Back Door: Disassembly

REMOVE REAR WIPER ARM
1. Open the cover.
2. Remove the nut and rear wiper arm.
  1. Torque: 5.5 N.m (56 kgf°Cm, 49 in..lbf)
3. Remove the rear wiper motor grommet.
Fig 1: Removing Nut Rear Wiper Arm
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEP LINER
Using a screwdriver, remove the step liner.

NOTE: Tape the screwdriver tip before use.

Fig 2: Removing Step Liner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTSIDE MOULDING
1. Remove the 2 nuts.
2. Using a screwdriver, remove the outside moulding.
3. Employ the same manner described above to the other side.
Fig 3: Removing Nuts And Outside Moulding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR PULL STRAP
1. Using a screwdriver, remove the strap cover.
  NOTE: Tape the screwdriver tip before use.
2. Remove the screw and back door pull strap.
REMOVE BACK DOOR CENTER GARNISH
Using a screwdriver, remove the back door center garnish.

NOTE: Tape the screwdriver tip before use.

Fig 4: Removing Back Door Center Garnish Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR SIDE GARNISH
1. Using a screwdriver, remove the back door side garnish.
  NOTE: Tape the screwdriver tip before use.
2. Employ the same manner described above to the other side.
Fig 5: Removing Back Door Side Garnish Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR TRIM BOARD
1. Insert a screwdriver between the back door and back door trim board to pry the back door trim board out.
  NOTE: Be careful not to damage the back door and back door trim board.
  
  NOTE: Tape the screwdriver tip before use.
2. Pull the back door trim board to remove it as shown in the illustration.
REMOVE INNER WEATHERSTRIP
Using a screwdriver, remove the inner weatherstrip from the back door trim board.

NOTE: Tape the screwdriver tip before use.
REMOVE NO. 1 SERVICE HOLE COVER
REMOVE NO. 2 SERVICE HOLE COVER
REMOVE BACK DOOR ECU
1. Using a drill of less than 3.2 mm (0.126 in.), drill out the 2 rivet heads.
  NOTE: Gentry and vertically put the drill to the rivets, and cut the rivet flanges.
  
  CAUTION: Take care as the cut rivets are hot.
  
  NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
2. Remove the back door ECU.
NOTE: At the time of reassembly, please refer to the following item. Using an air riveter with nose piece No. 1 or a hand riveter with nose piece No. 1 to install new 3 rivets to the front door outside lower moulding.

Fig 6: Locating Back Door Trim Board Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- At the time of reassembly, please refer to the following items.
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
  
  Fig 7: Identifying Riveter Prize
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Do not tilt the riveter disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
  
  Fig 8: Identifying Rivet Tilting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Install the rivet while attaching materials, as they are not tightened firmly.
Fig 9: Installing Rivet Attaching
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR GLASS
1. Open the back door glass until the bolts appear in the service hole.
2. Disconnect the connectors.
3. Remove the 2 bolts and guide bracket.
  
  Fig 10: Removing Bolts And Guide Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque: 8.0 N.m (82 kgf°Cm, 71 in..lbf)
4. Remove the 4 bolts and back door glass as shown in the illustration.
  
  Fig 11: Removing Back Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque: 8.0 N.m (82 kgf°Cm, 71 in..lbf)
NOTE: Be careful not to drop the back door glass.
REMOVE OUTER WEATHERSTRIP
1. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
  
  Fig 12: Applying Protective Tape Outer Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a moulding remover, remove the outer weatherstrip.
REMOVE BACK DOOR GLASS RUN
REMOVE BACK DOOR GLASS GUIDE RAIL
1. Disengage the clamps.
2. Remove the 3 nuts and back door glass guide.
3. Employ the same manner described above to the other side.
REMOVE POWER WINDOW REGULATOR
1. Disconnect the connector.
2. Disengage the connector and clamp.
3. Remove the 4 nuts and power window regulator.
  1. Torque: 5.5 N.m (56 kgf°Cm, 49 in..lbf)
  NOTE: Remove the power window regulator through the service hole.
  
  Fig 13: Removing Power Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 screws and power window regulator motor from the power window regulator.
5. Remove the nut and limit switch from the power window regulator.
NOTE: At the time of reassembly, please refer to following item.

Remove the window regulator gear, then apply MP grease to the power window regulator.

NOTE: At the time of reassembly, please refer to following item. Do not apply grease to the spring of the power window regulator.

Fig 14: Applying MP Gear To Power Window Regulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR WIPER MOTOR
1. Disconnect the connector.
2. Disengage the connector and clamp.
3. Remove the service hole plug.
4. Unfasten the 3 bolts, then remove the rear wiper motor.
  
  Fig 15: Removing Rear Wiper Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque: 5.5 N.m (56 kgf°Cm, 49 in..lbf)
5. REMOVE BACK DOOR LOCK
  1. Remove the back door handle protector.
  2. Disconnect the control cable from the back door outside handle.
  3. Using a screwdriver, remove the back door lock protector.
    NOTE: Tape the screwdriver tip before use.
  4. Remove the 3 bolts and back door lock.
    1. Torque: 8.0 N.m (82 kgf°Cm, 71 in..lbf)
6. REMOVE OUTSIDE GARNISH
  1. Remove the 2 service hole plugs.
  2. Remove the 2 nuts.
    
    Fig 16: Removing Service Hole Plug Nuts For Outside Garnish
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a screwdriver, remove the outside garnish.
    NOTE: Tape the screwdriver tip before use.
  4. Remove the 2 screws and outside handle from the outside garnish.
  5. Remove the nut and key cylinder from the outside garnish.
  6. Remove the 4 screws and licence plate light assembly from the outside garnish.
7. w/ Rear spoiler:
  REMOVE REAR SPOILER
8. w/ o Rear spoiler:
  REMOVE HIGH MOUNT STOP LIGHT
  
  Fig 17: Identifying Clip Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002