Body - Power Back Door Does Not Close Properly
T-SB-0091-12
June 21, 2012
Power Back Door Does Not Close Properly
Service Category
Vehicle Exterior
Section
Door/Hatch
Market
USA
Applicability
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 maybe 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.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
Required Tools & Equipment
Parts Information
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 Panel Sub-assembly is required. Proceed to step 2.
If a gap is not found, STOP - this bulletin does NOT apply.
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.
4. Proceed to Repair Procedure.
Repair Procedure
1. 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 model and model year Repair Manual and the following manuals:
^ Toyota Fundamental Body Repair Procedures Manual (Pub. No. BRM002E), available from the Materials Distribution Center (MDC) through Dealer Daily - Dealer Support Materials Orders
^ Toyota Collision Repair Manuals:
^ Toyota 2008 - 2012 Highlander Collision Repair Manual (BM06J0U)
^ Toyota 2008 - 2012 Highlander HV Collision Repair Manual (BM07V0U)
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.
2. Initialize the Power Back Door system.
3. Confirm repair by opening and closing the back door in the power mode and ensuring proper operation.
© 2012 Toyota Motor Sales, USA