T-SB-0048-16

T-SB-0048-16
May 25, 2016
HVAC Servo Motor Noise
Service
Category
Vehicle Interior
Section
Heating/Air Conditioning
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2015
Highlander, Highlander HV
Introduction
Some 2015 model year Highlander and Highlander HV vehicles equipped with Dual Front Air
Conditioning Systems may exhibit an intermittent buzzing noise condition coming from the center
of the instrument panel during HVAC operation. The noise occurs during the operation of the LH
and RH air mix servo motors. The Repair Procedure in this bulletin has been developed to
address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
ENGINE
DRIVE
PRODUCTION CHANGE EFFECTIVE VIN
2GR-F
2WD
5TD#KRFH#FS111214
2GR-F
4WD
5TD#KRFH#FS208541
1AR-F
2WD
5TD#ARFH#FS016550
HYBRID
ALL
5TD#CRFH#FS013137
Highlander
Highlander HV
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
AC1600
R & R Servo Sub-Assy, Damper
1.2
87106-07120
91
43
APPLICABLE WARRANTY
This repair is covered under the Toyota Basic 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.
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Parts Information
PART NUMBER
PART NAME
QTY
87106-0E090
Servo Sub-Assy, Damper
1
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite
1
TSLITEPDLR01
* Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 11.10.034 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Repair Procedure
1. Slide both front seats to the rearward most position.
2. Disconnect cable from negative ( – ) battery terminal.
CAUTION
Wait at least 90 seconds after disconnecting the cable from the negative ( – ) battery terminal to
disable the SRS system.
NOTICE
After turning the ignition switch off, waiting time may be required before disconnecting the
cable from the negative ( – ) battery terminal. Therefore, make sure to read the disconnecting
the cable from the negative ( – ) battery terminal notice before proceeding.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2015 Highlander:
General – Introduction – “Introduction: Repair Instruction: Precaution”

2015 Highlander HV:
General – Introduction – “Introduction: Repair Instruction: Precaution”
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Repair Procedure (Continued)
3. Remove the front door scuff plate LH.
A. Disengage the 2 claws.
B. Disengage the 8 claws and 2 guides to
remove the front door scuff plate LH.
Figure 1.
4. Remove the cowl side trim sub-assembly LH.
A. Remove the clip.
Figure 2.
B. Disengage the claw and clip to remove
the cowl side trim sub-assembly LH.
5. Remove the front door opening trim weather strip LH to the extent that allows the removal of
the instrument panel finish panel end.
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Repair Procedure (Continued)
6. Remove the instrument panel finish panel
end LH by using a molding remover and
disengaging the 5 claws and 3 guides.
Figure 3.
7. Remove the No. 1 instrument panel under
cover sub-assembly.
Figure 4.
A. Remove the 2 screws.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
B. Disengage the claw, clip, and guide.
8. Disconnect the hood lock control lever
sub-assembly by disengaging the claw
and 2 guides.
Figure 5.
Figure 6.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
9. Remove the lower instrument panel finish
panel sub-assembly.
Figure 7.
A. Remove the bolt.
B. Disengage the 10 claws and 4 clips.
Figure 8.
C. Disconnect each connector to remove
the lower instrument panel finish panel
sub-assembly.
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Repair Procedure (Continued)
10. Remove the lower No. 1 instrument panel airbag assembly.
CAUTION
When storing the lower No. 1 instrument panel airbag assembly, keep the airbag
deployment side facing upward.
A. Check that the ignition switch is off.
B. Check that the cable is disconnected from the negative ( – ) battery terminal.
C. Remove the 4 bolts.
D. Disengage the 2 clamps and the 3 hooks
to separate the lower No. 1 instrument
panel airbag assembly.
Figure 9.
NOTICE
When separating the lower No. 1
instrument panel airbag assembly, do
NOT pull the airbag wire harness.
1
Hook
2
Clamp
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HVAC Servo Motor Noise
Repair Procedure (Continued)
E. Disengage the 2 claws and clamp to
disconnect the DLC3.
Figure 10.
1
DLC3
2
Protective Tape
3
Airbag Connector
4
Airbag Connector Lock
F. Using a screwdriver with its tip wrapped with protective tape, release the airbag
connector lock.
G. Disconnect the airbag connector to remove the lower No.1 instrument panel
airbag assembly.
NOTICE
When disconnecting any airbag connector, take care not to damage the airbag
wire harness.
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Repair Procedure (Continued)
11. Remove the No. 4 air duct sub-assembly.
A. Remove the bolt.
B. Disengage the 2 claws (use a screw driver
to gently lift and release the claws) and
guide to remove the No. 4 air duct
sub-assembly.
Figure 11.
Figure 12.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
12. Remove the driver side HVAC servo motor.
A. Disconnect the servo motor connector.
Figure 13.
B. Remove the 2 servo motor screws.
NOTE
Once the servo motor is removed, the
gear on the HVAC case will
drop down.
1
Servo motor connector
2
Servo motor screws
13. Install the NEW Driver Side HVAC servo motor.
A. Position the gear on the HVAC case to the initialized position.
NOTICE
The NEW servo motor is in the initialized position.
(1) Use your finger and line up the top of
the gear with the rib on the side of the
HVAC case.
Figure 14.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
(2) Hold the HVAC gear in the initialized
position by placing bubble wrap, foam,
paper, etc. (rolled-up bubble wrap
shown), between the inside of the
gear and the HVAC case.
Figure 15.
1
Packing material (bubble wrap, foam, paper, etc.)
(3) Install the NEW servo motor by aligning the key feature on the servo motor gear with
the corresponding key feature on the HVAC case gear.
Figure 16.
1
Figure 17.
Align servo motor and HVAC case gear
key features
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HVAC Servo Motor Noise
Repair Procedure (Continued)
(4) Reinstall the 2 servo motor screws.
(5) Reconnect the servo motor connector.
(6) Remove the material (bubble wrap, foam, paper, etc.) used to hold the HVAC case gear
in place.
B. Reinstall all the driver side trim panels in the reverse order of removal.
14. Disassemble the Passenger Side Trim Panel.
A. Remove the front door scuff plate RH.
(1) Disengage the 2 claws.
(2) Disengage the 8 claws and 2 guides
to remove the front door scuff
plate RH.
Figure 18.
B. Remove the cowl side trim
sub-assembly RH.
(1) Remove the clip.
Figure 19.
(2) Disengage the claw and clip to
remove the cowl side trim subassembly RH.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
C. Remove the front door opening trim weather strip to the extent that allows the removal of
the instrument panel finish panel end.
D. Remove the instrument panel finish
panel end RH by using a molding
remover and disengaging the 5 claws
and 3 guides.
Figure 20.
E. Remove the No. 2 instrument panel
under cover sub-assembly by
disengaging the 4 claws and 2 guides.
Figure 21.
© 2016 Toyota Motor Sales, USA
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HVAC Servo Motor Noise
Repair Procedure (Continued)
F. Remove the lower instrument panel sub assembly.
(1) Open the lower instrument panel sub-assembly door.
(2) Remove the 3 screws.
Figure 22.
(3) Close the lower instrument panel sub-assembly door.
(4) Remove the 2 bolts.
Figure 23.
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Repair Procedure (Continued)
(5) Disengage the 3 clips and guides.
(6) Disconnect each connector and
remove the lower instrument panel
sub-assembly.
Figure 24.
G. Remove the No. 3 air duct sub-assembly
by disengaging the 2 claws and guide.
Figure 25.
H. Remove the push pin from the lower
trim panel.
Figure 26.
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HVAC Servo Motor Noise
Repair Procedure (Continued)
15. Install the Passenger Side Insulation Sheet.
The insulation sheet has adhesive applied to
the top corners of the inside of the sheet.
The adhesive areas are used to attach the
insulation sheet in place. The bottom portion
of the insulation sheet should be tucked
(NOT adhered) to the inside of the lower
trim panel.
Figure 27.
NOTE
Adhesive side faces servo motor.
A. Position the insulation sheet.
(1) Place the narrow side of the
insulation sheet adhesive against the
center console/dash metal brace.
1
Insulation sheet, narrow side
2
Insulation sheet, wide side
3
Insulation sheet, bottom portion
Figure 28.
(2) Place the wide side of the insulation
sheet adhesive against the blower
motor case covering the servo motor
and wire harness.
1
Center console/dash metal brace
2
Blower motor case
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HVAC Servo Motor Noise
Repair Procedure (Continued)
(3) Tuck the bottom portion of the
insulation sheet to the inside of the
lower trim panel.
Figure 29.
(4) Remove the two adhesive liners and
adhere to the respective locations.
1
Lower trim panel
16. Reinstall the passenger side trim panels in the reverse order from removal.
17. Reconnect the battery.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)
18. Initialize all affected systems.
Refer to TIS, applicable model and model year Repair Manual:

2015 Highlander:
General – Introduction – “Introduction: Repair Instruction: Initialization”

2015 Highlander HV:
General – Introduction – “Introduction: Repair Instruction: Initialization”
19. Verify normal operation of HVAC temperature control.
NOTE
Vehicle should be at normal operating temperature.
© 2016 Toyota Motor Sales, USA
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