REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL FRONT INNER BLACK OUT TAPE

    Click here

  4. INSTALL REAR INNER BLACK OUT TAPE

    Click here

  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

    Click here

  6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  7. INSTALL REAR DOOR NO. 3 WEATHERSTRIP


    1. Clean the rear door panel.

    2. B001O8PE06
      Text in Illustration
      *1 Double-sided Tape

      Install a new rear door No. 3 weatherstrip.

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  9. INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)


    1. B001O5R

      Engage the 4 claws and install the 2 curtain hooks.

    2. Engage the 2 pins as shown in the illustration.

  10. INSTALL REAR DOOR PANEL CUSHION


    1. B001NNT

      Engage the claw to install a new rear door panel cushion.

  11. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. B001O4Y

      Engage the 5 clips to install the rear door No. 2 weatherstrip.

  12. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. B001OHP

      Engage the 2 guides.

    2. Install the rear door inside panel reinforce sub-assembly with the 3 screws.

  13. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.

    2. B001OFJE04
      Text in Illustration
      *a Outside
      *b Inside

      Engage the claw.

    3. Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. B001O5Z

      Engage the clamp.

  14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B001O93

      Engage the 2 claws to install the rear door rear outside handle pad.

  15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B001OR3

      Engage the 3 claws to install the rear door front outside handle pad.

  16. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B001OPW

      Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.

      Note

      If the bellcrank lever is not pulled and held when installing the outside handle sub-assembly, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it.

    3. B001O41

      Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

    4. B001NTS

      Connect the connector.

    5. Engage the 2 claws.

  17. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B001O6D

      Engage the claw.

    2. Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  18. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B001OAM

      Install the rear door inside locking cable assembly as shown in the illustration.

    2. B001OMV

      Engage the 3 claws as shown in the illustration.

  19. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B001ONM

      Install the rear door lock remote control cable assembly as shown in the illustration.

    2. B001OM7

      Engage the claw as shown in the illustration.

  20. INSTALL REAR DOOR LOCK ASSEMBLY

    Note


    • When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock assembly.


    1. Apply MP grease to the sliding parts of the rear door lock assembly.

    2. When reusing the rear door lock assembly:


      1. B001O1N

        Install a new door lock wiring harness seal to the rear door lock assembly.

    3. B001NQQE04
      Text in Illustration
      *1 Release Plate

      Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.

    4. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

    5. Using a T30 "TORX" socket wrench, install the rear door lock assembly with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  21. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.


    1. B001NOC

      Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  22. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.

    2. Temporarily install the temporary bolt to the rear door window regulator assembly.

    3. B001NQ9E03
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window regulator assembly.

    4. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

    6. Connect the cable to the negative (-) battery terminal.

    7. Connect the rear power window regulator switch assembly.

    8. Operate the rear power window regulator switch assembly to lower the rear door window regulator assembly to the lowest position.

    9. Disconnect the rear power window regulator switch assembly.

    10. Disconnect the cable from the negative (-) battery terminal.

  23. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. Apply soapy water to a new rear door glass channel filler.

    2. B001OGDE01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install the rear door glass channel filler to the position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 10.0 mm (0.394 in.)
      B 10.0 mm (0.394 in.)

  24. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


    1. Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

    2. B001OQDE01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 15.0 mm (0.591 in.)
      B 14.2 mm (0.559 in.)

      Note

      To prevent damaging the rear door glass sub-assembly, be careful not to strike the channel with too much force.

  25. INSTALL REAR DOOR GLASS ASSEMBLY


    1. B001OM0

      Slide the rear door glass assembly to install it as shown in the illustration.

  26. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.

    2. B001OAT

      Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

  27. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. B001OP8

      Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

      Torque:
      Bolt
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  28. INSTALL REAR DOOR NO. 1 VENT SEAL


    1. B001NPN

      Install the rear door No. 1 vent seal.

  29. INSTALL REAR DOOR GLASS RUN


    1. B001OK5

      Install the rear door glass run.

  30. INSTALL REAR DOOR FRAME GARNISH


    1. B001OA3

      Engage the 3 claws to install the rear door frame garnish.

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. B001OH1E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 22 clips and guide to install a new rear door weatherstrip.

  32. INSTALL REAR DOOR CHECK ASSEMBLY


    1. Apply MP grease to the sliding parts of the rear door check assembly.

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001O5HE07
      Text in Illustration
      *1 Bolt (A)
      *2 Bolt (B)

      Install the rear door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Bolt (B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  33. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply new butyl tape to the rear door panel.

    2. B001NONE04
      Text in Illustration
      *a Reference Point

      Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector through a new rear door service hole cover.

    3. Attach the rear door service hole cover according to the reference points on the rear door panel.

      Note

      Securely install the rear door service hole cover preventing wrinkles and air bubbles.

    4. Engage the 2 clamps.

    5. Connect the connector.

  34. INSTALL REAR DOOR ARMREST SET BRACKET


    1. B001OG9

      Install the rear door armrest set bracket with the 2 screws.

  35. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  36. INSTALL REAR SIDE CURTAIN ASSEMBLY (w/ Rear Door Sunshade)


    1. B001OBO

      Engage the 2 clips and install the rear side curtain assembly.

  37. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. B001OIW

      Install the rear door inner glass weatherstrip.

  38. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 15 Speakers)

    Click here

  39. INSTALL REAR DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel)


    1. B001NN8

      Engage the claw.

    2. Install the rear door trim ornament sub-assembly with the screw.

    3. B001OK9

      Install the rear door trim ornament assembly with the 11 screws.

    4. w/ Illumination:


      1. B001OP5

        Engage the 3 clamps.

  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B001OAI

      Engage the 2 guides and claw to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

  41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B001OIQE04
      Text in Illustration
      *a Reference Point

      Install the No. 1 door scuff plate clamp as shown in the illustration.

    2. B001OQGE04
      Text in Illustration
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly

      Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

    3. w/ Illumination:


      1. Connect the connector.

    4. for 15 Speakers:


      1. Connect the connector.

    5. B001NRSE01
      Text in Illustration
      *1 Reference Boss
      *2 Rear Door Inner Glass Weatherstrip

      Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

    6. B001OC8

      Engage the 8 clips and install the rear door trim board sub-assembly.

    7. B001NZL

      Install the 3 screws.

  42. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  43. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. B001NXK

      Install the rear door No. 1 stiffener cushion with the screw.

  44. INSTALL DOOR PULL HANDLE COVER


    1. B001NP6

      Install the door pull handle cover.

  45. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL


    1. Connect the connector.

    2. B001NWS

      Engage the 2 guides, 2 clips and 4 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

  46. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. B001OAD

      Engage the 3 claws to install the rear door inside handle bezel plug.

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Click here

  48. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  49. INSPECT POWER WINDOW OPERATION

    Click here