Section 268 (Back Door): Overhaul

WARNING: This page is about a different car, the 2003 Lexus GX 470. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

REMOVE BACK DOOR GARNISH CENTER
1. Using a clip remover, disengage the 5 clips, and remove the garnish center.
Fig 1: Removing Back Door Garnish Center
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR SIDE GARNISH LH
1. Using a clip remover, disengage the 3 clips, and remove the side garnish.
REMOVE BACK DOOR SIDE GARNISH RH
1. Using a clip remover, disengage the 3 clips, and remove the side garnish.
REMOVE TOOL BOX PANEL SUB-ASSY UPPER
1. Remove the tool cover and tool set.
REMOVE ASSIST GRIP ASSY
1. Remove the 2 assist grip covers and assist grip assy.
REMOVE BACK DOOR TRIM BOARD
1. Remove the 2 trim board covers.
2. Remove the screw.
3. Using a screwdriver, disengage the 15 clips and remove the trim board.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 2: Identifying Trim Board Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 7 screws and trim pocket.
5. w/ Speaker
  Remove the 4 screws and rear speaker grille sub-assy LH and RH.
REMOVE BACK DOOR STOPPER LOWER
1. Remove the packing.
2. Using a screwdriver, disengage the claw, and remove the stopper lower.
  
  Fig 3: Removing Back Door Stopper Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR SERVICE HOLE COVER
NOTE: Remove the remaining tape on the door side.

Fig 4: Removing Back Door Service Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEREO COMPONENT SPEAKER ASSY (VW SPEAKER) (See REPLACEMENT )
REMOVE BACK DOOR OUTSIDE HANDLE
1. Remove the 2 bolts and outside handle.
2. Remove the cable.
  HINT:
  
  Remove the outside handle through the service hole.
  
  Fig 5: Removing Back Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE W/MOTOR BACK DOOR LOCK ASSY
1. Disconnect the door lock connector.
2. Using a torx socket wrench (T30), remove the 3 screws and door lock assy.
  HINT:
  
  Remove the door lock assy through the service hole.
  
  Fig 6: Removing W/Motor Back Door Lock Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LICENSE REAR LAMP COVER
REMOVE BACK DOOR GARNISH SUB-ASSY OUTSIDE
REMOVE REAR WIPER MOTOR ASSY (See REAR WIPER MOTOR ASSY )
REMOVE BACK DOOR SIDE FEMALE STOPPER SUB-ASSY RH
1. Remove the 2 bolts and female stopper sub-assy.
REMOVE BACK DOOR LINK SUB-ASSY LOWER
1. Remove the top set bolt cap B.
2. Remove the bolt and back door link sub-assy.
REMOVE BACK DOOR STAY RAIL SUB-ASSY RH
1. Remove the 2 bolts and stay rail sub-assy.
REMOVE REAR BUMPER COVER (See REPLACEMENT )
REMOVE BACK DOOR STAY BRACKET SUB-ASSY RH
1. Remove the 2 bolts and stay bracket sub-assy.
INSTALL BACK DOOR STAY BRACKET SUB-ASSY RH
1. Install the back door stay bracket sub-assy with the 2 bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
INSTALL BACK DOOR STAY RAIL SUB-ASSY RH
1. Apply MP grease to the sliding parts of the stay rail sub-assy, as shown in Fig 7 .
  
  Fig 7: Applying MP Grease To Sliding Parts Of Stay Rail Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the stay rail sub-assy with the 2 bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
3. Install the top set bolt cap B.
INSTALL BACK DOOR LINK SUB-ASSY LOWER
1. Install the link sub-assy with the bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
INSTALL BACK DOOR SIDE FEMALE STOPPER SUB-ASSY RH
1. Install the female stopper with the 2 bolts.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
INSTALL W/MOTOR BACK DOOR LOCK ASSY
1. Apply MP grease to the sliding and rotating parts of the door lock assy.
2. If reusing door lock assy:
  Install a new door lock wire harness packing.
  NOTE:
  - If reusing the door lock that has been removed, replace the packing in the connecting part with a new one.
  - Be careful that no grease and dirt sticks to the packing surface in the connecting part.
  - Reusing removed packing that is or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.
3. Insert the outside handle link into the door lock, and then set it to the door panel.
  NOTE: Make sure that the outside handle link is securely engaged with the lock assembly.
4. Apply adhesive to the threads of the screws.
  Adhesive:
  - Part No. 08833-00070, THREE BOND 1324 or equivalent
  Fig 8: Applying Adhesive To Threads Of Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a torx socket wrench (T30), install the door lock assy with the 3 screws.
  Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
6. Connect the door lock connector.
INSTALL BACK DOOR OUTSIDE HANDLE
1. Install the handle with the 2 bolts.
  Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
  
  Fig 9: Installing Back Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STEREO COMPONENT SPEAKER ASSY (W/ SPEAKER) (See REPLACEMENT )

INSTALL BACK DOOR SERVICE HOLE COVER (W/ SPEAKER)

Apply butyl tape to the door, as shown in Fig 10 .
Adhesive:
- Part No. 08850-00065, Butyl Tape Set or equivalent
Fig 10: Applying Butyl Tape To Door
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the service hole cover.

HINT:

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 attaching the service hole cover.

After attaching the service hole cover, confirm the sealing condition.

Dimensions:

DIMENSIONS CHART

A	6.0 mm (0.236 in.)
B	2.0 mm (0.079 in.)

Install the 2 tool box brackets with the 4 bolts.
Torque: 8.0 N.m (81 kgf.cm, 71 in.lbf)