Body - Power Rear Door Shudder/Water leaks

BODY
BO003-04
REVISED

Title:
BACK DOOR STAY LEAK &
COLD WEATHER SHUDDER
IMPROVEMENT

Models.

'04 - '06 Sienna

March 9, 2004

TSB REVISION NOTICE:

^ October 2, 2006: The VINs in the Production Change Information table have been updated.

^ December 8, 2005: The following sections have been updated:
Introduction Applicable Vehicles (2005 and 2006 model year added), Production Change Information (Production Change Effective VINs), Warranty Information (T1 code), Parts Information (2 parts added - back door stay brackets), and Repair Procedure (mounting point information added).
PLEASE READ ENTIRE TSB.
Previous versions of this TSB should be discarded.

Introduction

The back door stays for 2004 - 2006 model year Sienna vehicles have been redesigned to improve the operating effort of the rear hatch, provide improved resistance to seal damage, and prevent leakage. The improvement will also address the power back door shudder that can occur when operating during cold weather conditions.

Applicable Vehicles

^ 2004 - 2006 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.

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





2. Install 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. Dispose of previous back door stay sub-assembly.

A. Horizontally fix 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 gradually release the gas.





Dimensions: