Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISTECHNICAL SERVICE BULLETINSRECALLSSAFETYRECALL - CHILD PROTECTION LOCK MODIFICATIONTECHNICAL INSTRUCTIONSV. WORK PROCEDURE
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
V. Work Procedure
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION V. Work Procedure
A. CHILD PROTECTION LOCK REPAIR

1. REMOVE REAR DOOR CHILD PROTECTION LOCK COVER.
(a) Disengage the 4 claws and remove the protector cover.
2. INSTALL SUPPLIED SPACER.
(a) Install protective tape on the door panel.
(b) Set the lock lever into the locked position.

(c) Install the provided spacer over the child protection lock lever as shown in the illustration.
NOTE:
The supplied spacer may not fit flush against the door panel. The supplied spacer should bottom out on the lever.

3. SHORTEN THE CHILD PROTECTION LOCK LEVER.
(a) Use a file or Dremel(R) to grind down the portion of the lever that protrudes from the spacer.
NOTE:
The supplied spacer may not fit flush against the door panel. The supplied spacer should bottom out on the lever.
NOTE:
If the lever is already flush or does not extend beyond the special tool (washer) the lever is okay and further modification for that particular lever is not necessary.
NOTE:
Do not damage the body.
4. REMOVE THE SUPPLIED SPACER.

5. ROUND OUT THE EDGES ON CHILD PROTECTION LOCK LEVER
(a) Use high grit sandpaper (# 2000 or higher) or Dremel(R) Rotary Tool with # 511 Abrasive Buffs Bit or equivalent to round off and smooth the sharp edges on the child protection lock lever.
Dimension: Approximately 1.0 mm (0.0039 in.)
NOTE:
Do not damage the door with the file or the sandpaper.
(b) Reinstall the Rear Door Child Protection Lock Protector Cover.
6. REPEAT STEPS 1 THROUGH 5 ON THE OTHER REAR SIDE DOOR.
1. REMOVE REAR DOOR CHILD PROTECTION LOCK COVER.
(a) Disengage the 4 claws and remove the protector cover.
2. INSTALL SUPPLIED SPACER.
(a) Install protective tape on the door panel.
(b) Set the lock lever into the locked position.
(c) Install the provided spacer over the child protection lock lever as shown in the illustration.
NOTE:
The supplied spacer may not fit flush against the door panel. The supplied spacer should bottom out on the lever.
3. SHORTEN THE CHILD PROTECTION LOCK LEVER.
(a) Use a file or Dremel(R) to grind down the portion of the lever that protrudes from the spacer.
NOTE:
The supplied spacer may not fit flush against the door panel. The supplied spacer should bottom out on the lever.
NOTE:
If the lever is already flush or does not extend beyond the special tool (washer) the lever is okay and further modification for that particular lever is not necessary.
NOTE:
Do not damage the body.
4. REMOVE THE SUPPLIED SPACER.
5. ROUND OUT THE EDGES ON CHILD PROTECTION LOCK LEVER
(a) Use high grit sandpaper (# 2000 or higher) or Dremel(R) Rotary Tool with # 511 Abrasive Buffs Bit or equivalent to round off and smooth the sharp edges on the child protection lock lever.
Dimension: Approximately 1.0 mm (0.0039 in.)
NOTE:
Do not damage the door with the file or the sandpaper.
(b) Reinstall the Rear Door Child Protection Lock Protector Cover.
6. REPEAT STEPS 1 THROUGH 5 ON THE OTHER REAR SIDE DOOR.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- β’ You smell fuel, burning insulation, or see smoke.
- β’ Brakes feel soft, pull hard to one side, or make grinding noises.
- β’ The engine overheats, stalls repeatedly, or misfires under load.
- β’ You are missing required tools, torque specs, or safe lifting equipment.
- β’ You are not confident in the next step or safety outcome.