Modification Procedure
1. REMOVE REAR WIPER ARM AND BLADE ASSEMBLY2. REMOVE INSIDE UPPER DOOR TRIM PANEL (PLASTIC TRIM NEXT TO REAR WINDOW)
^ Grab the trim panel with both hands and pull it away from the door panel. NOTE: If the retaining clips become detached from the plastic trim and stick to the holes in the back door, pull the clips out of the holes in the backdoor and re-attach the clips to the trim panel before reinstalling the trim panel
3. REMOVE THE INSIDE LOWER TRIM PANEL
^ Remove the two rectangular access covers in the panel.
^ Remove the six plastic screw type retainers and pull the lower panel away from the door panel. A tape wrapped flat blade screwdriver used as a pry bar will aid in the removal of the lower trim panel
4. REMOVE THE TWO COMBINATION LAMPS
^ Twist the bulb socket out of the housing and pull the wiring connector away from the back door panel. Let the bulb socket and wiring harness hang down freely.
^ Remove the four attaching nuts for each combination lamp housing and remove both lamp housings from the outside of the back door panel. (See the attached illustration of the rear door assembly).
5. REMOVE THE LICENSE PLATE LAMPS (2)
^ Disconnect the wiring connectors.
^ Remove the two nuts from each lamp housing.
^ Remove the lamp housings from the outside of the back door panel.
6. REMOVE THE LICENSE PLATE ATTACHING SCREWS AND THE LICENSE PLATE
7. IF SO EQUIPPED, DISCONNECT AND MOVE THE ELECTRIC DOOR LOCK ACTUATOR (THIS WILL ALLOW ACCESS TO SEVERAL OF THE NUTS HOLDING THE GARNISH PANEL TO THE BACK DOOR).
^ Remove the lock rod protector plate.
^ Remove one end of all three actuator rods.
^ Remove the four bolts attaching the actuator to the back door.
^ Slide the actuator to the right (approximately 8 to 10 inches).
NOTE: Put the wooden block or several shop towels over the latch on the floor of the vehicle to prevent the lock mechanism on the back door from engaging the latch on the floor.
8. DISCONNECT THE WIPER MOTOR
^ Remove the three bolts.
^ Remove the wire connector and move the wiper motor out of the way to gain access to the nuts holding the garnish moulding to the back door.
9. REMOVE THE BACK DOOR GARNISH PANEL
^ Remove the five attaching nuts (A small, 1/4" drive universal or a 10 mm universal socket will aid in the removal of the nuts).
^ To facilitate panel removal and minimize breakage of the plastic retaining clips, use the long needle nose pliers or the angled needle nose pliers to squeeze the tabs together on the clips. (This can be done through the access holes in the back door).
^ When removing the panel end clips, it may be necessary to insert a long flat blade screwdriver through one of the access holes in the back door panel to force the tabs together. To prevent panel damage, it may be helpful to use a medium flat blade screwdriver (with protective tape wrapped around the metal shank) to separate the garnish panel and the back door housing.
10. REMOVE THE ORIGINAL PANEL EDGE PROTECTOR
^ Place the garnish panel on a flat work bench. IMPORTANT: Use a fender cover or cloth blanket under the plastic garnish panel to protect it from scratching.
^ Pull the original lower panel edge protector off of the garnish panel and discard the protector.
^ Clean all of the adhesive from the area where the edge protector was attached to the garnish panel. Use one of the grease, wax and silicone removing products or equivalent listed in the tools and materials section.
11. INSTALL THE NEW EDGE PROTECTOR
^ Peel the white adhesive cover strip from the new edge protector.
^ Press the new protector on the lower edge of the garnish panel. Be sure to install the protector so that the triangular cuts in the protector face the inside of the garnish panel.
12. INSPECT THE LOWER PORTION OF THE OUTER PANEL OF THE BACK DOOR FOR PAINT DAMAGE. YOU MAY ENCOUNTER ONE OF FOUR POSSIBILITIES:
A. No damage to paint found.
B. Minor paint damage (Paint not rubbed through to bare metal).
C. Moderate paint damage (Paint rubbed through to bare metal, either no rust or minor rust encountered in the area).
D. Severe paint damage (Paint rubbed through with rust bubbles or flakes).
NOTE: Procedures C and D may require the assistance of a qualified body paint technician.
13. REPAIR THE PAINTED AREA AS FOLLOWS:
A. No damage to paint - no repair necessary, B. Minor Paint damage
^ Clean the affected area with the wax, grease and silicone remover specified in the tools and materials section.
^ Use the 1/4 or 1/2 inch masking tape to mask off the affected area. (See illustration below).
^ Brush on two coats of Toyota Touch-up paint. You will find the vehicle paint code on the front I.D. plate located on the engine cowl. Allow 1/2 hour drying time between coats. The final coat should dry approximately 4 hrs. at 70 F., 6 hrs. at 50~ F. before proceeding to the next step.
C. Moderate paint damage -
^ Clean the affected area with the wax, grease and silicone remover specified in the tools and materials section.
^ Use metal prep cleaner, according to the instructions on the container.
^ Use the conversion coating, according to the instructions on the container.
^ Use 1/4 or 1/2 inch masking tape to mask off the affected area. (See illustration on page 3).
^ Brush on two coats of Toyota Touch up paint. You will find the vehicle paint code on the front I.D. plate located on the engine cowl. Allow 1/2 hour drying time between coats. The final coat should dry approximately 4 hrs. at 70~ F., 6 hrs. at 50~ F before proceding to the next step.
D. Severe Paint damage -
^ Clean the affected area with the wax, grease and silicone remover specified in the tools and materials section.
^ Scuff sand and then feather edge the affected area.
^ Remove any rust with a wire brush or other suitable device.
^ Remove any remaining rust with metal prep cleaner according to the instructions on the container.
^ Use a self etching primer. Do not use a lacquer base primer.
^ Top coat the affected area with an acrylic urethane or polyurethane type paint. Do not use a lacquer top coat.
NOTE: Carefully read all labels on the products specified in this bulletin.
14. INSTALL GUARD TAPE
^ After allowing the paint to dry completely, clean the area shown below with a wax, grease and silicone remover specified in the tools and equipment section of this bulletin.
^ Install one left hand and one right hand guard tape to the outside of the back door as shown in the illustration below.
15. INSTALL RUBBER STOPPER STRIPS
^ Install three rubber stopper strips to the lower, outer portion of the back door as shown in the illustration below.
16. REINSTALL THE GARNISH PANEL IN THE REVERSE ORDER OF DISASSEMBLY. NOTE:
^ When installing the garnish panel, be sure the rubber grommet around the door handle/ door lock actuator is in the proper position (If the grommet slips out of place, water may enter the back door and find its way to the carpet on the rear floor).
17. ENSURE THAT ALL LAMPS, WIPER AND DOOR LOCK FUNCTION PROPERLY.
18. FILL OUT AND INSTALL THE COMPLETION LABEL.
After completing repair and before returning the vehicle to a customer, a SSC completion label must be affixed to the engine cowl next to the factory I.D. plate.
The label is to be filled out as follows:
Additional SSC completion labels (P/N 00410-01917) may be ordered through the non-parts system on a 1450 order form or through the TDN system.