Toyota Highlander 6 2001-06

Door Glass & Regulator 1

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Power Windows



Removal & Installation
Motor & Regulator
Front
  1. Disconnect the negative battery cable.
  2.  
  3. Remove power window regulator/door lock master switch as follows:
    1. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), carefully disengage the hook, remove the power window regulator master switch.
    2.  
    3. Disconnect the electrical connector.

      Click image to see an enlarged view

      Fig. Using a suitable prytool (or a screwdriver with it-s tip taped to prevent damage), carefully disengage the hook, remove the power window regulator master switch

    4.  

  4.  
  5. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), carefully disengage the hook, remove the front door lower frame bracket garnish.

    Click image to see an enlarged view

    Fig. Using a suitable prytool (or a screwdriver with it-s tip taped to prevent damage), carefully disengage the hood, remove the front door lower frame bracket garnish

  6.  
  7. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the hook, remove the door pull handle.

    Click image to see an enlarged view

    Fig. Disengage the hook with a prytool, then remove the door pull handle

  8.  
  9. Remove front door trim panel, as follows:
    1. Remove the screw.
    2.  
    3. Using a prytool or taped screwdriver, disengage the hook, then remove the door inside handle bezel.
    4.  
    5. Remove the clip and screw.
    6.  
    7. Using a prytool or screwdriver with it-s end taped to prevent damage, disengage the hook, remove the front door trim panel.

      Click image to see an enlarged view

      Fig. Remove the screw. Then, using a prytool or taped screwdriver, disengage the hook, then remove the door inside handle bezel



      Click image to see an enlarged view

      Fig. Location of the front door trim panel retaining hooks

    8.  

  10.  
  11. If necessary, remove the inside handle, as follows:
    1. Remove the bolt and the inside handle.
    2.  
    3. Disconnect the 2 cables from the front door lock.

      Click image to see an enlarged view

      Fig. Front inside handle removal and installation

    4.  

  12.  
  13. If necessary, remove the service hole cover.
  14.  
  15. If necessary, remove the no. 2 speaker, as follows:
    1. Disconnect the connector.
    2.  
    3. Remove the bolt and front No.2 speaker.
    4.  

  16.  
  17. Remove the side rear view mirror, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the side rear view mirror.
    4.  

  18.  
  19. If necessary, remove the front no.1 speaker, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the front speaker.
    4.  

  20.  
  21. If necessary, remove front door belt molding.
  22.  
  23. Remove the front door glass run.
  24.  
  25. Remove the bolt, them remove the lower rear front door frame.
  26.  
  27. Remove the front door glass, as follows:
    NOTE
    Place a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass until you can access bolts through the service hole.
    2.  
    3. Remove the 2 bolts, then carefully remove the door glass by pulling it upward.
      WARNING
      Do not damage the door glass when removing it.



      Click image to see an enlarged view

      Fig. You must lower the door glass until you can get to the mounting bolts through the service hole

    4.  

  28.  
  29. Remove the front window regulator, as follows:
    1. Remove the 6 bolts.
    2.  
    3. Disconnect the connector, and then remove the front door window regulator.
    4.  

  30.  
  31. Remove the 3 Torx® (T25) screws, then remove the power window regulator motor.
  32.  
  33. Apply MP grease to the sliding and rotating parts of the regulator.
  34.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Install power window regulator motor assembly, as follows:
    1. If the jam protection function dose not operate properly, perform the following procedure.
      NOTE
      It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

    2.  
    3. Remove the power window motor.
      NOTE
      Place matchmarks on the power window motor and window regulator gear.

    4.  
    5. Connect the power window motor and power window switch to the wire harness of the vehicle.
    6.  
    7. Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
    8.  
    9. Assemble the power window motor and regulator.
      NOTE
      Install the motor when the regulator arm is below the middle point. Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.

    10.  

  4.  
  5. Assemble the power window regulator and door glass. Tighten the retainers to 35-61 inch lbs. (3.9-6.9 Nm).
    NOTE
    Never rotate the motor to the down direction until the window glass is completely installed.

  6.  
  7. Install front door window regulator sub-assembly, as follows:
    1. Install the front door window regulator with the 6 bolts. Tighten to 8 ft. lbs. (11 Nm).
    2.  

  8.  
  9. Make sure the power windows function properly.
  10.  
  11. Install a new service hole cover to the door panel.
    NOTE
    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 installing the service hole cover. After installing the service hole cover, check the sealing condition.

  12.  

Highlander Hybrid
  1. Disconnect the negative battery cable.
  2.  
  3. Remove power window regulator/door lock master switch as follows:
    1. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), carefully disengage the hook, remove the power window regulator master switch.
    2.  
    3. Disconnect the electrical connector.

      Click image to see an enlarged view

      Fig. Using a suitable prytool (or a screwdriver with it-s tip taped to prevent damage), carefully disengage the hook, remove the power window regulator master switch

    4.  

  4.  
  5. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), carefully disengage the hook, remove the front door lower frame bracket garnish.

    Click image to see an enlarged view

    Fig. Using a suitable prytool (or a screwdriver with it-s tip taped to prevent damage), carefully disengage the hood, remove the front door lower frame bracket garnish

  6.  
  7. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the hook, remove the door pull handle.

    Click image to see an enlarged view

    Fig. Disengage the hook with a prytool, then remove the door pull handle

  8.  
  9. Remove front door trim panel, as follows:
    1. Remove the screw.
    2.  
    3. Using a prytool or taped screwdriver, disengage the hook, then remove the door inside handle bezel.
    4.  
    5. Remove the clip and screw.
    6.  
    7. Using a prytool or screwdriver with it-s end taped to prevent damage, disengage the hook, remove the front door trim panel.

      Click image to see an enlarged view

      Fig. Remove the screw. Then, using a prytool or taped screwdriver, disengage the hook, then remove the door inside handle bezel



      Click image to see an enlarged view

      Fig. Location of the front door trim panel retaining hooks

    8.  

  10.  
  11. If necessary, remove the inside handle, as follows:
    1. Remove the bolt and the inside handle.
    2.  
    3. Disconnect the 2 cables from the front door lock.

      Click image to see an enlarged view

      Fig. Front inside handle removal and installation

    4.  

  12.  
  13. If necessary, remove the service hole cover.
  14.  
  15. If necessary, remove the no. 2 speaker, as follows:
    1. Disconnect the connector.
    2.  
    3. Remove the bolt and front No.2 speaker.
    4.  

  16.  
  17. Remove the side rear view mirror, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the side rear view mirror.
    4.  

  18.  
  19. If necessary, remove the front no.1 speaker, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the front speaker.
    4.  

  20.  
  21. If necessary, remove front door belt molding.
  22.  
  23. Remove the front door glass run.
  24.  
  25. Remove the bolt, them remove the lower rear front door frame.
  26.  
  27. Remove the front door glass, as follows:
    NOTE
    Place a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass until you can access bolts through the service hole.
    2.  
    3. Remove the 2 bolts, then carefully remove the door glass by pulling it upward.
      WARNING
      Do not damage the door glass when removing it.



      Click image to see an enlarged view

      Fig. You must lower the door glass until you can get to the mounting bolts through the service hole

    4.  

  28.  
  29. Remove the front window regulator, as follows:
    1. Remove the 6 bolts.
    2.  
    3. Disconnect the connector, and then remove the front door window regulator.
    4.  

  30.  
  31. Remove the 3 Torx® (T25) screws, then remove the power window regulator motor.
  32.  
  33. Apply MP grease to the sliding and rotating parts of the regulator.
  34.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Install power window regulator motor assembly, as follows:
    1. If the jam protection function dose not operate properly, perform the following procedure.
      NOTE
      It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

    2.  
    3. Remove the power window motor.
      NOTE
      Place matchmarks on the power window motor and window regulator gear.

    4.  
    5. Connect the power window motor and power window switch to the wire harness of the vehicle.
    6.  
    7. Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
    8.  
    9. Assemble the power window motor and regulator.
      NOTE
      Install the motor when the regulator arm is below the middle point. Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.

    10.  

  4.  
  5. Assemble the power window regulator and door glass. Tighten the retainers to 35-61 inch lbs. (3.9-6.9 Nm).
    NOTE
    Never rotate the motor to the down direction until the window glass is completely installed.

  6.  
  7. Install front door window regulator sub-assembly, as follows:
    1. Install the front door window regulator with the 6 bolts. Tighten to 8 ft. lbs. (11 Nm).
    2.  

  8.  
  9. Make sure the power windows function properly.
  10.  
  11. Install a new service hole cover to the door panel.
    NOTE
    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 installing the service hole cover. After installing the service hole cover, check the sealing condition.

  12.  
  13. Perform the initialization procedure, as outlined in the Chassis Electrical System.
  14.  

Rear
  1. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door pull handle.

    Click image to see an enlarged view

    Fig. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door pull handle

  2.  
  3. Remove the rear door trim panel, as follows:
    1. Remove the screw.
    2.  
    3. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door inside handle bezel.
    4.  
    5. Remove the screw.
    6.  
    7. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, remove the rear door trim panel, then disconnect the connector.

      Click image to see an enlarged view

      Fig. Remove the screw. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door inside handle bezel



      Click image to see an enlarged view

      Fig. Rear door trim panel retaining hook locations

    8.  

  4.  
  5. If necessary, remove rear door inside handle, as follows:
    1. Remove the bolt.
    2.  
    3. Remove the inside handle, and then disconnect the 2 cables from the rear door lock assembly.

      Click image to see an enlarged view

      Fig. Rear door inside handle removal and installation

    4.  

  6.  
  7. Remove the rear door service hole cover.
  8.  
  9. If necessary, remove rear speaker, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the rear speaker.
    4.  

  10.  
  11. Remove the rear door belt molding assembly, as follows:
    1. Remove the rear door glass run.
    2.  

  12.  
  13. Remove the 2 bolts and screw, then remove the rear door window division bar.

    Click image to see an enlarged view

    Fig. Remove the 2 bolts and screw, then remove the rear door window division bar

  14.  
  15. Remove the rear door quarter window glass
  16.  
  17. Remove the rear door glass, as follows:
    NOTE
    Insert a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass.
    2.  
    3. Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass. Pull the glass upward to remove it.
      WARNING
      Be careful not damage the door glass when removing it.



      Click image to see an enlarged view

      Fig. Rear door glass removal

    4.  

  18.  
  19. Remove the 4 bolts, then remove the rear door window regulator.
  20.  
  21. Using a Torx® driver (T25), remove the 3 screws and the window regulator motor.
  22.  
  23. Apply MP grease to the sliding and rotating parts of the regulator.
  24.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Using a Torx® driver (T25), install the power window regulator motor with the 3 screws. Tighten to 35-61 inch lbs. (3.9-6.9 Nm).
  4.  
  5. Install the rear door window regulator with the 4 bolts and tight to 8 ft. lbs. (11 Nm).
  6.  
  7. Install a new service hole cover to the door panel.
    NOTE
    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 installing the service hole cover. After installing the service hole cover, check the sealing condition.



    Click image to see an enlarged view

    Fig. Install a new service hold cover on the door panel

  8.  
  9. The remainder of installation is the reverse of the removal procedure.
  10.  

Highlander Hybrid
  1. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door pull handle.

    Click image to see an enlarged view

    Fig. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door pull handle

  2.  
  3. Remove the rear door trim panel, as follows:
    1. Remove the screw.
    2.  
    3. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door inside handle bezel.
    4.  
    5. Remove the screw.
    6.  
    7. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, remove the rear door trim panel, then disconnect the connector.

      Click image to see an enlarged view

      Fig. Remove the screw. Using a suitable prytool (or a screwdriver with its tip taped to prevent damage), disengage the claw, and remove the door inside handle bezel



      Click image to see an enlarged view

      Fig. Rear door trim panel retaining hook locations

    8.  

  4.  
  5. If necessary, remove rear door inside handle, as follows:
    1. Remove the bolt.
    2.  
    3. Remove the inside handle, and then disconnect the 2 cables from the rear door lock assembly.

      Click image to see an enlarged view

      Fig. Rear door inside handle removal and installation

    4.  

  6.  
  7. Remove the rear door service hole cover.
  8.  
  9. If necessary, remove rear speaker, as follows:
    1. Remove the 3 bolts.
    2.  
    3. Disconnect the connector then remove the rear speaker.
    4.  

  10.  
  11. Remove the rear door belt molding assembly, as follows:
    1. Remove the rear door glass run.
    2.  

  12.  
  13. Remove the 2 bolts and screw, then remove the rear door window division bar.

    Click image to see an enlarged view

    Fig. Remove the 2 bolts and screw, then remove the rear door window division bar

  14.  
  15. Remove the rear door quarter window glass
  16.  
  17. Remove the rear door glass, as follows:
    NOTE
    Insert a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass.
    2.  
    3. Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass. Pull the glass upward to remove it.
      WARNING
      Be careful not damage the door glass when removing it.



      Click image to see an enlarged view

      Fig. Rear door glass removal

    4.  

  18.  
  19. Remove the 4 bolts, then remove the rear door window regulator.
  20.  
  21. Using a Torx® driver (T25), remove the 3 screws and the window regulator motor.
  22.  
  23. Apply MP grease to the sliding and rotating parts of the regulator.
  24.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Using a Torx® driver (T25), install the power window regulator motor with the 3 screws. Tighten to 35-61 inch lbs. (3.9-6.9 Nm).
  4.  
  5. Install the rear door window regulator with the 4 bolts and tight to 8 ft. lbs. (11 Nm).
  6.  
  7. Install a new service hole cover to the door panel.
    NOTE
    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 installing the service hole cover. After installing the service hole cover, check the sealing condition.



    Click image to see an enlarged view

    Fig. Install a new service hold cover on the door panel

  8.  
  9. The remainder of installation is the reverse of the removal procedure.
  10.  
  11. Perform the initialization procedure, as outlined in the Chassis Electrical System.
  12.  

 
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