Body - Liftgate Garnish is Loose or Broken

S-SB-0012-13

March 12, 2013

Back Door Garnish Loose or Broken

Service Category
Vehicle Exterior

Section
Exterior Panels/Trim

Market
USA





Applicability

Introduction

Some 2004 - 2006 model year xB vehicles may exhibit a condition where the back door garnish becomes loose and in some cases continued usage of the loose garnish may result in breakage. Please follow the procedure contained in this bulletin which supplements the Repair Manual to replace the back door garnish if it is loose or broken.

Production Change Information





This bulletin applies to vehicles produced BEFORE the Production Change Effective VIN shown.





Warranty Information





Parts Information





Required Tools & Equipment

Repair Procedure

NOTICE

Do NOT use power tools for this repair procedure.

1. Disconnect cable from the negative (-) battery terminal.

CAUTION

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. Remove the back door trim board.

Using a plastic pry tool remove the 11 clips and trim board.

3. Remove the back door outside garnish.





Remove the 3 nuts and detach the clip then remove the garnish.

4. Remove the rear lamp set switch and mounting stud.





A. Remove the 2 lamp screws (silver) and the 2 switch screws (black).

B. Remove the mounting stud.

C. Set ALL removed parts aside for installation into the NEW garnish later in this repair.

5. Assemble the NEW back door garnish.





A. Lay the NEW back door garnish (P/N 76811-52122-##) down on a clean protected work surface to prevent scratching of the painted surface.





B. Remove the protective backing and install the foam strip (PIN 76821-52030 Back Door Garnish Protector) around the outer portion of the garnish as shown.

C. Transfer the mounting stud that was removed in step 4B to the NEW garnish.





D. Install the new mounting clip
(P/N 90467-10077 Clip) as shown in Figure 6.





E. Install the 3 foam washers (P/N 90562-04007 Ring) onto each of the 3 mounting studs.





F. Once the foam washers have been installed a strip of foam must be cut and placed on the NEW garnish to isolate the rear lamp wire harness.

Cut a foam strip from the Wind Noise Kit
(P/N 08231-00813).

Foam Strip Dimensions: 95 mm x 7 mm
(3.74 in. x 0.28 in.)





G. Place foam strip between the dotted alignment marks on the NEW garnish.





H. Transfer back door opener switch assembly over to the NEW garnish.

(1) Install switch and fasten with the 2 black screws previously removed from the OLD garnish in step 4A.

(2) Be sure the black wire harness protector is positioned as shown to protect the wires.

I. Transfer the rear lamp set to the NEW garnish. Use the silver screws previously removed from the OLD garnish in step 4A.





(1) Route wire harness as shown and make sure the wire harness is secured behind the previously installed foam strip.





(2) Secure the switch wire harness under the rear lamp set wire harness and route both wire harnesses under the light bulb housing as circled.

6. Insert the wire harness grommet into the rear hatch door and ensure it is seated properly to prevent leaks. Install the NEW back door garnish on the rear hatch door using the 3 previously removed nuts.

Torque: 3 N*m (30.6 kgf*cm, 26.6 in*lbf)

NOTICE

Do NOT use power tools during installation.

7. Reassemble vehicle in reverse order of disassembly steps 1 - 3.

8. Confirm proper operation of the rear lamp set and back door opener switch.

© 2013 Toyota Motor Sales, USA