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 DUST PROOF SEAL (w/ Door Dust Proof Seal)


    1. B00452T

      Engage the 6 claws to install 3 new rear door dust proof seals.

  6. INSTALL REAR DOOR PANEL CUSHION


    1. B004350

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

  7. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. B0042KC

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

  8. 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. B0044X0C01
      *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 }

  9. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B004251

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

  10. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B0043Q0

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

  11. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B0043JO

      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.

  12. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B0042T7

      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 }

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


    1. B0044Y4

      Install the rear door inside locking cable assembly.

    2. B0043ZH

      Engage the 3 claws.

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


    1. B0042NA

      Install the rear door inside locking cable assembly.

    2. B004353

      Engage the 3 claws.

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


    1. B0042Z9

      Install the rear door lock remote control cable assembly.

    2. B0043JL

      Engage the claw.

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


    1. B0043M2

      Install the rear door lock remote control cable assembly.

    2. B0043TY

      Engage the claw.

  17. 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. B0042GP

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

    3. B0043HEC01
      *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.

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


    1. B0043EFN01

      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 }

  19. 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. B0042JLC01
      *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.

  20. INSTALL REAR DOOR FRAME GARNISH


    1. B00430Q

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

  21. INSTALL REAR DOOR GLASS RUN


    1. B00449D

      Install the rear door glass run.

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. B0042YR

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

  23. INSTALL REAR DOOR REAR WINDOW GUIDE SUB-ASSEMBLY


    1. B00434E

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

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


    1. B0042YC

      Connect rear door glass run.

    2. B0041PO

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

  25. CONNECT REAR DOOR GLASS RUN


    1. B0043TT

      Connect rear door glass run.

  26. INSTALL REAR DOOR WEATHERSTRIP


    1. B0044KB

      Engage the 17 clips to install the rear door weatherstrip.

  27. 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. B0044PQN01

      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 }

  28. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. B00450BC02
      *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.

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


    1. except Rivet Type:


      1. B0043AAC01
        *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.

        B0043QZC01
        *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.

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

    Click here

  31. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. B0042DX

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

  32. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B00435G

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

  33. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B00431NC01
      *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. B0043CJ

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

    3. B0043UR

      Install the 2 screws.

    4. B00436Q

      Engage the claw and close the cover.

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


    1. Connect the connector.

    2. B0042C0

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

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


    1. B00421GC01
      *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. B0044WCC01
      *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°

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


    1. B00433B

      Engage the 4 guides.

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

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


    1. B0044M2

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

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

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

    Click here

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

    Click here