® TOYOTA
T-SB-0159-11

Rev2

October 14, 2011

Technical Service Bulletin

Rust Stain Below Outside Door Handle
Service
Category

Vehicle Exterior

Section

Door/Hatch

Market

USA

Toyota Supports ~
ASE Certification ~

Applicability
YEAR(S)

MODEL(S)

2008 - 2012

Highlander, Highlander

ADDITIONAL INFORMATION

HV
REVISION NOTICE
August 29, 2012 Rev2:
• The title has been updated.
• Applicability has been updated to include 2012 model year vehicles.
• The Introduction has been updated.
November 30, 2011 Rev1 :
• The Installation Procedure has 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 rust stains develop below one or more of the exterior door handles as shown in Figure 1.
An improved door handle nut has been developed to address this condition.

© 2012 Toyota Motor Sales, USA

Page 1 of 20

l

@TOYOTA

Rev2

T-SB-0159-11

Page 2 of 20

October 14, 2011

Rust Stain Below Outside Door Handle

Introduction (Continued)
Figure 1. Rust Stain Location Example

Production Change Information

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

ENGINE

PRODUCTION CHANGE EFFECTIVE VIN

5TDZK3EH#CS057287
2GR-FE

Highlander

5TDYK3EH#CS057291
5TDBK3EH#CS107940
5TDDK3EH#CS 107939

1AR-FE

5TDZA3EH#CS020084

Warranty Information
OP CODE

DESCRIPTION

TIME

OFP

T1

T2

BD9091

R & R Door Handle Nut (All Doors)

1.0

90179-05118

67

17

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.

© 2012 Toyota Motor Sales, USA

@TOYOTA

T-SB-0159-11

Rev2

Page 3 of 20

October 14, 2011

Rust Stain Below Outside Door Handle

Parts Information
PREVIOUS PART
NUMBER

CURRENT PART
NUMBER

PART NAME

PART IDENTIFICATION

QTY

90179-05118

Same

Nut

Glossy Silver

4 (1 per door handle)

Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)

Plastic Pry Tool Set*

PART NUMBER

QTY

00002-06000-01

1

REQUIRED TOOLS & MATERIAL

QTY

Razor Blade

1

Torx (T30) Socket Wrench

1

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
* Essential SST.

Service Bulletin Overview

This bulletin will instruct you to replace the Door Handle nuts on all 4 doors. The bulletin has been
divided into 2 sections, refer to page 3 (below) for the Front Door repair procedure and page 13 for
the Rear Door repair procedure. Any rust stain(s) should be cleaned after disassembly and prior
to reassembly.
Repair Procedure
Front Door Outside Handle Removal Procedure
NOTE
Perform the same procedure for the left and right front door handles.

© 201 2 Toyota Motor Sales, USA

@TOYOTA

T-SB-0159-11

Rev2

October 14, 2011

Page 4 of 20

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

1. Remove the front door lower frame bracket
garnish by disengaging the claw and clip.

Figure 2.

,I

c1;,

2

2. Remove the front door inside handle bezel plug
by using the plastic pry tool and disengaging the
3 claws.

Claw

Figure 3.
--------------~

1

© 2012 Toyota Motor Sales, USA

I

Claw

@TOYOTA

T-SB-0159-11

Rev2

October 14, 2011

Page 5 of 20

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

3. Remove the front door armrest upper base panel.
A. Using a plastic pry tool , disengage the 7 claws
and clip, and remove the front armrest upper
base panel.

Figure 4.
~--------------~

/'. : '1'

.... .... '-.!/

1
2

B. Disconnect the window control switch .

I

CUp
Claw

Figure 5.

© 2012 Toyota Motor Sales, USA

@TOYOTA

T-58-0159-11

Rev2

October 14, 2011

Page 6 of 20

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

4. Remove the assist grip cover by using the plastic
pry tool and disengaging the 4 claws.

Figure 6.

.-----------------..

1

5. Remove the courtesy light assembly.

I

Claw

Figure 7.

A. Using a plastic pry tool, disengage the claw
and remove the courtesy light assembly.
B. Disconnect the connector.

1

© 2012 Toyota Motor Sales, USA

I

Claw

@TOYOTA

T-SB-0159-11

Rev2

October 14, 2011

Page 7 of 20

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

6. Remove the front door trim board sub-assembly.
A. Remove the 3 screws.

Figure

s.

B. Using a plastic pry tool, disengage the 9 clips.

Figure 9.

NOTICE
Carefully remove the inner door panel
by lifting the panel rather than pulling
to prevent damage to inner belt molding
weather strip. Damage may occur if the
panel is not properly removed.

:~~ : @

1
2

I

Cl•w

Clip

C. Disengage the 5 claws and separate the front door trim board sub-assembly from the front
door inner glass weather-strip.

© 2012 Toyota Motor Sales, USA

@TOYOTA

Rev2

T-SB-0159-11

October 14, 2011

Page 8 of 20

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

D. Disengage the 2 clamps.

Figure 10.

1

I

Clamp

E. Disconnect the front door lock remote control cable and front door inside locking cable .
7. Disconnect the front door latch connector.

Figure 11.

© 2012 Toyota Motor Sales, USA

@TOYOTA

T-SB-0159-11

Rev2

October 14, 2011

Rust Stain Below Outside Door Handle

Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)

8. Peel back the corner of the moisture barrier.
HINT

Use a razor blade between butyl tape and moisture barrier.
Figure 12.

© 2012 Toyota Motor Sales, USA

Page 9 of 20

@TOYOTA

Rev2

T-SB-0159-11