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Body Mechanical PDF
Body Mechanical PDF
Body Mechanical PDF
COMPONENTS
Clip
Clip
Spacer
Spacer
Assist Grip
Assist Grip Plug
INSTALLATION
Adhesive
1. CLEAN AND SHAPE CONTACT SURFACE OF DOOR
PANEL
(a) Using a knife, cut away any rough areas on the door pan-
el.
HINT:
Leave as much of the adhesive on the door panel as possible.
(b) Clean the cutting surface of the adhesive with a piece of
BO4420
shop rag saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the door pan-
el.
BO5231
G H
H04494
H04079
H04080
7. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
a HINT:
After cutting off the tip, use all adhesive within the time de-
a scribed in the table below.
Temperature Tackfree time
35 C (95 F) 15 minutes
20 C (68 F) 100 minutes
5 C (41 F) 8 hours
(b) Load the cartridge into the sealer gun.
a-a
A (c) Coat the glass with adhesive, as shown in the illustration.
A: 8.0 mm (0.315 in.)
B: 12.0 mm (0.472 in.)
8. INSTALL BACK DOOR GLASS
B (a) Install the glass to the body.
(b) Hold back window glass in place securely with protective
tape or equivalent until the adhesive hardens.
NOTICE:
H04081
Take care not to drive the vehicle during the time described
in the table below.
Temperature Minimum time prior to moving a car
35 C (95 F) 1.5 hours
20 C (68 F) 5 hours
5 C (41 F) 24 hours
9. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the hardening time has elapsed.
(b) Seal any leak with sealant.
Part No. 08833-00030 or equivalent.
10. INSTALL REAR WIPER ARM (See page BO-42 )
: 10 Clips 11. INSTALL BACK DOOR GARNISH
H04848
a b
a-a b-b
H04847
REMOVAL
1. REMOVE ASSIST GRIP
(a) Using a screwdriver, remove the 2 assist grip plugs.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws and assist grip.
2. REMOVE INSIDE HANDLE BEZEL
a b
a b
a-a b-b
H04847
: 10 Clips
4. REMOVE BACK DOOR GARNISH
Using a screwdriver, remove the back door garnish.
HINT:
Tape the screwdriver tip before use.
5. REMOVE REAR WIPER ARM (See page BO-38 )
H04848
H04076
NOTICE:
Protective Tape
When separating the glass, take care not to damage the
paint and exterior ornaments.
(d) Cut the adhesive by pulling the piano wire around it.
(e) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.
H04077
REPLACEMENT
1. REMOVE BACK DOOR STAY
(a) Remove the bolts and back door stay from the back door.
HINT:
While supporting the back door with your hand, remove the
back door stay.
(b) Remove the bolt and back door stay from the body.
2. IF NECESSARY, REPLACE BACK DOOR STAY
NOTICE:
When handling the back door stay.
Do not disassemble the back door stay because the
cylinder is filled with pressurized gas.
COMPONENTS
H05285
INSTALLATION
1. CLEAN BODY MOUNTING SURFACE
(a) Using a heat light, heat the body mounting surface to 40
- 60 C (104 - 140 F).
NOTICE:
Do not heat the body excessively.
(b) Wipe off stains with cleaner.
2. If reusing the moulding:
CLEAN MOULDING
(a) Using a heat light, heat the moulding surface to 20 - 30
C (68 - 86 F).
NOTICE:
Do not heat the moulding excessively.
(b) Remove the adhesive tape from the moulding.
(c) Wipe off stains with cleaner.
(d) Apply new adhesive tape to moulding as shown in the il-
lustration.
Outside Rear
Adhesive Tape Door Moulding
Adhesive Tape
Adhesive Tape
Outside Quarter Moulding
H05286
3. INSTALL MOULDING
(a) Using a heat light, heat the body and moulding.
Body: 40 - 60 C (104 - 140 F)
Moulding: 20 - 30 C (68 - 86 F)
NOTICE:
Do not heat the body and moulding excessively.
(b) Lift moulding release sheet from the face of moulding.
NOTICE:
When the moulding release sheet is removed, make sure
that no dirt of dust can get onto the uncoated area.
BO5229
CLIP
BO023-04
REPLACEMENT
The removal and installation methods of typical clips used in body parts are shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.
Pliers
Clip Remover
Screwdriver
Scraper
V00005
2004 LAND CRUISER (RM1071U)
Removal Installation
V00012
FRONT BUMPER
BO1J6-03
COMPONENTS
Radiator Grille
58 (590, 43)
58 (590, 43)
58 (590, 43)
Energy Absorber
58 (590, 43)
Fog Light
Fog Light
SST ADJUSTMENT
1. ADJUST DOOR IN FORWARD/BACKWARD AND VER-
TICAL DIRECTIONS
Using SST, loosen the body side hinge bolts to adjust.
SST 09812-00010
Torque: 23 Nm (235 kgfcm, 17 ftlbf)
H04760
H04761
BO2556
FRONT DOOR
BO1JA-04
COMPONENTS
Door Glass
Outside Handle
Door Glass Run
Lower Frame
Inside Handle
Door Lock Link Tweeter Speaker
5.0 (51, 44 in.lbf)
Protector
8.0 (82, 71 in.lbf)
Door Inside
Handle Bezel
Lower Frame
No. 1
Bracket Garnish
8.0 (82, 71 in.lbf)
Service
Window Regulator Hole Cover
8.0 (82, 71 in.lbf) Door Inside
Handle Bezel No. 2
Power Window Switch
Door Check 23 (235, 17)
27 (275, 20)
Door Trim
23 (235, 17)
26 (265, 19)
Door Hinge
Nm (kgfcm, ftlbf) : Specified torque
Precoated part H20972
:2 Clips DISASSEMBLY
1. REMOVE LOWER FRAME BRACKET GARNISH
Using a screwdriver, remove the lower frame bracket garnish.
HINT:
Tape up the screwdriver tip before use.
H04748
H04749
H21407
H21408
H04752
H04756
H21413
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-9 ).
FRONT SEAT
BO1KT-04
COMPONENTS
Headrest
Headrest Support
Hog Ring Seatback Frame
Armrest
Seatback Cover w/ Side Airbag:
Armrest Cap 4.7 (48, 42 in.lbf)
Seatback Pad
Seatback Board
37 (380, 27)
Armrest Bush
Seat Cushion Cover
21 (210, 15)
Seat Position Control Relay
Seat Cushion
Inner Shield 21 (210, 15) 5.5 (56, 49 in.lbf)
Reclining Adjuster Inside Shield
42 (430, 31)
DISASSEMBLY
1. REMOVE HEADREST
H03732
H03733
(e) Remove the 3 screws and the power seat switch from the
seat cushion outer shield.
(f) Remove the 2 screws and lumber support switch from the
seat cushion outer shield.
H03734
H03735
H03736
H04737
H04738
H20963
H21292
H20961
H04468
H18929
INSTALLATION
Installation is in the reverse order of removal (See page BO-105 ).
REASSEMBLY
1. Drivers Side:
INSTALL SEAT POSITION SENSOR
Install the seat position sensor with a new bolt, then connect the
connector.
Part No.:
Bolt: 90119-06871
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
H18929
2. INSTALL SEAT POSITION CONTROL RELAY
Install the seat position control relay with the 2 bolts, then con-
nect the connectors.
Torque: 5.5 Nm (56 kgfcm, 49 in.lbf)
H04785
H04468
H21292
6. w/ Side Airbag:
INSTALL SEATBACK FRAME
(a) Install the seatback cover to the seatback frame.
(b) Install new hog rings, the clamps and the 2 bolts.
Torque: 4.7 Nm (48 kgfcm, 42 in.lbf)
(c) Install the 2 headrest supports.
7. INSTALL SEATBACK ASSEMBLY
(a) w/o Side Airbag:
H20961 Install the RH reclining adjuster inside shield with a screw.
H19941
H20959
H04738
H04737
H03736
H03735
H03733
REMOVAL
1. REMOVE SEAT TRACK OUTER COVERS
Using a screwdriver, remove the 4 seat track outer covers.
HINT:
Tape up the screwdriver tip before use.
2. REMOVE FRONT SEAT
(a) Remove the 4 bolts.
Torque: 42 Nm (430 kgfcm, 31 ftlbf)
(b) Disconnect the connectors, then remove the front seat.
NOTICE:
When handling the airbag connector, take care not to damage the airbag wire harness.
Be careful not to damage the body.
REPLACEMENT
HINT:
Following is the seat heater replacement procedure.
Care should be taken during operation to protect the seat
cover from scratches, dirt or accidental cut of thread.
H13373
H13388
(e) Remove the tack pins which are fastened to the heater.
(f) Remove the seat heater from the seat cushion cover.
H13374
2. Seatback cover:
REMOVE SEAT HEATER
(a) Remove the hog rings and the wires.
(b) Remove the seatback cover from the pad.
(c) Turn the seatback cover inside out.
H13381
H13389
(e) Remove the tack pins which are fastened to the seat heat-
er.
(f) Remove the seat heater from the seatback cover.
3. INSTALL SEAT HEATER TO SEAT COVER
Using a tacker, install a new seat heater to the seat cushion cov-
er with tack pins.
Tacker: BANZAI 303XT or equivalent
NOTICE:
H13374 Do not substitute other metal parts for the of tack pins. In-
sufficient distance between the heater and the cover may
result in damage to the heater.
HINT:
Illustration A and B:
Fasten the cover and the heater with the tack pins match-
ing the seam with the V slit of the heater.
Illustration C:
Fasten the out-stretch cloth pad and the heater with the
tack pins matching the edge of the cloth pad with the V slit
of the heater.
Sewing thread can be substituted for the tack pins. How-
ever, allow a distance of 6 - 7 mm (0.24 - 0.28 in.) be-
tween both sewed parts of the heater and the cover.
Seatback Cover: Seam
A :
B B
B B Tack Pin
B B V Slit
B B
Seat Heater
B :
A A Seat Heater
A A
Seam V Slit Tack Pin
B B
C B B C
C B B C C :
C C
B B
C C Tack Pin
B B
B B B B
C C
B B
C C
A A Seat Heater V Slit
H20974
H13373
H13381
ADJUSTMENT
2 - 2.5 mm ADJUST WASHER NOZZLE
(0.079 - 0.098 in.)
Using a tool like the one shown in the illustration, change the
direction of the nozzle hole to adjust the point where washer
fluid hits the windshield.
0.6 - 0.65 mm
(0.024 - 0.026 in.) BE3367
COMPONENTS
20 (204, 15)
Wiper Arm
Wiper Motor
5.4 (55, 48 in.lbf) 5.4 (55, 48 in.lbf)
Wiper Link
INSPECTION
INSPECT WASHER NOZZLE
While operating the washer, check if the point where the washer
fluid hits the windshield is within the range indicated by the
hatched line.
A: Approx. 311 mm (12.24 in.)
B: Approx. 110 mm (4.33 in.)
C: Approx. 86 mm (3.39 in.)
D: Approx. 116 mm (4.57 in.)
E: Approx. 205 mm (8.07 in.)
F: Approx. 22 mm (0.87 in.)
G: Approx. 138 mm (5.43 in.)
H: Approx. 60 mm (2.36 in.)
I: Approx. 85 mm (3.35 in.)
J: Approx. 364 mm (14.33 in.)
K: Approx. 496 mm (19.53 in.)
L: Approx. 81 mm (3.19 in.)
M: Approx. 35 mm (1.38 in.)
N: Approx. 157 mm (6.18 in.)
O: Approx. 159 mm (6.26 in.)
P: Approx. 63 mm (2.48 in.)
Q: Approx. 169 mm (6.65 in.)
R: Approx. 331 mm (13.03 in.)
S: Approx. 465 mm (18.31 in.)
T: Approx. 468 mm (18.43 in.)
U: Approx. 45 mm (1.77 in.)
V: Approx. 104 mm (4.09 in.)
W: Approx. 119 mm (4.69 in.)
X: Approx. 44 mm (1.73 in.)
A A
U H
M B
E D
C G
L I
W P
N
E
F Q F J
V S S
R
O
X
T K H04842
INSTALLATION
1. INSTALL WASHER NOZZLES
2. INSTALL WIPER LINK
Install the wiper link through the service hole, then torque the
6 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
HINT:
When installing the wiper link, connect the claw of wiper link to
the panel.
3. INSTALL WIPER MOTOR
(a) Connect the wiper motor to wiper link.
(b) Torque the 4 bolts.
(c) Connect the connector.
4. INSTALL COWL TOP VENTILATOR LOUVERS
H04844 (a) Install the cowl top ventilator louver LH.
(b) Install the cowl top ventilator louver RH.
5. INSTALL HOOD TO COWL TOP SEAL
6. INSTALL WIPER ARMS
(a) Operate the wipers once and turn the wiper switch OFF.
(b) Install the wiper arms and tighten nuts by hand.
REMOVAL
1. REMOVE WIPER ARMS
(a) Remove the 2 caps and 2 nuts.
(b) Remove the 2 wiper arms.
2. REMOVE HOOD TO COWL TOP SEAL
3. REMOVE COWL TOP VENTILATOR LOUVERS
(a) Remove the cowl top ventilator louver RH.
(b) Remove the cowl top ventilator louver LH.
H04841
H00735
ADJUSTMENT
2 - 2.5 mm ADJUST WASHER NOZZLE
(0.079 - 0.098 in.)
Using a tool like the one shown in the illustration, change the
direction of the nozzle hole to adjust the point where washer
fluid hits the windshield.
0.6 - 0.65 mm
(0.024 - 0.026 in.) BE3367
COMPONENTS
20 (204, 15)
Wiper Arm
Wiper Motor
5.4 (55, 48 in.lbf) 5.4 (55, 48 in.lbf)
Wiper Link
INSPECTION
INSPECT WASHER NOZZLE
While operating the washer, check if the point where the washer
fluid hits the windshield is within the range indicated by the
hatched line.
A: Approx. 311 mm (12.24 in.)
B: Approx. 110 mm (4.33 in.)
C: Approx. 86 mm (3.39 in.)
D: Approx. 116 mm (4.57 in.)
E: Approx. 205 mm (8.07 in.)
F: Approx. 22 mm (0.87 in.)
G: Approx. 138 mm (5.43 in.)
H: Approx. 60 mm (2.36 in.)
I: Approx. 85 mm (3.35 in.)
J: Approx. 364 mm (14.33 in.)
K: Approx. 496 mm (19.53 in.)
L: Approx. 81 mm (3.19 in.)
M: Approx. 35 mm (1.38 in.)
N: Approx. 157 mm (6.18 in.)
O: Approx. 159 mm (6.26 in.)
P: Approx. 63 mm (2.48 in.)
Q: Approx. 169 mm (6.65 in.)
R: Approx. 331 mm (13.03 in.)
S: Approx. 465 mm (18.31 in.)
T: Approx. 468 mm (18.43 in.)
U: Approx. 45 mm (1.77 in.)
V: Approx. 104 mm (4.09 in.)
W: Approx. 119 mm (4.69 in.)
X: Approx. 44 mm (1.73 in.)
A A
U H
M B
E D
C G
L I
W P
N
E
F Q F J
V S S
R
O
X
T K H04842
INSTALLATION
1. INSTALL WASHER NOZZLES
2. INSTALL WIPER LINK
Install the wiper link through the service hole, then torque the
6 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
HINT:
When installing the wiper link, connect the claw of wiper link to
the panel.
3. INSTALL WIPER MOTOR
(a) Connect the wiper motor to wiper link.
(b) Torque the 4 bolts.
(c) Connect the connector.
4. INSTALL COWL TOP VENTILATOR LOUVERS
H04844 (a) Install the cowl top ventilator louver LH.
(b) Install the cowl top ventilator louver RH.
5. INSTALL HOOD TO COWL TOP SEAL
6. INSTALL WIPER ARMS
(a) Operate the wipers once and turn the wiper switch OFF.
(b) Install the wiper arms and tighten nuts by hand.
REMOVAL
1. REMOVE WIPER ARMS
(a) Remove the 2 caps and 2 nuts.
(b) Remove the 2 wiper arms.
2. REMOVE HOOD TO COWL TOP SEAL
3. REMOVE COWL TOP VENTILATOR LOUVERS
(a) Remove the cowl top ventilator louver RH.
(b) Remove the cowl top ventilator louver LH.
H04841
H00735
HOOD BO1J8-03
ADJUSTMENT
HINT:
Since the centering bolt is used as a hood hinge set bolt, the
hood cannot be adjusted with it on. Substitute the bolt with a
washer for the centering bolt.
Centering Bolt Bolt with Washer
BO5235
H04837
H04838
H04839
REPLACEMENT
1. REMOVE HOOD SUPPORT
(a) Remove the bolt and hood support from the hood.
HINT:
While supporting the hood by hand, remove the hood support
from the hood.
(b) Remove the bolt and hood support.
2. IF NECESSARY, REPLACE HOOD SUPPORT
NOTICE:
Handling the hood support
Do not disassemble the support as the cylinder is
filled with pressurized gas.
INSTRUMENT PANEL
BO1KK-04
COMPONENTS
Center Register
Reinforcement H Radio With A/C Control Assembly
H
A A
A H
Floor Brace
I
H
I No. 3 Heater to
A Register Duct
No. 1 Brace Center Lower Front Ash Receptacle Retainer
A
Cluster Finish Panel F
E Front Ash F Lower No. 2
No. 4 Heater to E
Receptacle Box Panel
Register Duct F
C
J C Glove Compartment No. 1 Under Cover
J Door Damper
C Console Box F
C Transfer
Hole Cover
C
Shift F Glove Compartment Door
20 (204, 15) Front Console Lever
w/ Disc Player
Box bracket Knob Front
C Combination Meter Changer:
Console
Instrument Panel Panel F H
Front B
No. 2 Heater to D B
Console Box B H
Register Duct D F H F B
Rear Console B H
B B
Box B H H
B H
Cluster Finish C F B
H H
Panel C Rear Console Box
C H H
F Rear Radio
Combination H Control Panel
Switch F
LH Lower Panel
Lower No. 1 Panel Console Rear End Panel
E
50 (510, 37) E
Steering Wheel Pad
Steering Wheel
Column Cover
Front Pillar Garnish
Instrument Panel
Center Bracket
G
6.0 (61, 53 in.lbf)
Front Passenger
Airbag Assembly
Defroster Nozzle
G G
G
G 6.0 (61, 53 in.lbf)
G No. 2 Side Defroster
Nozzle Duct
G
No. 1 Side Defroster
Nozzle Duct
G
G
G
G No. 4 Register
G
No. 1 Heater to
Register Duct
No. 1 Register No. 5 Heater to
Register Duct
HINT:
Screw shapes and sizes are indicated in the table below. The codes (A to I) correspond to those indicated
on the previous page.
mm (in.)
Shape Size Shape Size Shape Size
=8 =6
=6
(0.31) (0.24)
A B L =18 C (0.24)
L =16 L =16
(0.63) (0.71)
(0.63)
=6 =6 =5
(0.24) (0.24) (0.20)
D L =11 E L =16 F L =16
(0.43) (0.63) (0.63)
=5 =5
(0.20) (0.20) =8
G H I (0.31)
L =14 L =14
(0.55) (0.55)
=6
J
(0.24)
H21419
DISASSEMBLY
1. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT
2. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT
3. REMOVE DEFROSTER NOZZLE
4. REMOVE CENTER BRACKET
5. REMOVE NO. 1 HEATER TO REGISTER DUCT
6. REMOVE INSTRUMENT PANEL WIRE HARNESS
7. REMOVE NO. 5 HEATER TO REGISTER DUCT
INSTALLATION
1. INSTALL REINFORCEMENT
2. INSTALL NO. 1 BRACE
3. INSTALL FLOOR BRACE
4. INSTALL GLOVE COMPARTMENT DOOR DAMPER
5. INSTALL NO. 4 HEATER TO REGISTER DUCT
6. INSTALL NO. 3 HEATER TO REGISTER DUCT
7. INSTALL ECM (See page SF-60 )
H18914
H21406
H20954
H20955
H18913
H21422
A
B
C
C
H21421
Check Pin
H05279
H04808
H21657
H21283
H21279
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-89 ).
REMOVAL
1. w/ CD Changer Built In The Audio System:
SHIP MODE SETTING
(a) Take out all of the CDs.
NOTICE:
If they cannot be taken out, do not attempt to take out forci-
bly and send the unit for repair.
H20976
HINT:
When the ship mode has been set, SHIP must be displayed.
(c) Turn the ignition switch to OFF and disconnect the battery
negative cable.
NOTICE:
Connecting the battery negative cable automatically end
the ship mode.
H20977
H18904
H21657
H04808
H04807
H21418
H18912
H20954
H20955
H21406
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Loosen the door side hinge bolts to adjust.
Torque: 28 Nm (286 kgfcm, 21 ftlbf)
H04871
H04872
COMPONENTS
Control Cable
Back Door Inside Handle
5.0 (51, 44 in.lbf) Spacer
5.0 (51, 44 in.lbf)
Clip
Rear Light Assembly
x5 28 (286, 21)
31 (316, 23)
DISASSEMBLY
1. REMOVE REAR MAT SET PLATE
(a) Remove the 5 screws.
(b) Using a screwdriver, remove the rear mat set plate.
HINT:
Tape the screwdriver tip before use.
H05258
H04862
H04869
H04863
H04865
H04866
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the rotating parts of the door lock.
(c) Employ the same manner described above to the other
side.
H04867
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-27 ).
COMPONENTS
Roof Headlining Rear Trim
Striker Plate
Quarter Window
Glass Weatherstrip
Striker Plate
Rear Mat
Rear Vent Window Motor Striker Plate
Quarter Window
Glass
x5
INSTALLATION
Installation is in the reverse order of removal (See page BO-62 ).
: 5 Clips REMOVAL
1. REMOVE ROOF HEADLINING REAR TRIM
Using a screwdriver, remove the roof headlining rear trim.
HINT:
Tape up the screwdriver tip before use.
2. REMOVE REAR NO. 2 SEATS
H05257
H05258
Clip H05403
H04110
COMPONENTS
INSTALLATION
1. INSTALL NO. 2 ROOF DRIP SIDE FINISH MOULDING CLIP
If the No. 2 roof drip side finish moulding clip comes off.
(a) Using a heat light, heat the body mounting surface to 40 - 60 C (104 - 140 F).
NOTICE:
Do not heat the body excessively.
(b) Remove the adhesive tape and adhesive from the body.
(c) Wipe off stains with cleaner.
(d) Using a heat light, heat the body and clip.
Body: 40 - 60 C (104 - 140 F)
Clip: 20 - 30 C (68 - 86 F)
NOTICE:
Do not heat the body and clip excessively.
(e) Install the clip.
2. INSTALL NO. 2 ROOF DRIP SIDE FINISH CENTER MOULDING
Install the No. 2 roof drip side finish center moulding to the roof drip side finish moulding.
3. INSTALL ROOF DRIP SIDE FINISH MOULDING
REMOVAL
1. REMOVE NO. 2 ROOF DRIP SIDE FINISH CENTER
MOULDINGS
2. REMOVE ROOF DRIP SIDE FINISH MOULDING
Using a moulding remover, remove the roof drip side finish
moulding.
NOTICE:
Do not damage the body.
Do not remove the No. 2 roof drip side finish moulding
clip.
When the clip comes off, replace it with a new one.
HINT:
Tape the moulding remover tip before use.
H05400
REAR BUMPER
BO1J7-03
COMPONENTS
19 (195, 14)
19 (195, 14)
Reflex Reflector
20 (204, 15)
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/BACKWARD AND VER-
TICAL DIRECTIONS
(a) Remove the front door scuff plate.
(b) Remove the rear door scuff plate.
(c) Remove the front door opening trim.
(d) Remove the rear door opening trim.
(e) Remove the center pillar lower garnish.
H04832
H04833
BO2556
REAR DOOR
BO1JE-03
COMPONENTS
Division Bar
Quarter Window Glass
with Weatherstrip Door Glass Run
Outside Handle
Door Check
Cover
23 (235, 17) 26 (265, 19)
27 (275, 20)
Door Courtesy Light Speaker
Door Trim
23 (235, 17)
26 (265, 19)
DISASSEMBLY
1. REMOVE DOOR INSIDE HANDLE BEZEL No. 2
Using a screwdriver, remove the door inside handle bezel No.
2 as shown in the illustration.
HINT:
Tape up the screwdriver tip before use.
H21407
H21408
H04820
H04752
H21409
H04824
H04825
H04826
H21415
H04829
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-15 ).
COMPONENTS
42 (430, 31)
Rear Seat Shoulder
Rear Seat
Headrest Belt Cover
Shoulder Belt Guide
Rear Seat Outer Belt
Seatback Cover 42 (430, 31)
No. 1 Reclining Cover
Headrest Support Seatback Pad
Corner Pad
Seatback Board
Rear No. 1
Seat Adjuster Reclining Adjuster
Release Handle
41 (420, 30)
Rear Seat
Seat Cushion Stay
Under Cover
Sub-Assembly Lock Striker
Stay Cover RH No. 1 Leg
C LH No. 1 Leg Stay
Stay
Nm (kgfcm, ftlbf) : Specified torque
Non-reusable part H16046
DISASSEMBLY
1. REMOVE HEADRESTS
H05304
H05308
H05321
H05329
H07957
H07940
H05324
HINT:
At the time of reassembly, please refer to the following items.
Tighten the 2 screws on the seatback side.
Fold down the seatback forward and raise it up to the first
lock position.
Turn A to the rear side of the seat cushion for initial posi-
tioning.
Check visually that the reference holes are penetrated.
A
H05730 Tighten the screws on the cushion side of seat belt reclin-
ing detecting part.
(b) Loosen the nut, remove the reclining connecting wire of
LH side edge.
H05325
H05326
H05327
H05333
INSTALLATION
Installation is in the reverse order of removal (See page BO-1 19).
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-120 ).
REMOVAL
REMOVE REAR NO. 1 SEAT
(a) Fold the seatback down.
(b) Unlock the seat lock, and swing the whole seat up and forward.
(c) Using a screwdriver, remove the seat leg covers.
HINT:
Tape the screwdriver tip before use.
(d) Remove the 4 bolts and rear No. 1 seat.
Torque: 37 Nm (380 kgfcm, 27 ftlbf)
COMPONENTS
Headrest
Seatback Pad
Headrest Support
Hog Ring
Reclining
Inner Rear No. 1
Cover Seat Inner Belt
Corner Pad
No. 1 Protector
Seatback Frame
41 (420, 30)
Reclining
Connecting Wire
Reclining Inner Cover Hinge Cover
37 (380, 27) Seat Cushion Cover
DISASSEMBLY
1. REMOVE HEADREST
2. REMOVE SEATBACK BOARD
Using a screwdriver, remove the seatback board as shown in
the illustration.
HINT:
Tape the screwdriver tip before use.
3. REMOVE RECLINING ADJUSTER RELEASE HANDLE
H05302
(a) Using a screwdriver, remove the cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw and reclining adjuster release handle.
4. REMOVE NO. 1 RECLINING COVER
(a) Remove the 4 hog rings and open the seatback cover.
HINT:
At the time of reassembly, please refer to the following item.
When installing hog rings, take care to prevent wrinkles as little
as possible.
(b) Remove the 2 corner pads.
H06471
H05305
H05306
H05310
INSTALLATION
Installation is in the reverse order of removal (See page BO-127 ).
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-128 ).
REMOVAL
REMOVE REAR NO.1 SEAT
(a) Fold the seatback down.
(b) Unlock the seat lock, and swing the whole seat up and forward.
(c) Using a screwdriver, remove the seat leg covers.
HINT:
Tape the screwdriver tip before use.
(d) Remove the 4 bolts and rear No.1 seat.
Torque: 37 Nm (380 kgfcm, 27 ftlbf)
COMPONENTS
Headrest Support
Headrest
Seatback Frame
Seatback Pad
41 (420, 30)
Seatback Cover
Seat Cushion Cover
Cushion
Seat Cushion Pad
41 (420, 30)
41 (420, 30)
Fold Seat Stopper
18 (184, 13) Rear Seat Stay
No. 2 Band
Seat Leg Seat Leg Rear
Cover
Seat Cushion
Under Cover
Seat Lock Striker Cover
DISASSEMBLY
1. REMOVE RECLINING ADJUSTER RELEASE HANDLE
(a) Using a screwdriver, remove the cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw and reclining adjuster release handle.
H04085
H04086
9. REMOVE ADJUSTER
A (a) Remove the 3 nuts.
(b) Remove the 4 bolts.
Torque:
A bolt: 18 Nm (185 kgfcm, 13 ftlbf)
B bolt: 37 Nm (380 kgfcm, 27 ftlbf)
A (c) Remove the adjuster.
B (d) Remove the seat leg bracket cover.
B
H04089 (e) Remove the 2 screws and seat leg No. 1 stay.
H04093
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-134 ).
ROOF HEADLINING
BO1KP-04
COMPONENTS
w/ Curtain Shield Airbag: Rear A/C Register
Assist Grip
Dome Light
Rear A/C Register
Room Temperature
Roof Headlining Sensor
Center Cap
Rear A/C Control Panel
Pillar Holder
Garnish Rear A/C Register
Overhead Map Lamp
Console Box
Lens
42 (430, 31)
Assist Grip Holder Striker Plate
Cap
Center Assist Grip Striker Plate
Center Pillar Garnish rear
Front Assist Grip Assist Grip
Striker Plate
Striker Plate x5
Rear Mat
Assist Grip Set Plate
Rear Door
Opening Trim
Rear
Assist Grip
Assist Grip Rear Mat
Center Pillar Striker Plate
Lower Garnish
Upper Roof
Center Assist Grip Side Inner Garnish
Assist Grip Quarter Trim
Front Door Assist Grip Jack Cover
Opening Trim Plug
Front Door Scuff Plate
Quarter Trim Panel
Front Assist Grip
Front Pillar Garnish
w/ Curtain Shield Airbag:
Center Assist Grip
Rear Door Center Pillar Garnish
42 (430, 31)
Scuff Plate
Cowl Side Trim
w/ Curtain Shield Airbag:
Center Pillar Lower Assist Grip Plug
Garnish Cover
Adjustable
Anchor
Assist
Nm (kgfcm, ftlbf) : Specified torque Grip 42 (430, 31)
H18921
INSTALLATION
Installation is in the reverse order of removal (See page BO-97 ).
: 5 Clips REMOVAL
1. REMOVE ROOF HEADLINING REAR TRIM
Using a screwdriver, remove the roof headlining rear trim.
HINT:
Tape up the screwdriver tip before use.
2. REMOVE REAR NO. 2 SEATS
H05257
H05258
H07941
H18904
Claw
H05264
: 4 Clips (b) Using a screwdriver, remove the center pillar lower gar-
nish as shown in the illustration.
HINT:
Tape up the screwdriver tip before use.
(c) Use the same manner described above to the other side.
H05265
H21424
w/o Curtain Shield Airbag (c) Using a clip remover, remove the clip.
(d) Using a screwdriver, remove the center pillar garnish.
HINT:
Tape up the screwdriver tip before use.
(e) Use the same manner described above to the other side.
22. REMOVE SUN VISOR
(a) Using a screwdriver, remove the caps.
HINT:
Tape the screwdriver tip before use.
w/ Curtain Shield Airbag (b) Remove the screws, then disconnect the connectors.
(c) Remove the sun visors.
23. REMOVE DOUBLE VISOR
Remove the screws and the double visors.
24. REMOVE HOLDER
Remove the screws and the holders.
H21425
H05268
H05270
ADJUSTMENT
2 - 2.5 mm ADJUST WASHER NOZZLE
(0.079 - 0.098 in.)
Using a tool like the one shown in the illustration, change the
direction of the nozzle hole to adjust the point where washer
fluid hits the back door glass.
0.7 - 0.75 mm
(0.028 - 0.030 in.) BE3367
COMPONENTS
Assist Grip
C INSPECTION
E
INSPECT WASHER NOZZLE
D
While operating the washer, check if the point where the washer
A F
fluid hits the back door glass is within the range indicated in the
B
G illustration.
A: Approx. 40 mm (1.57 in.)
B: Approx. 180 mm (7.09 in.)
C: Approx. 40 mm (1.57 in.)
H18919
D: Approx. 30 mm (1.18 in.)
E: Approx. 120 mm (4.72 in.)
F: Approx. 90 mm (3.54 in.)
G: Approx. 15 mm (0.59 in.)
INSTALLATION
1. INSTALL REAR WIPER MOTOR AND LINK AS-
SEMBLY
(a) Install the wiper motor and link assembly with 5 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(b) Connect the connector.
2. INSTALL BACK DOOR GARNISH
3. INSTALL CENTER BACK DOOR GARNISH
H18908
4. INSTALL INSIDE HANDLE BEZEL
5. INSTALL ASSIST GRIP
Install the assist grip with the 2 screws, then install the 2 assist
grip plugs.
6. INSTALL REAR WIPER ARM
(a) Install the grommet.
(b) Operate the wiper once and turn the wiper switch OFF.
(c) Install the wiper arm and tighten the nut by hand.
(d) Adjust the installation position of the wiper arm to the posi-
tion as shown in the illustration.
A: Approx. 38 10 mm (1.50 0.39 in.)
(e) Torque the nut.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(f) Close the cover.
A
H05251
REMOVAL
1. REMOVE REAR WIPER ARM
(a) Open the cover.
(b) Remove the nut and rear wiper arm.
(c) Remove the grommet.
2. REMOVE ASSIST GRIP
(a) Using a screwdriver, remove the 2 assist grip plugs.
HINT:
H04849
Tape up the screwdriver tip before use.
(b) Remove the 2 screws and assist grip.
3. REMOVE INSIDE HANDLE BEZEL
a b
a b
a-a b-b
H04847
H04848
H18908
DISPOSAL
HINT:
When scrapping vehicle equipped with an SRS or disposing of
a front seat outer belt (with seat belt pretensioner), always first
deploy the airbag in accordance with the procedure given in RS
section or activate the seat belt pretensioner. If any abnormality
occurs with the airbag deployment or seat belt pretensioner ac-
tivation, contact the SERVICE DEPT. of TOYOTA MOTORS
SALES, U.S.A., INC.. When disposing of a front seat outer belt
(with seat belt pretensioner) activated in a collision, follow the
same procedure given in step 1-(d) in DISPOSAL.
CAUTION:
Never dispose of front seat outer belt which has inac-
tivated pretensioner.
The seat belt pretensioner produces a sizeable ex-
SST ploding sound when it activates, so perform the op-
eration out-of-door and where it will not create a nui-
sance to nearby residents.
When activating the seat belt pretensioner, always
AB0152 use the specified SST. (SRS Airbag Deployment Tool)
Perform the operation in a place away from electrical
noise.
SST 09082-00700, 09082-00740
When activating a front seat outer belt (with seat belt
pretensioner), perform the operation at least 10 m (33
ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front
seat outer belt with activated pretensioner.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a front seat outer belt with
activated pretensioner.
AB0158
AB0152
AB0158
H04094
(2) Move the SST to at least 10 m (33 ft) away from the
front of the vehicle.
(3) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(4) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (-) termi-
10 m (33 ft) or more nal.
R13455 (d) Activate seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and activate the
seat belt pretensioner.
HINT:
The seat belt pretensioner operates simultaneously as the LED
of the SST activation switch lights up.
(e) Dispose of the front seat outer belt (with seat belt preten-
sioner).
CAUTION:
The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least
30 minutes after activation.
Use gloves and safety glasses when handling a front
seat outer belt with activated seat belt pretensioner.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a front seat outer belt with
activated seat belt pretensioner.
2. ACTIVATION WHEN DISPOSING OF FRONT SEAT
OUTER BELT ONLY
2004 LAND CRUISER (RM1071U)
HINT:
When scrapping a vehicle, activate the seat belt pretensioner
and scrap the vehicle with activated front seat outer belt still
installed.
NOTICE:
When disposing of the front seat outer belt (with seat
belt pretensioner) only, never use the customers ve-
hicle to activate the seat belt pretensioner.
Be sure to follow the procedure given below when ac-
tivating the seat belt pretensioner.
HINT:
Have a battery ready as the power source to activate the seat
belt pretensioner.
(a) Remove the front seat outer belt (See page BO-137 ).
HINT:
Cut the belt near the seat belt retractor.
Battery
SST
AB0158
H04099
(2) Place the front seat outer belt on the ground and
cover it with the disc wheel with tire.
NOTICE:
Place the front seat outer belt as shown in the illustration.
(3) Move the SST to at least 10 m (33 ft) away from the
disc wheel.
SST SST NOTICE:
Take care not to damage the SST wire harness.
H04100
(e) Dispose of the front seat outer belt (with seat belt preten-
sioner).
CAUTION:
The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least
30 minutes after activation.
Use gloves and safety glasses when handling a front
seat outer belt with activated seat belt pretensioner.
H04101 Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a front seat outer belt with
activated seat belt pretensioner.
(1) Remove the disc wheel and SST.
(2) Place the front seat outer belt in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts disposal.
INSPECTION
1. PRETENSIONER IS NOT ACTIVATED
(a) Perform a diagnostic system check (See page DI-692 ).
(b) Perform a visual check which includes the following items
with the front seat outer belt removed from the vehicle.
Check for cuts and cracks in, or marked discolor-
ation of the center pillar lower garnish.
Check for cuts and cracks in wire harness, and for
H07947
chipping in connectors.
Check for deformation of the center pillar.
CAUTION:
For removal and installation of the front seat outer belt, see
page BO-141 and BO-150 .
Be sure to follow the correct procedure.
2. PRETENSIONER IS ACTIVATED
(a) Perform a diagnostic system check (See page DI-692 ).
(b) Perform a visual check which includes the following items
with the front seat outer belt removed from the vehicle.
H04096
Check for deformation of the center pillar.
Check for damage on the connector and wire har-
ness.
H04097
INSTALLATION
NOTICE:
Never use seat belt pretensioner from another ve-
hicle. When replacing parts, replace them with new
parts.
Make sure that the front seat outer belt is installed
with the specified torque.
If the front seat outer belt has been dropped, or there
are cracks, dents or other defects in the case or con-
nector, replace the front seat outer belt with a new
one.
When installing the front seat outer belt, take care that
the wiring does not interfere with other parts and is
not pinched between other parts.
1. INSTALL RETRACTOR OF FRONT SEAT OUTER BELT
(a) Install the retractor of front seat outer belt with the bolt.
Torque:
Upper bolt: 4.9 Nm (50 kgfcm, 43 in.lbf)
H05265
REMOVAL
NOTICE:
If the wiring connector of the seat belt pretensioner
is disconnected with the ignition switch at ON or ACC,
diagnostic trouble codes will be recorded.
Never use seat belt pretensioner from another ve-
hicle. When replacing seat belt pretensioner, replace
it with a new one.
1. REMOVE FRONT DOOR SCUFF PLATE
2. REMOVE FRONT DOOR OPENING TRIM
3. REMOVE REAR DOOR SCUFF PLATE
4. REMOVE REAR DOOR OPENING TRIM
Claw
H05264
: 4 Clips (b) Using a screwdriver, remove the center pillar lower gar-
nish as shown in the illustration.
HINT:
Tape the screwdriver tip before use.
6. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR
7. REMOVE FRONT SEAT OUTER BELT FLOOR AN-
CHOR
H05265 8. REMOVE RETRACTOR OF FRONT SEAT OUTER
BELT
CAUTION:
Never disassemble the retractor of front seat outer belt.
NOTICE:
When removing the retractor of front seat outer belt, take
care not to pull the seat belt pretensioner wire harness.
REPLACEMENT
REPLACE REQUIREMENTS
In the following cases, replace the seat belt pretensioner.
If the seat belt pretensioner has been activated.
If the seat belt pretensioner has been found to be faulty in troubleshooting.
If the front seat outer belt has been found to be faulty during the check of items 1-(b) or 2-(b).
If the front seat outer belt has been dropped.
CAUTION:
For removal and installation of the seat belt pretensioner, see page BO-141 and BO-150 .
Be sure to follow the correct procedure.
SEAT BELT
BO1KY-04
COMPONENTS
Front Seat Belt:
Adjustable Anchor
Center Pillar Garnish
42 (430, 31)
42 (430, 31)
42 (430, 31)
Rear Door
Front Door Opening Trim
Opening Trim Front Seat Outer Belt
Front Seat
Front Seat
Inner Belt
42 (430, 31)
42 (430, 31)
42 (430, 31)
Roof Headlining
Rear Trim
Rear No. 2 Seat
Outer Belt
42 (430, 31)
42 (430, 31)
Rear No. 2 Seat
42 (430, 31)
Inner Belt
42 (430, 31) CRS Tether Anchor
27 (275, 20) Bracket Cover
Rear No. 1 Seat CRS Tether Anchor
Inner Belt Bracket
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill-bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. Except manual type:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and slam on the brakes.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly.
2. Drivers seat belt (ELR):
BO0632 STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
HINT:
Before removing the pretensioner connector, be sure to read
the precautionary notice in the RS section.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
15
grees or less, and cannot be pulled out over 45 degrees
45
of tilt.
If a problem is found, replace the assembly.
3. Except drivers seat belt (ELR/ALR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
BO0633 HINT:
Before removing the pretensioner connector, be sure to read
the precautionary notice in the RS section.
(c) Pull out the whole belt and measure the length of the
whole belt.
Then retract the belt slightly and pull it out again
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.)of the belt remaining in the retractor.
(f) Tilt the retractor slowly.
Full Belt Length Minus
200 mm (7.87 in.)
N10070
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
15 grees or less, and cannot be pulled out at over 45 degrees
45 of tilt.
If a problem is found, replace the assembly.
BO0633
4. Manual type:
TESTING
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.
BO5906
H05731
SIDE STEP
BO4J0-01
COMPONENTS
Except Full Cover Type:
Front Cover
Rear Cover
No.2 LH Step
Side Step Bracket Gusset
No.1 LH Step
Bracket Gusset
18 (184, 13)
12 (120, 9)
12 (120, 9)
No. 1 Side
Step Bracket
18 (184, 13)
LH Step Plate
LH Step Panel
18 (184, 13)
12 (120, 9)
x5
12 (120, 9)
18 (184, 13) 18 (184, 13)
ADJUSTMENT
1. REMOVE SIDE GARNISH
Before making adjustment, using a screwdriver, remove the
side garnishes.
HINT:
Tape the screwdriver tip before use.
After adjustment, reinstall the side garnishes.
H05288
H05706
H05708
BO3396
H05296
COMPONENTS
Side Garnish
Sliding Roof Glass
Rear Garnish
Sunshade Trim
Front Garnish
Drive Cable
H05287
DISASSEMBLY
1. REMOVE REAR DRIP CHANNEL
(a) Using a screwdriver, remove the front side of rear drip
channel.
HINT:
Tape the screwdriver tip before use.
H05293
H05294
H05295
HINT:
At the time of reassembly, please refer to the following items.
Adjust the drive cable to a closed and tilted down position.
Slide the cable forward or backward to align the 2 marks
as shown.
Slide the cable to the forefront with your hand.
(c) Employ the same manner described above to the other
side.
H05296
H05297
H05298
H05299
INSTALLATION
Installation is in the reverse order of removal (See page BO-74 ).
ON-VEHICLE INSPECTION
1. INSPECT SLIDING ROOF GLASS
(a) Start the engine and check the operation time of the slid-
ing roof.
Operation time:
Approx. 6 secs.
(b) Check for abnormal noise or binding during operation.
(c) With the sliding roof fully closed, check for water leakage.
2. INSPECT DIFFERENCE IN LEVEL
Inspect the difference in level between the roof panel and slid-
ing roof glass (weatherstrip part) when the sliding roof glass is
fully closed.
Except rear end:
0 + 1.5 mm (0 + 0.059 in.)
0 - 1.0 mm (0 - 0.039 in.)
Rear end:
H05709 0 1.5 mm (0 0.059 in.)
H05707
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-76 ).
REMOVAL
1. REMOVE ROOF HEADLINING (See page BO-97 )
H05290
H05289
(d) Turn the drive gear to align the point marks as shown in
the illustration.
(e) Install the cam plate cover.
NOTICE:
At the time of installation, please refer to the following item.
If the sliding roof position and drive gear fully closed posi-
tion are not matched, the sliding roof does not operate nor-
mally.
Point Make H05291
H05292
SRS AIRBAG
BO0RW-09
PRECAUTION
The LAND CRUISER is equipped with SRS (Supplemental Restraint System) such as the driver airbag and
the front passenger airbag. (The side airbag and the curtain shield airbag are optional.) Failure to carry out
service operation in the correct sequence could cause the SRS to unexpectedly deploy during the servicing,
possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection
or replacement), be sure to read the precautionary notices in the RS section.
ADJUSTMENT
1. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL
DIRECTIONS
Loosen the door side hinge bolts to adjust.
Torque: 28 Nm (286 kgfcm, 21 ftlbf)
H07961
H07962
H04860
COMPONENTS
Rear Wiper Arm
28 (286, 21)
Stopper Cushion
28 (286, 21) 17.5 (178, 13)
Center Back 5.0 (51, 44 in.lbf) Back Door Outside
Door Garnish 28 (286, 21) Handle Assembly
Back Door
Back Door Outside Handle
31 (316, 23) Hinge
28 (286, 21) Back Door
Inside Handle
Assist
31 (316, 23) Grip Inside Handle Bezel
Plug
Assist Grip
Back Door
Link Protector
DISASSEMBLY
1. REMOVE ASSIST GRIP
(a) Using a screwdriver, remove the 2 assist grip plugs.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws and assist grip.
2. REMOVE INSIDE HANDLE BEZEL
a b
a b
a-a b-b
H04847
H04848
H04849
H04851
H04852
H04853
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding surface of the back door control.
H04854
H04855
(b) Remove the 3 bolts and back door outside handle assem-
bly.
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
12. REMOVE LICENSE PLATE LIGHTS
13. REMOVE BACK DOOR LOCK
Remove the 4 bolts and back door lock.
Torque: 7.0 Nm (71 ftlbf, 62 in.lbf)
14. REMOVE BACK DOOR LINK PROTECTOR
H04856
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-21 ).
WINDSHIELD
BO1K7-04
COMPONENTS
Roof Headlining
Double Visor
Holder
Assist Grip
Holder
Front Pillar Garnish
Sun Visor
Outside No. 2 Moulding
Cap
Dam
Outside Upper Moulding
Stopper Outside Moulding
Assist Grip
Front Assist Grip
Outside Moulding
Windshield Glass Front Assist Grip
Wiper Arm Head Cap Front Pillar Garnish
Wiper Arm 20 (204, 15)
Dam
Wiper Arm
Outside No. 2
Moulding
Cowl Top Ventilator Louver LH
Hood to Cowl Top Seal Front Door
Opening Trim
Nm (kgfcm, ftlbf) : Specified torque
Non-reusable part H18903
Body INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
Adhesive
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a piece of
shop rag dampen with cleanser.
BO4420
H05704
B Dam
H05705
5. POSITION GLASS
(a) Place the glass in the correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(c) Place reference marks between the glass and the body.
(d) Remove the glass.
BO4421
Primer G Primer G
H05397
a 9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
a a
a Part No.08850-00801 or equivalent.
HINT:
After cutting off the tip, finish up all adhesive within the time de-
scribed in the table below.
b
Temperature Tackfree time
b 35 C (95 F) 15 minutes
a-a 20 C (68 F) 100 minutes
5 C (41 F) 8 hours
A
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown.
b-b
A: 12.0 mm (0.472 in.)
B
B: 8.0 mm (0.315 in.)
A
B H05398
BO3986
HINT:
Windshield Glass
Make sure the dam is attached to the body panel, as shown in
the illustration.
(d) Hold the windshield glass in place securely with a protec-
tive tape or equivalent until the adhesive hardens.
Adhesive
N08495
NOTICE:
Take care not to drive the vehicle within the time described
in the table below.
Temperature Minimum time prior to driving the vehicle
35 C (95 F) 1.5 hours
20 C (68 F) 5 hours
5 C (41 F) 24 hours
H02665
Body
H16066
NOTICE:
Riveter Do not prize a riveter. It could damage the riveter and
cause loose fitting and mandrel bend.
Mandrel
H02440
Do not tilt the riveter when fasten the rivet to the mate-
Riveter rial to avoid loose fitting.
Do not allow gap spacing between the rivet head and
the material.
Riveter
H02441
REMOVAL
1. REMOVE FRONT DOOR OPENING TRIMS
2. REMOVE FRONT ASSIST GRIP
(a) Using a screwdriver, remove the 2 assist grip plugs, then
remove the 2 screws and the front assist grip.
HINT:
Tape up the screwdriver tip before use.
(b) Use the same manner described above to the other side.
(c) Gently and vertically put the drill to the rivet and cut the
rivet flanges.
NOTICE:
Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.
Take cafe as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out
remaining fragments with the drill.
H05392 (e) Using a heat light, heat the moulding to 20 - 30 C (68 -
86 F).
NOTICE:
Do not heat the moulding excessively.
(f) Tie both piano wire ends to wooden blocks or similar ob-
jects.
Protective Tape (g) Cut the adhesive tape by pulling the piano wire as shown.
NOTICE:
If reusing the moulding, take care not to damage the
moulding.
Do not damage the body.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
Adhesive Tape
H05393 (h) Remove the moulding.
(i) Use the same manner described above to the other side.
Windshield Moulding 15. REMOVE OUTSIDE UPPER MOULDING
Windshield Glass Using a knife, cut off the moulding as shown in the illustration.
NOTICE:
Body
Do not damage the body with the knife.
H16045
NOTICE:
Plastic Sheet
When separating the glass, take care not to damage the
paint and interior and exterior ornaments. To prevent
scratching the safety pad from scratching when removing
the windshield, place a plastic sheet between the piano
wire and the safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
Protective Tape (d) Remove the windshield glass.
BO1689 NOTICE:
Leave as much of the adhesive on the body as possible
when cutting the glass.