Toyota PT278-48140 User manual

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Preparation
Page 1 of 7 pages
Issue: D 04/06/2015
Part Number: PT278-48140
Kit Contents
Item # Quantity Reqd. Description
1 1 Crossbar Assembly Front
2 1 Crossbar Assembly Rear
3 2 RH Crossbar Covers
4 2 LH Crossbar Covers
5 1 Hardware Bag
Hardware Bag Contents
Item # Quantity Reqd. Description
1 1 Torque Tool
2 4 Tethers
3 4 Anti-Rotation Caps
4 1 Users Guide
5
6
7
Additional Items Required For Installation
Item # Quantity Reqd. Description
1
2
3
Conflicts
Recommended Tools
Personal & Vehicle
Protection Notes
Safety Glasses
Safety Gloves
Vehicle Protection Cloth
Wrist & Belt Buckle
Protection
Special Tools Notes
Plastic trim removal tool
Installation Tools Notes
13mm Socket
Torque Wrench 0-75 lbf-in
Special Chemicals Notes
General Applicability
All models 2014-
Recommended Sequence of Application
Item # Accessory
1
2
3
*Mandatory
Vehicle Service Parts (may be required for reassembly)
Item # Quantity Reqd. Description
1
2
3
Legend
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the
specific tools and equipment recommended for this
process.
REVISION MARK: This mark highlights a change in
installation with respect to previous issue.
SAFETY TORQUE: This mark indicates that torque is
related to safety.

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Procedure
Page 2 of 7 pages
Issue: D 04/06/2015
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure a quality installation.
These guidelines can be found in the "Accessory Installation Practices" document.
This document covers such items as:-
Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
Safety (eye protection, rechecking torque procedure, etc.).
Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).
Please see your Toyota dealer for a copy of this document.
1. Remove the Side Rail Covers (Fig. 1-1).
(a) Use a plastic trim removal tool to carefully
remove the 4 trim covers by pressing the tabs
and prying up (4 places).
(b) Retain the covers for future use.
Fig. 1-1
Front of
Vehicle
Trim Removal Tool

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Procedure
Page 3 of 7 pages
Issue: D 04/06/2015
2. Install the Crossbars (Fig. 2-1).
(a) Make sure the arrows on the crossbar end
supports are pointing toward the front of the
vehicle.
NOTE: THE FRONT CROSSBAR HAS A
“FRONT” LABEL.
NOTE: FRONT AND REAR, LH AND RH,
ARE MOLDED INTO THE SUPPORT PAD
BOTTOM.
(b) MAKE SURE THE RECTANGULAR
SPACERS ARE ORIENTED
PROPERLY. The spacer should sit down
into the recess (Fig. 2-2) and not above it
(Fig. 2-3). Incorrect orientation will create a
large space between the crossbar and the
vehicle.
Fig. 2-2
Fig. 2-1
Front of
Vehicle
Fig. 2-3

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Procedure
Page 4 of 7 pages
Issue: D 04/06/2015
3. Secure the Crossbars (Fig. 3-1).
(a) Using a 13mm socket, tighten the bolt to
8 N-m (71 Lbf-in) (4 places).
Torque: 8 N•m (71 in•lbs)
(b) Verify all supports are snug and properly
fitted to the side rail (4 places).
4. Attach the Anti-rotation Caps to the
Crossbars (4 Places) (Fig. 4-1).
(a) Install the tether end of the anti-rotation cap
into the crossbar support.
(b) Install a cap over the crossbar bolt.
NOTE: Verify the proper orientation of the
tether into the hole specified in Fig. 4-1.
NOTE: Verify the tether is fully engaged and
locked into the support.
NOTE: Verify the caps are fully engaged over
the bolt.
NOTE: Verify the caps are centered between
the 2 small raised walls on the support.
Front of
Vehicle
Fig. 4-1 Support Hole
Raised Wall
TOP VIEW
LH shown
RH similar
13mm Socket,
Torque wrench
Fig. 3-1
Front of
Vehicle
LH shown
RH similar

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Procedure
Page 5 of 7 pages
Issue: D 04/06/2015
5. Attach the Tethers to the Crossbar Covers.
(a) Install the 4 tethers on the covers
(2 RH, 2 LH) (Fig. 5-1). Install the short end
of the tether through the loop on the cover.
NOTE: Verify the tether is centered in the
cover.
NOTE: Verify the tether is fully engaged and
locked into the cover.
6. Attach the Tethers to the Crossbars (Fig. 6-1).
(a) Install the 4 tethers (2 RH, 2 LH) with covers
on to the crossbar supports. The tether is flat
and must be bent during installation (Fig. 6-
1).
NOTE: Verify the proper orientation of the
keyed/raised end of the tether when inserting
into the “T” shape hole in the crossbar
support (Fig. 6-1).
NOTE: Verify the tether is fully engaged and
locked into the support.
Fig. 6-1 Front of
Vehicle
BEND
“T” Hole
LH shown
RH similar
Fig. 5-1 Front of
Vehicle
Short
End
Keyed/
Raised
LH shown
RH similar

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Procedure
Page 6 of 7 pages
Issue: D 04/06/2015
7. Install the Crossbar Covers.
(a) Install the crossbar covers (4 places)
(Fig. 7-1). Line up the cover posts with the
holes in the supports. Press down firmly
(Fig. 7-1).
NOTE: Make sure the covers are fully
engaged at each location marked with a
triangle (16 places) (Fig. 7-2).
8. Complete the Installation.
(a) Place the side rail covers removed in Step
1(b) and the crossbar users guide and torque
tool in the polybag.
(b) Place the polybag with the side rail covers,
crossbar users guide and torque tool in the
glove box.
Fig. 7-1
Front of
Vehicle
Fig. 7-2
Front of
Vehicle

TOYOTA Highlander/HV w/Side Rail 2014 - CROSSBAR KIT
Checklist - these points MUST be checked to ensure a quality installation.
Check: Look For:
Page 7 of 7 pages
Issue: D 04/06/2015
Accessory Function Checks
Inspect bolt torque
Ensure crossbars are secure and in correct
position
Side rail covers, crossbar users guide and
torque tool
Crossbar cover engagement
Vehicle Function Checks
Crossbar support bolt: 8 N•m (71 in•lbf)
Front crossbar has “FRONT” label.
Side rail covers, users guide and torque tool
inside vehicle glove box
Ensure crossbar covers are fully engaged.
Vehicle Appearance Check
After accessory installation, perform a
visual inspection.
Ensure no damage (including scuffs and
scratches) was caused during the
installation process.
(For PPO installations, refer to TMS
Accessory Quality Shipping Standard.)