Toyota Highlander Hybrid 6 2005-06

Locks & Lock Systems 1

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Power Door Locks



Removal & Installation
Door Lock Motor
Front
  1. 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.  

  2.  
  3. 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

  4.  
  5. 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

  6.  
  7. 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.  

  8.  
  9. 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.  

  10.  
  11. If necessary, remove the service hole cover.
  12.  
  13. Remove the front door lock assembly, as follows:
    1. Disconnect the connector.
    2.  
    3. Disconnect the links from the front door outside handle.
    4.  
    5. Using a Torx® wrench (T30), remove the 4 screws and front door lock.
    6.  
    7. Apply MP grease to the sliding and rotating parts of the door lock.

      Click image to see an enlarged view

      Fig. Front door lock removal and installation

    8.  

  14.  
  15. If necessary, remove the front door outside handle frame sub-assembly:
    1. Using a Torx® wrench (T30), remove the 2 screws and door lock cylinder.
    2.  
    3. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame.

      Click image to see an enlarged view

      Fig. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame

    4.  

  16.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Install the front door lock assembly, as follows:
    1. Using a Torx® wrench (T30), install the front door lock assembly with the 4 screws. As shown in the accompanying illustration, tighten screws A to 45 inch lbs. (5.0 Nm) and screw B to 49 inch lbs. (5.5 Nm).
    2.  
    3. Install the 2 bolts.
    4.  
    5. Connect the links to the front outside handle.
    6.  
    7. Connect the connector.

      Click image to see an enlarged view

      Fig. Location of the A and B screws for the front door lock

    8.  

  4.  
  5. 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

  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  

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. Remove the front door lock assembly, as follows:
    1. Disconnect the connector.
    2.  
    3. Disconnect the links from the front door outside handle.
    4.  
    5. Using a Torx® wrench (T30), remove the 4 screws and front door lock.
    6.  
    7. Apply MP grease to the sliding and rotating parts of the door lock.

      Click image to see an enlarged view

      Fig. Front door lock removal and installation

    8.  

  16.  
  17. If necessary, remove the front door outside handle frame sub-assembly:
    1. Using a Torx® wrench (T30), remove the 2 screws and door lock cylinder.
    2.  
    3. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame.

      Click image to see an enlarged view

      Fig. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame

    4.  

  18.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Install the front door lock assembly, as follows:
    1. Using a Torx® wrench (T30), install the front door lock assembly with the 4 screws. As shown in the accompanying illustration, tighten screws A to 45 inch lbs. (5.0 Nm) and screw B to 49 inch lbs. (5.5 Nm).
    2.  
    3. Install the 2 bolts.
    4.  
    5. Connect the links to the front outside handle.
    6.  
    7. Connect the connector.

      Click image to see an enlarged view

      Fig. Location of the A and B screws for the front door lock

    8.  

  4.  
  5. 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

  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  
  9. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  10.  

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. Remove the rear door lock assembly:
    1. Disconnect the connectors.
    2.  
    3. Disconnect the links from the rear door outside handle.
    4.  
    5. Using a Torx® socket wrench (T30), remove the 4 screws and rear door lock.
    6.  
    7. Apply MP grease to the sliding and rotating parts of the door lock.

      Click image to see an enlarged view

      Fig. Rear door lock removal

    8.  

  10.  
  11. If necessary, remove the rear door outside handle frame, as follows:
    1. Using a Torx® socket wrench (T30), remove the 2 screws.
    2.  
    3. Using a screwdriver, remove the rear outside handle cover.
    4.  
    5. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame.

      Click image to see an enlarged view

      Fig. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame

    6.  

  12.  

To install:

  1. Installation is the reverse of the removal procedure, but note the following important steps.
  2.  
  3. Install the rear door lock as follows:
    1. Using a Torx®socket wrench (T30), install the rear door lock with the 4 screws. As shown in the accompanying illustration, tighten the A screws to 44 inch lbs. (5.0 Nm) and the B screws to 49 inch lbs. (5.5 Nm).
    2.  
    3. Install the bolts.
    4.  
    5. Connect the links to the rear outside handle.
    6.  
    7. Connect the connectors.

      Click image to see an enlarged view

      Fig. Location of the A and B screws for the rear door lock

    8.  

  4.  
  5. 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

  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  

 
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