REAR DOOR REASSEMBLY

Info Added 2017-10-06

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. INSTALL REAR DOOR OUTSIDE STRIPE

    Click here

  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

    Click here

  3. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

    Click here

  4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

    Click here

  5. INSTALL REAR DOOR OUTSIDE MOULDING

    Click here

  6. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  7. INSTALL REAR DOOR PANEL CUSHION


    1. A005O1J

      Engage the claws to install the 2 rear door panel cushions.

  8. INSTALL REAR SPEAKER ASSEMBLY (w/ Rear Speaker)

    Click here

  9. INSTALL REAR DOOR SPEAKER COVER (w/o Rear Speaker)


    1. A005O5GN01

      Engage the guides to temporarily install the rear door speaker cover.

    2. Using an air riveter or a hand riveter, install the front speaker cover with 3 new rivets in the order shown in the illustration.

      Note


      • A005O2FC27
        *a Riveter
        *b Mandrel
        *c Incorrect

        Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

      • B0048TAC09
        *a Riveter
        *b Incorrect

        Confirm that the rivets are seated properly against the moulding.

      • Do not tilt the riveter when installing the rivet to the moulding.

      • Do not leave any space between the rivet head and moulding.

      • B0048V3C10
        *a Riveter
        *b Incorrect

        Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

    3. A005NRV

      Connect the connector.

  10. INSTALL REAR DOOR DUST PROOF SEAL


    1. A005O22

      Install the 3 rear door dust proof seals.

  11. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Click here

  12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A005O1N

      Engage the guide to connect the No. 1 rear door lock remote control cable assembly.

    2. A005NA9

      Engage the claws to install the rear door outside handle assembly.

    3. Install the 3 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. A005O30

      Connect the No. 1 rear door lock remote control cable assembly to the clamps.

  13. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. Clean the rear door outside handle assembly surface.

    2. Remove the release paper from the face of the rear door outside handle cover.

    3. A005MPRC02
      B0048V2 Double-sided Tape

      Engage the clips and guide to install a new rear door outside handle cover.

    4. Press the double-sided tape area of the rear door outside handle cover.

  14. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  15. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP


    1. A005O2X

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

  16. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. A005NNKC01
      B0048R7 Install in this Direction

      Install the rear door quarter window glass with rear door quarter window weatherstrip as shown in the illustration.

  17. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. A005O93C02
      *a Temporary Bolt

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

    3. Temporarily install the rear door window regulator sub-assembly with the 3 bolts.

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

  18. INSTALL REAR DOOR GLASS RUN


    1. A005NO0

      Install the rear door glass run.

  19. INSTALL REAR DOOR FRAME GARNISH


    1. A005N07

      Engage the guides to install the rear door frame garnish.

  20. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A005N4FC01
      B0048R7 Install in this Direction (1)
      B0048O3 Install in this Direction (2)

      Insert the rear door glass sub-assembly as shown in the illustration.

      Note

      Do not damage the rear door glass sub-assembly.

    2. A005NTPC01
      B0048R7 Install in this Direction

      Install the rear door glass sub-assembly to the rear door window regulator sub-assembly as shown in the illustration.

  21. INSTALL REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY


    1. A005O1T

      Temporarily install the rear door window rear lower frame sub-assembly with the 2 bolts.

    2. Install the screw.

    3. Tighten the 2 bolts.

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

    4. Connect the rear door glass run.

  22. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. Remove the release paper from a new rear door weatherstrip.

    3. A005O8PC04
      *a Clip (A)
      B0048V2 Double-sided Tape

      Engage the clip (A) and other clip to install the rear door weatherstrip.

    4. Press the double-sided tape area of the rear door weatherstrip.

  23. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole in the vehicle body.

    3. Clean the threads of the bolt (A).

    4. Apply adhesive to the threads of the bolt (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A005NE4C01
      *a Bolt (A)
      *b Bolt (B)

      Install the rear door check assembly with the bolt (A) and 2 bolts (B).

      Torque:
      Bolt (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Bolt (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  24. INSTALL REAR DOOR SERVICE HOLE COVER


    1. A005NMDC01
      *a Reference Point
      A005NFE Butyl Tape

      Apply new butyl tape to the rear door panel.

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

    3. Install the front door service hole cover according to the reference points on the front door panel.

      Note

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

  25. INSTALL REAR DOOR TRIM BRACKET


    1. A005MMJ

      Install the rear door trim bracket with the 2 screws.

  26. INSTALL NO. 2 REAR DOOR FRAME GARNISH


    1. A005NKJ

      Install the No. 2 rear door frame garnish.

  27. INSTALL HOLE PLUG


    1. A005NMA

      Install the 2 hole plugs.

  28. INSTALL REAR DOOR BELT SEAL


    1. A005N3CC01
      B0048R7 Install in this Direction

      Install the rear door belt seal to the rear door glass inner weatherstrip as shown in the illustration.

  29. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP


    1. A005N3ZC01
      B0048R7 Install in this Direction

      Install the rear door glass inner weatherstrip with the rear door belt seal as shown in the illustration.

  30. INSTALL REAR DOOR BELT REAR SEAL


    1. A005MW7

      Install the rear door belt rear seal.

  31. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A005NXN

      Engage the guides and claw to install the front door inside handle sub-assembly.

  32. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A005NVUC01
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
      B0048R7 Install in this Direction

      Engage the guides to connect the rear door inside locking cable assembly and rear door lock remote control cable assembly.

    2. A005NI4C01
      B0048R7 Install in this Direction

      Engage the claws as shown in the illustration.

    3. A005NMY

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

    4. Install the 2 screws.

    5. A005NJU

      Install the 3 screws.

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


    1. A005NM1

      Connect the connector.

    2. A005N2JC01
      B0048R7 Install in this Direction

      Engage the guides, clips and claws to install the rear power window regulator switch assembly with rear door armrest base upper panel as shown in the illustration.

  34. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A005NYIC01
      B0048R7 Install in this Direction

      Engage the claws to install the rear door inside handle bezel plug as shown in the illustration.

  35. INSTALL REAR DOOR REAR FRAME BRACKET


    1. A005NGCC01
      B0048R7 Install in this Direction

      Engage the claws and clip to install the rear door rear frame bracket as shown in the illustration.

  36. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

    Note

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

    Click here

  37. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  38. INSPECT POWER WINDOW OPERATION

    Click here