REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

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

    Click here

  2. INSTALL REAR DOOR UPPER OUTSIDE MOULDING PAD

    Click here

  3. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  4. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. A0027RX

      Engage the 6 clips to install the rear door No. 2 weatherstrip.

  5. INSTALL NO. 1 OUTSIDE MOULDING RETAINER


    1. A002BJI

      Engage the clip to install the No. 1 outside moulding retainer.

    2. A00282A

      Install the screw.

  6. INSTALL NO. 1 OUTSIDE MOULDING RETAINER


    1. A0029Z0

      Engage the 2 clips to install the 2 No. 1 outside moulding retainers.

    2. A002CH0

      Engage the 2 clips as shown in the illustration.

  7. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  8. REPAIR INSTRUCTION

    Click here

  9. INSTALL UPPER INNER BLACK OUT TAPE

    Click here

  10. INSTALL REAR INNER BLACK OUT TAPE

    Click here

  11. INSTALL FRONT INNER BLACK OUT TAPE

    Click here

  12. INSTALL REAR DOOR NO. 3 WEATHERSTRIP


    1. Clean the rear door panel.

    2. A002A2MC02
      B004057 Double-sided Tape

      Engage the claw and install a new rear door No. 3 weatherstrip.

  13. INSTALL REAR DOOR REAR UPPER OUTSIDE MOULDING

    Click here

  14. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

    Click here

  15. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

    Click here

  16. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  17. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  18. INSTALL UPPER QUARTER WINDOW STOP


    1. Apply soapy water to the upper quarter window stop.

    2. A002CM6

      Install the upper quarter window stop.

    3. Wipe off any soapy water on the door.

  19. INSTALL REAR DOOR LOWER HOLE COVER


    1. A002AIAN01

      Install the rear door lower hole cover as shown in the illustration.

  20. INSTALL REAR DOOR VENT SEAL


    1. A002BNWN01

      Install the rear door vent seal.

  21. INSTALL REAR DOOR PANEL CUSHION


    1. A0027C8

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

  22. INSTALL REAR DOOR FRAME GARNISH (w/o Rear Door Sunshade)


    1. A0029D7

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

  23. INSTALL REAR DOOR FRAME GARNISH (w/ Rear Door Sunshade)


    1. A00298T

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

  24. 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. A0026XJC01
      *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 }

  25. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A002835

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

  26. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A002CN6

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

  27. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A0029UP

      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, it will interfere with the rear door outside handle assembly and will be damaged.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle to install it.

  28. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A0029GO

      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 }

  29. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A0029Z1

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

  30. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A00289Z

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

    2. A002CNN

      Engage the 2 claws as shown in the illustration.

  31. 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. A0028PC

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

    3. A0028R0C01
      *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 }

  32. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

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


    1. A002AEE

      Using a T25 "TORX" socket wrench, install the power window regulator motor assembly with the 3 screws.

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

      Tech Tips

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

  33. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


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

    2. Temporary install the temporary bolt to the rear door window regulator assembly.

    3. A0027EKC02
      *a Temporary Bolt

      Temporarily install the rear door window regulator assembly with the 5 bolts.

    4. Tighten the temporary bolt and 5 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 }

  34. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the rear power window regulator switch assembly and move the rear door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the rear power window regulator switch assembly.

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

    5. A002AXH

      Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.

    6. A0029MJ

      Install the rear door glass sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    7. A0028RB

      Install the grommet.

  35. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


    1. A0027PFC01
      B003ZIE Bolt
      B003Z8F Nut
      B003ZMU Screw

      Install the 2 bolts.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

    2. Install the rear door lower window division bar sub-assembly with the nut and screw.

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

  36. INSTALL REAR DOOR GLASS RUN


    1. A002ATU

      Install the rear door glass run.

  37. INSTALL REAR DOOR WEATHERSTRIP


    1. A0026XU

      Engage the 20 clips to install the rear door weatherstrip.

  38. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the bolt threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A0027OEC02
      B003ZIE Bolt
      B003Z8F Nut

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

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

  39. INSTALL REAR DOOR PANEL PROTECTOR


    1. A0028J8

      Engage the 2 guides, claw and clip to install the rear door panel protector.

  40. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A0029JKC01
      *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. Install the new 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 2 clamps.

    5. Connect the 2 connectors.

  41. INSTALL REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade)


    1. A0027KN

      Engage the 3 guides.

    2. Install the rear curtain sub-assembly with the 7 screws.

  42. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A002C0F

      Engage the 7 claws to install the rear door inner glass weatherstrip as shown in the illustration.

  43. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  44. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A002C8M

      Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

  45. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A002A65C01
      *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. w/ Illumination:


      1. Connect the connector.

    3. A002BPJ

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

    4. A0026X0

      Install the 3 screws.

    5. A0029MY

      Engage the claw to close the cover.

  46. INSTALL REAR DOOR REAR GUIDE SEAL


    1. A002AH0

      Engage the 3 clips and claw to install the rear door rear guide seal.

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


    1. Connect the connector.

    2. A002AOC

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

  48. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A002A0V

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

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  50. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Models with Jam Protection Function on 4 Windows)

    Click here

  51. INSPECT POWER WINDOW OPERATION


    • for Models with Jam Protection Function on 4 Windows:

      Click here


    • for Models with Jam Protection Function on Front Door Windows:

      Click here