REAR DOOR(for Sedan) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure described below is for the LH side.

PROCEDURE


  1. REPAIR INSTRUCTION

    Click here

  2. INSTALL NO. 2 BLACK OUT TAPE

    Click here

  3. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  4. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  5. INSTALL REAR DOOR PANEL CUSHION


    1. B0043KB

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

  6. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. B0042XL

      Engage the 2 claws to install a new rear door window frame moulding clip.

  7. 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. B0041U2C01
      *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.

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

  8. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B00454W

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

  9. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B0043R9

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

  10. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B004209

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

      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, the release plate of the rear door outside handle frame sub-assembly will interfere with the rear door outside handle assembly 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.

  11. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B0042O4

      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 }

  12. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B0041YA

      Install the rear door inside locking cable assembly as shown in the illustration.

  13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B00449V

      Install the rear door lock remote control cable assembly as shown in the illustration.

    2. B00441C

      Engage the 2 claws as shown in the illustration.

  14. 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. B00448V

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

    3. B0041P2C01
      *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 }

    5. Connect the connector.

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


    1. B0042DBN01

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

    2. Install the rear door window regulator assembly with the 3 bolts in the order shown in the illustration.

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

  16. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY (w/ Power Window)


    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. B00429GC03
      *a 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 }

    5. Connect the connector.

  17. INSTALL REAR DOOR FRAME GARNISH


    1. B0044HI

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

  18. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. B0043ES

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

  19. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. B0044IS

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

  20. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. B004226

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

  21. INSTALL NO. 1 REAR DOOR VENT SEAL


    1. B0043EI

      Install the No. 1 rear door vent seal.

  22. INSTALL REAR DOOR GLASS RUN


    1. B0043YL

      Install the rear door glass run.

  23. INSTALL REAR DOOR WEATHERSTRIP


    1. B0041ZO

      Engage the 19 clips to install the rear door weatherstrip.

  24. 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. B0043AOC01
      B0042CO Bolt (A)
      B0043VS Bolt (B)

      Install the rear door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Bolt (B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  25. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. B0044BPC01
      *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. 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.

  26. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. B0042YN

      Install the rear door inner glass weatherstrip.

  27. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B00449R

      Engage the 4 guides to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

  28. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B004281C01
      *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.

    2. B0041SU

      Engage the 5 claws to temporarily install the rear door trim board sub-assembly.

    3. Engage the 9 clips to install the rear door trim board sub-assembly.

    4. B0042I1

      Install the 3 screws.

    5. B0043P1

      Engage the claw to close the cover.

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


    1. Connect the connector.

    2. B0042ES

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

  30. INSTALL REAR DOOR ARMREST UPPER BASE PANEL (w/o Power Window)


    1. B004234

      Engage the 3 guides, claw and clip to install the rear door armrest upper base panel.

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


    1. B0042NKC01
      *a Inside of vehicle

      install the rear door regulator inside handle plate.

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

    3. Fully close the rear door window.

    4. B0042B8N01

      Install the rear door window regulator handle assembly with rear door window regulator handle shaft snap ring at the angle shown in the illustration.

      Area Measurement
      A 5° to 15°

  32. INSTALL REAR ARMREST ASSEMBLY


    1. B00424K

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

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Power Window)

    Note

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

    Click here

  34. INITIALIZE POWER WINDOW CONTROL SYSTEM (w/ Power Window)

    Click here

  35. INSPECT POWER WINDOW OPERATION (w/ Power Window)

    Click here