Body - Power Back Door Shudder During Operation

BODY
BO001-07
REVISED

Title:
BACK DOOR STAY LEAK & COLD
WEATHER SHUDDER IMPROVEMENT

Models:
'04 - '07 Sienna

March 14, 2007

TSB REVISION NOTICE:

^ March 20, 2007: The introduction has been updated.

Previous versions of this TSB should be discarded.

TSB UPDATE NOTICE:
The information contained in this TSB supersedes TSB No. B0003-04.
TSB No. B0003-04 is now obsolete and should be discarded.

Introduction

The back door stays for 2004 - 2007 model year Sienna vehicles have been redesigned. The updated service parts are available to:

^ Reduce the operating effort of the rear hatch.

^ Prevent seal damage resulting in leakage.

^ Reduce the slight power back door shudder that can occur during cold weather conditions.

Applicable Vehicles

^ 2004 - 2007 model year Sienna vehicles produced BEFORE the Production Change Effective VINs shown below.





Production Change Information





Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.





Parts Information

Repair Procedure

1. Remove back door stay sub-assembly.





A. Remove the 2 bolts and disconnect the back door stay sub-assembly from the body panel (mounting point A).





B. Using a screwdriver, disengage the clips and remove the stay from the door panel.

NOTE:
Make sure to hold the door in position when removing the stay from the door panel.

C. Remove the bolt from the door panel (mounting point B).





2. Install the back door stay sub-assembly.

A. Install the back door stay sub-assembly with the bolt to the door panel (mounting point B).

For door side:

Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)

B. Install the bracket with the 2 bolts to the body panel (mounting point A).

C. Install the stay to the bracket by engaging the stay clip onto the bracket.

For body side:

Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)

3. Verify the back door opens and closes properly.

4. Dispose of the previous back door stay sub-assembly.

A. Horizontally position the stay in a vise with the piston-rod pulled out.





B. Wearing safety glasses, gradually cut between A and B as shown in the illustration using a metal saw to slowly release the gas.





Dimensions: