REAR DOOR REASSEMBLY

PROCEDURE


  1. REPAIR INSTRUCTION

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  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

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  3. INSTALL REAR DOOR OUTSIDE STRIPE

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  4. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

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  5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

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  6. INSTALL NO. 3 REAR DOOR WEATHERSTRIP

    Tech Tips

    When installing a new No. 3 rear door weatherstrip, heat the vehicle body and No. 3 rear door weatherstrip using a heat light.

    Note

    Do not heat the vehicle body or No. 3 rear door weatherstrip excessively.


    1. Using a heat light, heat the vehicle body surface.

      Heating Temperature
      Item Temperature
      Vehicle Body 40 to 60°C (104 to 140°F)
      No. 3 Rear Door Weatherstrip 20 to 30°C (68 to 86°F)

    2. Remove the double-sided tape from the vehicle body.

    3. Wipe off any tape adhesive residue with cleaner.

    4. B001L30E02
      Text in Illustration
      *1 Double-sided Tape

      Install a new No. 3 rear door weatherstrip.

  7. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

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  8. INSTALL REAR DOOR PANEL CUSHION


    1. B001MAW

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

  9. INSTALL NO. 2 REAR DOOR WEATHERSTRIP


    1. B001LM5

      Engage the 4 clips to install the No. 2 rear door weatherstrip.

  10. 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. B001MLU

      Engage the door handle nut and 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 }

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B001M13

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

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B001MO3

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

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B001LIV

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

      Note

      If the bellcrank lever is not pulled and held when installing the outside handle, 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. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it.

    3. B001KXQ

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

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B001N14

      Engage the claw and install the rear door outside handle cover.

    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 }

  15. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. B001MGE

      Install the rear door inside locking cable assembly.

    2. B001L86

      Engage the 3 claws.

  16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. B001LCS

      Install the rear door inside locking cable assembly.

    2. B001MPH

      Engage the 3 claws.

  17. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. B001NFJ

      Install the rear door lock remote control cable assembly.

    2. B001LFB

      Engage the claw.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. B001LD6

      Install the rear door lock remote control cable assembly.

    2. B001KN4

      Engage the claw.

  19. 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. B001MKO

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

    3. B001MR7

      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:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  20. 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. B001L7M

      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.

  21. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


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

    2. Install the temporary bolt to the rear door window regulator assembly.

    3. B001MUNE07
      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.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

  22. INSTALL REAR DOOR CUSHION


    1. When reusing the rear door cushion:


      1. Clean the rear door cushion.

      2. Remove the double-sided tape from the rear door cushion.

      3. Wipe off any tape adhesive residue with cleaner.

      4. B001MDVE02

        Apply new double-sided tape to the rear door cushion as shown in the illustration.

        Area Dimension
        (A) 80.0 mm (3.150 in.)
        (B) 20.0 mm (0.787 in.)
        (C) 4.0 mm (0.157 in.)

    2. Clean the rear door panel sub-assembly.

    3. B001LOQE02
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    4. Install the rear door cushion with the 2 bolts.

  23. INSTALL REAR DOOR GLASS CHANNEL FILLER


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

    2. B001KL4E02
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a 0 mm (0 in.)
      *b 0 mm (0 in.)
      *c Edge of curved surface

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

  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. B001MCQE01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a 14.0 mm (0.551 in.)
      *b 11.0 mm (0.433 in.)
      *c Edge of curved surface

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

      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 SUB-ASSEMBLY


    1. B001MXX

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

  26. INSTALL NO. 2 REAR DOOR VENT SEAL


    1. B001MZK

      Install the No. 2 rear door vent seal.

  27. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. B001LUB

      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.

  28. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


    1. Install the temporary bolt to the rear door window division bar sub-assembly.

    2. B001KGGE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window division bar sub-assembly.

    3. Install the bolt and screw.

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

    4. Tighten the temporary bolt to install the rear door window division bar sub-assembly.

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

  29. INSTALL NO. 1 REAR DOOR VENT SEAL


    1. B001MG3

      Install the No. 1 rear door vent seal.

  30. INSTALL REAR DOOR GLASS RUN


    1. B001KK5

      Install the rear door glass run.

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. B001KAHE02
      Text in Illustration
      *1 Double-sided Tape

      Engage the 23 clips 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 (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001MSBE02

      Install the rear door check assembly with the 3 bolts.

      Torque:
      (A)
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      (B)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  33. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. B001NFTE02
      Text in Illustration
      *1 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. Connect the connector.

    5. Engage the clamp.

  34. INSTALL REAR DOOR TRIM BRACKET


    1. B001NF3

      Install the rear door trim bracket with the 2 screws.

  35. INSTALL REAR DOOR FRAME GARNISH


    1. B001L41

      Engage the clip to install a new rear door frame garnish.

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


    1. B001LPJE02

      Install the rear door speaker cover with the 3 bolts.

      Tech Tips

      Install the bolts in the order shown in the illustration.

    2. Connect the connector.

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

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  38. INSTALL REAR DOOR TRIM SEAL


    1. B001LJ0

      Engage the 6 clips of the rear door trim seal.

  39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. B001KAB

      Engage the 3 claws and install the rear door inner glass weatherstrip as shown in the illustration.

  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B001M2X

      Engage the claw and 2 guides, and install the rear door inside handle sub-assembly to the rear door trim board sub-assembly as shown in the illustration.

  41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. Install a new rear door trim board clip (blue) to the rear door trim board.

    2. B001MTIE02
      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. Connect the connector.

    4. Engage the rear door trim board sub-assembly with the 3 claws to the rear door inner glass weatherstrip as shown in the illustration.

      B001MA6
    5. B001LMJE01

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

    6. Engage the clip <A> and install the rear door trim board sub-assembly.

    7. Install the 2 screws.

    8. Remove the protective tape.

  42. INSTALL REAR DOOR ARMREST COVER


    1. B001MCH

      Install the rear door armrest cover.

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


    1. Connect the connector.

    2. B001MEH

      Engage the 2 guides, 3 clips and 4 claws, and install the rear power window regulator switch assembly with rear door armrest base panel.

  44. INSTALL REAR DOOR REAR FRAME BRACKET


    1. B001NAG

      Engage the 3 guides, clip and 3 claws, and install the rear door rear frame bracket.

  45. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. B001KTM

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

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  47. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

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  48. INSTALL DECK FLOOR BOX RH

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  49. INSTALL REAR NO. 3 FLOOR BOARD

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  50. INSTALL REAR DECK FLOOR BOX

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  51. INSTALL REAR NO. 2 FLOOR BOARD

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  52. INITIALIZE POWER WINDOW CONTROL SYSTEM

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