REAR DOOR(for Hatchback, Wagon) 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 (w/ Black Out Tape)

    Click here

  2. INSTALL NO. 2 BLACK OUT TAPE (w/ 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. A012JHY

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

  6. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. A012NCU

      Engage the 2 claws to install a new 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. A012GLTC01
      *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. A012ILT

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

  9. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A012MID

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

  10. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A012HIK

      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.

  11. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A012IJ7

      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 }

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


    1. A012J93

      Install the rear door inside locking cable assembly.

    2. A012JV1

      Engage the 3 claws.

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


    1. A012JF8

      Install the rear door inside locking cable assembly.

    2. A012H7M

      Engage the 3 claws.

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


    1. A012LB8

      Install the rear door lock remote control cable assembly.

    2. A012IKR

      Engage the claw.

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


    1. A012J45

      Install the rear door lock remote control cable assembly.

    2. A012L6U

      Engage the claw.

  16. 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. When reusing the rear door lock assembly:


      1. A012I3V

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

    3. A012I6VC01
      *a Release Plate

      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 }

    6. Connect the connector.

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


    1. A012L75N01

      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 }

  18. 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. A012I8KC01
      *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.

  19. INSTALL REAR DOOR FRAME GARNISH


    1. A012FZ1

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

  20. INSTALL REAR DOOR GLASS RUN


    1. A012LLH

      Install the rear door glass run.

  21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A012MFN

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

  22. INSTALL REAR DOOR REAR WINDOW GUIDE SUB-ASSEMBLY


    1. A012LJZ

      Install the rear door rear window guide sub-assembly with the screw.

  23. INSTALL REAR DOOR REAR WINDOW GUIDE WITH REAR DOOR REAR GUIDE SEAL


    1. A012KQO

      Connect rear door glass run.

    2. A012F60

      Install the rear door rear window guide with rear door rear guide seal with the 2 screws and 2 bolts.

  24. CONNECT REAR DOOR GLASS RUN


    1. A012JFB

      Connect rear door glass run.

  25. INSTALL REAR DOOR WEATHERSTRIP


    1. A012FG4

      Engage the 17 clips to install the rear door weatherstrip.

  26. 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.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A012JUPN01

      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 }

  27. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A012LOTC01
      *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.

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


    1. except Rivet Type:


      1. A012L3QC01
        *a Reference Point

        Attach a new rear door speaker cover according to the reference points on the rear door panel.

        Note

        Securely install the rear door speaker cover preventing wrinkles and air bubbles.

    2. for Rivet Type:


      1. Using an air riveter or a hand riveter, install the rear door speaker cover with 3 new rivets.

        A012MZNC01
        *a Incorrect *b Correct
        *c Riveter *d Mandrel

        Note


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

        • Confirm that the rivets are seated properly against the rear door speaker cover.

        • Do not tilt the riveter when installing the rivets to the rear door speaker cover.

        • Do not leave any clearance between the rivet heads and rear door speaker cover.

        • Do not leave any clearance between the rear door speaker cover and door. Firmly hold the 2 items together while installing the rivets.

        Tech Tips


        • Install the rivets in the order shown in the illustration.

        • If the rivet cannot be cut, pull it once and cut it.

      2. Connect the connector.

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

    Click here

  30. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A012LOS

      Engage the 6 claws to install the rear door inner glass weatherstrip as shown in the illustration.

  31. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A012JJC

      Engage the 4 guides 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. A012F5HC01
      *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. A012G8D

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

    3. A012GZQ

      Install the 2 screws.

    4. A012I5W

      Engage the claw and close the cover.

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


    1. Connect the connector.

    2. A012KCZ

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

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


    1. A012NASC01
      *a Inside of vehicle

      install the window rear door regulator inside handle plate.

    2. Install the clip to the rear door window regulator handle assembly.

    3. Fully open the rear door window.

    4. A012H5IC01
      *a Assembly when fully open

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

      Area Measurement
      A 45°
      B 60°

  35. INSTALL REAR ARMREST ASSEMBLY (w/o Power Window)


    1. A012JRG

      Engage the 4 guides.

    2. Engage the 5 claws and 2 clips to install the rear armrest assembly.

  36. INSTALL REAR ARMREST ASSEMBLY (w/ Power Window)


    1. A012FVC

      Engage the 6 claws and 2 clips to install the rear armrest assembly.

  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  38. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  39. INSPECT POWER WINDOW OPERATION

    Click here