REAR DOOR REASSEMBLY

Tech Tips


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

  • The following procedure is for the LH side.


  1. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


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

        Heating Temperature
        Item Temperature
        Vehicle Body 40 to 60°C (104 to 140°F)

        Note

        Do not heat the vehicle body excessively.

      2. Wipe off any tape adhesive residue with cleaner.

    2. Installation temperature


      1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.

        Tech Tips


        • The most appropriate temperature for installing the tape is 25°C (77°F).

        • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.

    3. Before installation


      1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.

        Tech Tips

        Spray water on the shop floor to settle any dust.

    4. Key points for handling the tape


      1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.

        Note

        Do not bend the tape or leave it in high temperature places.

    5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

      Note


      • Position the tape accurately to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit any more after being removed.


      1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body prematurely. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 30 to 70 mm (1.18 to 2.76 in.) per second.

        A01I53DE06
        Text in Illustration
        *A Pressing Forward *B Pulling
        *1 Door Stripe - -
        *a Side View *b Non-padded Side
        *c Padded Side *d Squeegee
        *e Release Paper - -
        Standard Measurement
        Area Measurement Area Measurement
        A 10 to 20 mm (0.394 to 0.787 in.) B 30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
        C 40 to 50° (for pressing forward) D 30 to 45° (for pulling)

        Note

        Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

        Tech Tips


        • Either angle of the squeegee (pressing forward or pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

    6. Key points for installation of the tape (How to use a squeegee and installation procedure for hemmed surfaces)


      1. A01I562E12
        Text in Illustration
        *a Squeegee
        *b Hem
        *c First
        *d Second
        *e Third

        If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

        Tech Tips

        When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

    7. Key points for installation of the tape (How to use a squeegee and installation procedure for corners)


      1. Remove the release paper and apply the tape carefully with your fingers.

      2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.

    8. Check after installation


      1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.

        Note

        Do not reuse the tape.

  2. INSTALL NO. 2 BLACK OUT TAPE


    1. Refer to the illustration to position a new No. 2 black out tape.

      A01I2B1E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Triangle - -
      Standard Measurement
      Area Measurement Area Measurement
      A 1.0 mm (0.0394 in.) B 1.5 mm (0.0591 in.)

    2. Remove the release paper and install the No. 2 black out tape.

  3. INSTALL REAR DOOR LOWER OUTSIDE STRIPE


    1. Refer to the illustration to position a new rear door lower outside stripe.

      A01I32JE01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Triangle - -
      Standard Measurement
      Area Measurement Area Measurement
      A 1.5 mm (0.0591 in.) B 1.0 mm (0.0394 in.)

    2. Remove the release paper and install the rear door lower outside stripe.

  4. INSTALL REAR DOOR OUTSIDE STRIPE


    1. Refer to the illustration to position a new rear door outside stripe.

      A01I2I6E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Triangle - -
      Standard Measurement
      Area Measurement Area Measurement
      A 1.0 mm (0.0394 in.) B 1.5 mm (0.0591 in.)

    2. Remove the release paper and install the rear door outside stripe.

  5. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING


    1. A01I4LC

      Using an air riveter or hand riveter with a nose piece, install the rear door rear window frame moulding with 4 new rivets.

      Tech Tips

      If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

      Note


      • A01I5OXE10

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

        Text in Illustration
        *a Riveter
        *b Mandrel
        *c Incorrect
      • A01I59RE11

        Confirm that the rivets are seated properly against the moulding.

        Text in Illustration
        *a Riveter
        *b Incorrect

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

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

      • A01I4UYE13

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

        Text in Illustration
        *a Riveter
        *b Incorrect

  6. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING


    1. A01I48L

      Engage the guide of the rear door upper window frame moulding to the door frame.

    2. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 4 new rivets.

      Tech Tips

      If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

      Note


      • A01I5OXE10

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

        Text in Illustration
        *a Riveter
        *b Mandrel
        *c Incorrect
      • A01I59RE11

        Confirm that the rivets are seated properly against the moulding.

        Text in Illustration
        *a Riveter
        *b Incorrect

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

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

      • A01I4UYE13

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

        Text in Illustration
        *a Riveter
        *b Incorrect

  7. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    When installing a new rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light.

    Heating Temperature
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Rear Door Front Window Frame Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or rear door front window frame moulding excessively.


    1. Clean the vehicle body surface.


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

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

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new rear door front window frame moulding.


      1. Using a heat light, heat the vehicle body and rear door front window frame moulding.

      2. Remove the release paper from the rear door front window frame moulding.

        Tech Tips

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

      3. A01I4GQE01
        Text in Illustration
        *a Caulking Sponge
        A01I3GM Double-sided Tape

        Engage the clip and guide, and attach the double-sided tape to install the rear door front window frame moulding.

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A01I4L6

      Engage the 6 claws to install the rear door belt moulding assembly as shown in the illustration.

  9. INSTALL REAR DOOR PANEL CUSHION


    1. A01I3VJ

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

  10. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. A01I39G

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

  11. 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. A01I3SFE01
      Text in Illustration
      *1 Door Handle Nut
      *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 and door handle nut.

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

  12. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01I3X9

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

  13. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01I5H8

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

  14. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01I2RN

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

      Note

      If the release plate of the rear door outside handle frame sub-assembly is not pulled and held when installing the rear door outside handle assembly, it will interfere with the rear door outside handle assembly and will be damaged.

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

  15. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A01I3WL

      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 }

  16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A01I2HO

      Install the rear door inside locking cable assembly.

    2. A01I45K

      Engage the 3 claws as shown in the illustration.

  17. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A01I31A

      Install the rear door lock remote control cable assembly.

    2. A01I4HT

      Engage the claw as shown in the illustration.

  18. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Note


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

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

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


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

    2. When reusing the rear door lock with motor assembly.


      1. A01I39D

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

    3. A01I3KJE03
      Text in Illustration
      *a Release Plate

      Connect the rear door lock with motor assembly to the release plate of the rear door outside handle frame sub-assembly, and set it to the rear door panel.

      Tech Tips

      Make sure that the release plate of the rear door outside handle frame sub-assembly is securely connected to the rear door lock with motor assembly.

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

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

  19. 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. A01I35Y

      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 a rear power window regulator motor assembly, a new rear power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are installed.

  20. 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. A01I52HE06
      Text in Illustration
      *a Temporary Bolt

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

    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 }

  21. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. A01I4V3

      Engage the guide.

    2. Install a new rear door inside panel reinforce sub-assembly with the 4 screws.

  22. INSTALL REAR DOOR FRAME GARNISH


    1. A01I3RM

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

  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A01I4FX

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

      Note

      Do not damage the rear door glass sub-assembly.

  24. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. A01I43Y

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

  25. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. A01I4X3

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

  26. INSTALL REAR DOOR GLASS RUN


    1. A01I3EG

      Install the rear door glass run.

  27. INSTALL REAR DOOR WEATHERSTRIP


    1. A01I2FH

      Engage the 20 clips to install the rear door weatherstrip.

  28. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the bolt threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A01I4VR

      Install the rear door check assembly with the 2 nuts and bolt.

      Torque:
      Bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  29. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A01I4TEE02
      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. Install the new 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.

  30. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A01I3NI

      Install the rear door inner glass weatherstrip.

  31. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01I2UW

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

  32. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A01I325

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

    2. A01I3DQE02
      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. A01I2ODE02
      Text in Illustration
      *a Reference Boss

      Engage the 4 claws and reference boss as shown in the illustration.

    4. A01I31I

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

    5. Install the 3 screws.

    6. Remove protective tape.

  33. INSTALL REAR ARMREST ASSEMBLY


    1. A01I623

      Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

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


    1. Connect the connector.

    2. A01I4L4

      Engage the 3 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

  35. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A01I5UH

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

  36. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  37. INSTALL LUGGAGE TRIM SERVICE HOLE COVER


    1. Engage the claw to connect the luggage trim service hole cover.

  38. INSPECT POWER WINDOW OPERATION

    Click here