Canada - Body - Water Leak At Rear Hatch

T-TCI-3744

March 30, 2012

WATER LEAK AT BACK DOOR HATCH

Service Category
Vehicle Exterior

Section
Door/Hatch

Market
Canada





APPLICABILITY:





INTRODUCTION:

Some 2001 - 2007 model year Highlander / Highlander HV vehicles may exhibit water intrusion into the rear of the vehicle due to a cracked body seam sealer just above the back door stay mount area. Use the following repair information to address this condition.





WARRANTY INFORMATION:





REPAIR PROCEDURE:

1. Visually inspect the left and right rear hatch seams above the upper back door stay mounting bracket.

A. If separation is present, proceed to step 2 of the repair procedure.

B. If no separation is present, STOP. The source of water is coming from a different location. This TSB does NOT apply. Continue diagnostics per the Repair Manual.

2. Send the vehicle to the body shop.

3. Repair the back door seam area by removing the left and right rear hatch stays, back door weatherstrip, and the interior left and right roof side rail garnish sub-assembly in the recommended repair procedures below.
Refer to the Technical Information System (TIS), applicable model and model year Repair Manual:

^ 2001 / 2002 / 2003 / 2004 / 2005 Highlander:
Vehicle Exterior - Engine Hood/Door - "Back Door Stay Assy: Replacement"

^ 2006 / 2007 Highlander HV:
Vehicle Exterior - Engine Hood/Door - "Back Door Support: Components / Removal / Installation"

^ 2001/ 2002 / 2003 / 2004 / 2005 Highlander:
Vehicle Interior - Exterior/Interior Trim - "Roof Headlining Assy: Components"

^ 2001 / 2002 / 2003 / 2004 / 2005 Highlander:
Vehicle Interior - Exterior/Interior Trim - "Roof Headlining Assy: Replacement"

^ 2006 / 2007 Highlander:
Vehicle Interior - Interior Panels/Trim - "Roof Headlining: Components / Removal / Installation"

^ 2006 / 2007 Highlander HV:
Vehicle Interior - Interior Panels/Trim - "Roof Headlining (w/ Rear No.2 Seat): Components / Removal / Installation"

^ 2006 /2007 Highlander HV:
Vehicle Interior - Interior Panels/Trim - "Roof Headlining (w/o Rear No.2 Seat): Components / Removal / Installation"

^ Complete set of Collision Repair Manuals

4. Record radio presets.

5. Disconnect the cable from the negative battery terminal BEFORE welding.

CAUTION

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

6. Remove the seam sealer from the left and right upper rear hatch seam located just above the rear hatch upper stay mount.





7. Adjust the deformed area by using a wooden hammer.





8. Mark the location for an additional plug weld on the left and right side as shown in Figure 4 (left side image shown as reference).





9. Drill a 5mm hole in the area shown in Figure 5.

10. Add a plug weld to the location as shown in Figure 5 to the left and right stay mount area (right side shown for reference).

11. Apply an epoxy primer in between seams prior to adding seam sealer.

12. Apply seam sealer to the weld location and repaint the rear hatch area according to the paint manufacturer's recommendations.





13. Inspect and replace any deformed rear hatch stay brackets as shown in Figure 6.

14. Reassemble the interior roof side rail garnish, back door weatherstrip, and hatch stays in reverse order.

15. Confirm leak is eliminated by water testing.

16. Connect the battery and reset radio as necessary.



NOTE:
Issue of the Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.

© 2012 Toyota Motor Sales, Canada