Back Door: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
REMOVE ASSIST GRIP
1. Using a screwdriver, remove the 2 assist grip plugs.
  HINT:
  
  Tape the screwdriver tip before use.
2. Remove the 2 screws and assist grip.
REMOVE BACK DOOR INSIDE HANDLE BEZEL
REMOVE CENTER BACK DOOR GARNISH
1. Using a screwdriver, remove the center back door garnish.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 1: Removing Center Back Door Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR GARNISH
1. Using a screwdriver, remove the center back door garnish.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 2: Removing Back Door Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR WIPER ARM
1. Open the cover.
2. Remove the nut and rear wiper arm.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
3. Remove the grommet.
  
  Fig 3: Removing Rear Wiper Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR WIPER MOTOR AND LINK ASSEMBLY
1. Disconnect the connector.
2. Remove the 2 bolts.
3. Unfasten the 3 bolts and remove the rear wiper motor and link assembly.
Fig 4: Removing Rear Wiper Motor & Link Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR WIPER MOTOR RELAY
1. Remove the bolt and rear wiper motor relay.
REMOVE BACK DOOR WEATHERSTRIP
1. Remove the back door weatherstrip.
  NOTE: Do not pull strongly on the weatherstrip as it may tear.
  
  Fig 5: Removing Back Door Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR INSIDE HANDLE
1. Remove the 2 bolts.
2. Disconnect the back door lock locking rod and back door lock inside opening link, and then remove the back door inside handle.
  
  Fig 6: Removing Back Door Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK CONTROL ASSEMBLY
1. Disconnect the links.
2. Remove the 3 bolts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 7: Removing Back Door Lock Control Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the connector, and then remove the back door control.
  HINT:
  
  At the time of reassembly, please refer to the following item. Apply MP grease to the sliding surface of the back door control.
  
  Fig 8: Removing Back Door Control
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR OUTSIDE HANDLE
1. Using a screwdriver, remove the back door outside handle.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 9: Removing Back Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and back door outside handle assembly.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Fig 10: Removing Back Door Outside Handle Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LICENSE PLATE LIGHTS
REMOVE BACK DOOR LOCK ASSEMBLY
1. Remove the 4 bolts and back door lock.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
REMOVE BACK DOOR LINK PROTECTOR
REMOVE REAR MAT SET PLATE
1. Remove the 5 screws.
2. Using a screwdriver, remove the rear mat set plate.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 11: Removing Rear Mat Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR TRIM PANEL ASSEMBLY
1. Insert a screwdriver between the door and door trim to pry out.
  HINT:
  
  Tape the screwdriver tip before use.
2. Remove the back door trim.
  
  Fig 12: Removing Back Door Trim
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOWER TORSION BAR ASSEMBLY
1. Remove the rear bumper (see REMOVAL ).
2. Remove the 4 bolts and lower torsion bar as shown in Fig 13 .
3. Remove the torsion bar guide.
  
  Fig 13: Removing Lower Torsion Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR INSIDE HANDLE
1. Remove the screw and back door inside handle.
2. Remove the spacer.
  
  Fig 14: Removing Screw & Back Door Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK CONTROL ASSEMBLY
1. Remove the 2 screws.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Disconnect the back door lock control cables, and then remove the back door control.
Fig 15: Disconnecting Back Door Lock Control
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SERVICE HOLE COVER
NOTE: Do not tear the service hole cover.
REMOVE BACK DOOR KEY CYLINDER
1. Disconnect the connector.
2. Remove the 2 bolts and key cylinder.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 16: Removing Key Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK
1. Disconnect the control cable from the clamp.
2. Using a "torx" wrench, remove the 3 screws and back door lock.
  - "Torx" wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  - Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  Fig 17: Removing Back Door Lock (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of reassembly, please refer to the following item. Apply MP grease to the rotating parts of the door lock.
3. Employ the same manner described above to the other side.
  
  Fig 18: Removing Back Door Lock (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR LIGHT ASSEMBLY
1. Disconnect the connector.
2. Remove the 2 nuts.
3. Using a screwdriver, remove the rear light.
  HINT:
  
  Tape the screwdriver tip before use.
4. Employ the same manner described above to the other side.
  
  Fig 19: Removing Rear Light
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TAIL GATE STAY SUB-ASSEMBLY
1. Using a torx wrench, remove the 2 screws and tail gate stay.
  "Torx" wrench:
  
  T30 (Part No. 09042-00010 or locally manufactured tool)
  
  Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf)
2. Employ the same manner described above to the other side.
  
  Fig 20: Removing Tail Gate Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002