T-SB-0023-16 March 25, 2016 CG) TOYOTA

Technical Service Bulletin

Power Back Door Inoperative

Service
Category Vehicle Exterior
Toycta Supports
Section — Door/Hatch Market USA ASE Certification
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2014 - 2015 Highlander, Highlander HV = WMIs): STD
VDS(s): BCRFH, BKRFH, DCRFH, DKRFH,
JCRFH, JKRFH, KKRFH, YKRFH, ZKRFH
Plant Code(s): S
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0027-15.
e The entire bulletin has been updated.
Service Bulietin No. T-SB-0027-15. is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
Introduction

Some 2014 ~ 2015 model year Highlander and Highlander HV vehicles may exhibit a condition in
which the Power Back Door is inoperative or stops during operation. In some cases this condition
may be associated with cold weather. Follow the Repair Procedure in this bulletin to address

this condition.

© 2016 Toyota Motor Sales, USA Page 1 of7

TOYOTA _ T-SB-0023-16 March 25, 2016 Page 2 of 7

Power Back Door Inoperative

Production Change Information

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

shown below.
MODEL PLANT DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN

STDYKRFH#FS118557

2wD STDKKRFH#FS118557

Highlander STDZKRFH#FS118557

STDDKRFH#FS221250

TMM! 4wD STDJKRFH#FS22 1250

S5TDBKRFH#FS221250

STDDCRFH#FS013629

Highlander HV HV STDJCRFH#FS013629

STDBCRFH#FS013629

Warranty Information

OP CODE DESCRIPTION TIME OFP m1 | 12

68910-09020
68910-09021
68910-09030

R&R Unit Assy Set, Power Back Door, 68910-09031

BD1600 RH&LH 06 68920-09020 QA] 14
68920-09021
68920-09030
68920-09031
BD1600A R & R Computer, Mutiplex Network Door 0.5 89222-0E080 9A | 71
APPLICABLE WARRANTY

¢ This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 35 months
or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

e Warranty application is limited to occurrence of the specified condition described in
this bulletin.

© 2016 Toyota Motor Sales, USA

@TOYOTA T-SB-0023-16 March 25, 2016 Page 3 of 7
Power Back Door Inoperative
Parts Information
NOTE
There is NO Power Back Door Unit Assembly service part number change specific to
this countermeasure.
PART NUMBER PART NAME SPEC ary
68910-09021 or 68910-09022 Unit Assy Set, Power Back Door, RH Without 1
68920-09021 or 68910-09051" Unit Assy Set, Power Back Door, LH Subwoofer 1
68910-09031 or 68910-09040 Unit Assy Set, Power Back Door, RH With 1
68920-09031 or 68910-09052* Unit Assy Set, Power Back Door, LH Subwoofer 1
PREVIOUS NEW e mA fl
‘omputer, Mutiplex Network Dov
89222-0£080 | _89222-0E081 ° a er
*Note usual 5 digit P/N supersession from 68920 to 68910 on Unit Assy Set, Power Back Door, LH
Required Tools & Equipment
SPECIAL SERVICETOOLS (SST) PART NUMBER ary

Plastic Pry Tool Kit"

90002-06020-01

* Essential SST.

NOTE

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

Repair Procedure

1. Before proceeding with diagnosis, check the following:
A. Confirm the Power Back Door Main Switch (located in the glovebox) is turned on.

B. Set the power back door opening adjustment to position 5 (maximum opening position).

Refer to the Technical Information System (TIS), applicable model and model year

Repair Manual:

e $2014 / 2015 Highlander:
Vehicle Exterior — Door/Hatch — “Door/Hatch: Power Back Door System:
Customize Parameters”

© 2014 / 2015 Highlander HV:
Vehicle Exterior - Door/Hatch ~ “Door/Hatch: Power Back Door System:
Customize Parameters”

© 2016 Toyota Motor Sales, USA

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Power Back Door Inoperative

Repair Procedure (Continued)
C. Confirm hatch alignment and adjust or repair if necessary.
Referto TIS, applicable model and model year Repair Manual:
« 2014/2015 Highlander:
Vehicle Exterior — Door/Hatch — “Door/Hatch: Back Door: Adjustment”

© 2014/2015 Highlander HV:
Vehicle Exterior — Door/Hatch — “Door/Hatch: Back Door: Adjustment”

D. Confirm touch sensors are undamaged and operating normally

2. Operate the Power Back Door and attempt to duplicate the condition.

NOTE

Some failure modes occur only when the ambient temperature is below freezing. if the
customer experienced the condition in cold weather, cold soak the vehicle outside
overnight, then perform diagnosis in steps 2 — 4 (if required) before warming the vehicle
in the shop.

e If the PBD begins to open or close, then stops, proceed to step 5.

e If the PBD is inoperative (no movement in the closing direction, no movement
beyond latch release in the opening direction), proceed to step 3.

3. Turn off the Power Back Door system using the main switch lacated in the glove
compartment and attempt to operate the back door manually.

© If the door cannot be opened or closed manually, or if the force required to manually
operate the door is abnormally high, proceed to step 5.

«If manual operating effort is normal, and the ambient temperature was below
freezing when the condition was duplicated, proceed to step 4.

e If manua! operating effort is normal, and the ambient temperature was above
freezing when the condition was duplicated, STOP. This bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.

NOTE

The force required for manual operation may be higher in cold temperatures. If
necessary, a similar vehicle can be used for comparison.

© 2016 Toyota Motor Sales, USA

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Power Back Door Inoperative

Repair Procedure (Continued)

4. Turn ON the Power Back Door system using the main switch located in the glove
compartment. Remove the back door trim panel and use a heat gun to warm the Door
Computer (Computer, Multiplex Network Door) for 2 - 3 minutes, then attempt to operate
the Power Back Door.

« If normal operation is restored, replace the Door Computer and proceed to step 7.

¢ If there is no change to the condition, STOP. This bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.

Refer to TIS, applicable model and model year Repair Manual:

e §=2014 / 2015 Highlander:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Back Door Closer ECU: Removal”

© 2014/2015 Highlander HV:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Back Door Closer ECU: Removal”

© $2014 / 2015 Highlander:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Back Door Closer
ECU: Installation”

* 2014/2015 Highlander HV:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Back Door Closer
ECU: Installation”

5. Remove and replace the LH and RH power back door actuators (Unit Assy Set, Power
Back Door). Refer to TIS, applicable model and model year Repair Manual:

« =2014 / 2015 Highlander:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Power Back Door Drive
Unit: Removal”

e §=2014 / 2015 Highlander HV:
Vehicle Exterior — Door/Hatch — “Door/Hatch: Power Back Door Drive
Unit: Removal”

© 2014/2015 Highlander:
Vehicle Exterior - Door/Hatch — “Door/Hatch: Power Back Door Drive Unit:
Installation”

e 2014/2015 Highlander HV:
Vehicle Exterior ~ Door/Hatch — “Door/Hatch: Power Back Door Drive Unit:
Installation”

© 2016 Toyota Motor Sales, USA

CP TOYOTA T-SB-0023-16 March 25, 2016 Page 6 of 7

Power Back Door Inoperative

Repair Procedure (Continued)

6. After installing the new Power Back Door actuators, confirm that the ball and socket joints
(2 LH and 2 RH) are properly seated, and have approximately 1 mm of free-play as
indicated in Figure 1.

To check for free-play: first push, then pull, then push again on the power back door
actuator unit near each socket.

e If free-play is present, continue to step 7.
© If there is NO free-play as shown in Figure 2, the ball mount is not fully seated in
the socket.

Figure 4. Expected Free-Play Condition Figure 2. No Free-Play Condition.

4 1mm Free-Play: Ball Mount is Fully Seated in 2 No Free-Play: Ball Mount is Not Fully Seated in
the Socket the Socket
NOTICE

e Ifthe ball mount is not fully seated in the socket mount separation may occur, which
may cause damage to the vehicle.

e Attempt to seat the joint by pushing on the actuator near the socket. If free play cannot
be achieved, replace the actuator and ball mounts with another new service part.

© 2016 Toyota Motor Sales, USA

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Power Back Door inoperative

Repair Procedure (Continued)

7. Perform the Power Back Door initialization procedure.

Refer to TIS, applicable model and model year Repair Manual:
© 2014/2015 Highlander:
Vehicle Exterior — Door/Hatch — “Daor/Hatch: Power Back Door
System: Initialization”
e 2014/2015 Highlander HV:
Vehicle Exterior — Door/Hatch — “Door/Hatch: Power Back Door
System: Initialization”

8. Confirm normal Power Back Door operation.

Refer to TIS, applicable model and model year Repair Manual:
« 2014 / 2015 Highlander:
Vehicle Exterior — Door/Hatch - “Door/Hatch: Power Back Door System:
Operation Check”
e 2014 / 2015 Highlander HV:
Vehicle Exterior - Door/Hatch - “Door/Hatch: Power Back Door System:
Operation Check”

© 2016 Toyota Motor Sales, USA