Toyota Highlander Service Manual: Overhaul

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ).

1. REMOVE DOOR PULL HANDLE

(a) Using a screwdriver, disengage the 2 clips and remove the door pull handle.

HINT: Tape the screwdriver tip before use.

2. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH

(a) Remove the screw.

(b) Using a screwdriver, disengage the 3 claws and remove the door inside handle bezel.

3. REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH

(a) Remove the screw.

(b) Using a screwdriver, disengage the 7 clips and remove the trim board, and then disconnect the connector.

HINT: Tape the screwdriver tip before use.

4. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSY LH

(a) Remove the bolt.

(b) Remove the inside handle, and then disconnect the 2 cables from the rear door lock.

5. REMOVE REAR DOOR SERVICE HOLE COVER LH

6. REMOVE REAR SPEAKER ASSY

(a) Remove the 3 bolts.

(b) Disconnect the connector and remove the rear speaker.

7. REMOVE REAR DOOR BELT MOULDING ASSY LH (See page 76-12 )

8. REMOVE REAR DOOR GLASS RUN LH

9. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH

(a) Remove the 2 bolts, screw and division bar.

10. REMOVE REAR DOOR QUARTER WINDOW GLASS LH

11. REMOVE REAR DOOR GLASS SUB-ASSY LH

HINT: Insert a shop rag inside the door panel to prevent scratching the glass.

(a) Open the door glass.

(b) Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass.

NOTICE: Do not damage the door glass.

HINT: Pull the glass upward to remove it.

12. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH

(a) Remove the 4 bolts and window regulator.

13. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH

(a) Using a torx) driver (T25), remove the 3 screws and motor.

14. APPLY BODY GREASE

(a) Apply MP grease to the sliding and rotating parts of the regulator.

15. REMOVE REAR DOOR LOCK ASSY LH

(a) Disconnect the connectors.

(b) Disconnect the links from the rear door outside handle.

(c) Remove the bolt.

(d) Using a torx) socket wrench (T30), remove the 4 screws and rear door lock.

16. APPLY BODY GREASE

(a) Apply MP grease to the sliding and rotating parts of the door lock.

17. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH

(a) Using a torx) socket wrench (T30), remove the 2 screws.

(b) Using a screwdriver, pry out the rear outside handle cover.

(c) Pushing the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle and outside handle frame.

(d) Using a torx) socket wrench (T30), remove the screw and frame.

Torque: 4.0 NVm (41 kgfVcm, 36 in.Vlbf)

18. INSTALL REAR DOOR LOCK ASSY LH

(a) Using a torx) socket wrench (T30), install the rear door lock with the 4 screws.

Torque: 5.0 NVm (50 kgfVcm, 44 in.Vlbf) for A 5.5 NVm (56 kgfVcm, 49 in.Vlbf) for B

(b) Install the bolts.

(c) Connect the links to the rear outside handle.

(d) Connect the connectors.

19. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH

(a) Using a torx) driver (T25), install the regulator motor with the 3 screws.

Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)

20. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH

(a) Install the window regulator with the 4 bolts.

Torque: 11.0 NVm (112 kgfVcm, 8 in.Vlbf)

21. INSTALL REAR DOOR SERVICE HOLE COVER LH

(a) Install a new service hole cover to the door panel.

HINT:

• When installing the service hole cover, pull out the links and connectors through the service hole cover.
• There should be no wrinkles or folds after attaching the service hole cover.
• After attaching the service hole cover, check the sealing condition.

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