Toyota Prius: Back Door

• Disassembly
• Adjustment
• Reassembly

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during back door disassembly/reassembly are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedures	Effect/Inoperative Function When Necessary Procedures are not Performed	Link
*: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation. *1: w/ Power Back Door System
Rear television camera assembly*	Parking assist monitor system initialization Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Rear television camera view adjustment	Parking Support Brake System
		Panoramic View Monitor System
		Advanced Park
Multiplex network door ECU*1 Power back door unit assembly set LH* Power back door unit assembly set RH*	Reset back door close position	Power Back Door System
Replacement or removal and installation of 2 or more parts: Front television camera assembly, Radiator grille or Front bumper assembly Rear television camera assembly Side television camera assembly LH, Parking assist light LH or Outer rear view mirror assembly LH Side television camera assembly RH, Parking assist light RH or Outer rear view mirror assembly RH	Television camera view adjustment	Panoramic View Monitor System

CAUTION / NOTICE / HINT

COMPONENTS (DISASSEMBLY)

Procedure		Part Name Code
1	BACK DOOR UPPER TRIM PANEL ASSEMBLY	64790B	-	-	-
2	BACK DOOR SIDE GARNISH LH	67938A	-	-	-
3	BACK DOOR SIDE GARNISH RH	67937B	-	-	-
4	GLIDE DOOR INSIDE HANDLE BASE ASSEMBLY	69290G		-	-
5	DOOR PULL HANDLE	74811D		-	-
6	BACK DOOR TRIM BOARD ASSEMBLY	67750	-	-	-
7	LUGGAGE COMPARTMENT TRIM COVER	64721K	-	-	-
8	POWER BACK DOOR SENSOR ASSEMBLY LH	84280D	-	-	-
9	POWER BACK DOOR SENSOR ASSEMBLY RH	84270G	-	-	-

*A

w/ Power Back Door

-

-

Procedure		Part Name Code
10	MULTIPLEX NETWORK DOOR ECU	89222A	-	-	-
11	POWER BACK DOOR WARNING BUZZER	89747E	-	-	-
12	BACK DOOR LOCK ASSEMBLY WITH COURTESY LIGHT SWITCH	69350P		-	-
13	BACK DOOR LOWER STOPPER LH	67282F	-	-	-
14	BACK DOOR LOWER STOPPER RH	67281G	-	-	-

*A

w/ Power Back Door

*B

w/o Power Back Door

Procedure		Part Name Code
15	BACK DOOR OUTSIDE GARNISH LOWER MOULDING LH	76816	-	-	-
16	BACK DOOR OUTSIDE GARNISH LOWER MOULDING RH	76815	-	-	-
17	REAR LIGHT ASSEMBLY	-		-	-
18	TELEVISION REAR CAMERA ASSEMBLY	86790D	-	-	-
19	BACK DOOR OPENER SWITCH ASSEMBLY	84840G	-	-	-
20	HOLE PLUG	-	-	-	-

Procedure		Part Name Code
21	DOOR DUST PROOF SEAL	67837L	-	-	-
22	BACK DOOR PANEL CUSHION	67005B	-	-	-
23	BACK DOOR STAY ASSEMBLY LH	68960		-	-
24	BACK DOOR STAY ASSEMBLY RH	68950C		-	-
25	BACK DOOR DAMPER STAY UPPER BRACKET LH	68946	-	-	-
26	BACK DOOR DAMPER STAY UPPER BRACKET RH	68945	-	-	-
27	BACK DOOR STAY BOLT	68961	-	-	-
28	POWER BACK DOOR UNIT ASSEMBLY LH	68920A		-	-
29	POWER BACK DOOR UNIT ASSEMBLY RH	68910B		-	-
30	BACK DOOR DAMPER STAY UPPER BRACKET LH	68946	-	-	-
31	BACK DOOR DAMPER STAY UPPER BRACKET RH	68945	-	-	-
32	BACK DOOR DAMPER STAY LOWER BRACKET LH	68948	-	-	-
33	BACK DOOR DAMPER STAY LOWER BRACKET RH	68947	-	-	-

*A	w/o Power Back Door	*B	w/ Power Back Door
●	Non-reusable part	-	-

PROCEDURE

1. REMOVE BACK DOOR UPPER TRIM PANEL ASSEMBLY

2. REMOVE BACK DOOR SIDE GARNISH LH

Place Hand Here

Remove in this Direction

3. REMOVE BACK DOOR SIDE GARNISH RH

(a) Use the same procedure as for the LH side.

4. REMOVE GLIDE DOOR INSIDE HANDLE BASE ASSEMBLY (w/ Power Back Door)

(1) Apply protective tape to the back door panel assembly as shown in the illustration.

(2) Using a moulding remover, disengage the 2 claws.

(3) Disconnect the 2 connectors to remove the glide door inside handle base assembly.

5. REMOVE DOOR PULL HANDLE

(1) Apply protective tape to the back door panel assembly as shown in the illustration.

(2) Using a moulding remover, disengage the 4 claws to remove the door pull handle.

6. REMOVE BACK DOOR TRIM BOARD ASSEMBLY

7. REMOVE LUGGAGE COMPARTMENT TRIM COVER

8. REMOVE POWER BACK DOOR SENSOR ASSEMBLY LH (w/ Power Back Door)

Click here

9. REMOVE POWER BACK DOOR SENSOR ASSEMBLY RH (w/ Power Back Door)

(a) Use the same procedure as for the LH side.

10. REMOVE MULTIPLEX NETWORK DOOR ECU (w/ Power Back Door)

Click here

11. REMOVE POWER BACK DOOR WARNING BUZZER (w/ Power Back Door)

Click here

12. REMOVE BACK DOOR LOCK ASSEMBLY WITH COURTESY LIGHT SWITCH

Click here

13. REMOVE BACK DOOR LOWER STOPPER LH

14. REMOVE BACK DOOR LOWER STOPPER RH

(a) Use the same procedure as for the LH side.

15. REMOVE BACK DOOR OUTSIDE GARNISH LOWER MOULDING LH

Click here

16. REMOVE BACK DOOR OUTSIDE GARNISH LOWER MOULDING RH

(a) Use the same procedure as for the LH side.

17. REMOVE REAR LIGHT ASSEMBLY

Click here

18. REMOVE TELEVISION REAR CAMERA ASSEMBLY

Click here

19. REMOVE BACK DOOR OPENER SWITCH ASSEMBLY

Click here

20. REMOVE HOLE PLUG

21. REMOVE DOOR DUST PROOF SEAL

22. REMOVE BACK DOOR PANEL CUSHION

23. REMOVE BACK DOOR STAY ASSEMBLY LH (w/o Power Back Door)

Click here

24. REMOVE BACK DOOR STAY ASSEMBLY RH (w/o Power Back Door)

(a) Use the same procedure as for the LH side.

25. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET LH (w/o Power Back Door)

Click here

26. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET RH (w/o Power Back Door)

(a) Use the same procedure as for the LH side.

27. REMOVE BACK DOOR STAY BOLT (w/o Power Back Door)

Click here

28. REMOVE POWER BACK DOOR UNIT ASSEMBLY LH (w/ Power Back Door)

Click here

29. REMOVE POWER BACK DOOR UNIT ASSEMBLY RH (w/ Power Back Door)

(a) Use the same procedure as for the LH side.

30. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET LH (w/ Power Back Door)

Click here

31. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET RH (w/ Power Back Door)

(a) Use the same procedure as for the LH side.

32. REMOVE BACK DOOR DAMPER STAY LOWER BRACKET LH (w/ Power Back Door)

Click here

33. REMOVE BACK DOOR DAMPER STAY LOWER BRACKET RH (w/ Power Back Door)

(a) Use the same procedure as for the LH side.

Adjustment

ADJUSTMENT

CAUTION / NOTICE / HINT

*a	Centering Bolt
*b	Standard Bolt

PROCEDURE

1. INSPECT BACK DOOR

(a) for Normal Roof:

(1) Check that the clearance measurements of areas a through h are within each standard range.

Standard Clearance

Area	Measurement	Area	Measurement
a	6.6 to 10.6 mm (0.260 to 0.417 in.)	b	0 to 4.0 mm (0 to 0.157 in.)
c	6.6 to 10.6 mm (0.260 to 0.417 in.)	d	-0.1 to 3.9 mm (-0.004 to 0.154 in.)
e	4.0 to 8.0 mm (0.157 to 0.315 in.)	f	3.4 to 8.4 mm (0.134 to 0.331 in.)
g	3.1 to 8.1 mm (0.122 to 0.319 in.)	h	5.8 to 9.9 mm (0.228 to 0.390 in.)

(b) except Normal Roof:

(1) Check that the clearance measurements of areas a through h are within each standard range.

Standard Clearance

Area	Measurement	Area	Measurement
a	6.5 to 11.5 mm (0.256 to 0.453 in.)	b	-0.5 to 4.5 mm (-0.020 to 0.177 in.)
c	6.5 to 11.5 mm (0.256 to 0.453 in.)	d	-0.4 to 4.6 mm (-0.016 to 0.181 in.)
e	4.0 to 8.0 mm (0.157 to 0.315 in.)	f	3.4 to 8.4 mm (0.134 to 0.331 in.)
g	3.1 to 8.1 mm (0.122 to 0.319 in.)	h	5.8 to 9.9 mm (0.228 to 0.390 in.)

2. REMOVE DECK BOARD ASSEMBLY

Click here

3. REMOVE DECK FLOOR BOX RH

Click here

4. REMOVE DECK FLOOR BOX LH

Click here

5. REMOVE BATTERY SERVICE HOLE COVER ASSEMBLY (w/ Battery Cover)

Click here

6. REMOVE REAR DECK TRIM COVER

Click here

7. ADJUST BACK DOOR

(a) Loosen the 4 hinge bolts on the back door and adjust the back door position.

(b) Tighten the 4 hinge bolts on the Toyota Prius vehicle body after adjustment.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(c) Using a T40 "TORX" socket wrench, slightly loosen the 2 striker mounting screws.

(d) Using a brass bar and a hammer, hit the striker to adjust its position.

(e) Using a T40 "TORX" socket wrench, tighten the 2 striker mounting screws after adjustment.

Torque:

23 N·m {235 kgf·cm, 17 ft·lbf}

8. INSTALL REAR DECK TRIM COVER

9. INSTALL BATTERY SERVICE HOLE COVER ASSEMBLY (w/ Battery Cover)

10. INSTALL DECK FLOOR BOX LH

11. INSTALL DECK FLOOR BOX RH

12. INSTALL DECK BOARD ASSEMBLY

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	BACK DOOR DAMPER STAY LOWER BRACKET LH	68948		-	-
2	BACK DOOR DAMPER STAY LOWER BRACKET RH	68947		-	-
3	BACK DOOR DAMPER STAY UPPER BRACKET LH	68946		-	-
4	BACK DOOR DAMPER STAY UPPER BRACKET RH	68945		-	-
5	POWER BACK DOOR UNIT ASSEMBLY LH	68920A		-	-
6	POWER BACK DOOR UNIT ASSEMBLY RH	68910B		-	-
7	BACK DOOR STAY BOLT	68961		-	-
8	BACK DOOR DAMPER STAY UPPER BRACKET LH	68946		-	-
9	BACK DOOR DAMPER STAY UPPER BRACKET RH	68945		-	-
10	BACK DOOR STAY ASSEMBLY LH	68960		-	-
11	BACK DOOR STAY ASSEMBLY RH	68950C		-	-
12	BACK DOOR PANEL CUSHION	67005B	-	-	-
13	DOOR DUST PROOF SEAL	67837L	-	-	-

*A	w/o Power Back Door	*B	w/ Power Back Door
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part
★	Precoated part	-	-

Procedure		Part Name Code
14	HOLE PLUG	-	-	-	-
15	BACK DOOR OPENER SWITCH ASSEMBLY	84840G	-	-	-
16	TELEVISION REAR CAMERA ASSEMBLY	86790D	-	-	-
17	REAR LIGHT ASSEMBLY	-		-	-
18	BACK DOOR OUTSIDE GARNISH LOWER MOULDING LH	76816	-	-	-
19	BACK DOOR OUTSIDE GARNISH LOWER MOULDING RH	76815	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure		Part Name Code
20	BACK DOOR LOWER STOPPER LH	67282F	-	-	-
21	BACK DOOR LOWER STOPPER RH	67281G	-	-	-
22	BACK DOOR LOCK ASSEMBLY WITH COURTESY LIGHT SWITCH	69350P		-	-
23	POWER BACK DOOR WARNING BUZZER	89747E	-	-	-
24	MULTIPLEX NETWORK DOOR ECU	89222A	-	-	-

*A	w/ Power Back Door	*B	w/o Power Back Door
	N*m (kgf*cm, ft.*lbf): Specified torque		MP grease

Procedure		Part Name Code
25	POWER BACK DOOR SENSOR ASSEMBLY LH	84280D	-	-	-
26	POWER BACK DOOR SENSOR ASSEMBLY RH	84270G	-	-	-
27	LUGGAGE COMPARTMENT TRIM COVER	64721K	-	-	-
28	BACK DOOR TRIM BOARD ASSEMBLY	67750	-	-	-
29	DOOR PULL HANDLE	74811D	-	-	-
30	GLIDE DOOR INSIDE HANDLE BASE ASSEMBLY	69290G	-	-	-
31	BACK DOOR SIDE GARNISH LH	67938A	-	-	-
32	BACK DOOR SIDE GARNISH RH	67937B	-	-	-
33	BACK DOOR UPPER TRIM PANEL ASSEMBLY	64790B	-	-	-
34	INITIALIZE POWER BACK DOOR SYSTEM (w/ Power Back Door)	-	-	-
35	INSPECT POWER BACK DOOR SYSTEM (w/ Power Back Door)	-		-	-
36	PERFORM CALIBRATION	-	-	-
37	ADJUST BACK DOOR	-		-	-

*A

w/ Power Back Door

-

-

PROCEDURE

1. INSTALL BACK DOOR DAMPER STAY LOWER BRACKET LH (w/ Power Back Door)

Click here

2. INSTALL BACK DOOR DAMPER STAY LOWER BRACKET RH (w/ Power Back Door)

HINT:

Use the same procedure as for the LH side.

3. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET LH (w/ Power Back Door)

Click here

4. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET RH (w/ Power Back Door)

HINT:

Use the same procedure as for the LH side.

5. INSTALL POWER BACK DOOR UNIT ASSEMBLY LH (w/ Power Back Door)

Click here

6. INSTALL POWER BACK DOOR UNIT ASSEMBLY RH (w/ Power Back Door)

HINT:

Use the same procedure as for the LH side.

7. INSTALL BACK DOOR STAY BOLT (w/o Power Back Door)

Click here

8. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET LH (w/o Power Back Door)

Click here

9. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET RH (w/o Power Back Door)

HINT:

Use the same procedure as for the LH side.

10. INSTALL BACK DOOR STAY ASSEMBLY LH (w/o Power Back Door)

Click here

11. INSTALL BACK DOOR STAY ASSEMBLY RH (w/o Power Back Door)

HINT:

Use the same procedure as for the LH side.

12. INSTALL BACK DOOR PANEL CUSHION

13. INSTALL DOOR DUST PROOF SEAL

14. INSTALL HOLE PLUG

15. INSTALL BACK DOOR OPENER SWITCH ASSEMBLY

16. INSTALL TELEVISION REAR CAMERA ASSEMBLY

17. INSTALL REAR LIGHT ASSEMBLY

Click here

18. INSTALL BACK DOOR OUTSIDE GARNISH LOWER MOULDING LH

19. INSTALL BACK DOOR OUTSIDE GARNISH LOWER MOULDING RH

20. INSTALL BACK DOOR LOWER STOPPER LH

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

21. INSTALL BACK DOOR LOWER STOPPER RH

HINT:

Use the same procedure as for the LH side.

22. INSTALL BACK DOOR LOCK ASSEMBLY WITH COURTESY LIGHT SWITCH

Click here

23. INSTALL POWER BACK DOOR WARNING BUZZER (w/ Power Back Door)

24. INSTALL MULTIPLEX NETWORK DOOR ECU (w/ Power Back Door)

Click here

25. INSTALL POWER BACK DOOR SENSOR ASSEMBLY LH (w/ Power Back Door)

26. INSTALL POWER BACK DOOR SENSOR ASSEMBLY RH (w/ Power Back Door)

27. INSTALL LUGGAGE COMPARTMENT TRIM COVER

28. INSTALL BACK DOOR TRIM BOARD ASSEMBLY

29. INSTALL DOOR PULL HANDLE

30. INSTALL GLIDE DOOR INSIDE HANDLE BASE ASSEMBLY (w/ Power Back Door)

31. INSTALL BACK DOOR SIDE GARNISH LH

32. INSTALL BACK DOOR SIDE GARNISH RH

33. INSTALL BACK DOOR UPPER TRIM PANEL ASSEMBLY

34. INITIALIZE POWER BACK DOOR SYSTEM (w/ Power Back Door)

Click here

35. INSPECT POWER BACK DOOR SYSTEM (w/ Power Back Door)

Click here

36. PERFORM CALIBRATION

(a) w/ Parking Assist Monitor System:

Click here

37. ADJUST BACK DOOR

HINT: When the back door damper stay lower bracket is removed, it is necessary to perform back door position adjustment. Click here