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.

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

    Click here

PROCEDURE


  1. INSTALL REAR DOOR PANEL CUSHION


    1. Install a new rear door panel cushion.

  2. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH

    Click here

  3. INSTALL REAR DOOR LOWER OUTSIDE STRIPE LH

    Click here

  4. INSTALL REAR DOOR OUTSIDE STRIPE LH

    Click here

  5. INSTALL DOOR WINDOW FRAME MOULDING CLIP

    Click here

  6. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH

    Click here

  7. INSTALL REAR DOOR FRAME GARNISH LH


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

  8. INSTALL REAR DOOR WEATHERSTRIP LH


    1. Attach the 19 clips to install the rear door weatherstrip LH.

  9. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. When reusing a bolt labeled B:


      1. Clean the threads of the bolt with non-residue solvent.

      2. Apply adhesive to the threads of the bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A01VAP1C01
      *1 Bolt A
      *2 Bolt B

      Install the door check to the door panel with the 2 bolts labeled A.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    4. Install the rear door check assembly with the 2 bolts labeled B.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

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


    1. A01V8JYC01
      *A Outside
      *B Inside

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

    2. Attach the claw to install the rear door outside handle frame sub-assembly LH.

    3. Using a T30 "TORX" socket wrench, tighten the screw.

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

  11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. Attach the 2 claws to install the rear door front outside handle pad.

  12. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. Attach the 2 claws to install the rear door rear outside handle pad.

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. Apply MP grease to the sliding area of the rear door outside handle assembly LH.

    2. A01VAHW

      Install the rear door outside handle assembly LH by moving it in the direction indicated by the arrow shown in the illustration.

      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.

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Using a T30 "TORX" socket wrench, tighten the screw to install the rear door outside handle cover LH.

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

  15. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the rear door inside locking cable assembly LH.

    2. Attach the 3 claws to close the cover.

  16. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


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

    2. Attach the claw to close the cover.

  17. INSTALL REAR DOOR WITH MOTOR LOCK ASSEMBLY LH

    Click here

  18. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH


    1. Install the rear door lock child protection cover LH.

  19. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

    Click here

  20. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  21. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the rear door window regulator.

    2. Temporarily install the temporary bolt to the rear door window regulator.

    3. A01V8Y5C02
      *1 Temporary Bolt

      Install the rear door window regulator with the 3 bolts, and then tighten the temporary bolt.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

      Note

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

    4. Connect the connector.

  22. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A01V84WC01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install a new rear door glass channel filler to the rear door glass as shown in the illustration.

      Standard
      Area Dimension
      A 42 mm (1.65 in.)
      B 12 mm (0.472 in.)

  23. 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. A01V8I6C01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

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

      Standard
      Area Dimension
      A 42 mm (1.65 in.)
      B 12 mm (0.472 in.)

      Note

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

  24. INSTALL REAR DOOR GLASS RUN LH


    1. Install the front side of the rear door glass run.

  25. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the rear power window regulator switch assembly with rear door armrest base panel.

    2. Connect the cable to the negative (-) battery terminal.

    3. Operate the rear door window regulator so that the rear door glass can be installed.

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

      Note

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

      Click here

    5. Remove the rear power window regulator switch assembly with rear door armrest base panel.

    6. A01V9Z6C01
      *1 MP Grease

      Apply MP grease to the sliding area of the rear door glass channel as shown in the illustration.

      Standard
      Area Specified Condition
      A 157 mm (6.18 in.)
      B 25 mm (0.984 in.)
      C 5 mm (0.197 in.)
    7. A01V8VJ

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

      Note

      Do not damage the door glass.

  26. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


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

  27. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. Install the rear door quarter window glass LH.

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


    1. Align the rear door glass run with the rear door window division bar.

    2. Insert the rear door window division bar together with the rear door glass run into the rear door panel.

    3. Install the screw and 2 bolts.

      Torque:
      Screws
      3.6 N*m  { 37 kgf*cm, 32 in.*lbf }
      Bolt
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

    4. Finish installing the upper side of the rear door glass run.

  29. INSTALL REAR DOOR SERVICE HOLE COVER LH


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

    2. A01V6T5C01
      *a Reference Point

      Pass the rear door inside locking cable, rear door lock remote control cable and wire harness through a new rear door service hole cover, and then attach the rear door service hole cover using the reference points on the rear door panel.

      Note


      • Securely install the rear door service hole cover to prevent wrinkles and air bubbles.

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

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

  30. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  31. INSTALL REAR DOOR SPEAKER COVER


    1. Place the riveter upright against the rear door speaker cover and install the 3 rivets.


      1. Install a nose piece to an air riveter or hand riveter.

      2. Insert the mandrel part of a new rivet into the nose piece.

      3. Using the riveter, install the rear door speaker cover with the 3 rivets as shown in the illustration.

        Tech Tips

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

        A01V7MO

        Note


        • A01V9DCC06
          *1 Riveter
          *2 Mandrel
          *a INCORRECT
          *b CORRECT

          Do not pry the rivet with the riveter as this will cause damage to the riveter and mandrel.

        • A01V7DNC06
          *1 Riveter
          *a INCORRECT
          *b CORRECT

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

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

        • Do not leave any space between the rivet head and rear door speaker cover.

        • A01V8ZRC06
          *1 Riveter
          *a INCORRECT
          *b CORRECT

          Do not leave any space between the rear door speaker cover and rear door panel. Firmly hold together the 2 items while installing the rivet.

      4. Connect the connector.

  32. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A01V92N

      Install the rear door inner glass weatherstrip LH to the rear door trim board sub-assembly LH and fold down the 6 claws in the directions indicated by the arrows in the illustration.

  33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


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

  34. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the rear door lock remote control cable LH and rear door inside locking cable LH.

    2. Engage the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH to the 2 clamps.

    3. Attach the 8 clips to install the rear door trim board sub-assembly LH.

    4. Install the 3 screws.

  35. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


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

  36. INSTALL DOOR ASSIST GRIP COVER LH


    1. Attach the 5 claws, 2 clips and guide to install the door assist grip cover LH.

  37. INSTALL REAR SEAT HEATER SWITCH (w/ Seat Heater System)

    Click here

  38. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

    Click here

  39. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL


    1. w/ Seat Heater System:

      Connect the connector.

    2. Connect the connector.

    3. Attach the 5 claws, 2 guides and 2 clips to install the rear power window regulator switch assembly with rear door armrest base panel.

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  41. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  42. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here