REAR DOOR INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.

PROCEDURE


  1. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 7 clips to install the rear door No. 2 weatherstrip.

  2. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING LH (for Wagon)

    Click here

  3. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING LH (for Wagon)

    Click here

  4. INSTALL REAR DOOR MOULDING SUB-ASSEMBLY OUTSIDE LH (for Sedan)

    Click here

  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY LH

    Click here

  6. INSTALL REAR DOOR BELT MOULDING LH


    1. for Sedan:

      Install the rear door belt moulding LH Click here.

    2. for Wagon:

      Install the rear door belt moulding LH Click here.

  7. INSTALL REAR DOOR WEATHERSTRIP LH (for Sedan)


    1. Clean the door surface.


      1. Wipe off any tape adhesive residue with cleaner.

    2. If reusing the weatherstrip:

      Clean the weatherstrip:


      1. Remove the double-sided tape from the weatherstrip.

      2. Wipe off any tape adhesive residue with cleaner.

      3. A0056AVE02
        Standard
        Area Specified Condition
        *1 Length: 30 mm (1.18 in.)
        *2 Width: 5.0 mm (0.197 in.)
        *3 Thickness: 0.8 mm (0.0315 in.)

        Apply new double-sided tape to the weatherstrip, as shown in the illustration.

        Standard
        Area Specified Condition
        *1 Length: 30 mm (1.18 in.)
        *2 Width: 5.0 mm (0.197 in.)
        *3 Thickness: 0.8 mm (0.0315 in.)

    3. Install the weatherstrip.


      1. Using a heat light, heat the door surface.

      2. Remove the peeling paper from the face of the weatherstrip.

        Tech Tips

        After removing the peeling paper, keep the exposed adhesive free from foreign matter.

      3. A0055O0
        Area Specified Condition
        *1 Length: 30 mm (1.18 in.)
        *2 Width: 5.0 mm (0.197 in.)
        *3 Thickness: 0.8 mm (0.0315 in.)

        Attach the 19 clips to install the weatherstrip.

  8. INSTALL REAR DOOR WEATHERSTRIP LH (for Wagon)


    1. A00549P

      Attach the 18 clips to install the weatherstrip.

  9. INSTALL REAR DOOR CHECK ASSEMBLY LH


    1. A0058R9

      Apply MP grease to the sliding areas of the door check.

    2. Install the door check to the door panel with the 2 nuts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the door check to the body panel with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  10. INSTALL NO. 2 SEPARATOR DOOR STIFFENER CUSHION


    1. A0052HE

      Install the No. 2 separator door stiffener cushion to the body panel with the bolt.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  11. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY LH


    1. A0054H5

      Install the rear door inside panel reinforce sub-assembly to the door panel with the 4 bolts.

  12. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


    1. A0057QN

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

    2. Attach the claw to install the rear door outside handle frame sub-assembly.

    3. Using a T30 "TORX" socket, tighten the screw.

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

  13. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A0058QB

      Attach the 2 claws to install the pad.

  14. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A0056SJ

      Attach the 3 claws to install the pad.

  15. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A0055JO

      Install the handle by pushing it in the direction of the arrow in the illustration.

    2. A0054NVE05
      Text in Illustration
      *1 Holder
      *2 Rear Door Outside Handle Frame LH

      Attach the holder of the front door outside handle frame LH.

  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to install the cover.

    2. A005488

      Using a T30 "TORX" socket, tighten the screw.

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

  17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A0053IDE01
      *1 w/o Double Locking System:
      *2 w/ Double Locking System:

      Install the rear door inside locking cable.

    2. A005529

      Attach the 3 claws.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A00538G

      Install the rear door lock remote control cable.

    2. A0058OK

      Attach the claw.

  19. INSTALL REAR DOOR WITH MOTOR LOCK ASSEMBLY LH

    Click here

  20. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY LH


    1. w/ Power Window:


      1. A00539XE02
        *1 MP grease

        Apply MP grease to the sliding and rotating areas of the window regulator.

      2. A0052ANE01
        Text in Illustration
        *1 Temporary Bolt

        Temporarily install the temporary bolt onto the window regulator.

      3. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

        Note

        Be careful not to drop the window regulator as it may become damaged.

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

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

      5. Connect the connector.

    2. w/o Power Window:


      1. A00590CE01
        *1 MP grease

        Apply MP grease to the sliding and rotating areas of the window regulator.

      2. A0057WO

        Install the rear door window regulator assembly with the 3 bolts.

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

  21. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A0053X7E03
      Text in Illustration
      *1 Front Side

      Install the rear door glass channel filler to the glass sub-assembly.

      Standard
      Area Specified Condition
      A 14.5 mm (0.571 in.)

  22. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


    1. Apply soapy water to the inside of the glass channel.

    2. A0054AZE03
      Text in Illustration
      *1 Front Side

      Using a plastic-faced hammer, tap the channel onto the glass to install the glass channel.

      Note

      Be careful not to damage the glass or glass channel.

      Standard
      Area Specified Condition
      A 14.5 mm (0.571 in.)

  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. A0059I0

      Install the front side of the glass run.

    2. A00568IE01
      *1 MP grease

      Apply MP grease to the sliding areas of the glass channel as shown in the illustration.

      Standard
      Area Specified Condition
      A 130 mm (5.12 in.)
      B 29 mm (1.14 in.)
    3. A00544U

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

  24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. A0054ZPE01
      *1 for Sedan:
      *2 for Wagon:

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

  25. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. A0056OVE01
      *1 for Sedan:
      *2 for Wagon:

      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.

  26. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH


    1. A0058GK

      Insert the rear door window division bar sub-assembly from above.

    2. Install the rear door window division bar sub-assembly to the glass run.

    3. A0058SQE01
      *1 for Sedan:
      *2 for Wagon:

      Install the rear door window division bar sub-assembly with the 2 bolts and screw.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }
      for bolt and screw

  27. INSTALL REAR DOOR GLASS RUN LH


    1. A0059ACE01
      *1 for Sedan:
      *2 for Wagon:

      Completely install the glass run.

  28. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

    2. A0056NAE01
      Text in Illustration
      *1 Reference Point

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

      Note


      • When installing the service hole cover, pull the links and connectors through the service hole cover.

      • There should be no wrinkles or folds after attaching the service hole cover.

      • After attaching the service hole cover, check the seal quality.

    3. Attach the rear door service hole cover by using the reference points on the rear door panel.

    4. Connect the connector.

  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A0052MV

      Install the rear door inner glass weatherstrip to the door panel.

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


    1. A0057W0

      Install the curtain hook to the rear door frame garnish with the 2 screws.

      Tech Tips

      Use the same procedure for all curtain hooks.

  31. INSTALL REAR DOOR FRAME GARNISH LH


    1. A0054X6E02
      *1 for Sedan:
      *2 for Wagon:

      Attach the 2 clips to install the garnish.

  32. INSTALL REAR NO. 1 SPEAKER ASSEMBLY

    Click here

  33. INSTALL REAR DOOR SPEAKER GRILLE SUB-ASSEMBLY (for 11 Speakers)


    1. A00583Q

      Attach the 3 claws to install the rear door speaker grille sub-assembly.

  34. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 11 Speakers)

    Click here

  35. INSTALL REAR CURTAIN SUB-ASSEMBLY LH (w/ Rear Door Sunshade)


    1. Install the clip to the rear curtain sub-assembly.

    2. A005405

      Attach the 2 claws to install the rear curtain sub-assembly to the door trim board.

    3. Install the 6 screws.

  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A005812

      Connect the 2 cables to the inside handle.

    2. for 11 Speakers:

      Connect the connector.

    3. A00542KE02
      Text in Illustration
      *1 w/ Rear Door Sunshade
      *2 w/o Rear Door Sunshade

      Attach the rear door trim board with the 4 claws on the rear door inner glass weatherstrip.

    4. A0054CP

      Install the rear door trim board with the 8 clips.

    5. Install the 3 screws.

  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL (w/ Power Window)


    1. Connect the connector.

    2. A0055FM

      Attach the 6 claws and clip to install the rear power window regulator switch assembly with rear door armrest base panel.

  38. INSTALL DOOR ASSIST GRIP COVER LH


    1. A0052PP

      Attach the 10 claws to install the door assist grip cover.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


    1. A0054EM

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

  40. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. A0054LS

      Install the rear door No. 1 stiffener cushion.

  41. INSTALL REAR DOOR REGULATOR INSIDE HANDLE PLATE (w/o Power Window)


    1. Install the rear door regulator inside handle plate.

  42. INSTALL REAR DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. Temporarily install the rear door window regulator handle assembly and fully open the window.

    2. Install the snap ring to the rear door window regulator handle assembly.

    3. A0056R8E03

      Install the rear door window regulator handle assembly as shown in the illustration.

      Standard
      Area Specified Condition
      A 2.4° to 22.4°
      Text in Illustration
      *1 Front Side

  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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