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BO-65 BODY - BACK DOOR GLASS BACK DOOR GLASS BO1KA-02 COMPONENTS Clip Back Window Outside Moulding Back Door Glass Clip Spacer Spacer Center Back Door Garnish Back Door Garnish Assist Grip Assist Grip Plug Inside Handle Bezel Rear Wiper Arm N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part 5.4 (55, 48 in.·lbf) H06468 2004 LAND CRUISER (RM1071U) Author: Date: 2639 BO-68 BODY - BACK DOOR GLASS BO21C-02 INSTALLATION Adhesive (a) BO4420 CLEAN AND SHAPE CONTACT SURFACE OF DOOR PANEL Using a knife, cut away any rough areas on the door panel 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 shop rag saturated in cleaner HINT: Even if all the adhesive has been removed, clean the door panel (a) (b) CLEAN REMOVED GLASS Remove the damaged clips and spacers Using a scraper, remove the adhesive sticking to the glass (c) Clean the glass with cleaner NOTICE: Do not touch the glass after cleaning it BO5231 a b a b A E B C INSTALL NEW CLIPS AND SPACERS Install new clips and spacers onto the glass as shown in the illustration A: 24.3 mm (0.957 in.) B: 18.6 mm (0.732 in.) C: 33.1 mm (1.303 in.) D: 52.8 mm (2.079 in.) E: 14.4 mm (0.567 in.) F: 18.0 mm (0.709 in.) G: 156.6 mm (6.165 in.) H: 176.8 mm (6.961 in.) F D G H H04494 2004 LAND CRUISER (RM1071U) Author: Date: 2642 BO-69 BODY - BACK DOOR GLASS INSTALL BACK WINDOW MOULDING Install a new back window moulding as shown in the illustration NOTICE: Do not touch the glass face after cleaning it H04079 COAT CONTACT SURFACE OF DOOR PANEL WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of door panel on the vehicle side NOTICE: Let the primer coating dry for minutes or more Do not coat Primer M to the adhesive Do not keep any of the opened Primer M for later use Primer M Primer M Adhesive H02865 COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and contact surface with Primer G (b) When the primer coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries NOTICE: Let the primer coating dry for minutes or more Do not keep any of the opened Primer G for later use a a a-a Primer G H04080 2004 LAND CRUISER (RM1071U) Author: Date: 2643 BO-70 BODY - BACK DOOR GLASS APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle HINT: After cutting off the tip, use all adhesive within the time described in the table below a a Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes °C (41 °F) hours (b) (c) a-a A B H04081 Load the cartridge into the sealer gun Coat the glass with adhesive, as shown in the illustration A: 8.0 mm (0.315 in.) B: 12.0 mm (0.472 in.) INSTALL BACK DOOR GLASS (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: Take care not to drive the vehicle during the time described in the table below (a) (b) 10 11 : 10 Clips Temperature Minimum time prior to moving a car 35 °C (95 °F) 1.5 hours 20 °C (68 °F) hours °C (41 °F) 24 hours INSPECT FOR LEAKS AND REPAIR Conduct a leak test after the hardening time has elapsed Seal any leak with sealant Part No 08833-00030 or equivalent INSTALL REAR WIPER ARM (See page BO-42 ) INSTALL BACK DOOR GARNISH H04848 2004 LAND CRUISER (RM1071U) Author: Date: 2644 BO-71 BODY BACK DOOR GLASS 12 INSTALL CENTER BACK DOOR GARNISH 13 INSTALL INSIDE HANDLE BEZEL 14 INSTALL ASSIST GRIP Install the assist grip with the screws, then install assist grip plugs : Clips b a b a a-a - b-b H04847 2004 LAND CRUISER (RM1071U) Author: Date: 2645 BO-66 BODY - BACK DOOR GLASS BO21B-01 REMOVAL REMOVE ASSIST GRIP (a) Using a screwdriver, remove the assist grip plugs HINT: Tape the screwdriver tip before use (b) Remove the screws and assist grip REMOVE INSIDE HANDLE BEZEL REMOVE CENTER BACK DOOR GARNISH Using a screwdriver, remove the center back door garnish HINT: Tape the screwdriver tip before use : Clips a b b a a-a b-b H04847 REMOVE BACK DOOR GARNISH Using a screwdriver, remove the back door garnish HINT: Tape the screwdriver tip before use REMOVE REAR WIPER ARM (See page BO-38 ) : 10 Clips H04848 REMOVE OUTSIDE BACK WINDOW MOULDING Using a knife, cut off the moulding as shown in the illustration NOTICE: Do not damage the body with the knife H04076 2004 LAND CRUISER (RM1071U) Author: Date: 2640 BO-67 BODY (a) (b) - BACK DOOR GLASS REMOVE BACK DOOR GLASS Disconnect the connector Push piano wire through between the body and glass from the interior Tie both wire ends to wooden blocks or similar objects (c) HINT: Apply protective tape to the outer surface to keep the surface from being scratched BO5232 NOTICE: 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 Protective Tape H04077 2004 LAND CRUISER (RM1071U) Author: Date: 2641 BO-31 BODY - BACK DOOR STAY BACK DOOR STAY BO1JQ-03 REPLACEMENT 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 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 150 mm (5.91 in.) H05391 (a) (b) If the back door stay is to be replaced, drill a 2.0 - 3.0 mm (0.079 - 0.118 in.) hole in the bottom of the back door stay as shown in the illustration to completely release the high-pressure gas before disposing of it When drilling, chips may fly out so work carefully The gas is colorless, odorless and non-toxic When working, handle the back door stay carefully Never score or scratch the exposed part of the piston rod, and never allow paint or oil to get on it Do not turn the piston rod and cylinder with the back door stay fully extended INSTALL BACK DOOR STAY Install the bolt and back door stay to the body Torque: 17.5 N·m (178 kgf·cm, 13 ft·lbf) Install the bolts and back door stay to the back door Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) 2004 LAND CRUISER (RM1071U) Author: Date: 2605 BO-43 BODY - BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO1K1-02 COMPONENTS Outside Rear Door Moulding Outside Quarter Moulding Upper Rear Outside Rear Door Moulding Outside Front Door Moulding Outside Front Fender Moulding H05285 2004 LAND CRUISER (RM1071U) Author: Date: 2617 BO-46 BODY - BODY OUTSIDE MOULDING BO1K3-02 INSTALLATION (a) CLEAN BODY MOUNTING SURFACE 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 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 illustration Outside Rear Door Moulding Adhesive Tape Adhesive Tape Outside Front Outside Front Fender Moulding Door Moulding Adhesive Tape Adhesive Tape Upper Rear Outside Rear Door Moulding Adhesive Tape Outside Quarter Moulding H05286 (a) INSTALL MOULDING 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 2004 LAND CRUISER (RM1071U) Author: Date: 2620 BO-20 BODY - UPPER BACK DOOR UPPER BACK DOOR BO1JI-04 COMPONENTS Rear Wiper Arm 5.4 (55, 48 in.·lbf) 13 (133, 10) Rear Wiper Motor Relay Back Door Stay Lower Stopper Back Door Stay 5.0 (51, 44 in.·lbf) Grommet Rear Wiper Motor and Link Stopper Cushion 5.0 (51, 44 in.·lbf) 13 (133, 10) Lower Stopper 17.5 (178, 13) 5.0 (51, 44 in.·lbf) Back Door Control Back Door Hinge 5.0 (51, 44 in.·lbf) 5.0 (51, 44 in.·lbf) 28 (286, 21) Stopper Cushion 28 (286, 21) 17.5 (178, 13) 5.0 (51, 44 in.·lbf) Center Back Door Garnish Back Door Outside Handle Assembly Back Door Outside Handle 28 (286, 21) Back Door Hinge 31 (316, 23) Back Door Inside Handle 28 (286, 21) 31 (316, 23) Assist Grip Plug Inside Handle Bezel Assist Grip Back Door Link Protector 7.0 (71, 62 in.·lbf) Back Door Lock 7.0 (71, 62 in.·lbf) License Plate Light Back Door Garnish Back Door Weatherstrip N·m (kgf·cm, ft·lbf) : Specified torque H18907 2004 LAND CRUISER (RM1071U) Author: Date: 2594 BO-21 BODY - UPPER BACK DOOR BO1JJ-04 DISASSEMBLY REMOVE ASSIST GRIP (a) Using a screwdriver, remove the assist grip plugs HINT: Tape the screwdriver tip before use (b) Remove the screws and assist grip REMOVE INSIDE HANDLE BEZEL REMOVE CENTER BACK DOOR GARNISH Using a screwdriver, remove the center back door garnish HINT: Tape up the screwdriver tip before use : Clips a b b a a-a b-b H04847 REMOVE BACK DOOR GARNISH Using a screwdriver, remove the back door garnish HINT: Tape up the screwdriver tip before use : 10 Clips H04848 (a) (b) (c) REMOVE REAR WIPER ARM Open the cover Remove the nut and rear wiper arm Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the grommet H04849 2004 LAND CRUISER (RM1071U) Author: Date: 2595 BO-22 BODY - UPPER BACK DOOR H18908 REMOVE REAR WIPER MOTOR AND LINK ASSEMBLY (a) Disconnect the connector (b) Remove the bolts (c) Unfasten the bolts and remove the rear wiper motor and link assembly Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) REMOVE REAR WIPER MOTOR RELAY Remove the bolt and rear wiper motor relay REMOVE BACK DOOR WEATHERSTRIP Remove the back door weatherstrip NOTICE: Do not pull strongly on the weatherstrip as it may tear : 30 Clips H04851 (a) (b) REMOVE BACK DOOR INSIDE HANDLE Remove the bolts Disconnect the back door lock locking rod and back door lock inside opening link, then remove the back door inside handle 10 (a) (b) REMOVE BACK DOOR CONTROL Disconnect the links Remove the bolts Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) Disconnect the connector, then remove the back door control H04852 (c) 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 2004 LAND CRUISER (RM1071U) Author: Date: 2596 BO-23 BODY 11 (a) - UPPER BACK DOOR REMOVE BACK DOOR OUTSIDE HANDLE ASSEMBLY Using a screwdriver, remove the back door outside handle HINT: Tape up the screwdriver tip before use H04855 (b) Remove the bolts and back door outside handle assembly Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) 12 REMOVE LICENSE PLATE LIGHTS 13 REMOVE BACK DOOR LOCK Remove the bolts and back door lock Torque: 7.0 N·m (71 ft·lbf, 62 in.·lbf) 14 REMOVE BACK DOOR LINK PROTECTOR H04856 2004 LAND CRUISER (RM1071U) Author: Date: 2597 BO-25 BODY - UPPER BACK DOOR BO1JL-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-21 ) 2004 LAND CRUISER (RM1071U) Author: Date: 2599 BO-51 BODY - WINDSHIELD WINDSHIELD BO1K7-04 COMPONENTS Roof Headlining Double Visor Sun Visor Inner Rear View Mirror Overhead Console Box Cap Holder Double Visor Front Door Opening Trim Assist Grip Holder Front Pillar Garnish Sun Visor Outside No Moulding Cap Dam Stopper Outside Upper Moulding Outside Moulding Assist Grip Front Assist Grip Outside Moulding Windshield Glass Wiper Arm Head Cap 20 (204, 15) Wiper Arm Front Assist Grip Front Pillar Garnish Cowl Top Ventilator Louver RH 20 (204, 15) Wiper Arm Dam Outside No Moulding Cowl Top Ventilator Louver LH Front Door Opening Trim Hood to Cowl Top Seal N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part H18903 2004 LAND CRUISER (RM1071U) Author: Date: 2625 BO-55 BODY - WINDSHIELD BO4IV-01 INSTALLATION Body CLEAN AND SHAPE CONTACT SURFACE OF BODY (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 Adhesive BO4420 (a) (b) CLEAN REMOVED GLASS Remove the damaged stoppers and dams Using a scraper, remove the adhesive sticking to the glass (c) Clean the glass with cleanser NOTICE: Do not touch the glass surface after cleaning it Be careful not to damage the glass BO5231 INSTALL NEW STOPPERS Install new stoppers onto the glass A: mm (0.35 in.) B: 25 mm (0.98 in.) B A H05704 A INSTALL NEW DAMS Install new dams with adhesive tape as shown in the illustration A: mm (0.28 in.) B: 20 mm (0.79 in.) NOTICE: Do not touch the glass surface after cleaning it A Stopper A B Dam H05705 2004 LAND CRUISER (RM1071U) Author: Date: 2629 BO-56 BODY (a) (b) (c) (d) Reference Marks - WINDSHIELD POSITION GLASS Place the glass in the correct position Check that all contacting parts of the glass rim are perfectly even Place reference marks between the glass and the body Remove the glass BO2820 CLEAN CONTACT SURFACE OF GLASS Using cleanser, clean the contact surface which is black-colored area around the entire glass rim NOTICE: Do not touch the glass surface after cleaning it BO4421 COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, apply Primer M to the exposed part of the body on the vehicle side NOTICE: Let the primer coating dry for more than minutes Do not coat Primer M to the adhesive Do not keep remaining Primer M for later use Primer M Primer M Primer M Adhesive H02865 COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G (b) If the primer is coated wrongly to the area not specified by accident, wipe it off with a clean shop rag before the primer dries NOTICE: Let the primer coating dry for more than minutes Do not keep remaining Primer G for later use a a a a b b a-a b-b Primer G Primer G H05397 2004 LAND CRUISER (RM1071U) Author: Date: 2630 BO-57 BODY (a) a a a a WINDSHIELD APPLY ADHESIVE Cut off the tip of the cartridge nozzle Part No.08850-00801 or equivalent HINT: After cutting off the tip, finish up all adhesive within the time described in the table below b Temperature Tackfree time b 35 °C (95 °F) 15 minutes a-a 20 °C (68 °F) 100 minutes °C (41 °F) hours A B - (b) (c) Load the cartridge into the sealer gun Coat the glass with adhesive as shown A: 12.0 mm (0.472 in.) B: 8.0 mm (0.315 in.) 10 (a) INSTALL WINDSHIELD GLASS Position the glass so that the reference marks are lined up, and press in gently along the rim Using a spatula, apply adhesive on the glass rim b-b A B H05398 (b) Reference Marks BO2821 (c) Use a scraper to remove any excess or protruding adhesive BO3986 HINT: 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 protective tape or equivalent until the adhesive hardens Windshield Glass Adhesive N08495 2004 LAND CRUISER (RM1071U) Author: Date: 2631 BO-58 BODY - WINDSHIELD NOTICE: Take care not to drive the vehicle within the time described in the table below 11 (a) (b) Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) hours °C (41 °F) 24 hours INSPECT FOR LEAK AND REPAIR Conduct a leak test after the adhesive dried completely Seal any leak with sealant Part No 08833-00030 or equivalent 12 APPLY ADHESIVE TO MOULDING INSTALLATION AREA Apply adhesive to the moulding installation area between the glass and the body Part No 08833-00030 or equivalent H02665 13 INSTALL UPPER OUTSIDE MOULDING Place a new moulding onto the body and tap it by hand Windshield Moulding Windshield Glass Body H16066 mm (0.20 in.) 14 (a) INSTALL OUTSIDE NO MOULDING Using an air riveter with nose piece No 4, install new rivets and the outside No moulding HINT: Before using the air riveter with nose piece No 4, cut mm (0.20 in.) from the edge of nose piece No as shown in the illustration Cutting Area H07493 2004 LAND CRUISER (RM1071U) Author: Date: 2632 BO-59 BODY WINDSHIELD NOTICE: Do not prize a riveter It could damage the riveter and cause loose fitting and mandrel bend Riveter Mandrel - H02440 Riveter Do not tilt the riveter when fasten the rivet to the material to avoid loose fitting Do not allow gap spacing between the rivet head and the material Riveter H02441 (b) 15 (a) (b) 16 17 (a) Riveter H02442 (b) (c) (d) (e) Do not allow gap spacing between the materials Use the same manner described above to the other side INSTALL COWL TOP VENTILATOR LOUVERS Install the cowl top ventilator louver LH Install the cowl top ventilator louver RH INSTALL HOOD TO COWL TOP SEAL INSTALL WIPER ARMS Operate the wiper motor once and turn the wiper switch OFF Install the wiper arms and tighten the nuts by hand Adjust the installation positions of the wiper arms to the positions as shown in the illustration A: Approx 33 mm (1.30 in.) B: Approx 21 mm (0.83 in.) Torque the nuts Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) Install the wiper arm head caps A B H04845 H21532 18 INSTALL INNER REAR VIEW MIRROR (a) Install the inner rear view mirror with the screws (b) Connect the connector 19 INSTALL FRONT SIDE OF ROOF HEADLINING 20 INSTALL ASSIST GRIPS 21 INSTALL OVERHEAD CONSOLE BOX Connect the connector, then install the overhead console box with the bolt 22 INSTALL HOLDER Install the holders with the screws 2004 LAND CRUISER (RM1071U) Author: Date: 2633 BO-60 BODY - WINDSHIELD 23 INSTALL DOUBLE VISOR Install the double visors with the screws 24 INSTALL SUN VISOR (a) Install the sun visors with the screws, then connect the connectors (b) Install the caps 25 (a) (b) 26 (a) (b) 27 INSTALL FRONT PILLAR GARNISH Install the front pillar garnish Use the same manner described above to the other side INSTALL FRONT ASSIST GRIP Install the front assist grip with the screws, then install the assist grip plugs Use the same manner described above to the other side INSTALL FRONT DOOR OPENING TRIMS H18904 2004 LAND CRUISER (RM1071U) Author: Date: 2634 BO-52 BODY - WINDSHIELD BO4IU-01 REMOVAL (a) REMOVE FRONT DOOR OPENING TRIMS REMOVE FRONT ASSIST GRIP Using a screwdriver, remove the assist grip plugs, then remove the 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 H18904 REMOVE FRONT PILLAR GARNISH (a) Using a screwdriver, remove the front pillar garnish HINT: Tape up the screwdriver tip before use (b) Use the same manner described above to the other side REMOVE SUN VISOR (a) Using a screwdriver, remove the caps HINT: Tape up the screwdriver tip before use (b) Remove the screws, then disconnect the connectors (c) Remove the sun visors REMOVE DOUBLE VISOR Remove the screws and the double visors REMOVE HOLDER Remove the screws and the holders (a) (b) Clips REMOVE OVERHEAD CONSOLE BOX Remove the bolt Using a screwdriver, remove the overhead console box, then disconnect the connector HINT: Tape up the screwdriver tip before use REMOVE ASSIST GRIPS PULL DOWN FRONT SIDE OF ROOF HEADLINING H21423 10 (a) (b) H21532 11 (a) (b) 12 13 (a) REMOVE INNER REAR VIEW MIRROR Disconnect the connector Unfasten a screw, and remove the other screw and the inner rear view mirror REMOVE WIPER ARMS Remove the wiper arm head caps and the nuts Remove the wiper arms REMOVE HOOD TO COWL TOP SEAL REMOVE COWL TOP VENTILATOR LOUVERS Remove the cowl top ventilator louver RH 2004 LAND CRUISER (RM1071U) Author: Date: 2626 BO-53 BODY - WINDSHIELD (b) Remove the cowl top ventilator louver LH 14 REMOVE OUTSIDE NO MOULDING (a) Using a screwdriver, remove the outside No moulding HINT: Tape up the screwdriver tip before use (b) Using a drill of less then ø mm (0.16 in.) (c) H05392 Protective Tape Adhesive Tape H05393 Windshield Moulding Windshield Glass Body 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 (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 objects (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 (h) Remove the moulding (i) Use the same manner described above to the other side 15 REMOVE OUTSIDE UPPER MOULDING Using a knife, cut off the moulding as shown in the illustration NOTICE: Do not damage the body with the knife H16045 2004 LAND CRUISER (RM1071U) Author: Date: 2627 BO-54 BODY 16 (a) Protective Tape Body Windshield Glass - WINDSHIELD REMOVE WINDSHIELD GLASS Push piano wire through between the body and glass from the interior Tie both wire ends to wooden blocks or similar objects (b) HINT: Apply protective tape to the outer surface to keep the surface from being scratched BO5232 Plastic Sheet Protective Tape BO1689 NOTICE: 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 (d) Remove the windshield glass NOTICE: Leave as much of the adhesive on the body as possible when cutting the glass 2004 LAND CRUISER (RM1071U) Author: Date: 2628