T-SB-0091-12 Service Bulletin/Repair Instructions

®TOYOTA

T-SB-0091-12
Rev2
Technical Service Bulletin
June 21, 2012
Power Back Door Does Not Close Properly

Service

Category
Vehicle Exterior
Section
Door/Hatch
Market
USA
Toyota Supports ~

ASE Certification. .
Applicability

YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2008 - 2012
Highlander, Highlander
WMl(s): 5TD, JTE
HV

REVISION NOTICE
July 18, 2013 Rev2:

• Production Change Information section has been updated.

October 22, 2012 Rev1:

• Production Change Information, Warranty Information, and Parts Information sections have

been updated.

Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2008 - 2012 model year Highlander and Highlander HV vehicles may exhibit a condition

where the Power Back Door does not close properly. The Back Door may get to the fully closed

position and then reverse to the open position. In cases where the Power Back Door does close,

a pop or clunk noise may also be heard when the back door latch reaches the striker during the

power close function. In some cases, Diagnostic Trouble Codes (DTCs) B2222 and/or U0230 may

be present. Use the following information to inspect the Power Back Door and address this condition .

NOTICE
The purpose of this Service Bulletin is to provide repair instructions for the Power Back Door. It

enhances the durability of the Power Back Door when operating using the Power Close function.

When the Power Close function is used, if objects or cargo are continually interfering with the

closure of the back door, damage to the back door and/or back door hinges may occur.

To minimize the possibility of damage occurring, before closing the Power Back Door, customers

should always confirm that objects in the cargo area will not impede or interfere with the closing

operation of the back door. Additionally, customers should not use any part of their body to

intentionally activate the Jam Protection function of the Power Back Door. Please see the Owner's

Manual for additional information on the Power Back Door Jam Protection function.
© 2013 Toyota Motor Sales, USA
Page 1 of 8
@ TOYOTA
T-SB-0091-12
Rev2
June 21, 2012
Page 2 of 8
Power Back Door Does Not Close Properly
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown

below.

DRIVE TYPE
GRADE
PRODUCTION CHANGE EFFECTIVE VIN
2WD
All
5TD#K3EH#CS088602
4WD
All
5TD#K3EH#CS 173141
4 Cyl
2WD
All
5TDZA3EH#CS030853
4WD
Base
JTEDC3EH#C2010777
HV
Limited
JTEDC3EH#C2010780
ENGINE
6 Cyl
Warranty Information

DESCRIPTION
OP CODE
801122
Inspection of Rear Hinges, Hatch Assembly,

& Door Motor Only*
TIME
OFP
T1
T2
0.5
68810-48040

68810-48041

68810-48090

68810-0E070

68810-0E071
9A
13
* Use typical body shop sublet type "ZZ" other to claim practice for claiming preparation, repair, sealing , and painting of the

rear hinges and back door panel assembly.
APPLICABLE WARRANTY
• This repair is covered under the Toyota Comprehensive 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.
© 2013 Toyota Motor Sales, USA
@TOYOTA
Rev2
T-SB-0091-12
June 21, 2012
Page 3 of 8
Power Back Door Does Not Close Properly
Parts Information

NOTE

Please review entire Inspection Procedure BEFORE ordering parts, all parts shown below may

NOT be necessary to correct this condition.

PART NUMBER

PART NAME
QTY
68810-0E120
Hinge Assy, Back Door, RH

(Pad Thickness = 2 mm)
1
68820-48030

68820-48031

68820-0E060

68820-0E061
68820-0E090
Hinge Assy, Back Door, LH

(Pad Thickness = 2 mm)
1
67005-48430

67005-48431

67005-0E230

67005-0E231
67005-0E232
Panel Sub-Assy, Back Door (PBD)
1
85007-09001
85007-09002
Motor Unit, Back Door

(Includes Upper Rod and Stud)
1
69356-48010
Back Door Upper Rod

(Includes Lift Arm Stud)
1
68961-23010
Lift Arm Stud
1
90080-11194*
Bolt, w/Washer*
4
PREVIOUS
NEW
68810-48040

68810-48041

68810-0E070

68810-0E071
* Non-reusable part.
Required Tools & Equipment

REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0**

TIS Techstream
PART NUMBER
QTY
TS2UNIT

ADE
Techstream Lite

** Essential SST.
© 2013 Toyota Motor Sales, USA
TSPKG1

TSLITEDLR01
1
@TOYOTA
T-SB-0091-12
Rev2
June 21, 2012
Page 4 of 8
Power Back Door Does Not Close Properly
Required Tools & Equipment (Continued)

NOTE

• Only ONE of the Techstream units listed above is required.

• Software version 8.10.021 or later is required.

• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at

1-800-368-6787.

REQUIRED MATERIAL
QUANTITY
Feeler Gauge
As Needed
Inspection Procedure
Inspect the Power Back Door Assembly.

1. Inspect the upper hinges for any gaps present by placing a 0.05 mm (0.002 in.) or greater

feeler gauge between the 2 bolts mounted to the back door as shown in Figure 1. If a gap

exists, replacement of both Back Door Hinges AND the Back Door Panel Sub-assembly is

required . Proceed to step 2.

If a gap is not found , STOP - this bulletin does NOT apply.

Figure 1.
1
I
Gap Location
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0091-12
Rev2
June 21, 2012
Page 5 of 8
Power Back Door Does Not Close Properly
Inspection Procedure (Continued)
2. Visually inspect the back door motor teeth for damage by opening the back door and manually

moving the door towards the half-closed position while observing the large gear teeth for damage,

as shown in Figure 2. If damage is found, replacement of the Back Door Motor Unit is required.

Figure 2.
3. Visually inspect the Back Door Upper Rod and Lift Arm Stud for bends or damage. If it is bent, or

damage is found, replacement is required.

Figure 3.
NOTE
The Back Door Upper Rod and Lift Arm

Stud are available as separate service

parts from the Back Door Motor Unit if

found damaged or bent.
1
Lift Arm Stud
2
Back Door Upper Rod
4. Proceed to Repair Procedure.
© 2013 Toyota Motor Sales, USA
I
@TovoTt

Power
T-SB-0091-12
Bae~
Rev2
June 21, 2012
Page 6 of 8
Door Does Not Close Properly
Repair Procedle

I
1. )Sublet vehicle repair of the back door and back door hinges refinishing to a body shop if

necessary. Repainting and repair of the back door and hinges should be done in accordance

\with Toyota's body repair recommendations.

IRemove and replace the back door, hinges, and lift arm/Power Back Door motor as needed
based off inspection procedures in this bulletin.

NOTE

Original centering bolts used for the hinge assemblies are NOT reusable. Substitute referenced

hardware in the Parts Information table (P/N 90080-11194).
Refer to the Technical Information System (TIS), applicable model and model year Repair

Manual and the following manuals:

• Toyota Fundamental Body Repair Procedures Manual (Pub. No. BRM002E), available from

the Materials Distribution Center (MDC) through Dealer Daily - Dealer Support Materials

O~ra

.

• Toyota Collision Repair Manuals:

•
Toyota 2008-2013 Highlander Collision Repair Manual (BM06JOU)
•
Toyota 2008-2013 Highlander HV Collision Repair Manual (BM07VOU)
© 2013 Toyota Motor Sales, USA
- --
I
·~·
@TOYOTA
T-SB-0091-12
Rev2
June 21, 2012
Page 7 of 8
Power Back Door Does Not Close Properly
Repair Procedure (Continued)

NOTE
To ensure correct installation of the back door struts, note the markings on the assembly

(Figure 4). The markings indicate on which side of the car the strut should be installed, and the

direction of the braces on the strut.

Figure 4.
© 2013 Toyota Motor Sales, USA
@TOYOTI

Power
T-SB--0091-12
Rev2
June 21, 2012
Page 8 of 8
Baer Door Does Not Close Properly
Repair Procedure (Continued)

!
2.1 Initialize the Power Back Door system.

I
i
Refer to TIS, applicable model and model year Repair Manual:
I,
• 2008 I 2009 I 2010 I 2011 I 2012 Highlander:

Vehicle Exterior - Door/Hatch - "Engine Hood I Door: Power Back Door System:

Initialization"

• 2008 I 2009 I 2010 I 2011 I 2012 Highlander HV:

Vehicle Exterior - Door/Hatch - "Engine Hood I Door: Power Back Door System:

Initialization"
3. \Confirm repair by opening and closing the back door in the power mode and ensuring proper

operation.

·

f
© 2013 Toyota Motor Sales, USA
-- 1-

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