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INSTRUCCIONES TECNICAS
INSTALACIÓN DEL REFUERZO EN EL PANEL DE
ACCESO DEL FJ CRUISER (Traducción al Español – Parcialmente)
1. FUNCIONAMIENTO ORGANIGRAMA ······································································· 3
2. IDENTIFICACIÓN DE VEHÍCULOS AFECTADOS ························································ 4
3. PREPARACIÓN ····································································································· 5
4. DESCRIPCIÓN GENERAL ······················································································· 7
5. MEDIDAS DE SEGURIDAD PARA LA REMACHADORA ·············································· 8
6. PRECAUCIONES PARA COMPLETAR EL TRABAJO ·················································· 10
7. COMPONENTES ···································································································· 12
8. PROCEDIMIENTO DE TRABAJO ············································································· 13
8.1 REMOVER LAS PARTES INTERIORES ································································· 13
8.2 INSPECCIONAR EL PANEL PUERTA TRASERA
(VER NECESIDAD DE INSTALACIÓN DEL REFUERZO EN EL PANEL DE ACCESO) ··· 19
8.3 INSPECCION DEL PANEL DE LA PUERTA TRASERA POR ROTURA
(INSPECCIONAR LA NECESIDAD DEL REEMPLAZO DEL PANEL DEL LA PUERTA) ·· 20
8.4 INSPECCIÓN DEL PANEL LA PUERTA TRASERA POR GRIETAS
(NECESIDAD DE INSPECCIONAR EL CINTURON POR REEMPLAZO) ····················· 21
8.5 INSTALAR EL REFUERZO EN EL PANEL DE ACCESO ··········································· 22
8.6 RE-INSTALAR LAS PARTES INTERIORES ···························································· 39
2
<<SAFETY PRECAUTIONS>>
A. Be sure to observe the following precautions to prevent accidents and
injuries.
Park the vehicle and chock the wheels.
If it is necessary to start the engine, perform the operation in a well ventilated area.
Before removing and reinstalling heavy parts such as the engine, transmission and
differential using lifting equipment, check that there are no problems with the equipment.
When working in a group of 2 or more, each person must work to ensure the safety of all
team members.
To prevent burns and other injuries, use extra caution when handling parts that are
subject to high temperatures, as well as rotating, sliding, or vibrating parts.
When lifting the vehicle using a jack, support it in the specified location using a rigid rack.
When lifting the vehicle using a lift, lock the lift for safety.
B. Also perform the following operation with care.
Use of auto lift
Make absolutely certain that there are no other workers and no tools, parts, or other
objects within the movable range of the lift. Also, be sure to announce all lift operations
out loud (such as “Raising the lift!” and “Lowering the lift!”) to alert other workers.
When raising or lowering the lift to adjust the vehicle position, etc., pay attention to the
positions of your arms, legs, and other body parts, and be extremely careful to prevent
them from being caught in the lift.
Use of brake cleaner
Use brake cleaner for appropriate purposes in accordance with instructions in the
manual.
Do not use brake cleaner to remove dirt or stains from work clothes, etc. It can catch on
fire and cause serious burns.
<Precautions>
Do not use brake cleaner near flame or fire.
Do not use large amounts of brake cleaner in a room where a fire is burning.
Do not keep brake cleaner in a place subject to high temperatures exceeding 40° C , such as a
place subject to direct sunlight or near fire.
Do not put brake cleaner in fire.
Edges
When handling the edges of parts and panels, wear protective gloves or apply
protective tape to the edges to prevent injuries to your hands and fingers.
3
1. DIAGRAMA DE LA OPERACIÓN
Realice los siguientes procedimientos para las puertas derecha e izquierda del FJ.
REMUEVA LAS PARTES INTERIORES
VER EL PANEL DE PUERTA TRASERA
Compruebe visualmente si el panel de la puerta tiene una mejora o no.
INSPECCIÓN PANEL PUERTA TRASERA - POR FRACTURA
INSPECCIÓN PANEL PUERTA TRASERA - POR GRIETAS
FIN
REINSTALE LAS PARTES INTERIORES
Sin Grietas
Agrietado
Sin Fractura
Fracturado
Mejorado
No Mejorado
INSTALL THE
ACCESS PANEL
REINFORCEMENT
REPLACE THE
DOOR PANEL
REPLACE THE
SEAT OUTER
BELT ASSEMBLY
INSTALL THE
ACCESS PANEL
REINFORCEMENT
AND
REPLACE THE
SEAT OUTER
BELT ASSEMBLY
REPLACE THE
SEAT OUTER
BELT ASSEMBLY
AND
4
2. IDENTIFICACION DE LOS VEHICULOS AFECTADOS
AFFECTED VEHICLE IDENTIFICATION NUMBER
Model WMI VIN Range
VDS Range
FJ CRUISER JTE
BU# 0001006 - K167477
ZU# 0001015 - K013359
NOTICE:
# indicates that various characters may occupy that position. As for the total number of affected
vehicles shipped to your country, please refer to the attached VIN-list.
1. CHECK THE VEHICLE IDENTIFICATION
NUMBER
(a) Confirm that the VIN is within the range
shown in the table above.
HINT:
The Vehicle Identification Number (VIN) is
stamped on location A and B shown in the
illustration.
5
3. PREPARACION
PARTS
Part Number Part Description Quantity Others
04003-09135 Body Fitting Reinforcement Kit 1 -
67385-35010 Access Panel Reinforcement RH 1 -
67386-35010 Access Panel Reinforcement LH 1 -
90269-05071 Rivet 20 *16 Rivets used for a vehicle.
(Kit includes 20 Rivets.)
91552-81025 Bolt 2 -
67187-35010 w/ Washer Bolt 2 -
67447-35030 Nut Plate 2 -
TOOLS&EQUIPMENT
Part Number Name Quantity Others
- Global TechStream (GTS) or Intelligent Tester II 1 -
- Standard Hand Tools - -
- Torque Wrench - -
- Drill 1 -
- Drill Bits （5mm, 8mm, 10mm） 1 -
- “TORX” Socket Wrench T30 1 -
- Clip Remover 1 -
- Moulding Remover 1 -
- Punch 1 -
- Protective eyewear 1 -
- gloves - -
- Vacuum Cleaner 1 -
- Riveter 1 -
- Socket wrench (15mm) 1 -
- Burr Remover 1 -
6
ATERIALS
Part Number Name Quantity Others
- Brake Cleaner - -
- Protective Tape - -
- Strings - -
- Shop Cloth - -
- Touch-up Paint - -
- Seal Packing - -
7
4. DESCRIPCION GENERAL
1. Inspect the right and left rear doors for cracking, and determine
whether it is necessary to replace the front seat outer belt assembly
and rear door panel sub-assembly.
2. Install the access panel reinforcement (black; paint application not
required) to the installation area of the front seat outer belt assembly with
seal packing, rivets and bolts.
8
5. MEDIDAS DE SEGURIDAD PARA LA REMACHADORA
1. DO NOT POINT A RIVETER AT ANOTHER PERSON OR LOOK DIRECTLY INTO A RIVETER
(a) When using a riveter, ensure it is pressed firmly against the panel intended to be riveted. If not
pressed firmly against a panel, the rivet may be forcibly shot out of the riveter. Never point a
riveter at another person or look into the riveter regardless of whether a rivet is loaded.
2. ATTACH THE MANDREL CUP TO REAR
OF AIR RIVETER
(a) A rivet mandrel (center pin) is shot out of the
rear of an air riveter with great force when a
rivet is installed. Always be sure to attach the
air riveter mandrel cup.
9
3. HOW TO USE THE RIVETER
(a) Use the riveter properly according to the
manufacturer's instruction manual.
10
6. PRECAUCIONES PARA COMPLETAR EL TRABAJO
1. PAY ATTENTION TO LIFTING UP OR
JACKING UP A VEHICLE
(a) Perform safe and secure work according to
instructions in general description of a
repair manual.
(b) When operate a lifting or jacking device,
make sure that all workers around the
device including your self are safe and call
to each other in order to prevent a trample
accident.
2. WEAR PROTECTIVE EYEWEAR
(a) Always wear protective eyewear in
situations where gas or contaminations
may fly such as fuel leakage prevention,
carbon removal from a piston head, work
on underbody parts etc.
3. DO NOT CLEAN CLOTHES WITH BRAKE
CLEANER
(a) Never spray brake cleaner on your clothes
since it is easy to evaporate and flammable.
A cigarette or a stove may cause a serious
burn accident.
4. TAKE CARE NOT TO BURN YOURSELF
(a) When the engine is hot, wear gloves etc. to
protect yourself against burn injury.
11
5. PROTECT THE VEHICLE
(a) In order not to contaminate or damage the
vehicle, be sure to install the fender cover,
the grill cover and the seat cover, and
attach the masking tape etc.
HINT:
Some illustrations in the relevant instructions
manual may not show the above-mentioned
protective parts to make the target part easy and
simple to recognize.
6. PAY ATTENTION TO HANDLING
REPLACEMENT PARTS
(a) The removed parts shall be marked or
broken and stored in a replacement parts
box etc. to avoid reassembling in error.
(b) Check the replacement parts in final
inspection.
HINT:
Illustrations are for work description only and not
related to actual replacement parts.
7. DO NOT BREAK PARTS DURING WORK
INSIDE ENGINE ROOM
(a) Do not be absorbed in work and place your
hand carelessly in the engine room
resulting in breakage of parts.
8. CHECK THE ENGINE ROOM BEFORE
STARTING THE ENGINE
(a) Check if you have forgotten to attach any
parts.
(b) Check if you have forgotten to remove any
tools, shop cloths, etc.
12
7. COMPONENTES
13
8. PROCEDIMIENTO DEL TRABAJO
8.1 REMOVER LAS PARTES INTERIORES NOTICE:
THE WORK PROCEDURES ARE PERFORMED ON BOTH THE RIGHT AND LEFT SIDES. THESE
INSTRUCTIONS USE THE RIGHT SIDE IN EXPLAINING THE PROCEDURES. ALWAYS BE SURE
TO PERFORM THE SAME PROCEDURES ON BOTH THE LEFT AND RIGHT SIDES.
1. RECORD AUDIO SETTINGS
(a) When the battery cable is disconnected, some audio settings may be reset. Therefore, before
disconnecting the cable from the negative (-) battery terminal, make a note of the settings.
2. CHECK FOR DTCs
(a) When error codes are output, confirm and record the codes and the freeze frame data, and repair
as necessary.
3. DISCONNECT NEGATIVE BATTERY CABLE
NOTICE:
Always be sure to disconnect the negative (-)
battery terminal before starting work in order to
prevent improper operation of the pretensioner
system.
4. REMOVE THE REAR ACCESS PANEL
WEATHERSTRIP
14
5. REMOVE THE No.1 CUP HOLDER
(a) Remove the screw.
(b) Affix protective tape to the locations shown in
the figure.
(c) Using moulding remover, disengage the 4
claws and remove the cup holder.
(d) Remove the protective tape.
6. REMOVE THE REAR DOOR INSIDE HANDLE
SUB-ASSEMBLY
(a) Press the snap ring with a flat-head
screwdriver wrapped with protective tape to
remove the snap ring.
NOTICE:
Cover the snap ring with a shop cloth when
working to prevent the snap ring from flying
off.
(b) Remove the rear door inside handle
sub-assembly.
(c) Set the snap ring in the inside handle.
NOTICE:
Be sure to always perform this procedure in
order not to lose the snap ring.
15
7. REMOVE THE LAP BELT OUTER ANCHOR
COVER
8. DISCONNECT FRONT SEAT OUTER BELT
ASSEMBLY
9. PROTECT PARTS AGAINST DAMAGE
(a) Affix protective tape to the seatbelt anchor.
NOTICE:
Always be sure to affix protective tape as
the anchor can possibly contact and
damage the trim board, body or other parts.
10. REMOVE THE REAR DOOR TRIM BOARD
SUB-ASSEMBLY
(a) Remove the 9 clips.
(b) Pull in the direction indicated by the arrow
to disengage the claw, and remove the trim
board.
16
11. REMOVE THE UPPER CENTER PILLAR
GARNISH
(a) Remove the clip and 2 screws.
(b) Disengage the 2 claws by using a clip
remover wrapped with protective tape.
(c) Disengage the 2 clips and garnish.
12. PROTECT AGAINST INJURY
(a) Wear gloves in order to protect your hands
from injury due to burrs and other sharp
parts of panels and reinforcements.
17
13. REMOVE THE FRONT SEAT OUTER BELT
ASSEMBLY
NOTICE:
Completely remove the seatbelt due to the
possibility that it will interfere with work or get
dirty.
(a) Record the height of the shoulder part.
(b) Remove the nut and disconnect the
shoulder part.
(c) for 1 CONNECTOR TYPE:
(1) Disconnect the pretensioner connector
by using a screwdriver wrapped with
protective tape.
NOTICE:
Do not start this procedure until 90 seconds
or more have elapsed after disconnecting the
negative (-) terminal of the battery due to the
backup power source equipped to the
pretensioner system.
(d) for 2 CONNECTORS TYPE:
(1) Disconnect the pretensioner connector
by using a screwdriver wrapped with
protective tape.
NOTICE:
Do not start this procedure until 90 seconds
or more have elapsed after disconnecting the
negative (-) terminal of the battery due to the
backup power source equipped to the
pretensioner system.
(2) Disconnect the connector. (LH Only)
(e) Remove the 2 bolts and front seat outer belt
assembly.
(f) Store the 2 removed bolts because they
are used in procedures described below.
18
14. DISCONNECT THE DOOR WIRE
(a) Remove the ground bolt.
(b) Disengage each clamp and remove the door
wire.
(c) Secure the door wire by using string.
15. REMOVE THE LOWER ACCSESS PANEL
LOCK ASSEMBLY
(a) Disconnect the connector and clamp.
(b) Disconnect the control cable.
(c) Using T30 Torx socket. Remove the 3 screws.
(d) Hold the access panel lock and disengage
the clip.
NOTICE:
As the clip is firmly engaged, be careful not
to injure yourself when disengaging it.
This clip is used as a positioner during the
manufacturing process. If it is damaged,
remove it and reuse the lock assembly.
There is no need to replace this clip.
(e) Remove the access panel lock.
19
8.2 INSPECCIONAR EL PANEL DE PUERTA TRASERA (CHECK NECESSITY OF ACCESS PANEL REINFORCEMENT INSTALLATION)
Visually inspect that the rear door panel is an improved one in order to determine the necessity of
access panel reinforcement installation. (Inspect right and left doors.)
It is not necessary to install an access panel reinforcement if the vehicle has had the door panel
replaced with an improved part. This could have occurred during sheet metal repair due to an
accident or similar occurrence before the vehicle was brought to the dealer for this repair.
IMPORTANT: If the door panel has been replaced due to a previous repair, replace the seat outer belt
assembly with a new part because the condition before the door panel was replaced is not known.
1. INSPECT THE REAR DOOR PANEL
(a) Visually inspect the inside of the door panel (from the underside) to determine whether there is a large
retainer present.
HINT:
You can also make a determination based on the amount of spot welding locations.
Resultados Procedimientos
No
Mejo
rad
o/
No
t im
pro
ved
pa
nel
Ir a: INSPECCION DEL PANEL DE LA PUERTA POR
FRACTURA
Mejo
rad
o/
Imp
rove
d
pan
el
(1) NO ES NECESARIO INSTALAR UN REFUERZO EN EL PANEL DE ACCESO
(2) REEMPLAZAR EL CONJUNTO DEL
CINTURON DE SEGURIDAD
Ir a: INSTALAR LAS PARTES INTERIORES
20
8.3 INSPECCION DEL PANEL DE LA PUERTA POR FRACTURA (INSPECT NECESSITY OF DOOR PANEL REPLACEMENT)
Visually inspect for any door panel (part where the seat outer belt assembly is installed) breakage,
and determine whether it is necessary to replace the door panel (inspect doors on both sides).
If breakage is found, replace the seat outer belt assembly due to the possibility of load being applied
to the seat outer belt assembly.
1. VISUALLY INSPECT FOR ANY BREAKAGE
Resultados Procedimientos
No Fracturado
(con grietas)
No Breakage
(Cracks Found)
NO HAY QUE CAMBIAR EL PANEL PUERTA TRASERA Ir a la INSPECCIÓN por AGRIETAMIENTO del PANEL DE LA PUERTA TRASERA
NO HAY QUE CAMBIAR EL PANEL PUERTA TRASERA Ir a la INSPECCIÓN por AGRIETAMIENTO del PANEL DE LA PUERTA TRASERA
Si la ruptura se produce durante el trabajo, lleve a cabo los mismos procedimientos que para la "fractura".
Fractura/
Breakage
SUSTITUIR EL PANEL DE LA PUERTA TRASERA Y EL CONJUNTO DEL CINTURON Remplace el panel y el cinturón, y vuelva a INSTALAR PARTES circundantes.
2. APPLY ANTI-RUST TREATMENT TO THE
REAR DOOR PANEL (IF CRACKING IS
PRESENT)
(a) Apply touch-up paint to the crack in order
to prevent rust formation.
No es necesario instalar un refuerzo en el panel de la
puerta mejorada debido a que ya está equipado con un
retén grande. Este retenedor proporciona el mismo
propósito que el panel de refuerzo acceso.
21
8.4 INSPECCION DEL PANEL DE LA PUERTA POR GRIETAS (INSPECT NECESSITY OF SEAT OUTER BELT ASSEMBLY REPLACEMENT)
Visually inspect for cracking of the 2 spot welding locations on the door panel, and determine
whether it is necessary to replace the seat outer belt assembly (inspect doors on both sides).
If cracking is found, replace the seat outer belt assembly because of the possibility of load
being applied to the seat outer belt assembly.
1. VISUALLY INSPECT FOR ANY CRACKING
NOTICE:
Do not confuse cracking with normal wear and paint being peeled off due to the use of seat outer belt assembly.
Do not confuse cracking with welding spatter.
Resultados Procedimientos
Sin
Grietas
No
Cracking
NO HAY QUE REEMPLAZAR EL CONJUNTO
DEL CINTURON DE SEGURIDAD
Ir a: INSTALAR EL REFUERZO EN EL PANEL DE
ACCESO
Agrietado
Cracking
REEMPLAZAR EL CINTURON DE
SEGURIDAD LUEGO DE LA INSTALACIÓN
DEL REFUERZO EN EL PANEL DE ACCESO
Aplicar el tratamiento anti-óxido y luego ir a INSTALAR
EL REFUERZO EN EL PANEL DE ACCESO
2. APPLY ANTI-RUST TREATMENT TO THE
REAR DOOR PANEL (IF CRACKING IS
PRESENT)
(a) Apply touch-up paint to the crack in order
to prevent rust formation.
22
8.5 INSTALACION DEL REFUERZO EN EL PANEL DE ACCESO
1. WRAP DRILL BITS WITH TAPE
(a) Wrap the 3 drill bits (5mm, 8mm, and
10mm) with tape at approximately 10mm
from the tip. This is done in order to
prevent damage to the outer panel.
NOTICE:
Failure to apply a secure, thick wrapping of
tape can result in the drill piercing the inner
door panel, resulting in damage to the outer
panel.
2. PREPARE FOR INSTALLATION OF THE
ACCESS PANEL REINFORCEMENT
(a) Prepare the correct access panel
reinforcement for the corresponding door.
(b) Prepare the 2 bolts that were previously
removed from the vehicle. These will be
used to align the access panel
reinforcement prior to final installation.
NOTICE:
Do not use a new upper bolt (black) with
locking agent applied at this stage.
Do not confuse the removed lower bolt
with the new lower bolt, as it is a different
size.
23
3. DRILL THE INSTALLATION HOLES FOR
THE ACCESS PANEL REINFORCEMENT
(a) Press the access panel reinforcement
upwards and hold it while installing the 2
bolts.
Torque Spec:
8.5 N*m (87 kgf*cm, 75 in.*lbf) (Bolt A)
42 N*m (428 kgf*cm, 31 ft.*lbf) (Bolt B)
NOTICE:
Be sure to press upwards while tightening the
bolts to ensure close contact of the door panel
and access panel reinforcement.
(b) Affix tape to the holes shown in the figure
to prevent shavings from getting into the
holes.
NOTICE:
The number of holes differs depending on the
specifications.
(c) Lay a shop cloth inside of the door panel to
catch shavings when drilling.
(d) Always be sure to wear protective eye
wear for safety when drilling holes,
removing burrs, and installing/removing
rivets.
24
(e) Drill holes using the 8mm and 10mm drill bits that match the holes in the access panel reinforcement.
NOTICE:
Do not wear gloves when using the drill to prevent them from being caught in the drill.
(f) Continue to use the drill in the drilled
10mm hole to widen it until is the same
diameter as the hole of the access panel
reinforcement.
NOTICE:
Only widen the 10mm diameter hole.
25
(g) Remove any burrs created on the back
side of the 2 drilled holes using the burr
remover.
NOTICE:
Failure to remove burrs can result in the
access panel becoming loose, and not firmly
seating against the door.
(1) Insert the tool into the hole.
(2) Firmly press the blade against the edge
of the hole.
(3) Pull the blade towards you while moving
it around the edge of the hole to remove
the burrs.
(4) Wear gloves and check that all burrs have
been removed.
26
(h) Hold the nut plate using a 15mm socket
and install the added nut plate with the
NEW bolt.
Torque Spec:
64 N*m (653 kgf*cm, 47 ft.*lbf)
NOTICE:
Failure to hold the nut plate when installing
the bolt can result in deformation of the
positioner.
Be sure to always install the nut plate in
order to prevent misalignment when
drilling the rivet holes.
(i) Using the 5mm drill bit, drill the eight holes
in the door panel according to the existing
holes in the access panel reinforcement.
NOTICE:
Do not wear gloves when using the drill to
prevent them from being caught in the drill.
(j) Hold the nut plate by using the 15mm
socket, and remove the added nut plate
and bolt.
NOTICE:
Failure to hold the nut plate and allowing it to
be loose can result in deformation of the
positioner.
27
(k) Remove the 2 bolts and the access panel
reinforcement.
(l) Remove any burrs that have formed in the
5mm rivet holes (eight for each door panel)
by using the burr remover.
NOTICE:
Failure to remove burrs can result in the
access panel becoming loose, and not firmly
seating against the door.
(1) Insert the tool into the hole.
(2) Firmly press the blade against the edge
of the hole.
(3) Pull the blade towards you while moving
it around the edge of the hole to remove
the burrs.
28
(4) Wear gloves and check that the burrs
have been removed from the eight holes.
(m) Remove the burrs from the front side of all
10 holes (5mm, 8mm, and 10mm) using
the burr remover.
NOTICE:
Remove burrs from the 8mm and 10mm holes.
(1) Insert the tool into the hole.
(2) Firmly press the blade against the edge
of the hole.
(3) Push the blade towards door panel while
moving it around the edge of the hole to
remove the burrs.
(4) Wear gloves and check that the burrs
have been removed from the 10 holes.
29
4. CLEAN UP THE SHAVINGS
(a) Remove the shop cloth and tape from the
door panel.
(b) Use a vacuum cleaner to remove the
shavings.
5. CLEAN/DEGREASE THE MATING SURFACES OF THE DOOR PANEL AND ACCESS PANEL
REINFORCEMENT
(a) Clean the mating surface of the door panel by using brake cleaner and allow it to dry completely.
(b) Clean the mating surface of the access panel reinforcement (side where punch marks have been
made) by using brake cleaner and allow it to dry completely.
30
6. APPLY ANTI-RUST TREATMENT TO THE
NUT PLATE INSTALLATION HOLES
(a) Apply touch-up paint to the nut plate
installation holes (8mm and 10mm) to
prevent rust formation.
NOTICE:
Rivet installation holes (5mm) do not
require touch-up paint because seal
packing will be applied later.
If the paint on the access panel
reinforcement mounting hole is peeling,
apply touch-up paint to prevent rust
formation.
31
7. APPLY SEAL PACKING TO ACCESS PANEL REINFORCEMENT
(a) Apply seal packing with a diameter of approximately 3mm, ensuring that the punch marks are
connected.
NOTICE:
For the one location where there is no mating punch mark, apply seal packing as shown in the
figure (for each side).
After applying the seal packing, be sure to replace the lid and properly store the seal packing
so that it does not harden.
32
8. REINSTALL THE ACCESS PANEL REINFORCEMENT
(a) Set the upper right and left rivets of the access panel reinforcement so that they serve as guides.
(b) Affix access panel reinforcement to the door panel.
9. PREPARE FOR RIVET INSTALLATION
(a) Set rivets by hand in the remaining rivet
installation holes.
NOTICE:
Set all bolts and rivets as indicated in order to
prevent misalignment.
HINT:
There are 20 rivets supplied in the kit. Four of
these are spares.
(b) Temporarily install the two bolts previously
removed from the vehicle.
NOTICE:
Do not use a new upper bolt (black) with
locking agent applied at this stage.
Do not confuse the removed lower bolt
with the new lower bolt, as it is a different
size.
33
(c) Hold the nut plate by using the 15mm
socket and install the added nut plate with
the added bolt.
Torque Spec:
64 N*m (653 kgf*cm, 47 ft.*lbf)
NOTICE:
Failure to hold the nut plate and allowing it to
be loose can result in deformation of the
positioner.
34
10. INSTALL THE RIVET
■ DO NOT POINT A RIVETER AT ANOTHER PERSON OR LOOK DIRECTLY INTO A RIVETER
When using a riveter, ensure it is pressed firmly against the panel intended to be riveted. If not
pressed firmly against a panel, the rivet may be forcibly shot out of the riveter. Never point a
riveter at another person or look into the riveter regardless of whether a rivet is loaded.
■ATTACH THE MANDREL CUP TO REAR OF AIR RIVETER
A rivet mandrel (center pin) is shot out of the
rear of an air riveter with great force when a
rivet is installed. Always be sure to attach the
air riveter mandrel cup.
35
■HOW TO USE THE RIVETER
Use the riveter properly according to the
manufacturer's instruction manual.
36
11. INSTALL THE RIVET
NOTICE:
Perform steps (a), (b), and (c) one rivet at a time.
Always be sure to install the rivets in the order shown in the figure in order to prevent the
access panel reinforcement from moving up.
Failure to press the riveter perpendicularly can result in gaps between the panel and
reinforcement. If a rivet is installed incorrectly, remove the rivet according to the procedures
below and install a NEW rivet.
(a) Starting with number 1 remove the rivet and apply seal packing as shown in the figure.
(b) Place the rivet in the door panel.
(c) Press the riveter perpendicularly against the door panel and install the rivets following the order shown
in the figure.
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(d) If seal packing is found on the riveter, clean
it before it hardens.
(e) Wipe away any seal packing that is
protruding from the rivets to prevent the
seat belts from getting dirty.
NOTICE:
Do not use brake cleaner as it can cause the
rivet seal packing to peel off.
(f) Check that there are no gaps by pressing a
flat-head screwdriver against all rivets.
NOTICE:
Do not pry under the rivet head. Only press
the screwdriver against the rivet.
Perform steps (f) and (g) one rivet at a time
to ensure that the work is performed
properly.
If there are any gaps between the rivet
head and reinforcement panel, remove the
rivet and reinstall according to the
procedures on the following page.
(g) After confirming the rivet is secure, apply
touch-up paint to the hole in the center of
the rivet to indicate it has been checked,
and to prevent rust.
(h) Confirm paint has been applied to all eight
rivets.
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12. REMOVING A RIVET
HINT:
If a rivet has not been properly installed, remove
the rivet according to the following procedures.
(a) Affix tape to the holes previously shown in
the figure found in step 8.5 3. (b) to prevent
shavings from getting into the holes.
(b) Lay a shop cloth inside of the door panel to
catch shavings when drilling.
(c) Drill out the center of the rivet using a 5mm
drill bit and remove the rivet.
(d) If the rivet turns with the drill and cannot be
removed when performing step (c), cut the
rivet using side cutters.
NOTICE:
Use caution as the rivet head may fly off
unexpectedly.
(e) Repeat steps (c) and (d) to remove rivet
heads, Once the head is removed, use a
punch or similar tool to remove the rivet.
(f) Remove the shop cloth and tape from within
the door panel.
(g) Use a vacuum cleaner to remove the
shavings.
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8.6 RE-INSTALAR LAS PARTES INTERIORES
1. RECONNECT THE DOOR WIRE TO THE
LOWER ACCESS PANEL LOCK
ASSEMBLY
(a) Insert the hook through the body hole and
engage the clip.
NOTICE:
This clip is used as a positioner during the
manufacturing process. If it is damaged,
remove it and reuse the lock assembly.
(b) Using a T30 Torx socket, Install the access
panel lock with the 3 screws.
Torque Spec:
5.0 N*m (51 kgf*cm, 44 in.*lbf)
(c) Connect the control cable.
(d) Connect the clamp and connector.
NOTICE:
Pass the control cable under the door harness (cabin side).
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2. RECONNECT THE DOOR WIRE
(a) Remove the string.
(b) Connect each clamp with the door wire.
(c) Install the ground bolt.
Torque Spec:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
3. REINSTALL THE FRONT SEAT OUTER
BELT ASSEMBLY
NOTICE:
If the door panel was cracked as indicated in
step 8.4. install a NEW seat outer belt
assembly.
(a) Remove the 2 bolts.
(b) Put a mark on the removed upper bolt and
dispose of it according to the recalled parts
disposal procedure.
(c) Insert the 2 hooks through the retractor
bracket, and temporarily install it with a
NEW bolt A (black, and with locking agent
applied) and bolt B (reused part, silver).
NOTICE:
Only replace upper bolt A with a new part.
(d) Install the NEW bolt (A).
Torque Spec:
8.5 N*m (87 kgf*cm, 75 in.*lbf)
(e) Install the bolt (B).
Torque Spec:
42 N*m (428 kgf*cm, 31 ft.*lbf)
41
(f) for 1 CONNECTOR TYPE:
(1) Connect the pretensioner connector.
(g) for 2 CONNECTORS TYPE:
(1) Connect the pretensioner connector.
(2) Connect the connector. (LH Only)
(h) Install the shoulder nut.
Torque Spec:
42 N*m (428 kgf*cm, 31 ft.*lbf)
NOTICE:
The locking function is activated if the seat belt
is pulled out with the door completely open.
Move the door in the closing direction to release
the lock.
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4. REINSTALL THE UPPER CENTER PILLAR
GARNISH
(a) Engage the 2 claws 2 clips.
NOTICE:
The clips cannot be engaged unless the pillar
garnish is correctly set on the shoulder
adjuster.
(b) Install the garnish with the clip and 2
screws.
(c) Return the seat belt shoulder part to the
recorded position.
5. REINSTALL THE REAR DOOR TRIM
BOARD SUB-ASSEMBLY
(a) Engage the 9 clips and claws to install the
trim board.
6. RECONNECT FRONT SEAT OUTER BELT
ASSEMBLY
(a) Remove the protective tape.
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(b) Install the outer belt with the bolt.
Torque Spec:
42 N*m (428 kgf*cm, 31 ft.*lbf)
(c) Install the lap outer anchor cover.
7. REINSTALL THE REAR DOOR INSIDE
HANDLE SUB-ASSEMBLY
(a) Check that the snap ring is attached, and
install the inside handle.
8. REINSTALL THE No.1 CUP HOLDER
(a) Engage the 4 claws and install the cup
holder.
(b) Install the screw.
44
9. REINSTALL THE REAR ACCESS PANEL
WEATHERSTRIP
10. RECONNECT NEGATIVE BATTERY
CABLE
11. INSPECT SRS WARNING LIGHT
(a) Turn the ignition switch on (IG), and check
that the SRS warning light comes on for
approximately 6 seconds (primary check).
(b) Check that the SRS warning light goes off
approximately 6 seconds after the ignition
switch is turned on (IG) (constant check).
HINT:
If the warning light remains lit, the
pretensioner connector may not have been
properly connected.
12. CHECK FOR DTCs
13. CHECK OPERATION OF ALL PARTS
14. INSPECT THE SEAT BELT ELR LOCK
(a) Check that the seat belt locks when it is pulled out quickly.
15. PERFORM SETTING AFTER CONNECTION OF BATTERY TERMINAL
(a) After connecting the terminal, perform setting of systems.
(1) Restore data recorded before disconnection of the terminal.
