Back Door: Overhaul

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• A bolt without a torque specification is shown in SPECIFIED TORQUE FOR STANDARD BOLTS ).

1. REMOVE BACK DOOR TRIM BOARD 
   1. Using a clip remover, remove the 11 clips and cover.
2. REMOVE BACK DOOR GARNISH OUTSIDE (See  REPLACEMENT  ) 
3. REMOVE CENTER STOP LAMP ASSY (See  OVERHAUL  ) 
4. REMOVE REAR WIPER MOTOR ASSY (See  REPLACEMENT  ) 
5. REMOVE BACK DOOR LOCK ASSY 
   1. Disconnect the door lock connector.
   2. Remove the 3 bolts and door lock.

      HINT:

      Remove the door lock through the service hole.

      Fig 1: Removing Door Lock Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE BACK WINDOW GLASS CHANNEL LH 
   1. Using a clip remover, remove the 2 clips.
   2. Using a heat light, heat the channel.

      Heating temperature: 20 to 30°C (68 to 86°F) 

      NOTE: Do not heat the body and channel excessively.
   3. Using a screwdriver, remove the channel.

      HINT:

      Tape the screwdriver tip before use.

7. REMOVE BACK WINDOW GLASS CHANNEL RH 
   1. Use the same procedures described for the LH side.
8. REMOVE DOOR PULL HANDLE 
   1. Using a screwdriver, disengage the 4 claws and remove the pull handle.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Identifying Door Pull Handle Claws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE BACK DOOR STAY SUB-ASSY LH (See  REPLACEMENT  ) 
10. REMOVE BACK DOOR STAY SUB-ASSY RH 
    1. Use the same procedures described for the LH side.
11. REMOVE BACK DOOR STOPPER LOWER 
    1. Remove the bolt and stopper LH and RH.
12. INSTALL BACK DOOR STOPPER LOWER 
    1. Install the stopper LH and RH with the bolt.

       Torque: 12.5 N.m (112 kgf.cm, 9 ft.lbf) 

13. INSTALL BACK WINDOW GLASS CHANNEL LH 
    1. Clean the contact surface of the door with a sponge saturated with white gasoline.
    2. Using a heat light, heat the door and new channel.

       Heating temperature: 

       HEATING TEMPERATURES FOR DOOR AND CHANNEL
       
       

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

       NOTE: Do not heat the door and channel excessively.
    3. Remove peeling paper from the channel face.
    4. Install the channel and 2 clips.
14. INSTALL BACK WINDOW GLASS CHANNEL RH 
    1. Use the same procedures described for the LH side.
15. INSTALL BACK DOOR LOCK ASSY 
    1. Install the door lock with the 3 bolts.

       Torque: 12.5 N.m (112 kgf.cm, 9 ft.lbf) 

       Fig 3: Installing Door Lock With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the door lock connector.