T-SB-0159-11

® 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
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@TOYOTA
Rev2
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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
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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
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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
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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
October 14, 2011
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Rust Stain Below Outside Door Handle
Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)
9. Remove the front door outside handle cover (for driver side).
A. Remove the hole plug.
Figure 13.
\
B. Using a Torx socket (T30), loosen the screw and remove the front door outside handle
cover and the door lock key cylinder as a unit.
Torque: 4.0 N*m (41 kgf*cm, 35 in*lbf)
HINT
The screw cannot be removed because it is integrated into the front door outside handle
frame sub-assembly.
C. Using a plastic pry tool, disengage the 2 claws
and remove the front door outside handle
cover.
Figure 14.
---------------~
. ' .·©·.
·. -~
.. #
1
© 2012 Toyota Motor Sales, USA
I
Claw
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
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Rust Stain Below Outside Door Handle
Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)
10. Remove the front door outside handle cover (for passenger side).
Figure 15.
A. Remove the hole plug.
I
B. Using a Torx socket (T30) , loosen the screw and remove the front door outside handle
cover and the door lock key cylinder as a unit.
HINT
The screw cannot be removed because it is integrated into the front door outside handle
frame sub-assembly.
11. Remove the front door outside handle assembly
(w/o Smart Key System) by removing the front
door outside handle assembly as shown.
Figure 16.
~--------------~
© 2012 Toyota Motor Sales, USA
@TOYOTA
Rev2
T-SB-0159-11
October 14, 2011
Rust Stain Below Outside Door Handle
Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)
12. Remove the front door outside handle assembly (w/Smart Key System).
A. Disconnect the connector.
Figure 17.
HINT
Place a small pick under the connector tab to release.
B. Remove the front door outside handle
assembly as shown.
Figure 18.
© 2012 Toyota Motor Sales, USA
Page 12 of 20
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
Rust Stain Below Outside Door Handle
Repair Procedure
Front Door Outside Handle Removal Procedure (Continued)
13. Remove the front door outside handle pad by
disengaging the 3 claws.
Figure 19.
1
14. Remove the forward front door outside handle
Torx screw by using a Torx socket (T30) and
removing the screw.
I
Claw
Figure 20. Remove Torx Screw
© 2012 Toyota Motor Sales, USA
Page 13 of 20
®TOYOTA
Rev2
T-SB-0159-11
October 14, 2011
Page 14 of 20
Rust Stain Below Outside Door Handle
Repair Procedure (Continued)
Rear Door Outside Handle Removal Procedure
HINT
Perform the same procedure for the left and right rear door handles.
1. Remove the rear door inside handle bezel plug
by using a plastic pry tool and disengaging the
3 claws.
Figure 21 .
1
I
Claw
2. Remove the rear door armrest upper base panel.
A. Using a plastic pry tool , disengage the 6 claws
and 2 clips.
Figure 22.
~--------------~
B. Disconnect the connector.
© 2012 Toyota Motor Sales, USA
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
Page 15 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
3. Remove the rear power window regulator switch
assembly by disengaging the 2 claws.
Figure 23.
.------------------.
.-•.
... 0·
'
1
4. Remove the door assist grip cover by using a
plastic pry tool and disengaging the 4 claws.
I
Claw
Figure 24.
1
© 2012 Toyota Motor Sales, USA
I
Claw
I •
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
Page 16 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
5. Remove the door trim board sub-assembly.
Figure 25.
A. Remove the 3 screws.
B. Using a plastic pry tool, disengage the 9 clips.
C. Disengage the 5 claws and separate the rear
door trim board sub-assembly from the rear
door inner glass weatherstrip.
Figure 26.
.--------------------.
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
© 2012 Toyota Motor Sales, USA
I
Cl•w
Clip
@TOYOTA
T-58-0159-11
Rev2
October 14, 2011
Page 17 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
D. Disengage the 2 clamps.
Figure 27 .
1
I
Clamp
E. Disconnect the front door lock remote control cable and rear door inside locking cable.
6. Disconnect the rear door latch connector and peel back the upper corner of the moisture barrier.
HINT
Use a razor blade between butyl tape and moisture barrier.
Figure 28.
© 2012 Toyota Motor Sales, USA
@TOYOTA
T-58-0159-11
Rev2
October 14, 2011
Page 18 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
7. Remove the rear door lock assembly.
A. Using the Torx socket (T30), remove the 3
screws.
Figure 29 .
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
B. Move the rear door lock assembly downward and pull the release plate out of the rear door
outside handle frame.
8. Remove the rear door outside handle cover.
A. Using a Torx socket wrench (T30), loosen the
screw.
Figure 30.
Torque: 4.0 N*m (41 kgf*cm, 35 in*lbf)
HINT
The screw cannot be removed because it is
integrated into the rear door outside handle
frame sub-assembly.
© 2012 Toyota Motor Sales, USA
II
,
>
W
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
Page 19 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
B. Disengage the claw and remove the rear door
outside handle cover.
Figure 31.
.--------------------.
r.'11
•.-•
..., _, •.. \.!.I
1
9. Remove the rear door outside handle assembly
as shown .
I
Claw
Figure 32.
.--------------------.
© 2012 Toyota Motor Sales, USA
@TOYOTA
T-SB-0159-11
Rev2
October 14, 2011
Page 20 of 20
Rust Stain Below Outside Door Handle
Repair Procedure
Rear Door Outside Handle Removal Procedure (Continued)
10. Remove the rear door outside handle pad by
disengaging the 3 claws.
Figure 33.
1
11. Remove the forward rear door outside handle Torx
screw by using a Torx socket (T30) as shown.
I
Claw
Figure 34. Remove Torx Screw
Installation Procedure
1. Clean the area around the door handles to remove any rust staining by using a micro finishing
compound. If the rust cannot be removed by using adequate micro finishing compound , further
refinishing techniques may need to be used such as a rubbing compound .
2. Install the new nut, re-using the original Torx screw removed previously, and then reassemble in
reverse order.
Torque: 4.0 N*m (42 kgf*cm, 35 in*lbf)
3. Check operation of inner and outer door handles.
© 2012 Toyota Motor Sales, USA