CG) TOYOTA

T-SB-0091-12 Rev1 June 21, 2012 Technical Service Bulletin

Power Back Door Does Not Close Properly

Service ;
Category Vehicle Exterior

Toyota Supports pts
ASE Certification fc=EE

Section Door/Hatch Market USA
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2008 - 2012 Highlander, Highlander WMi(s}: 57D, JTE
HV

REVISION NOTICE
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.

© 2012 Toyota Motor Sales, USA Page 1 of 7
CPTOYOTA T-SB-0091-12 Revi June 21, 2012 Page 2 of 7

Power Back Door Does Not Close Properly

Production Change Information
This butletin applies to:
+ All 2008 — 2010 CBU built (WMI = JTE) non-hybrid Highlander vehicles.
* Vehicles produced BEFORE the Production Change Effective VINs shown below.

ENGINE DRIVE TYPE GRADE PRODUCTION CHANGE EFFECTIVE VIN
Base/SE 5TDZK3EH#CS077863
6 Cyl ew Limited STDYK3EH#CS077863
Base/SE 5TDBK3EH#CS 152419
aw Limited STDDK3EH#CS 152419
4 Cyl 2WD Base/SE STDZA3EH#CS027 153
ny hae Base JTEBC3EH#C2009730
Limited JTEDC3EH#C2009729

Warranty Information

OP CODE DESCRIPTION TIME OFP T1 T2
68810-48040
68810-48041

BD1122 | Inspection of Rear Hinges, Match Assembly, | 95 68810-48090 | 9A | 13
y 68810-0E070
68810-0E071

* 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.

© 2012 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0091-12 Revt June 21, 2012 Page 3 of 7

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.
PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME arty
68810-48040
68810-48041 Hinge Assy, Back Door, RH
68810-0E070 68810-0E 120 (Pad Thickness = 2 mm) 1
§8810-0E071
68820-48030
68820-48031 Hinge Assy, Back Door, LH
68820-0E060 68820-0E090 (Pad Thickness = 2 mm) '
68820-0E061
67005-48430
§7005-0E230 67005-0E232 Panel Sub-Assy, Back Door (PBD) 1
67005-0E231
Motor Unit, Back Door
85007-09001 85007-09002 (Includes Upper Rod and Stud) 1
_ Back Door Upper Rod
59356-48010 (Includes Lift Arm Stud) 1
a 68961-23010 Lift Arm Stud 4
a 90080-11194" Bolt, w/Washer* 4

* Non-reusable part.

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER ary
TIS Techstream**
or TSPKG1
Techstream Lite ADE or 1
TSLITEDLRO1
NOTE: Software version 7.20.041 or later is required.

** Essential SST.

NOTE
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.

REQUIRED MATERIAL QUANTITY
Feeler Gauge As Needed

© 2012 Toyota Motor Sales, USA

CP TOYOTA T-SB-0091-12 Revi June 21, 2012 Page 4 of 7

Power Back Door Does Not Close Properly

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 Pane! Sub-assembly is

required. Proceed to step 2.

if a gap is not found, STOP — this bulletin does NOT apply.
Figure 1.

| 1 | Gap Location

© 2012 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0091-12 Rev1 June 21, 2012 Page 5 of 7

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.

© 2012 Toyota Motor Sales, USA
CP) TOYOTA T-SB-0091-12 Rev4 June 21, 2012 Page 6 of 7

Power Back Door Does Not Close Properly

Repair Procedure

4. 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.

Remove 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 mode! and model year Repair
Manual and the following manuals:

¢ Toyota Fundamental Body Repair Procedures Manual (Pub. No. BRMO002E), available from
the Materials Distribution Center (MDC) through Dealer Daily — Dealer Support Materials
Orders

* Toyota Collision Repair Manuals:
* Toyota 2008-2013 Highlander Collision Repair Manual (BMO6J0U)
* Toyota 2008-2013 Highlander HV Collision Repair Manual (BM07VO0U)

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.

© 2012 Toyota Motor Sales, USA
CG) TOYOTA T-SB-0091-12 Rev1 June 21, 2012 Page 7 of 7

Power Back Door Does Not Close Properly

Repair Procedure (Continued)

Figure 4,

2. Initialize the Power Back Door system.
Refer to TIS, applicable mode! and model year Repair Manual:
* 2008 / 2009 / 2010 / 2011 / 2012 Highlander:

Vehicle Exterior — Door/Hatch - “Engine Hood / Door: Power Back Door System:
Initialization”

* 2008 / 2009 / 2010 / 2011 / 2012 Highlander HV:

Vehicle Exterior — Door/Hatch - “Engine Hood / Door: Power Back Door System:
Initialization”

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

© 2012 Toyota Motor Sales, USA