HVAC Drain Hose Disconnected From HVAC Case And/Or Oil/Grease Odor From Vents (T-SB-0021-23 REV1)

Publication date: 2023-08-21
Reference number: T-SB-0021-23 REV1
Supersedes refnos: T-SB-0021-23

HVAC DRAIN HOSE DISCONNECTED FROM HVAC CASE AND/OR OIL/GREASE ODOR FROM VENTS

TECHNICAL SERVICE BULLETIN

Reference Number(s): T-SB-0021-23 Rev1, Date of Issue: August 21, 2023

TOYOTA:	2020 - 2022 Highlander, RAV4; 2022 Tundra
SERVICE CATEGORY:	Vehicle Interior
SECTION:	Heating/Air Conditioning
MARKET:	USA
COPYRIGHT:	© 2023 Toyota, USA License Agreement TMS1002

Superceded Bulletin(s): T-SB-0021-23, Date of Issue: May 11, 2023

APPLICABILITY

YEAR(S)	MODEL(S)	ADDITIONAL INFORMATION
2020 - 2022	Highlander, RAV4
2022	Tundra

REVISION NOTICE

August 21, 2023 Rev1:

The Parts Information section has been updated.

Any previous printed versions of this bulletin should be discarded.

INTRODUCTION

Some 2020 - 2022 model year Highlander and RAV4 vehicles, and 2022 model year Tundra vehicles equipped with a start/stop switch may exhibit water entry to the vehicle from the HVAC drain hose being disconnected from the air conditioning radiator assembly and/or a grease/oil odor emitting from the vents. This condition may be caused by paraffin wax leaking from the evaporator. Follow the repair procedure in this bulletin to address this condition.

PRODUCTION CHANGE INFORMATION

This bulletin applies to:

All 2020 model year RAV4 vehicles.
All 2021 model year RAV4 vehicles produced by Takaoka* and TMMC*.
All 2021 model year RAV4 vehicles produced by Shokki Nagakusa* BEFORE the Production Change Effective VIN shown below.
All 2022 model year RAV4 vehicles produced by Takaoka* and TMMC* BEFORE the Production Change Effective VINs shown below.
All 2020 - 2021 model year Highlander vehicles.
All 2022 model year Tundra and Highlander vehicles produced BEFORE the Production Change Effective VINs shown below.

PRODUCTION CHANGE INFORMATION

MODEL

MODEL YEAR

PLANT⁽¹⁾

DRIVETRAIN⁽²⁾

VIN

RAV4

2021

Shokki Nagakusa (D)

FWD

JTM#1RFV#MD084963

AWD

JTM#1RFV#MD084913

2022

Takaoka (J)

FWD

JTM#1RFV#NJ024345

AWD

JTM#1RFV#NJ040396

TMMC Cambridge (C)

2WD

2T3#1RFV#NC207902

AWD

2T3#1RFV#NC313526

TMMC Woodstock (W)

2WD

2T3#1RFV#NW230598

AWD

2T3#1RFV#NW317011

⁽¹⁾	The plant is determined by the 11th digit of the VIN: D = Shokki Nagakusa, J = Takaoka, C = TMMC Cambridge, and W = TMMC Woodstock.

⁽²⁾	The drivetrain is determined by the 4th digit of the VIN: C or W = FWD and A, B, F, G, R, or P = AWD.

PRODUCTION CHANGE INFORMATION

MODEL

MODEL YEAR

PLANT⁽¹⁾

LINE⁽²⁾

DRIVETRAIN

VIN

Highlander

2022

TMMI (S)

Line 1

2WD

5TD#ZRAH#NS112708

AWD

5TD#ZRBH#NS199947

Line 2

2WD

5TD#ZRAH#NS546859

AWD

5TD#ZRBH#NS571677

⁽¹⁾	The plant is determined by the 11th digit of the VIN: S = TMMI.

⁽²⁾	The line is determined by the 12th digit of the VIN: 0 - 4 = Line 1 and 5 - 9 = Line 2.

PRODUCTION CHANGE INFORMATION

MODEL

MODEL YEAR

PLANT⁽¹⁾

DRIVETRAIN

CAB

BED LENGTH

VIN

Tundra

2022

TMMTX (X)

2WD

Double Cab

6.5 ft.

5TF##5AA#NX007791

8.1 ft.

5TF##5CD#NX001184

Crew MAX

5.5 ft.

5TF##5AB#NX007791

6.5 ft.

5TF#A5BC#NX001595

4WD

Double Cab

6.5 ft.

5TF##5DA#NX024925

8.1 ft.

5TF##5GD#NX001416

Crew MAX

5.5 ft.

5TF##5DB#NX024925

6.5 ft.

5TF#A5EC#NX005221

⁽¹⁾	The plant is determined by the 11th digit of the VIN: X = TMMTX.

WARRANTY INFORMATION

OP CODE

MODEL

DESCRIPTION

TIME

OFP

883621

RAV4

R & R the Air Conditioner Radiator Assy & Drain Hose

5.4

87050-####⁽¹⁾

Highlander

5.1

Tundra

6.0

⁽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 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.

PARTS INFORMATION

PART NUMBER	PART NAME	QTY
870500R160	Radiator Assy, Air Conditioner	1
870500R161
870500R110
870500R120
870500E280
870500C210
870500C200
870500R320
885390R050	Hose, Drain Cooler	1
885390E100
885390C080

REQUIRED TOOLS & EQUIPMENT

REQUIRED TOOLS & MATERIAL	QTY
Robinair R1234YF A/C Machine	1

PARTS INFORMATION

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.
GTS+ software version 2023.03.001.02 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.

REPAIR PROCEDURE

Is the vehicle equipped with a start/stop switch?
NOTE: ALL 2022 model year Tundra vehicles are equipped with a start/stop switch.
- YES - Continue to step 2.
- NO - This bulletin does NOT apply. Continue diagnosis using the applicable
  Repair Manual.
Is the drain cooler hose detached from the air conditioning radiator assembly and/or a grease/oil odor emitting from the vents?
- YES - Continue to step 3.
- NO - This bulletin does NOT apply. Continue diagnosis using the applicable
  Repair Manual.
NOTE: If there is evidence of water intrusion or a musty smell is present in the vehicle interior, follow the procedures outlined in T-SB-0094-21 Odor Remediation After Water Intrusion, to remediate the odor and address this concern.
Remove the air conditioning radiator assembly and drain cooler hose.
Refer to TIS, applicable model and model year Repair Manual:
- 2020 - 2022 Highlander:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Front Air Conditioning Unit (for Gasoline Model): Removal"
- 2020 RAV4:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Air Conditioning Unit (for A25A-FKS): Removal"
- 2021 - 2022 RAV4:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Air Conditioning Unit (for A25A-FKS): Removal"
- 2022 Tundra:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Front Air Conditioning Unit: Removal"
Install the NEW air conditioning radiator assembly and drain cooler hose.
Refer to TIS, applicable model and model year Repair Manual:
- 2020 - 2022 Highlander:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Front Air Conditioning Unit (for Gasoline Model): Installation"
- 2020 RAV4:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Air Conditioning Unit (for A25A-FKS): Installation"
- 2021 - 2022 RAV4:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Air Conditioning Unit (for A25A-FKS): Installation"
- 2022 Tundra:
  Vehicle Interior - Heating/Air Conditioning - "Heating/Air Conditioning: Front Air Conditioning Unit: Installation"
Confirm the condition no longer exists.