REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

  • Use the same procedure for RHD and LHD vehicles.

  • he procedure listed below is for LHD vehicles.

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

PROCEDURE


  1. INSTALL REAR DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the rear door weatherstrip, heat the vehicle body and rear door weatherstrip using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Rear Door Weatherstrip 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or rear door weatherstrip excessively.


    1. Clean the vehicle body surface.


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

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

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install the rear door weatherstrip LH.


      1. Using a heat light, heat the vehicle body and a new rear door weatherstrip LH.

      2. Remove the peeling paper from the face of the rear door weatherstrip LH.

        Tech Tips

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

      3. Attach the 21 clips to install a new rear door weatherstrip LH.

        Tech Tips


        • If clips are damaged during installation, replace them.

        • Press the rear door weatherstrip LH firmly to install it.

  2. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. Install the rear door check assembly LH 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 bolt.

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

  3. INSTALL NO. 4 ELECTRICAL KEY WIRE HARNESS


    1. Attach the 2 clamps to install the wire No. 4 electrical key wire harness to the rear door outside handle frame sub-assembly LH.

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


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

    2. B0018RBE08
      Text in Illustration
      *a Nut
      *b Guide

      Attach the nut and 2 guides to install the rear door outside handle frame sub-assembly LH.

    3. Using a T30 "TORX" wrench, install the rear door outside handle frame sub-assembly LH with the screw.

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

    4. Attach the clamp.

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


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

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


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

  7. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B00197X

      Install the rear door outside handle assembly LH.

      Note

      If the bellcrank lever is not pulled and held when installing the rear door outside handle assembly LH, the bellcrank lever will interfere with the rear door outside handle assembly LH and the release plate may be damaged.

    2. Attach the 2 claws and connect the holder.

    3. Attach the 3 claws to install the connector and connector cover.

  8. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to temporarily install the rear door outside handle cover LH.

    2. Using a T30 ''TORX'' socket, install the rear door outside handle cover LH with the "TORX" screw.

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

  9. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    Click here

  10. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    Click here

  11. INSTALL REAR DOOR LOCK COVER SUB-ASSEMBLY LH

    Click here

  12. INSTALL REAR DOOR LOCK ASSEMBLY LH

    Click here

  13. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

    Click here

  14. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

    Click here

  15. INSTALL REAR DOOR NO. 3 WEATHERSTRIP LH


    1. Clean the vehicle body surface.


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

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

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new rear door No. 3weatherstrip LH.


      1. Using a heat light, heat a new rear door No. 3 weatherstrip LH and the vehicle body surface.

      2. Remove the peeling paper from the face of the rear door No. 3 weatherstrip LH.

        Tech Tips

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

      3. Attach the claw and double-sided tape to install the rear door No. 3 weatherstrip LH.

        Tech Tips

        Press the rear door No. 3 weatherstrip LH firmly to install it.

  16. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  17. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. B001ANPE04
      Text in Illustration
      *1 Temporary Bolt

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

    2. Temporarily install the temporary bolt onto the rear door window regulator sub-assembly LH.

    3. Insert the rear door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the rear door window regulator sub-assembly LH on the door panel.

      Note

      Be careful not to drop the rear door window regulator sub-assembly LH as it may become damaged.

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

    5. Tighten the 4 bolts in the order shown in the illustration.

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

  18. INSTALL REAR DOOR NO. 2 FRAME GARNISH LH


    1. Attach the clip to install a new rear door No. 2 frame garnish LH.

  19. INSTALL REAR DOOR FRAME GARNISH LH


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

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. B001A4TE03
      Text in Illustration
      *a Front Side
      *b 8.0 mm (0.327 in.)

      Install the rear door glass channel filler onto the rear door glass.

  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


    1. Apply soapy water to the inside of the rear door glass channel sub-assembly LH.

    2. B001AFJE03
      Text in Illustration
      *a Front Side
      *b 8.0 mm (0.327 in.)

      Using a plastic-faced hammer, tap the channel onto the glass to install the rear door glass channel sub-assembly LH.

      Note

      Be careful not to damage the glass or rear door glass channel sub-assembly LH.

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. B001ASN

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

  23. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


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

  24. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. B001A3J

      Install the rear door quarter window glass LH together with the rear door quarter window weatherstrip LH in the direction indicated by the arrow in the illustration.

  25. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH


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

  26. INSTALL REAR DOOR GLASS RUN LH


    1. Install the rear door glass run LH.

  27. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

    2. B0018XS

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

      Note


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

      • There should be no wrinkles or folds after installing the rear door service hole cover LH.

      • After installing the rear door service hole cover LH, check the sealing quality.

    3. B001AQG

      Connect the 3connectors.

    4. Attach the 8 clamps.

    5. B001APUE02
      Text in Illustration
      *a 45°

      Install the bolt as shown in the illustration.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  28. INSTALL REAR SPEAKER SET

    Click here

  29. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 19 Speakers)

    Click here

  30. INSTALL REAR NO. 3 SPEAKER ASSEMBLY (for 19 Speakers)

    Click here

  31. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the 2 guides and claw to install the rear door inside handle sub-assembly LH.

  32. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH

    Click here

  33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. B00191D

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

  34. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect each connector.

    2. B001A08

      Attach the 2 claws to connect the rear door inside locking cable assembly LH to the rear door trim board sub-assembly LH.

    3. B0019WD

      Connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH to the rear door inside handle sub-assembly LH.

    4. Attach the 2 clamps.

    5. B001ALE

      Attach the 4 claws and 8 clips, pin to install the rear door trim board sub-assembly LH.

    6. Install the 2 screws.

  35. INSTALL DOOR ASSIST GRIP COVER LH


    1. Attach the 2 guides.

    2. Attach the 2 claws to install the door assist grip cover LH.

    3. Remove the protective tape.

  36. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  37. INSTALL REAR DOOR TRIM COVER


    1. Attach the clip to install the rear door trim cover.

  38. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

    Click here

  39. INSTALL REAR POWER WINDOW SWITCH ASSEMBLY WITH BEZEL

    Click here

  40. INSTALL REAR DOOR UPPER ARMREST BASE PANEL LH


    1. Connect the connector.

    2. Attach the guide and 2 claws, 2 clips to install the rear door upper armrest base panel LH.

  41. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


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

  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. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here