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Section 448 (Back Door): Overhaul

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

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

  1. REMOVE BACK DOOR TRIM BOARD 
    1. Remove the assist strap hole cover.
      Fig 1: Removing Back Door Trim Board
      G02814281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw and assist strap.
      3. NOTE:

      Tape the screwdriver tip before use.

    3. Using a screwdriver, remove the back door trim cover.

      In order to prevent the back door from being damaged, cover the parts indicated by arrow marks in Fig 1 with tape.

    4. Using a clip remover, remove the 10 clips and trim board.
    5. Remove the inner weatherstrip.
  2. REMOVE BACK DOOR SERVICE HOLE COVER LH 
    CAUTION: Remove the remaining tape on the back door side.
    Fig 2: Removing Back Door Service Hole Cover LH
    G02814282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE BACK DOOR GLASS 
    1. Remove the 5 screws and service hole cover.
      NOTE:
      • Do not disconnect the multiplex network door ECU connector.
      • Fix the multiplex network door ECU with tape.
      • If the door lock protector are damaged, exchange it for new door lock protector.
    2. Open the door glass until the bolts appear in the service hole.
      Fig 3: Lowering Door Glass
      G02814283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the door glass run.
      NOTE:

      Since removing the glass run will make the glass loose, insert shop rag between the door glass and body panel.

    4. Disconnect the window defogger connector.
    5. Remove the 4 bolts and door glass.
      Fig 4: Removing Door Glass Bolts
      G02814284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. remove the door glass as shown in Fig 5.
      Fig 5: Removing Door Glass
      G02814285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the rear window connector.
    8. Remove the multiplex network door ECU.
  4. REMOVE BACK DOOR GLASS WEATHERSTRIP ASSY OUTER (See  REPLACEMENT  ) 
  5. REMOVE W/MOTOR BACK DOOR LOCK ASSY 
    1. Disconnect the back door lock connector.
    2. Remove the 2 back window regulator control wires.
      Fig 6: Removing Back Window Regulator Control Wires
      G02814286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws and remove the lock protector as shown in Fig 7.
      Fig 7: Removing Bolts And Back Door Lock
      G02814287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and back door lock.
    NOTE:

    Remove the door lock through the service hole.

  6. REMOVE BACK DOOR POWER WINDOW REGULATOR SUB-ASSY 
    1. Remove the 2 cushion rubbers.
      Fig 8: Removing Back Door Power Window Regulator Sub-Assembly
      G02814288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the window regulator connector.
      3. NOTE:

      Remove the power window regulator through the service hole.

    3. Remove the 6 bolts and window regulator.
  7. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Remove the 2 nuts and window regulator motor.
    2. Remove the 2 screws and cover plate.
      3. CAUTION: Do not use a screwdriver, etc. when removing them.
      Fig 9: Remove Power Window Regulator Motor Assembly LH
      G02814289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using needle nose pliers, remove the drum and wire guide from the motor.
  8. REMOVE REAR WIPER MOTOR ASSY (See  REAR WIPER MOTOR ASSY  ) 
    1. Remove the liner wiper step LH as shown in Fig 10.
      Fig 10: Removing Rear Wiper Motor Assembly
      G02814290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BACK DOOR LOCK CYLINDER ASSY 
    1. Disconnect the connector.
    2. Remove the tailgate control switch.
      3. NOTE:

      Remove the back door lock cylinder assy through the service hole.

    3. Remove the 2 nuts and lock cylinder.
  10. REMOVE BACK DOOR GARNISH SUB-ASSY OUTSIDE (See  BACK DOOR GARNISH SUB-ASSY OUTSIDE  ) 
  11. REMOVE TELEVISION CAMERA ASSY (See  TELEVISION CAMERA ASSY  ) 
  12. REMOVE BACK DOOR STOPPER LOWER 
    1. Remove the bolt and stopper lower.
  13. REMOVE BACK DOOR LOWER STOPPER CUSHION 
    1. Remove the 2 bolts and stopper cushion.
  14. REMOVE REAR SPOILER SUB-ASSY (See  REAR SPOILER  ) 
  15. REMOVE CENTER STOP LAMP ASSY (See  CENTER STOP LAMP ASSEMBLY  ) 
  16. INSTALL CENTER STOP LAMP ASSY (See  CENTER STOP LAMP ASSEMBLY  ) 
  17. INSTALL REAR SPOILER SUB-ASSY (See  REAR SPOILER  ) 
  18. INSTALL BACK DOOR LOWER STOPPER CUSHION 
    1. Install the lower stopper cushion with the 2 bolts.

      Torque: 5.5 N.m (56 kgf.cm, 48 in..lbf) 

  19. INSTALL BACK DOOR STOPPER LOWER 
    1. Install the stopper lower with the bolt.

      Torque: 5.5 N.m (56 kgf.cm, 48 in..lbf) 

  20. INSTALL TELEVISION CAMERA ASSY (See  TELEVISION CAMERA ASSY  ) 
  21. INSTALL BACK DOOR GARNISH SUB-ASSY OUTSIDE (See  BACK DOOR GARNISH SUB-ASSY OUTSIDE  ) 
  22. INSTALL BACK DOOR LOCK CYLINDER ASSY 
    1. Install the lock cylinder with 2 the nuts.

      Torque: 5.5 N.m (56 kgf.cm, 48 in..lbf) 

    2. Install the tailgate control switch.
  23. INSTALL REAR WIPER MOTOR ASSY (See  REAR WIPER MOTOR ASSY  ) 
  24. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    NOTE:
    • To prevent the drum and cable from coming off, do not tilt the drum, subject it to shocks or use force on it. 
    • If the cable comes off the drum, do not rewind the cable and do not reuse it. 
    • After installing the window regulator, do not operate it by itself, because some types of regulator do not have a stopper. 
    1. Apply MP grease to the as shown in Fig 11.
      Fig 11: Applying MP Grease
      G02814291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. With the holding tool installed, match the holding tool with the motor housing.
      Fig 12: Matching Holding Tool
      G02814292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push down on the wire guide and drum, and insert the drum into the motor housing.
      CAUTION: If you can not insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.
      Fig 13: Insert Drum Into Motor Housing
      G02814293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the cover plate with the 2 screws.
      Fig 14: Installing Cover Plate
      G02814294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 1.7 N.m (56 kgf.cm, 48 in..lbf) 

    5. Install the window regulator motor with the window regulator.
  25. INSTALL BACK DOOR POWER WINDOW REGULATOR SUB-ASSY 
      CAUTION: Do not apply grease to the spring of the window regulator.
      Fig 15: Identifying Sliding And Rotating Parts
      G02814295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply MP grease to the sliding and rotating parts of the window regulator.
    2. Install the power regulator sub-assy with the 6 bolts, nut.
      Fig 16: Installing Power Regulator Sub-Assembly
      G02814296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

    3. Connect the window regulator connector.
    4. Install the 2 cushion rubbers.
  26. INSTALL W/MOTOR BACK DOOR LOCK ASSY 
    1. Install the door lock with 4 bolts.
      Fig 17: Installing Door Lock With Bolts
      G02814297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

    2. Connect the connector.
    3. Install the door lock protector.
    4. Install the 2 regulator control wires as shown in Fig 18.
      Fig 18: Installing Regulator Control Wires
      G02814298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL BACK DOOR GLASS 
    1. Insert the door glass as shown in Fig 19.
      Fig 19: Inserting Door Glass
      G02814299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the door glass with the 4 bolts.
      Fig 20: Connecting Rear Window Defogger Connector
      G02814300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

    3. Connect the rear window defogger connector.
  28. INSTALL BACK DOOR GLASS RUN 
    1. Install the door glass run.
    2. Check that the glass run position is as shown in Fig 21.
      Fig 21: Installing Back Door Glass Run
      G02814301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL BACK DOOR SERVICE HOLE COVER 
    1. If replacing protector:

      Install the protector, as shown in Fig 22.

      Fig 22: Installing Back Door Service Hole Cover
      G02814302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the back door service hole cover with the 5 bolts.
    3. Install the multiplex network door ECU with the 2 bolts.
    4. Connect the multiplex network door ECU connector.
  30. INSTALL BACK DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door.
      Fig 23: Identifying Butyl Tape Surface Area
      G02814303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: 

      Part No. 08850-00065, Butyl Tape Set or equivalent 

    2. Install the service hole cover, as shown in Fig 23.
    NOTE:
    • There should be no wrinkles or folds after attaching the service hole cover.
    • After attaching the service hole cover, check the sealing condition.
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