NEW
Highlander	2020	2GR-FKS	896630E62000 896630E62100 896630E62200 896630E62300 896630E62400	896630E62500
			896630E63000 896630E63100 896630E63200	896630E63300
			896630E64000 896630E64100 896630E64200 896630E64300 896630E64400	896630E64500
	2021		896630EB1000 896630EB1100 896630EB1200	896630EB1300
			896630E53000 896630E53100	896630E53200
			896630EB2000 896630EB2100 896630EB2200	896630EB2300
	2022		896630ED9000	896630ED9100
	2022		896630EE1000	896630EE1100
Highlander HV	2020	A25A-FXS	896630E66000 896630E66100	896630E66200
	2021		896630EB3000 896630EB3100	896630EB3200
	2022		896630EE4000	896630EE4100
Sienna HV	2021		896630857001 896630857101	896630857201
Sienna HV	2022		896630841000	896630841100

REPAIR PROCEDURE

Confirm the condition exists.
Using Techstream, check for the following stored DTCs:
- P0087 - Fuel Rail/System Pressure - Too Low
- P107A2A - Fuel Rail Pressure Sensor (Low) Signal Stuck in Range
Are ANY of the DTCs listed above present?
- YES - Continue to step 2.
- NO - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual
Confirm the freeze frame data for DTCs P0087 and/or P107A2A.
1. Is the ambient temperature above 85°F (30°C)?
  - YES - Continue to substep B.
  - NO - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
2. Is the atmospheric pressure at or below 12.7 psi gauge (-2 atm)?
  - YES - Continue to substep C.
  - NO - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
3. Confirm remaining fuel volume. Is the remaining fuel volume above 15%?
  - YES - Continue to step 3.
  - NO - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
Use Techstream to confirm if the ECM (PCM) calibration has been updated and check for the Authorized Modifications Label affixed to the vehicle in the locations shown below.
Is the calibration ID listed in Techstream and on the label the latest ECM (PCM) calibration?
- YES - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
- NO - Continue to step 4.
Flash reprogram the ECM (PCM).
NOTE:
- The battery diagnostic tool MUST be used in Power Supply Mode to maintain battery voltage at 13.5V while flash reprogramming the vehicle.
- For details on how to use the battery diagnostic station, refer to the DCA-8000 Instruction Manual located at TIS - Diagnostics - Tools & Equipment - Battery Diagnostics.
For 2020 - 2022 model year Highlander and Highlander Hybrid vehicles follow the procedures outlined in T-SB-0134-16 , Techstream ECU Flash Reprogramming Procedure, and flash the ECM (PCM) with the NEW calibration file update.

For 2021 - 2022 model year Sienna Hybrid vehicles follow the procedures outlined in T-SB-0107-20 , ECU Flash Reprogramming With Security Signature, and flash the ECM (PCM) with the NEW calibration file update.
Prepare and install the Authorized Modifications Label.
1. Using a permanent marker, enter the following information on the label:
  - ECM (PCM) part number [Refer to the PARTS INFORMATION section for the NEW PART NUMBER]
  - Calibration ID(s) [Refer to the CALIBRATION INFORMATION section for the NEW CALIBRATION ID]
  - Dealer Code
  - Repair Date
  - Change Authority [This bulletin number]
2. Install the Authorized Modifications Label onto the vehicle at the locations shown in Figures 1 and 2. The Authorized Modifications Label is available through the MDC, P/N 00451-00001-LBL.
Using Techstream, perform a Health Check to confirm that the NEW calibrations updated successfully.
Clear DTCs and confirm the condition is no longer present.