REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • 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. REPAIR INSTRUCTION

    Click here

  2. INSTALL REAR DOOR OUTSIDE STRIPE LH

    Click here

  3. INSTALL BLACK OUT TAPE LH

    Click here

  4. INSTALL REAR DOOR LOWER OUTSIDE STRIPE LH

    Click here

  5. INSTALL NO. 2 BLACK OUT TAPE LH

    Click here

  6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

    Click here

  7. INSTALL REAR DOOR BELT MOULDING LH

    Click here

  8. INSTALL REAR DOOR PANEL CUSHION


    1. Attach the clip to install a new door panel cushion.

  9. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 6 clips and guide to install the rear door No. 2 weatherstrip.

  10. INSTALL REAR DOOR WEATHERSTRIP LH


    1. Attach the 19 clips and guide to install the rear door weatherstrip.

  11. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. B001DFB

      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:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

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


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

    2. B001CEG

      Attach 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 }

  13. INSTALL REAR DOOR NO. 2 OUTSIDE HANDLE PAD LH


    1. Attach the 2 claws to install the rear door No. 2 outside handle pad.

  14. INSTALL REAR DOOR NO. 1 OUTSIDE HANDLE PAD LH


    1. Attach the 3 claws to install the rear door No. 1 outside handle pad.

  15. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B001FIL

      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. B001GQB

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

  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to 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 }

  17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the rear door inside locking cable assembly.

    2. Attach the 3 claws.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the rear door lock remote control cable assembly.

    2. Attach the claw.

  19. INSTALL REAR DOOR LOCK ASSEMBLY LH

    Click here

  20. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  21. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY LH


    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. B001DUAE07
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window regulator assembly with the temporary bolt.

    4. Temporarily install the 3 bolts, and then tighten the temporary bolt and 3 bolts.

      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 GLASS CHANNEL FILLER


    1. B001I66E02
      Text in Illustration
      *a Front Side
      *b Rear Side

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

      Standard
      Area Specified Condition
      A 21 mm (0.827 in.)
      B 22.5 mm (0.886 in.)

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

  23. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


    1. B001CQQE03
      Text in Illustration
      *a Front Side
      *b Rear Side

      Apply soapy water to a new rear door glass channel sub-assembly.

      Standard
      Area Specified Condition
      A 21 mm (0.827 in.)
      B 22.5 mm (0.886 in.)

      Note

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

    2. Install the rear door glass channel sub-assembly to the position shown in the illustration.

  24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. Connect the cable to the negative (-) battery terminal and rear power window regulator motor connector.

    2. B001EIY

      Connect the power window regulator switch assembly and move the arm of the regulator so that the roller on the arm can be seen through the service hole.

    3. Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

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

      Note


      • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

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

    5. B001CXR

      Insert the rear door glass sub-assembly into the rear door panel along the rear door glass run as indicated by the arrow in the illustration.

  25. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. B001DJU

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

  26. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. B001HBU

      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 FRAME GARNISH LH


    1. Attach the clip to install a new door frame garnish.

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


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

    4. Install the rear door window division bar sub-assembly.

    5. Install the 2 bolts and screw.

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

  29. INSTALL REAR DOOR GLASS RUN LH


    1. Install the glass run.

  30. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. B001DKOE04
      Text in Illustration
      *1 Reference Point

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

      Note


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

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

    4. Connect the connector.

    5. Attach the 2 clamps to the rear door wire.

  31. INSTALL REAR SPEAKER SET

    Click here

  32. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B001EL4

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

    2. Install the 2 screws.

    3. B001DOR

      Install the 8 screws to the rear door armrest.

  33. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 14 Speakers)

    Click here

  34. INSTALL NO. 2 INTERIOR ILLUMINATION LIGHT SUB-ASSEMBLY

    Click here

  35. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH

    Click here

  36. INSTALL REAR REFLEX REFLECTOR ASSEMBLY


    1. Attach the 2 claws to install the rear reflex reflector assembly.

  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

    Click here

  38. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. B001DDL

      Attach the 3 claws to install the rear door inner glass weatherstrip as shown in the illustration.

  39. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B001HYQ

      Install the clamp to the door panel.

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

    3. Connect each connector.

    4. B001GFB

      Attach the rear door trim board sub-assembly by attaching the 4 claws of the rear door inner glass weatherstrip as shown in the illustration.

    5. Attach the 9 clips and install the rear door trim board sub-assembly.

    6. Install the 3 screws.

  40. INSTALL ASSIST GRIP COVER LH


    1. B001HM6

      Attach the 8 claws to install the assist grip cover.

  41. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL LH


    1. B001IDO

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

  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  43. INITIALIZE POWER WINDOW CONTROL SYSTEM


    1. Initialize the power window control system Click here.