REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure described below is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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  2. REPAIR INSTRUCTION

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  3. INSTALL INNER UPPER BLACK OUT TAPE

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  4. INSTALL FRONT INNER BLACK OUT TAPE

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  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

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  6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

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  7. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

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  8. INSTALL REAR DOOR PANEL CUSHION


    1. A0022AH

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

  9. 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. A0022VDC01
      *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 }

  10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A0022TA

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

  11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A0021DX

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

  12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A0021AL

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

      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 sub-assembly, and slide the rear door outside handle assembly toward the front of the vehicle to install it.

    3. A0021PB

      Move the lever as shown in the illustration to lock the rear door outside handle assembly.

  13. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A0020AT

      Engage the claw to temporary 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 }

  14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A00233J

      w/o Double Locking System:


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

    2. w/ Double Locking System:


      1. A0022O4

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

      2. A0021EH

        Engage the 3 claws as shown in the illustration.

  15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A00229S

      w/o Double Locking System:


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

    2. A0020NS

      Engage the 2 claws as shown in the illustration.

    3. w/ Double Locking System:


      1. A002265

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

      2. A0020SS

        Engage the claw as shown in the illustration.

  16. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Note


    • When reusing a removed rear door lock with motor assembly, replace the door lock wire harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wire harness seal installation surface of the connector.

    • Reusing the door lock wire harness seal or using a damaged door lock wire 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. A00231P

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

    3. A0021G7C01
      *a Release Plate

      Connect the rear door lock with motor assembly to the release plate, and set it to the rear door panel.

      Tech Tips

      Make sure that the release plate 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:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.


    1. A00230S

      Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws to the rear door window regulator sub-assembly.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      When replacing a rear power window regulator motor assembly, a new rear power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  18. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


    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. A0022W1C01
      *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:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    5. Connect the connector.

  19. INSTALL REAR DOOR FRAME GARNISH


    1. A0022RX

      Engage the 3 claws to install the rear door frame garnish.

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. Apply soapy water to a new rear door glass channel filler.

    2. A002126C01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install the rear door glass channel filler to the rear door glass assembly at position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 25.8 mm (1.0157 in.)
      B 15.6 mm (0.6142 in.)

  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


    1. Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

    2. A0022CXC01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

      Note

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

      Standard Dimension
      Area Measurement
      A 25.8 mm (1.0157 in.)
      B 15.6 mm (0.6142 in.)

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A0022R3

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

  23. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. A0021TX

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

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

  24. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. A0020YU

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

  25. INSTALL REAR DOOR GLASS RUN


    1. A0022LG

      Install the rear door glass run.

  26. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel sub-assembly.

    2. Remove the release paper from a new rear door weatherstrip.

      Tech Tips

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

    3. A0020EXC01
      B003YLR Double-sided Tape

      Engage the 23 clips to install the rear door weatherstrip.

  27. INSTALL REAR DOOR PANEL PROTECTOR


    1. A0020G9

      Install the rear door panel protector.

  28. 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. A0020PMC02
      B003XUN Nut
      B003YHT Bolt

      Install the rear door check assembly with the 2 nuts and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  29. INSTALL REAR DOOR DUST PROOF SEAL


    1. A0021KA

      Engage the 2 claws to install a new rear door dust proof seal.

  30. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A0020VPC01
      *a Reference Point

      Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and 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.

    4. Engage the clamp.

  31. INSTALL REAR SPEAKER ASSEMBLY

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  32. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 15 Speakers)

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  33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A00235E

      Install the rear door inner glass weatherstrip.

  34. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0022CS

      Engage the 3 guides.

    2. A0021VS

      Install the rear door inside handle sub-assembly with the 6 screws.

  35. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. for 15 Speakers:


      1. Connect the connector.

    2. A002291C01
      *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.

    3. A00208WC01
      *a Reference Boss

      Engage the 3 claws and reference boss as shown in the illustration to temporarily install the rear door trim board sub-assembly.

    4. A0020OZ

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

    5. Install the 3 screws.

      Tech Tips

      If protective tape has been applied, remove it.

  36. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. A0022G5

      Install the rear door No. 1 stiffener cushion with the screw.

  37. INSTALL REAR DOOR NO. 3 ARMREST COVER


    1. A0022TR

      Engage the 2 guides.

    2. Engage the 2 claws, and install the rear door No. 3 armrest cover.

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


    1. Connect the connector.

    2. A0022L5

      Engage the 2 clips, 5 claws and 6 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A0021WX

      Engage the 3 claws to install the rear door inside handle bezel plug.

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  41. INSTALL BATTERY SERVICE HOLE COVER LH

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  42. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  43. INSPECT POWER WINDOW OPERATION

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