Back Door: Overhaul

NOTE: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

REMOVE BACK DOOR TRIM BOARD

Fig 1: Removing Back Door Trim Board
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, disengage the 9 clips and remove the board.
  NOTE: Tape the screwdriver tip before use.
REMOVE BACK DOOR LOCK ASSY
1. Remove the rod from the cylinder.
2. Remove the cable from the handle.
3. Disconnect the connector.
4. Remove the wire from the door panel.
5. Remove the 3 bolts and door lock.
  NOTE: Remove the lock through the service hole.
  
  Fig 2: Removing Back Door Lock Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR OUTSIDE HANDLE
1. Remove the 2 nuts and handle.
  NOTE: Remove the handle through the service hole.
  
  Fig 3: Removing Back Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK CYLINDER ASSY
1. Remove the 2 nuts and cylinder.
  NOTE: Remove the cylinder through the service hole.
  
  Fig 4: Removing Back Door Lock Cylinder Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR WEIGHT
1. Remove the 4 bolts and weight.
REMOVE BACK DOOR PANEL NO.2 PROTECTOR
1. Using a clip remover, remove the 2 clips.
2. Using a heat light, heat the protector.
  Heating temperature:20 to 30°C (68 to 86°F)
  
  NOTE: Do not heat the protector excessively.
3. Using a screwdriver, remove the protector.
  NOTE:
  - If reusing the protector, take care not to damage the protector.
  - Be careful not to damage the body.
  NOTE: Tape the screwdriver tip before use.
REMOVE BACK DOOR PANEL NO.1 PROTECTOR
NOTE: Use the same procedures described for the No. 2 side.
REMOVE BACK DOOR GARNISH SUB-ASSY OUTSIDE
REMOVE BACK DOOR STAY ASSY LH
REMOVE BACK DOOR STAY ASSY RH
REMOVE DOOR PULL HANDLE
1. Using a screwdriver, disengage the 4 claws and remove the pull handle.
  NOTE: Tape the screwdriver tip before use.
  
  Fig 5: Removing Door Pull Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER STOP LAMP ASSY (See OVERHAUL )
REMOVE REAR WIPER MOTOR ASSY (See REPLACEMENT )
INSTALL BACK DOOR WEIGHT
1. Install the weight with the 4 bolts.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

INSTALL BACK DOOR PANEL NO. 2 PROTECTOR

Clean the contact surface of the door panel with shop rag saturated with white gasoline.

Using a heat light, heat the door panel and new protector.

Heating temperature:

TEMPERATURE SPECIFICATION

Item	Temperature
Door panel	40 to 60°C (104 to 140°F)
Protector	20 to 30°C (68 to 86°F)

NOTE: Do not heat the door panel and protector excessively.

Remove peeling paper from the protector face.
NOTE: Be careful that dirt or foreign objects do not stick to the adhesive when removing the peeling paper.
Install the protector.
NOTE: Use steady pressure with your thumbs on the protector, not excessive force.

INSTALL BACK DOOR PANEL NO.1 PROTECTOR
NOTE: Use the same procedures described for the No. 2 side.
INSTALL BACK DOOR LOCK CYLINDER ASSY

Fig 6: Installing Back Door Lock Cylinder Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the cylinder with the 2 nuts.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
INSTALL BACK DOOR OUTSIDE HANDLE

Fig 7: Installing Back Door Outside Handle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the handle with the 2 nuts.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
INSTALL BACK DOOR LOCK ASSY

Fig 8: Installing Back Door Lock Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the lock with the 3 bolts.
  Torque: 7.0 N.m (71 kgf.cm, 44 in.lbf)
2. Connect the connector.
3. Install the cable to the handle.
4. Install the rod to the cylinder.